JLG 600s-600sj Ingles Manual de Servicio

Service and Maintenance Manual
Model
600S
660SJ
SN 0300235168* &
B300002655*
to Present
*See inside front cover for exceptions
PN - 3121728
May 30, 2018 - Rev C
AS/NZS
This manual also applies to machine with following Serial Numbers.
0300224266 0300224756 0300233720 B300002216

0300224267 0300224757 0300233721 B300002217
0300224755 0300224758 0300233722 B300002383
INTRODUCTION
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A GENERAL C MAINTENANCE
This section contains the general safety precautions which
must be observed during maintenance of the aerial platform.
It is of utmost importance that maintenance personnel pay FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
strict attention to these warnings and precautions to avoid COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
possible injury to themselves or others, or damage to the SAFETY VIOLATION.
equipment. A maintenance program must be followed to
ensure that the machine is safe to operate. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE
IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR
COMPONENTS.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELEC-
MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. TRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND
SECURE AT ALL OTHER TIMES.
The specific precautions to be observed during maintenance • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PER-
are inserted at the appropriate point in the manual. These pre- FORMING ANY MAINTENANCE.
cautions are, for the most part, those that apply when servic-
ing hydraulic and larger machine component parts. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FIT-
TING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME
Your safety, and that of others, is the first consideration when CAUGHT ON OR ENTANGLED IN EQUIPMENT.
engaging in the maintenance of equipment. Always be con-
scious of weight. Never attempt to move heavy parts without • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON
the aid of a mechanical device. Do not allow heavy objects to MACHINE AND IN SERVICE MANUAL.
rest in an unstable position. When raising a portion of the • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING
equipment, ensure that adequate support is provided. SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOL-
ANT SYSTEM.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE
• NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS
FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBIL-
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY
ITY OF THE OWNER/OPERATOR.
BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP
HAS BEEN ENGAGED.
B HYDRAULIC SYSTEM SAFETY • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PER-
FORMING ANY OTHER MAINTENANCE, SHUT OFF ALL
It should be noted that the machines hydraulic systems oper-
POWER CONTROLS.
ate at extremely high potentially dangerous pressures. Every
effort should be made to relieve any system pressure prior to • BATTERY SHOULD ALWAYS BE DISCONNECTED DURING
disconnecting or removing any portion of the system. REPLACEMENT OF ELECTRICAL COMPONENTS.
Do not use your hand to check for leaks. Use a piece of card- • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
board or paper to search for leaks. Wear gloves to help protect STOWED IN THEIR PROPER PLACE.
hands from spraying fluid. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOL-
VENTS.
3121728 A-1
INTRODUCTION
REVISON LOG
Original Issue A - August 04, 2017

Revised B - January 11, 2018
Revised C - May 30, 2018
A-2 3121728
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
C Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
SECTION 1 - SPECIFICATIONS
1.1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION 2 - GENERAL
2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Lubrication and Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Changing Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Thermal Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.6 Welding on JLG Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Do NOT Do the Following When Welding on JLG Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3121728 i
TABLE OF CONTENTS

SECTION 3 - CHASSIS & TURNTABLE
3.1 Tires & Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Oscillating Axle Bleeding Procedure and Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Lockout Cylinder Bleeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Oscillating Axle Lockout Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Chassis Tilt Indicator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Cold Start System (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 Auxiliary Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.6 Drive Orientation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.7 Oscillating Axle System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.8 Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.9 Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.10 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Assembly/Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.11 Swing Drive Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Procedure For Setting Swing Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Swing Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.12 Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Turntable Bearing Mounting Bolt Condition Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Wear Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Swing Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Swing Bearing Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.13 Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.14 Deutz TD2.9 L4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Check Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Change Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
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3.15 Deutz D2011L04 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Changing Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Replace Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Clean Fuel Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.16 Spark Arrester Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.17 Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
3.18 Ford Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.19 Counterweight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3.20 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Overload Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
SECTION 4 - BOOM & PLATFORM
4.1 Transport Position Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Beyond Transport - Drive Speed Cutback System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Drive/Steer - Boom Function Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 Dual Capacity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.5 Platform Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.6 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.7 Fuel level Cutout System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.8 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.9 Rotator and Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.10 Main Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.11 Main Boom Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.12 Main Boom Powertrack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.13 Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Three Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
12 Year or 7000 Hour Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Additional Replacement Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
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4.14 Wire Rope Tensioning Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.15 Wire rope Service indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.16 Jib (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.17 Boom Cleanliness Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.18 Foot Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.19 Platform Control Enable System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.20 Powertrack Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Remove Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Install New Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Replace Fixed End Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Replace Moving End Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.21 Skyguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Functional Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Diagnostic & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4.22 Bolt On Fall Arrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.1 Lubricating O-rings In The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cup and Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Dip Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spray Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brush-on Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Platform Level (Slave) Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Jib Lift Cylinder (660SJ Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.3 Hydraulic Pump (Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5.4 Variable Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
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5.5 Main Valve Block Pressure Setting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Load Sense Compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Load Sense Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
2 Wheel Steer, Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
4 Wheel Steer, Front & Rear Steering Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Rear Axle Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Turntable Swing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.6 Platform Valve Block Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Main High Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Low Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Platform Jib Down Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.7 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
SECTION 6 - JLG CONTROL SYSTEM
6.1 JLG Control System Analyzer Kit Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Connect JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Using Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Changing Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Adjust Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Level Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2 Machine Personality Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6.3 Machine Orientation When Setting Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Test Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6.4 CANBUS Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6.5 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Test from the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6.7 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6.8 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-62
6.9 Calibrating Boom Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66
6.10 Calibrating Level Up CRKPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-70
6.11 Calibrating Level Down CRKPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-72
6.12 Calibrating Platform Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-74
6.13 Calibrating Load Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-78
6.14 Calibrating MSSO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-82
6.15 LSS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-84
Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86
Testing & Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-91
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
6.16 Machine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
3121728 v
TABLE OF CONTENTS

SECTION 7 - BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Voltage Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3 Applying Silicone Dielectric Compound to Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installation of Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Deutsch HD, DT, DTM, DRC Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
AMP Mate-N-Lok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIN Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.4 AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.5 Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.6 Telematics Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Telematics-Ready (TCU) Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
7.7 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Component Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.8 Wiring Harness Connector Label Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7.9 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
3121728 vi
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.

1-1. Maintenance and Lubrication Diagram - Deutz D2011L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-2. Maintenance and Lubrication Diagram - Deutz TD2.9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1-3. Maintenance and Lubrication Diagram - Ford MSG425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4. Torque Chart (SAE Fasteners - Sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
2-1. Engine Operating Temperature Specifications - Deutz D2011L04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-2. Engine Operating Temperature Specifications - Deutz TD2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-3. Engine Operating Temperature Specifications - Ford MSG425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-4. Hydraulic Oil Operating Temperature Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3-1. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-2. Bleeder Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-3. Axle Installation - Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4. Axle Installation - Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5. Steering Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-6. Drive Hub Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7. Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-8. Drive Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-9. Swing Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-10. Swing Bearing Bolt Feeler Gauge Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-11. Swing Bearing Tolerance Measuring Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-12. Swing Bearing Tolerance Measurement Location & Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-13. Swing Bearing Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3-14. Swing Bearing Removal - 600S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-15. Swing Bearing Removal - 660SJ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
3-16. Rotary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-17. Rotary Coupling - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3-18. Rotary Coupling - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-19. Rotary Coupling Port Location - 2WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3-20. Rotary Coupling Port Location - 4WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-21. Rotary Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
3-22. Deutz TD2.9 L4 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3-23. Deutz TD2.9 L4 Engine and Pumps Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3-24. Deutz TD2.9 L4 Engine Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
3-25. Deutz TD2.9 L4 Engine Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3-26. Deutz 2.9 T4F Dipstick Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-27. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3-28. Deutz D2011 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
3-29. Deutz D2011 Engine and Pumps Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
3-30. Deutz D2011 Engine Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
3-31. Deutz D2011 Engine Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
3-32. Deutz Dipstick Markings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-33. Engine Oil Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
3-34. Ford MSG425 Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3-35. Ford Engine and Pumps Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
3-36. Ford Engine Assembly - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3-37. Ford Engine Assembly - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3-38. Counterweight Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
3-38. Generator Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-39. Generator Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-40. Generator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-41. Generator Circuit Breaker Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
3-42. Generator Circuit Breaker Location 
(If Equipped with 4000W)3-83
3-43. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
3121728 vii
LIST OF FIGURES

4-1. Platform Support Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-2. Removal of Components - Rotator and Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-3. Boom Assembly Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-4. Main Boom Lift Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-5. Powertrack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-6. Wire Rope Wire Breaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-7. Wire Rope Kink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-8. Sheave Groove Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-9. Dimensions of Boom Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-10. Clamping Wire Ropes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-11. Foot Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-12. Skyguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4-13. Bolt On Fall Arrest Cable Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-14. Bolt On Fall Arrest System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
5-1. Hydraulic Cylinder Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-1. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-2. Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-4. Main Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-5. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6. Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-7. Composite Bushing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-8. Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-9. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-10. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-12. Marking Cylinder for Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-13. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-14. Telescope Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-15. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-17. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-18. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-19. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-20. Head Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-21. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-22. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-23. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-27. Platform Level (Slave) Cylinder - 600S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-28. Platform Level (Slave) Cylinder - 660SJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-29. Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-32. Cylinder Head Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-34. Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-35. Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-36. Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-40. Jib Lift Cylinder Assembly(660SJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-41. Tapered Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
3121728 viii
LIST OF FIGURES

5-43. Rod Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-44. Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-45. Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-46. Head Seal Kit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5-47. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-48. Tapered Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-49. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-51. Removing Spanner Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-53. Steer Cylinder Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-54. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-58. Piston Seal and Wear Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-59. Spanner Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-60. Axle Lockout Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-61. Main Control Valve Block (2WS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-61. Hydraulic Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
5-62. Variable Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-65. Platform Control Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
5-66. Main Control Valve (2WS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-67. Main Control Valve (4WS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-68. Main Control Valve Torque Values (2WS) - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-74. Platform Valve Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
5-75. 2-Wheel Steer (2WS) without Jib Hydraulic Schematic - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5-77. 2-Wheel Steer (2WS) with Jib Hydraulic Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-83. 4-Wheel Drive (4WD) Hydraulic Schematic - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-87. Hydraulic Oil Cooler Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
6-1. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2. Analyzer Software - Sheet 1 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
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LIST OF FIGURES

6-11. Analyzer Software - Sheet 10 of 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-15. Control Module Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-16. Ground Control Module Pin Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6-17. Platform Control Module Pin Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-18. System Test Flow Chart - Platform Tests (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-19. System Test Flow Chart - Platform Tests (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6-20. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5. Applying Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6. Deutsch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7. Application to plug/male connector housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-8. Use of Seal Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9. AMP Mate-N-Lok Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10. DIN Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-11. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-16. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-17. Connector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-18. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-19. DT/DTP Contact Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-20. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-21. HD/HDP Locking Contacts Into Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-22. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-23. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-24. Telematics Gateway Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7-27. Platform Box Harness - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
7-33. Main Boom Harness (Without Jib). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7-34. Main Boom Harness (With Jib) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-35. Main Boom Harness (TT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
7-36. Proximity Switch Harness (Telescope In) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
7-37. Proximity Switch Harness (Capacity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
7-38. Turntable Harness - Sheet 1 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-46. Boom Angle Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7-47. Main valve Harness (4WS) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
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LIST OF FIGURES

7-55. Ground Control Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
7-56. Ground Control Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
7-57. Lift Cylinder Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
7-58. Deutz D2011L04 Engine Harness - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
7-61. Deutz T4F Engine Harness - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94
7-66. Ford Engine Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106
7-67. Chassis Head and Tail Lights Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108
7-68. Chassis Head and Tail Lights Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110
7-69. Chassis Work Lights Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
7-70. Chassis Work Lights Harness - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114
7-71. ClearSky Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-116
7-72. Platform Valve Harness - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-118
7-73. Platform Valve Harness Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-120
7-74. Skyguard Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-122
7-75. Electrical Schematic - Sheet 1 of 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-125
7-84. Electrical Schematic - Sheet 10 of 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-134
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This Page Left Blank Intentionally
3121728 xii
LIST OF TABLES
TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4 Deutz TD 2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-5 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6 Ford MSG425 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-7 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-9 Mobilfluid 424 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-10 Mobil DTE 10 Excel 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-11 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-12 Mobil EAL 224 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-13 Mobil EAL Envirosyn H 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-14 Exxon Univis HVI 26 (Arctic). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-15 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-16 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Inspection and Preventive Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2 Coupling Port Information Table - 2WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-3 Coupling Port Information Table - 4WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
3-4 Deutz Trouble Codes (TD2.9 L4 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
3-5 Deutz Trouble Codes (D2011L04 Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3-6 Fault Code Cross Reference List (Ford MSG425 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
3-7 CAN to DTC Cross Reference (Ford MSG425 Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
4-1 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
6-1 Analyzer Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6-3 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-4 Machine Configuration Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6-5 Machine Personality Settings and Function Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-6 System Test Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
6-7 Machine Diagnostics Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
6-8 Diagnostic Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-85
6-9 Accessory Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-87
6-10 SkyGlazier Capacity Reductions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6-11 Pipe Rack Capacity Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-89
6-12 LSS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-92
6-13 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-93
7-1 Wiring Harness Connector Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
3121728 xiii
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
3121728 xiv
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 DIMENSIONAL DATA
Table 1-1. Operating Specifications Table 1-2. Dimensional Data
Maximum Work Load (Capacity) - 600S Machine Height (Stowed) 8 ft. 2.4 in. (2.48 m)
Unrestricted: 600 lbs (272 kg)
Restricted: 1000 lbs (454 kg) Machine Length (Stowed)
600S 28 ft. 7 in. (8.71 m)
Maximum Work Load (Capacity) - 660SJ 660SJ 35ft. 4.7 in. (10.79 m)
Unrestricted: 550 lbs (250 kg)
Restricted: 750 lbs (340 kg) Machine Width 8 ft. 2 in. (2.48 m)
Maximum Travel Grade (Gradeability) Turning Radius (Outside)

4WD 45% 2WS 19 ft. 7 in. (5.96 m)
4WS 12 ft. 8 in. (3.87 m)
Maximum Travel Grade (Side Slope) 5°
Turning Radius (Inside)
Ground Bearing Pressure - 600S 2WS 9 ft. 7 in. (2.92 m)
Foam Filled  83.1 psi (5.84 kg/cm2) 4WS 5 ft. 3 in. (1.61 m)
Pneumatic 77.7 psi (5.46 kg/cm2) Wheelbase 8 ft. 2.7 in. (2.51 m)
Ground Bearing Pressure - 660SJ Total Axle Oscillation 8 in. (0.2m)
Foam Filled  86.4 psi (6.07 kg/cm2)
Ground Clearance 11.3 in. (0.39 m)
Pneumatic 85.1 psi (5.98 kg/cm2)
Platform Height
Maximum Drive Speed (4WD) 3.8 MPH (6.3 Km/hr.)
600S 59 ft. 8 in. (18.186 m)
Electrical System 12V DC 660SJ 65 ft. 8 in. (20.02 m)
Gross Machine Weight (Approximate) Horizontal Reach from center of rotation -

600S - 2WS 21,461 lbs (9735 kg) 600S
600S - 4WS 21,647lbs (9819 kg) 600 lbs (272 kg) Zone 50 ft. 2 in. (15.29 m)
660SJ - 2WS 25,341 lbs (11494 kg) 1000 lbs (454 kg) Zone 41 ft. 1.2 in. (12.53 m)
660SJ - 4WS 25,581 lbs (11603 kg)
Horizontal Reach over end - 600S
600 lbs (272 kg) Zone 45 ft. 2.5 in. (13.78 m)
1000 lbs (454 kg) Zone 36 ft. 1.6 in. (11.01m)
Horizontal Reach over side - 600S

600 lbs (272 kg) Zone 46 ft.1.3 in. (14.05 m)
1000 lbs (454 kg) Zone 37 ft. 0.2in. (11.28 m)
Horizontal Reach from center of rotation -

660SJ
550 lbs (250 kg) Zone 57 ft. 1 in. (17.4 m)
750 lbs (340 kg) Zone 47 ft.11 in. (14.60 m)
Horizontal Reach over end - 660SJ

550lbs (250 kg) Zone 52 ft. 1 in. (15.87 m)
750 lbs (340 kg) Zone 42 ft. 11.4 in. (13.09 m)
Horizontal Reach over side - 660SJ

550 lbs (250 kg) Zone 52 ft.11.6 in. (16.14 m)
750 lbs (340 kg) Zone 43 ft. 10.2in. (13.36 m)
Tail Swing 4 ft. (1.22 m)
3121728 1-1
1.3 CAPACITIES Table 1-6. Ford MSG425 Specifications

Table 1-3. Capacities Type Liquid Cooled
Fuel Tank Number of Cylinders 4
Diesel 31 Gallons (117 L) Displacement 2.5 L
Diesel (Steel Tank) 52 Gallons (200 L)
Oil Capacity 7 qt (6.6 L)
Gasoline 31 Gallons (117 L)
Coolant Capacity 0.63 Gallon (2.4 L)
Hydraulic Oil Tank 21 Gallons (79.5 L)
Low RPM 1000 ± 50 rpm
Hydraulic System (Including Tank) 40 Gallons (121 L)
High RPM 3200 ± 50 rpm
Torque Hub, Drive* 24 ounces (0.7 L)
Alternator 150 Amp
*Fill torque hubs half (1/2) full of lubricant. Starter 64.4 Amp @ 3574 rpm
Fan Ratio 1:3
1.4 ENGINE DATA Fuel Consumption
Table 1-4. Deutz TD 2.9L4 Specifications Gas 1.05 GPH (3.98 lph)
LP 1.37 GPH (5.19 lph)
Fuel Ultra Low Sulfur Diesel (15 ppm)
Max Output (Power)
Output 67 HP (50 kW) Gasoline 62.1 HP @ 2600
Torque 173 ft.lbs. (234 Nm) @ 1800rpm LP 62.7 HP @ 2600
Oil Capacity (Crankcase) 9.6 Quarts (9.1L) w/Filter Max Output (Torque)
Cooling System 3.3 gal (12.5 L) Gasoline 142 ft. lbs. (192 Nm) @ 2400 RPM
LP 145 ft. lbs. (197 Nm) @ 2400 RPM
Low RPM 1200 ± 50 rpm
Battery 950 Cold Cranking Amps, 205 Minutes
High RPM 2600 ± 50 rpm Reserve Capacity, 12 VDC
Alternator 95 Amp Acceptable Fuel Grades
Fuel Consumption 1.06 GPH (4.02lph) Unleaded 87 or 89 Octane Gasoline
Battery 950 Cold Cranking Amps, 205 Minutes Ethanol/Gasoline Mix: 10%
Reserve Capacity, 12 VDC
HD-5 LPG
Table 1-5. Deutz D2011L04 Specifications
Fuel Diesel
Oil Capacity
Cooling System 5 Quarts (4.7 L)
Crankcase 11 Quarts (10.4 L) w/Filter
Total Capacity 16 Quarts (15.1 L)
Idle RPM 1000
Low RPM 1800
High RPM 2500
Alternator 60 Amp, belt drive
Battery 950 Cold Cranking Amps, 205 Minutes
Reserve Capacity, 12 VDC
Fuel Consumption 0.79 GPH (2.99 lph)
Horsepower 49
1-2 3121728
1.5 TIRES 1.6 CRITICAL STABILITY WEIGHTS

Table 1-7. Tire Specifications
Size 355/55D 625
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT
Load Range G
WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLAT-
Ply Rating 14 FORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Fill Type Foam/Crumb
Components LBS. KG.
Diameter 36.9
Width 13.95 Tire and Wheel 355/55D625(FF) 440 200
Rim Size 11.75 x 24.5 41/18LLx22.5 (FF) 700 318
Tire & Wheel Weight 228 lbs (103.5 kg)
355/55D625 (Pneumatic) 225 102
Max Tire Load 15,120 lbs (6858 kg)
Size 355/55D 625 355/55D625 (Pneumatic- 242.5 110
Non Marking)
Load Range G
Ply Rating 14 41/18LLx22.5 (Pneumatic) 265 120
Fill Type Pneumatic
355/55D625 (Pneumatic/ 233 106
Diameter 36.9 Sealant)
Width 13.95
Deutz TD2.9L 1433 650
Rim Size 11.75 x 24.5
Engine (Complete
Tire & Wheel Weight 228 lbs (103.5 kg) Deutz D2011L04 983 445
tray)
Max Tire Load 15,120 lbs (6858 kg) @ 100 psi (6.9 bar) Ford 340 154
Size 41/18LL x 22.5
Chassis 453 205.5
Load Range G
Ply Rating 14 Counterweight Turntable (600S) 4922 2233
Fill Type Soft Foam Turntable (660SJ) 5844 2653
Diameter 41
30x48 132 60
Width 18.4
Rim Size 14 x 22.5 30x60 145.5 66
Platform Only (No
Tire & Wheel Weight 700 lbs (318 kg)
Control Box or Foot- 36x72 159 72
Max Tire Load 19,000 lb s switch)
Size 41/18LL x 22.5 36x96 185 84
Load Range G 36x72 (Shipyard Gate) 247 112
Ply Rating 14
Fill Type Pneumatic
Diameter 41
Width 18.4
Rim Size 14 x 22.5
Tire & Wheel Weight 265 lbs (120 kg)
Max Tire Load 19,000 lb s
3121728 1-3
1.7 HYDRAULIC OIL

Table 1-11. Quintolubric 888-46
Density 0.92 @ 15°C (59°F)

Table 1-8. Hydraulic Oil
Pour Point <-22°F (<-4°C)
Hydraulic System S.A.E. Viscosity Flash Point 572°F (300°C)
Operating Temperature Range Grade Fire Point 680°F (360°C)
+0° to + 180° F (-18° to +83° C) 10W Auto Ignition Temperature >842°F(>450°C)
+0° to + 210° F (-18° to +99° C) 10W-20, 10W-30 Viscosity
+50° to + 210° F (+10° to +99° C 20W-20 at 0° C (32° F) 320 cSt
at 20° C (68° F) 109 cSt
NOTE: Hydraulic oils require anti-wear qualities at least API Ser-
at 40° C (104° F) 47.5 cSt
vice Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service. at 100° C (212° F) 9.5 cSt
Viscosity Index 190
NOTE: Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types. They may not contain
required additives or be of comparable viscosities. If
hydraulic oil other than Mobil 424 is desired, contact JLG Table 1-12. Mobil EAL 224 H
Industries for proper recommendations.
Type Biodegradable Vegetable
ISO Viscosity Grade 32/46
Table 1-9. Mobilfluid 424
Specific Gravity 0.922
SAE Grade 10W-30
Pour Point -25°F (-32°C)
Gravity, API 29.0 Flash Point 428°F (220°C)
Density, Lb/Gal. 60°F 7.35 Operating Temp. 0 to 180°F (-17 to 162°C)
Pour Point, Max -46°F (-43°C) Weight 7.64 lb. per gal.
(0.9 kg per liter)
Flash Point, Min. 442°F (228°C)
Viscosity
Viscosity
at 40° C (104° F) 37 cSt
Brookfield, cP at -18°C 2700
at 100° C (212° F) 8.4 cSt
at 40° C (104° F) 55 cSt
Viscosity Index 213
at 100° C (212° F) 9.3 cSt
Viscosity Index 152
Table 1-13. Mobil EAL Envirosyn H 46
Table 1-10. Mobil DTE 10 Excel 32 Type Synthetic Biodegradable

ISO Viscosity Grade 46
ISO Viscosity Grade #32
Density 0.874 @ 15°C (59°F)
Specific Gravity 0.877
Pour Point -49°F (-45°C)
Pour Point, Max -129°F (-54°C)
Flash Point 500°F (260°C)
Flash Point, Min. 330°F (166°C)
Operating Temp. -20 to 200°F (-29 to 93°C)
Viscosity
Viscosity
at 40° C (104° F) 32.7 cSt
at 40° C (104° F) 48.8 cSt
at 100° C (212° F) 6.63 cSt
at 100° C (212° F) 7.8 cSt
cp at -20° F 6200
Viscosity Index 145
Viscosity Index 164
1-4 3121728
1.8 TORQUE REQUIREMENTS

Table 1-14. Exxon Univis HVI 26 (Arctic)
Specific Gravity 32.1 Table 1-15. Torque Requirements

Pour Point -76°F (-60°C) Interval
Flash Point 217°F (103°C) Description Torque Value (Dry)
Hours
Viscosity
Bearing To Chassis 18X
at 40° C (104° F) 25.8 cSt
at 100° C (212° F) 9.3 cSt Bearing To Turntable 18X
Viscosity Index 376 Wire Rope 15 ft. lbs (20 Nm) 150
NOTE: Mobil/Exxon recommends this oil be checked on a yearly basis for
viscosity. Wheel Lugs 170 ft.lbs (230 Nm)
Engine Mounting Bolt

M12 84.8 ft.lbs (115 Nm)
M16 206.5 ft.lbs (280 Nm)
*Check swing bearing bolts after first 50 hours of operation and every 600 hours
thereafter. (See Swing Bearing in Section 3.)
3121728 1-5
18
660SJ
18
600S
3 3
2
17
13
8 19
3 3
5
4
6
MAE20570
Figure 1-1. Maintenance and Lubrication Diagram - Deutz D2011L04
1-6 3121728
18
660SJ
18
600S
3 3
2
17
13 12
10
3 3
11 7
5
4
6
MAE20580
Figure 1-2. Maintenance and Lubrication Diagram - Deutz TD2.9
3121728 1-7
18
660SJ
18
600S
3 3
2
17
16
15
3 3
14
5
4
6
MAE20560
Figure 1-3. Maintenance and Lubrication Diagram - Ford MSG425
1-8 3121728
1.9 MAINTENANCE AND LUBRICATION 2. Swing Drive Hub
NOTE: The following numbers correspond to those in Figure 1-1.,

Figure 1-2. and Figure 1-3.
Table 1-16. Lubrication Specifications. FILL PORT
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type. 
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MIL-Spec MIL-L-2105
HO Hydraulic Oil. Refer Section 1.7, Hydraulic Oil.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API
CC/CD class, MIL-L-2104B/MIL-L-2104C
Lube Point(s) - Level/Fill Plug 
Capacity - 32 oz. (0.95 L)
Lube - 80w90 Gear Oil
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NOR- operation
MAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/
OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION 3. Wheel Drive Hub
FREQUENCIES MUST BE INCREASED ACCORDINGLY.
1. Swing Bearing
Lube Point(s) - Level/Fill Plug

Capacity - 24 oz. (0.7 L)
Lube - 80w90 Gear Oil
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation.
Lube Point(s) - 1 Grease Fittings

Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access. Apply grease and rotate
in 90 degree intervals until bearing is completely
lubricated.
3121728 1-9
4. Hydraulic Charge Filter 7. Hydraulic Tank

Interval - Change after first 50 hrs. and every 6 months
Lube Point(s) - Fill Cap Capacity - 21 gal tank (79.5 L)
or 300 hrs.
40.0 gal system (151 L) Lube - HO Interval - Check
5. Hydraulic Return Filter Level daily; Change every 2 years or 1200 hours of
operation 
Comments - On new machines, those recently over-
hauled, or after changing hydraulic oil, operate all sys-
tems a minimum of two complete cycles and recheck
oil level in reservoir.
8. Oil Change w/Filter - Deutz D2011

or 300 hrs.
6. Hydraulic Tank Breather
Lube Point(s) - Fill Cap/Spin-on Element 

Capacity - 11 Quarts (10.4 L) Crankcase; 
5 Quarts (4.7 L) Cooler
Type - Deutz approved engine oil.
Lube - EO 
Interval - Every Year or 1200 hours of operation
Comments - Check level daily/Change in accordance
with engine manual. Use Deutz approved engine oil
type.

or 300 hrs. thereafter. 
Comments - Remove wing nut and cover to replace.
Under certain conditions, it may be necessary to
replace on a more frequent basis.
1-10 3121728
9. Fuel Filter - Deutz 2011 12. Fuel Pre-Filter - Deutz D2.9
Lube Point(s) - Replaceable Element 

Interval - Every Year or 600 hours of operation.
10. Oil Change w/Filter - Deutz 2.9
Lube Point(s) - Replaceable Element

Interval - Drain water daily; 
Filter must be replaced every year or 600 hours of
operation (whichever comes first).
13. Engine Coolant - Deutz D2.9
Lube Point(s) - Fill Cap 
Lube Point(s) - Fill Cap/Spin-on Element  Capacity (Deutz 2.9L)- 13.2 quart (12.5 L)
Capacity - 9.6 Quarts (9.1 L) Crankcase;  Type - Deutz approved engine coolant
Lube - EO Lube - Anti-Freeze
Interval - Every Year or 600 hours of operation Interval - Check level daily; change every 1000 hours
Comments - Check level daily/Change in accordance or two years, whichever comes first.
with engine manual.
11. Fuel Filter - Deutz 2.9

Interval - Every Year or 600 hours of operation
3121728 1-11
14. Oil Change w/Filter - Ford MSG425 17. A. Air Filter - Deutz 2.9L
B. Air Filter - Deutz 2011
MAE18190
Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 7 Quarts (6.6 L)
Lube - EO
Interval - Change in accordance with engine manual
Comments - Check level daily
15. Fuel Filter - Ford MSG425 Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or
as indicated by the condition indicator.
MAE21960

Interval - Every Year or 600 hours of operation
16. Engine Coolant - Ford MSG425
Lube Point(s) - Fill Cap

Capacity (Deutz 2.9L)- 2 gal. quart (7.5 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours
or two years, whichever comes first
1-12 3121728
18. A. Platform Filter - 600S 19. Optional Fuel Filter - Deutz 2011 - China Market
B. Platform Filter - 660SJ Lube Point(s) - Replaceable Element (optional fuel fil-
ter)
Interval - Drain water daily; Every year or 600 hours of
operation.
Type - Deutz approved engine coolant
Lube Point - Replaceable Element

Interval - Change after first 50 hours and then every
year or 600 hours of operation, whichever comes first.
3121728 1-13
Torq ue
Torq ue
To rqu e
Torq ue
To rqu e
Torq ue
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 1 of 5)
1-14 3121728
To rqu e
Torqu e
Torq ue
Tor que
Torq ue
3121728 1-15
Torq ue
Tor que
Torqu e
Cl amp L oa d
Torq ue
To rqu e
To rque
1-16 3121728
To rq ue
To rqu e
To rq ue
Torq u e
To rqu e
To rqu e
3121728 1-17
To rq ue
To rqu e
To rqu e
Tor qu e
Torqu e
Torq ue
Figure 1-8. Torque Chart (METRIC Fasteners - Sheet 5 of 5)
1-18 3121728
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION, AND items requiring inspection. Reference appropriate areas of this
manual for servicing and maintenance procedures.
MAINTENANCE
Annual Machine Inspection
General
The Annual Machine Inspection must be performed on an
This section provides the necessary information needed by annual basis, no later than thirteen (13) months from the date
those personnel that are responsible to place the machine in of the prior Annual Machine Inspection. JLG Industries recom-
operation readiness and maintain its safe operating condition. mends this task be performed by a Factory-Trained Service
For maximum service life and safe operation, ensure that all Technician. JLG Industries, Inc. recognizes a Factory-Trained
the necessary inspections and maintenance have been com- Service Technician as a person who has successfully com-
pleted before placing the machine into service. With proper pleted the JLG Service Training School for the subject JLG
care, maintenance, and inspections performed per JLG's rec- product model. Reference the machine Service and Mainte-
ommendations, and with any and all discrepancies corrected, nance Manual and appropriate JLG inspection form for perfor-
this product will be fit for continued use. mance of this inspection.
Preparation, Inspection, and Maintenance Reference the JLG Annual Machine Inspection Form and
Inspection and Preventive Maintenance Schedule for items
It is important to establish and conform to a comprehensive requiring inspection. Reference appropriate areas of this man-
inspection and preventive maintenance program. The follow- ual for servicing and maintenance procedures.
ing table outlines periodic machine inspections and mainte-
For the purpose of receiving safety-related bulletins, it is
nance recommended by JLG Industries, Inc. Consult your
important that JLG Industries, Inc. has updated ownership
national, regional, or local regulations for further requirements
information for each machine. When performing each Annual
for aerial work platforms. Frequency of inspections and main-
Machine Inspection, notify JLG Industries, Inc. of current
tenance must be increased as environment, severity and fre-
machine ownership.
quency of usage requires.
Pre-Start Inspection Preventive Maintenance

In conjunction with specified inspections, maintenance shall
It is the User’s or Operator’s primary responsibility to perform a
be performed by a qualified JLG equipment mechanic. JLG
Pre-Start Inspection of the machine before use daily or at each
Industries, Inc. recognizes a qualified JLG equipment
change of operator. Reference the Operator’s and Safety Man-
mechanic as a person who, by possession of a recognized
ual for Pre-Start Inspection procedures. The Operator and
degree, certificate, extensive knowledge, training, or experi-
Safety Manual must be read and understood in its entirety
ence, has successfully demonstrated the ability and profi-
before performing the Pre-Start Inspection.
ciency to service, repair, and maintain the subject JLG product
model.
Pre-Delivery Inspection and Frequent Inspection
Reference the Preventive Maintenance Schedule and appro-
The Pre-Delivery Inspection and Frequent Inspection shall be priate areas of this manual for servicing and maintenance pro-
performed by a qualified JLG equipment mechanic. JLG Indus- cedures. Frequency of service and maintenance must be
tries, Inc. recognizes a qualified JLG equipment mechanic as a increased as environment, severity and frequency of usage
person who, by possession of a recognized degree, certificate, requires.
extensive knowledge, training, or experience, has successfully
demonstrated the ability and proficiency to service, repair, and
maintain the subject JLG product model.
The Pre-Delivery Inspection and Frequent Inspection proce-
dures are performed in the same manner, but at different
times. The Pre-Delivery Inspection shall be performed prior to
each sale, lease, or rental delivery. The Frequent Inspection
shall be accomplished for each machine in service for 3
months or 150 hours (whichever comes first); out of service for
a period of more than 3 months; or when purchased used. Fre-
quency of this inspection must be increased as environment,
severity and frequency of usage requires.
Reference the JLG Pre-Delivery and Frequent Inspection Form
and Inspection and Preventive Maintenance Schedule for
3121728 2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Prior to use each day; or

User or Operator User or Operator Operation and Safety Manual
Inspection at each Operator change.
Pre-Delivery Prior to each sale, lease, or Service and Maintenance Manual

Owner, Dealer, or User Qualified JLG Mechanic
Inspection rental delivery. and applicable JLG inspection form.
In service for 3 months or 150 hours, whichever

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

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Maintenance nance Manual.
2.2 SERVICE AND GUIDELINES 3. Clean and inspect all parts during servicing or mainte-
nance. Ensure all passages and openings are unob-
structed. Cover all parts to keep them clean. Make sure
General all parts are clean before they are installed. New parts
Following information is provided to assist you in using servic- should remain in their containers until ready to be used.
ing and maintenance procedures in this manual.
Components Removal and Installation
Safety and Workmanship 1. Use adjustable lifting devices, whenever possible, if
Your safety, and that of others, is the first consideration in mechanical assistance is required. All slings (chains,
maintenance of equipment. Always be conscious of weight. cables, etc.) should be parallel to each other and as near
Never attempt to move heavy parts without aid of a mechani- perpendicular as possible to top of part being lifted.
cal device. Do not allow heavy objects to rest in an unstable 2. Should it be necessary to remove a component on an
position. Ensure adequate support is provided when raising a angle, keep in mind the capacity of an eyebolt or similar
portion of the equipment. bracket lessens, as the angle between the supporting
structure and component becomes less than 90
Cleanliness degrees.
1. The most important single item in preserving the long 3. If a part resists removal, check to see if all nuts, bolts,
service life of a machine is to keep dirt and contamina- cables, brackets, wiring, etc., have been removed and no
tion out of vital components. Shields, covers, seals, and adjacent parts are interfering.
filters are provided to keep air, fuel, and oil supplies
clean; however, these items must be maintained on a
schedule to function properly.
2. Any time air, fuel, or oil lines are disconnected, clean
adjacent areas as well as the openings and fittings them-
selves. As soon as a line or component is disconnected,
cap or cover all openings to prevent contamination.
2-2 3121728
SECTION 2 - GENERAL
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within the
text, use standard torque values on heat-treated bolts,
Complete procedural steps in sequence when disassembling studs, and steel nuts, in accordance with recommended
or reassembling a component. Do not partially disassemble or shop practices. (See Torque Chart in Section 1.)
assemble one part, then start on another. Always recheck your
work to ensure nothing is overlooked. Do not make any Hydraulic Lines and Electrical Wiring
adjustments, other than those recommended, without obtain-
Clearly mark or tag hydraulic lines and electrical wiring, and
ing proper approval.
their receptacles, when disconnecting or removing them from
the unit. This ensures correct reinstallation.
Pressure-Fit Parts
Hydraulic System
When assembling pressure-fit parts, use a molybdenum disul-
fide base compound or equivalent to lubricate the mating sur- 1. Keep the system clean. If evidence of metal or rubber
face. particles are found in the hydraulic system, drain and
flush the entire system.
Bearings 2. Disassemble and reassemble parts on clean work sur-

face. Clean all metal parts with non-flammable cleaning
1. When a bearing is removed, cover it to keep out dirt and solvent. Lubricate components as needed to aid assem-
abrasives. Clean bearings in nonflammable cleaning sol- bly.
vent and allow to drip dry. Compressed air can be used,
but do not spin the bearing. Lubrication
Service applicable components with the amount, type, and
2. Discard bearings if races and balls (or rollers) are pitted,
grade of lubricant recommended in this manual at the speci-
scored, or burned.
fied intervals. When recommended lubricants are not avail-
3. If bearing is found to be serviceable, apply a light coat of able, consult your local supplier for an equivalent that meets
oil and wrap it in clean (waxed) paper. Do not unwrap or exceeds the specifications listed.
reusable or new bearings until ready to install.
Battery
4. Lubricate new or used serviceable bearings before
Clean battery using a non-metallic brush and a solution of
installation. Apply pressure to the outer race when
baking soda and water. Rinse with clean water. After cleaning,
pressing a bearing into a retainer or bore. Apply pres-
thoroughly dry battery and coat terminals with an anti corro-
sure to the inner race If bearing is installed on a shaft.
sion compound.
Gaskets Lubrication and Servicing

Check holes in gaskets align with openings in mating parts. If Components and assemblies requiring lubrication and servic-
it is necessary to hand-fabricate a gasket, use gasket material ing are shown in the Lubrication Chart in Section 1.
or stock of equivalent material and thickness. Be sure to cut
holes in the correct location. Blank gaskets can cause serious
system damage.
Bolt Usage and Torque Application
SELF LOCKING FASTENERS, SUCH AS NYLON INSERT AND THREAD DEFORMING

LOCKNUTS, ARE NOT INTENDED TO BE REINSTALLED AFTER REMOVAL.
1. Always use new replacement hardware when installing

locking fasteners. Use bolts of proper length. A bolt
which is too long will bottom before the head is tight
against its related part. If a bolt is too short, there will
not be enough thread area to engage and hold the part
properly. When replacing bolts, use only those having
the same specifications of the original, or one which is
equivalent.
3121728 2-3
SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION functional check of each system, before placing
machine back in service.
Hydraulic System Lubrication Specifications
1. The primary enemy of a hydraulic system is contamina- Specified lubricants, as recommended by component manu-
tion. Contaminants can enter the system by using inade- facturers, are always the best choice. However, multi-purpose
quate hydraulic oil; allowing moisture, grease, filings, greases usually have qualities which meet a variety of single
sealing components, sand, etc., to enter when perform- purpose grease requirements. Should questions arise regard-
ing maintenance; or allowing the pump to cavitate due ing use of greases in maintenance stock, consult your local
to insufficient system warm-up or leaks in pump supply supplier for evaluation. Refer to Section 1 for an explanation of
(suction) lines. lubricant key designations in the Lubrication Chart.
2. Design and manufacturing tolerances of component
working parts are very close. The smallest amount of dirt 2.4 CYLINDER DRIFT
or other contamination entering a system can cause
wear or damage to components and faulty operation. Theory
Take every precaution to keep hydraulic oil clean -
When a hydraulic cylinder is supporting a load, cylinder drift
including reserve oil in storage. Check, clean, and may occur as a result of any of the circumstances below:
replace hydraulic system filters as at intervals specified
in the Lubrication Chart in Section 1. Always examine fil- • Normal leakage of load holding valves or malfunction of
ters for metal particles. load holding valves. See Cylinder Leakage Test and 
Table 2- 2, Cylinder Drift below for evaluation.
3. Cloudy oils indicate high moisture content which per-
mits organic growth and causes oxidation or corrosion. • Damaged or worn piston seals.
If this condition occurs, the system must be drained, • Normal thermal expansion or contraction of the hydraulic
flushed, and refilled with clean oil. oil within cylinders (See Cylinder Thermal Drift below).
4. It is not advisable to mix oils of different brands or types. The first two circumstances may result in cylinder movement
They may not contain required additives or be of com- due to oil leaking out of the cylinder externally or by leaking
parable viscosities. Good grade mineral oils, with viscos- back to tank or due to oil leaking internally from one cylinder
ities suited to ambient temperatures in which the chamber to the other.
machine is operating, are recommended for use.
Thermal expansion or contraction of oil in hydraulic cylinders
NOTE: Metal particles may appear in oil or filters of new machines is a normal occurrence and does not result in oil leaking out of
due to wear-in of meshing components. the cylinder or leaking internally from one cylinder chamber
to the other. Thermal expansion or contraction is the tendency
Hydraulic Oil for materials to change size in response to a change in 
temperature.
1. Refer to Section 1 for viscosity ranges.
Cylinder Leakage Test
Changing Hydraulic Oil Cylinder oil must be at stabilized ambient temperature
before beginning this test.
1. Filter elements must be changed after the first 50 hours
of operation and every 300 hours (unless specified oth- Measure drift at cylinder rod with a calibrated dial indicator.
erwise) thereafter. If it is necessary to change the oil, use
In an area free of obstructions, cylinder must have load
only those oils meeting or exceeding specifications in
applied and appropriately positioned to detect drift.
this manual. If unable to obtain the same type of oil sup-
plied with the machine, consult local supplier for assis- Cylinder leakage is acceptable if it passes this test.
tance in selecting the proper equivalent. Avoid mixing
petroleum and synthetic base oils.
2. Keep hydraulic oil clean. If oil must be poured from orig-
inal container into another, clean all possible contami-
nants from the service container. Always clean filter
mesh element and replace cartridge any time system oil
is changed.
3. While the unit is shut down, a good preventive mainte-
nance measure is to make a thorough inspection of all
hydraulic components, lines, fittings, etc., as well as a
2-4 3121728
SECTION 2 - GENERAL
4. Re-assembly of pinned joints using filament wound

bearings:
Table 2-2. Cylinder Drift
a. Blow out housing using compressed air to remove
Cylinder Bore Max. Acceptable Drift
Diameter in 10 Minutes all dirt and debris. Bearings and bearing housings
must be free of all contamination.
inches mm inches mm
3 76.2 0.026 0.66 b. Clean bearings and pins with solvent to remove all
grease and oil.
3.5 89 0.019 0.48
4 101.6 0.015 0.38 NOTE: Filament wound bearings are a dry joint and should not be
5 127 0.009 0.22 lubricated unless otherwise instructed (i.e. sheave pins).
6 152.4 0.006 0.15
7 177.8 0.005 0.13 c. Inspect pin to ensure it is free of burrs, nicks, and
8 203.2 0.004 0.10 scratches which can damage bearing during instal-
9 228.6 0.003 0.08 lation and operation.
NOTE: This information is based on 6 drops per minute cylinder
leakage. 2.6 WELDING ON JLG EQUIPMENT
NOTE: This instruction applies to repairs, or modifications to the
Cylinder Thermal Drift machine and to welding performed from the machine on
The oil in all hydraulic cylinders will expand or contract due to an external structure, or component,
thermal effects over time and may result in changes to the
boom and/or platform position while the machine is station-
ary. These effects occur as the cylinder oil changes tempera- Do the Following When Welding on JLG Equipment:
ture, usually from a higher oil temperature as it cools and
approaches the ambient air temperature. Results of these • Disconnect battery.
effects are related to several factors including cylinder length
• Disconnect moment pin connection (where fitted)
and change in temperature over the time the cylinder remains
stationary. • Ground only to structure being welded.
2.5 PINS AND COMPOSITE BEARING REPAIR Do NOT Do the Following When Welding on JLG
GUIDELINES Equipment:
Filament wound bearings.
• Do NOT ground on frame and weld on any other area than
1. Pinned joints should be disassembled and inspected if chassis.
the following occurs:
• Do NOT ground on turntable and weld on any other area
a. Excessive sloppiness in joints.
than turntable.
b. Noise originating from joint during operation.
• Do NOT ground on platform/support and weld on any
2. Filament wound bearings should be replaced if any of
other area than platform/support.
the following is observed:
a. Frayed or separated fibers on the liner surface. • Do NOT ground on a specific boom section and weld on
any other area than that specific boom section.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing. • Do NOT allow pins, wear pads, wire ropes, bearings, gear-
d. Debris embedded in liner surface. ing, seals, valves, electrical wiring, or hoses to be between
grounding position and welded area.
3. Pins should be replaced if any of the following is
observed (Clean pin before inspection):
a. Detectable bearing area wear.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN COMPO-
b. Flaking, peeling, scoring, or scratches on pin surface. NENT DAMAGE (I.E. ELECTRONIC MODULES, SWING BEARING, COLLECTOR
c. Rusting of pin in bearing area. RING, BOOM WIRE ROPES ETC.
3121728 2-5
SECTION 2 - GENERAL
Table 2-3. Inspection and Preventive Maintenance Schedule
INTERVAL
AREA Pre-Delivery2 Annual4 Every 2

or Frequent3 (Yearly) Years
Inspection Inspection
Boom Assembly
Boom Weldments 1,2,4 1,2,4
Hose/Cable Carrier Installations 1,2,9,12 1,2,9,12
Pivot Pins and Pin Retainers 1,2 1,2
Sheaves, Sheave Pins 1,2 1,2
Bearings 1,2 1,2
Wear Pads 1,2 1,2
Covers or Shields 1,2 1,2
Extend/Retract Chain or Cable Systems 1,2,3 1,2,3
Boom Assembly 14
Platform Assembly
Platform 1,2
Railing 1 1,2
Gate 1,5 1,5
Floor 1 1,2
Rotator 9,5,15
Lanyard Anchorage Point 1,2,10 1,2,10
Turntable Assembly
Swing Bearing 1,2,14 1,2,3,13,14
Oil Coupling 9
Swing Drive System 11 11
Turntable Lock 1,2,5 1,2,5
Hood, Hood Props, Hood Latches 5 1,2,5
Chassis Assembly
Tires 16,17,18 16,17,18
Wheel Nuts/Bolts 15 15
Wheel Bearings 14,24
Oscillating Axle/Lockout Cylinder Systems 5,8
Steer Components
Spindle Thrust Bearing/Washers 1,2
Drive Hubs 11 11
2-6 3121728
SECTION 2 - GENERAL
INTERVAL

Functions/Controls
Platform Controls 5,6 6
Ground Controls 5,6 6
Function Control Locks, Guards, or Detents 1,5 5
Footswitch 5 5
Emergency Stop Switches (Ground & Platform) 5 5
Function Limit or Cutout Switch Systems 5 5
Drive Brakes 5 5
Swing Brakes 5 5
Auxiliary Power 5 5
Power System
Engine Idle, Throttle, and RPM 3 3
Engine Fluids (Oil, Coolant, Fuel) 9,11 11
Air/Fuel Filter 1,7 7
Exhaust System 1,9 9
Batteries 1,9 19
Battery Fluid 11 11
Fuel Reservoir, Cap, and Breather 1,2,5 1,5
Hydraulic/Electric System
Hydraulic Pumps 1,2,9
Hydraulic Cylinders 1,2,7,9 1,2,9
Cylinder Attachment Pins and Pin Retainers 1,2,9 1,2
Hydraulic Hoses, Lines, and Fittings 1,2,9,12 1,2,9,12
Hydraulic Reservoir, Cap, and Breather 1,2,5,9 1,5 24
Hydraulic Filter 1,7,9 7
Hydraulic Fluid 7,11 7,11
Electrical Connections 1,20 20
Instruments, Gauges, Switches, Lights, Horn 5,23
General
Operation and Safety Manuals in Storage Box 21 21
ANSI and AEM Manuals/Handbooks Installed (ANSI Markets Only) 21
Capacity Decals Installed, Secure, Legible 21 21
All Decals/Placards Installed, Secure, Legible 21 21
Annual Machine Inspection Due 21 21
3121728 2-7
SECTION 2 - GENERAL
INTERVAL

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21
General Structural Condition and Welds 2,4 2,4
All Fasteners, Pins, Shields, and Covers 1,2 1,2
Grease and Lubricate to Specifications 22 22
Function Test of All Systems 21 21, 22
Paint and Appearance 7 7
Stamp Inspection Date on Frame 22
Notify JLG of Machine Ownership 22
Footnotes:
1 Prior to use each day; or at each Operator change
2 Prior to each sale, lease, or delivery
3 In service for 3 months or 150 Hours; or Out of service for 3 months or more; or Purchased used
4 Annually, no later than 13 months from the date of the prior inspection
Performance Codes:
1 - Check for proper and secure installation
2 - Visual inspection for damage, cracks, distortion or excessive wear
3 - Check for proper adjustment
4 - Check for cracked or broken welds
5 - Operates Properly
6 - Returns to neutral or “off” position when released
7 - Clean and free of debris
8 - Interlocks function properly
9 - Check for signs of leakage
10 - Decals installed and legible
11 - Check for proper fluid level
12 - Check for chafing and proper routing
13 - Check for proper tolerances
14 - Properly lubricated
15 - Torqued to proper specification
16 - No gouges, excessive wear, or cords showing
17 - Properly inflated and seated around rim
18 - Proper and authorized components
19 - Fully charged
20 - No loose connections, corrosion, or abrasions
21 - Verify
22 - Perform
23 - Sealed Properly
24 - Drain, Clean, Refill
2-8 3121728
SECTION 2 - GENERAL
ENGINE OIL OPERATION CHART
DEUTZ D2011 SERIES T4I
NOTICE:
MACHINE OPERATION USING NON-JLG APPROVED
ENGINE OIL OR OPERATION OUTSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN
THE "ENGINE OIL OPERATION CHART" MAY
RESULT IN PREMATURE WEAR OR DAMAGE TO
COMPONENTS OF THE ENGINE.
1001151190_B
Figure 2-1. Engine Operating Temperature Specifications - Deutz D2011L04
3121728 2-9
SECTION 2 - GENERAL

DEUTZ 2.9 L04 T4F AND 3.6L4 TCD
NOTICE:
MACHINE OPERATION USING NON-JLG APPROVED

1001159163_B
Figure 2-2. Engine Operating Temperature Specifications - Deutz TD2.9L4
2-10 3121728
SECTION 2 - GENERAL

FORD MSG425 DUAL FUEL
NOTES:
1. MACHINE OPERATION USING NON-JLG APPROVED

2. SYNTHETIC OIL IS NOT RECOMMENDED.
1001226664-A
MAE20460
Figure 2-3. Engine Operating Temperature Specifications - Ford MSG425
3121728 2-11
SECTION 2 - GENERAL
NOTICE:
MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY
RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.
1001206353_B
Fluid Properties Base Classifications

Viscosity at 40° C (cSt, Typical)
Readily Biodegradable*
Synthetic Polyol Esters
Virtually Non-toxic**
Fire Resistant***
Viscosity Index
Vegetable Oils
Mineral Oils
Description
Synthetic



Mobilfluid 424 55 145 X

Mobil DTE 10 Excel 32 32 141 X
Univis HVI 26 26 376 X
Mobil EAL 224 H 36 212 X X X
Mobil Envirosyn H46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/6-82-003
CO2 Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
Figure 2-4. Hydraulic Oil Operating Temperature Specifications
2-12 3121728
SECTION 3. CHASSIS & TURNTABLE
3.1 TIRES & WHEELS Wheel Replacement

Rims installed on each product model are designed for stabil-
Tire Inflation ity requirements which consist of track width, tire pressure,
Pneumatic tire air pressure must be equal to air pressure sten- and load capacity. Size changes such as rim width, center
ciled on side of JLG product or rim decal for safe and proper piece location, larger or smaller diameter, etc., without written
machine operational characteristics. factory recommendations, may result in unsafe stability condi-
tions.
Tire Damage
Wheel Installation
For pneumatic tires, JLG Industries, Inc. recommends when
any cut, rip, or tear is discovered that exposes sidewall or tread It is extremely important to apply and maintain proper wheel
area cords in the tire, measures must be taken to remove the mounting torque.
JLG product from service immediately and arrangements must
be made for replacement of the tire or tire assembly.
For polyurethane foam filled tires, JLG Industries, Inc. recom- WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT PROPER TORQUE TO
mends that when any of the following are discovered, mea- PREVENT LOOSE WHEELS, BROKEN STUDS, AND DANGEROUS SEPARATION OF
sures must be taken to remove the JLG product from service WHEEL FROM AXLE. USE ONLY NUTS MATCHED TO CONE ANGLE OF WHEEL.
immediately and arrangements must be made for replace-
ment of the tire or tire assembly. Tighten lug nuts to proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten fasteners. If you
• Smooth, even cut through cord plies which exceeds do not have a torque wrench, tighten fasteners with a lug
3 inches (7.5 cm) in total length. wrench, then immediately have a service garage or dealer
• Tears or rips (ragged edges) in cord plies which tighten lug nuts to proper torque.
exceeds 1 inch (2.5 cm) in any direction. Over-tightening will break studs or permanently deform
• Any punctures which exceed 1inch in diameter. mounting stud holes in wheels.
• Any damage to the bead area cords of the tire. 1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
If a tire is damaged but within above criteria, it must be
inspected daily to ensure damage does not exceed allowable 2. Tighten nuts in the following sequence:
criteria.
Tire Replacement
JLG recommends a replacement tire be the same size, ply, and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for part number of approved tires for a par-
ticular machine model. If not using a JLG approved replace-
ment tire, we recommend that replacement tires have the
following characteristics:
• Equal or greater ply/load rating and size of original
• Tire tread contact width equal or greater than original
• Wheel diameter, width, and offset dimensions equal to the
original
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not Figure 3-1. Wheel Lug Nut Tightening Sequence
replace a foam filled or ballast filled tire assembly with a pneu-
matic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to pressure recommended by 3. The tightening of the nuts should be done in stages. Fol-
JLG. Due to size variations between tire brands, both tires on lowing the recommended sequence, tighten nuts per
the same axle should be the same. wheel torque chart.
3121728 3-1
Table 3-1. Wheel Torque Chart Oscillating Axle Lockout Test

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-
40 ft-lbs. 95 ft-lbs. 170 ft-lbs. TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS
(55 Nm) (130 Nm) (230 Nm) SUSPECTED.
4. Wheel nuts should be torqued after first 50 hours of NOTE: Ensure boom is fully retracted, lowered, and centered
operation and after each wheel removal. Check torque between drive wheels before starting lockout cylinder test.
every 3 months or 150 hours of operation.
1. Place a 6 inch (15.2 cm) high block with ascension ramp
in front of left front wheel.
3.2 OSCILLATING AXLE BLEEDING PROCEDURE AND
2. From platform control station, start engine.
LOCKOUT TEST
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left
Lockout Cylinder Bleeding front wheel is on top of block.
1. Start the engine. 4. Carefully activate telescope and extend the boom at
2. Position the turntable to the normal stowed position. least 2 ft. (0.6 m).
3. Attach clear tubing to bleeder valve nipple. 5. Place Drive control lever to Reverse and drive machine
off of block and ramp.
6. Have an assistant check to see that left front wheel
remains locked in position off of ground.
7. Carefully activate telescope and return boom to stowed
position. The lockout cylinders should release and allow
wheel to rest on ground, it may be necessary to activate
Drive to release cylinders.
8. Repeat the procedure for the right front wheel.
9. If lockout cylinders do not function properly, have quali-
fied personnel correct the malfunction prior to any fur-
ther operation.
MAE21490
Figure 3-2. Bleeder Valve Location

4. Position a small bucket or bottle in front of the lockout
cylinder bleeder valve and insert clear tubing.
5. Loosen the bleeder valve, turning counter-clockwise
slowly. Bleed air from the top of ram cylinder. Capture
hydraulic oil until steady unbroken stream of hydraulic
oil is viewed. Tighten or close the bleeder valve while
stream of hydraulic oil is running.
6. Locate the bleeder valve on the opposite side lockout
cylinder. Repeat the process.
3-2 3121728
3.3 CHASSIS TILT INDICATOR SYSTEM 3.6 DRIVE ORIENTATION SYSTEM

The Chassis Tilt Indicator System measures the turntable angle The Drive Orientation System (DOS) indicates the conditions
with respect to level ground. The control system reads the that could make the direction of movement of the chassis dif-
reading and compares it to a pre-set turntable tilt angle value. ferent than the direction of movement of the drive/steer con-
When the machine is in transport position, it can travel at up trol handle to the operator. The system indicates to the
to maximum speed until it tilts more than 8.0°, then the sys- operator the need to match the black and white directional
tem will limit the drive speed to maximum displacement arrows on the platform control panel to the arrows on the
mode (slow drive speed). However, when the machine is out of chassis. The system uses a proximity switch mounted on the
transport position and the turntable tilts more than the pre- hydraulic swivel, an indicator light and a spring return override
set value, the boom functions can only operate in creep speed switch on the platform display panel. The proximity switch
mode, and the drive function is disabled. The operator has to trips when the turntable is swung ± 45 degrees off center of
return the machine into transport mode in order to continue the normal driving position. This occurs roughly when the
to drive the machine. By factory default, the tilt sensor pre-set main boom is swung past a rear tire. When the turntable is in
value is 5.0°, but it can be selected between 5.0°, 4.0° and 3.0° the normal drive position with the boom between the rear
by JLG hand held Analyzer. tires, no indications or interlocks are made. When the machine
is actively driving when the turntable is swung past the switch
3.4 COLD START SYSTEM (DIESEL) point, the system is ignored until drive/steer is released. When
drive is initiated with the boom swung past the switch point,
The machine control system monitors the engine coolant and the DOS indicator will flash and the drive/steer functions will
ambient temperature to make an assessment of cylinder pre- be disabled. The operator must engage the DOS override
heating requirements. If the coolant temperature is below  switch to enable Drive/steer (high drive will remain disabled).
50° C when control power is turned on, the glow plugs will be When the DOS is enabled, the DOS indicator will be illumi-
automatically fired for a duration that is based on the ambient nated continuously and a 3-second enable timer will be
temperature up to a maximum of 20 seconds. During this pre- started and will continue for 3 seconds after the end of the last
heat period, the glow plug indicators will flash. The glow plugs drive/steer command. If the timer expires, the DOS override
will be turned off before the engine begins to crank. switch must be re-engaged to enable drive/steer.
3.5 AUXILIARY POWER SYSTEM

The Auxiliary Power System is intended as a secondary means
to bring an operator from work height down to the ground in
the event of primary power loss. This system uses an electric
motor/pump unit powered by a 12V battery. It is not intended
to be used as the main power source. All functions can be
retracted or lowered and the jib can be lifted up. The auxiliary
system levels the platform when lifting down. The drive func-
tion is excluded from the auxiliary system.
3121728 3-3
3.7 OSCILLATING AXLE SYSTEM 3.8 DRIVE SYSTEM

The oscillating front axle is attached to the frame by a pivot The four wheel drive system consists of one variable displace-
pin, which allows all four wheels to remain on the ground ment closed loop pump, four variable displacement piston
when traveling on rough terrain. The oscillating axle also incor- motors, gear reduction hubs and a traction control manifold
porates two lockout cylinders connected between the frame that includes three flow dividers/combiners. 
and the axle. The lockout cylinders permit axle oscillation The two wheel drive system consists of one variable displace-
when the boom is in Transport Position as described in the ment closed loop pump, two variable displacement piston
Transport Position Sensing System and telescoped in. The motors, gear reduction hubs and a traction control manifold
lockout cylinders will hold down the oscillating axle to prevent that includes one flow dividers/combiner. 
its further movement if (1) the main boom arises more than 5° Drive speed is varied by a combination of drive pump displace-
above horizontal (with respect to turntable); OR (2) the boom ment, engine speed, and motor displacement. Traction control
telescopes out 22.4 inches or more. is full time and is present in all drive modes. There are three
drive modes that can be selected at the platform console. The
The UGM monitors the boom angle through the angular sen-
functionality of the drive system is dependent on the position
sor mounted at the pin location that connects the main boom
of the boom (In Transport or Out of Transport).
to the tension link and the boom telescope is monitored by
two proxy switches mounted on the main boom side wall.
When the UGM / Software determines the conditions to
unlock the axle are met, electronic signals are sent to the 2-
speed/lockout combination valve to supply hydraulic pilot
pressures to the lockout cylinders. Pilot pressure is supplied via
the Drive Pump charge pressure and the cylinders unlock
when pilot pressure is applied to the holding valves mounted
on the cylinders and lock when pilot pressure is removed. The
first valve of the lockout combination valve is normally closed
and opens when actuated to allow flow to the Lock-Out cylin-
ders. The second valve (located between the first valve and the
Lock-Out cylinders) is normally open to tank. This valve closes
when actuated to block the tank path and force the flow to the
Lock-Out cylinders. If either of these valves is in its normal
state, the axle will be locked. The Ground Control Module sup-
plies power and monitors the state of the boom elevation and
extension sensors. If the sensor / switch states are not congru-
ent, the Ground Control Module will remove power, thereby
causing the oscillating axle to lock in the failsafe position until
power is cycled.
3-4 3121728
10 6
1
11
8
9
3
7
2
8
4 9
3 11
5
13
12
1001181774-B
MAE21090
1. Bolt 6. Washer 11. Wear Pad

2. Bolt 7. Bolt 12. Axle
3. Bearing 8. Shim 13. Pin
4. Keeper Pin 9. Shim
5. Washer 10. Axle Lockout Cylinder
Figure 3-3. Axle Installation - Front
3121728 3-5
13
11
12
4 10
3
11
6 12
13 5 9
4
9
7 2
19
18
1
17
8
15
16
14
1001181775-A
MAE21100
1. Bolt 6. Keeper Pin 11. Shim 16. Shim

2. Bolt 7. Washer 12. Shim 17. Axle
3. Bolt 8. Washer 13. Pad 18. Bracket
4. Bearing 9. Washer 14. Block 19. Pin
5. Nut 10. Bolt 15. Shim
Figure 3-4. Axle Installation - Rear
3-6 3121728
2 3
1 6
3 5
14
13
8
10
7
4
11
12
1001181770-C
MAE21080
1. Bolt 5. Washer 9. Kingpin 13. Pin

2. Pin 6. Bolt 10. Steer Cylinder Assembly 14. Bracket
3. Keeper Pin 7. Nut 11. Tie-Rod
4. Washer 8. Knuckle 12. Bearing
Figure 3-5. Steering Installation
3121728 3-7
3.9 DRIVE HUB 5. Remove the hub from machine and place in a clean work
area.
Removal Installation
NOTE: Refer Figure 3-6., Drive Hub Installation 1. Use suitable lifting device to support the drive hub.
1. Place machine on the firm level surface. NOTE: The drive hub weighs approximately 110 lbs. (50 kg).
2. Remove and cap all hydraulic hoses from the drive 2. Install the drive hub to the machine.
motor assembly.
3. Use six bolts and attach the drive hub to the machine.
3. Use suitable lifting device to support the drive hub. Torque the bolts to 190 ft.lbs. (260 Nm).
NOTE: The drive hub weighs approximately 110 lbs. (50 kg). 4. Install previously removed hydraulic hoses to drive
motor.
4. Remove six bolts attached drive hub to the frame.
DRIVE MOTOR
FLANGE
BOLT
NUT
BOLT
WASHER
DRIVE HUB
MAE22590
Figure 3-6. Drive Hub Installation
3-8 3121728
3.10 DRIVE MOTOR Installation

1. Use suitable lifting device to support the drive motor.
Removal
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg).
NOTE: Refer Figure 3-7., Drive Motor Installation.
2. Install the drive motor to the machine.
1. Place machine on the firm level surface.
2. Tag and disconnect all hydraulic connections from the
drive motor. INCORRECT SHAFT ALIGNMENT MAY RESULT IN DAMAGE TO DRIVE SHAFT,
3. Use suitable lifting device to support the drive motor. BEARINGS, OR SEAL WHICH CAN CAUSE EXTERNAL OIL LEAKAGE.
NOTE: The drive motor weighs approximately 34 lbs. (15.4 kg). 3. Make sure that the pump shaft is properly aligned.
4. Remove two bolts attached drive motor to the frame. 4. Use the two bolts and attach the drive motor to the
machine. Tighten the bolts to torque 70 ft. lbs. (95 Nm).
5. Remove the motor from machine and place in a clean
work area. NOTE: Apply JLG Threadlocker P/N 0100011 to bolts before instal-
lation.
6. Clean the motor for dirt. Remove rust or corrosion from
coupling shaft. 5. Install drive brake on to the drive motor.
Assembly/Disassembly 6. Install Previously removed hydraulic hoses to the drive

motor.
For detail assembly/disassembly procedures, contact local JLG
or local JLG dealer for information. 7. Start the machine and check the motor for proper func-
tioning.
DRIVE MOTOR
FLANGE
BOLT
NUT
BOLT
WASHER
DRIVE HUB
MAE22640
Figure 3-7. Drive Motor Installation
3121728 3-9
27 29
25 28
39 37
24
26 36
5
35
2 6
23
21
8
20 22
5
14
17
15
16
9
11
10 13
4
12
7 1
31 31
32 1
32
33
34
18 30
38
19
3
40
41
3
3160350-B
MAE22600
Figure 3-8. Drive Motor Assembly
3-10 3121728
1. Journal Bearing, 10. Slipper Retainer Guide 19. Retaining Ring 28. O-Ring 37. Servo Piston
2. Pin 11. Slipper Hold Down Pin 20. End - Axial Cap 29. Spring Seat 38. Bearing
3. Retaining Ring 12. Piston Assembly 21. Screw 30. Housing 39. Spring
4. Swash Plate 13. Slipper Retainer 22. Needle Bearing 31. Plug 40. Lip Seal
5. Pin 14. Retaining Ring 23. Plug 32. O-Ring 41. Support Washer
6. Gasket 15. Spring 24. O-Ring 33. Plug
7. Cylinder Block Kit 16. Washer 25. Plug 34. O-Ring
8. Valve Plate 17. Spring Retainer, 26. O-Ring 35. O-Ring
9. Cylinder Block 18. Shaft 27. Plug 36. Seal Ring
3121728 3-11
3.11 SWING DRIVE HUB 6. Place swing drive hub in the clean area.
7. Refer to Section 3-9., Swing Drive Installation, for swing
Removal drive maintenance.
1. Disconnect all wiring harness terminals connected to Assembly/Disassembly

the swing motor (2).
For detail assembly/disassembly instructions, Refer Swing
2. Gently loosen the set screw. Do not remove.
Drive Hub Manual (PN 3128853)
3. Remove the pivot bolt (4).
Installation
4. Remove the mounting bolts (7) securing swing drive
hub to the turntable. Ensure mounting plate and mounting location of the base
plate are clean and painted with a uniform coating of mini-
5. Using the suitable lifting device, remove the swing drive
mum thickness (no runs, drips, etc.).
hub from mounting plate without damaging the swing
gear.
2
1
4 4
6 7
8
6
1001185842-D
MAE22620
1. Motor Control Valve 4. Bolt 7. Bolt

2. Swing Motor 5. Nut 8. Spacer
3. Swing Hub Assembly 6. Washer
Figure 3-9. Swing Drive Installation
3-12 3121728
Procedure For Setting Swing Gear Backlash 7. Apply JLG Threadlocker P/N 0100019 and torque jack
bolt 50 ft. lbs. (68 Nm).
Set backlash to 0.010 inch to 0.015 inch (0.254 mm - 0.381
8. Apply JLG Threadlocker P/N 0100019 and tighten jam
mm) using the following procedure:
nut.
1. Place the machine on firm, level ground. 9. Torque mounting bolts to 340 ft. lbs. (Nm).
2. Place shim between pinion and bearing at bearing high
spot (shown below).
HIGH SPOT in this area with
two x's and yellow paint in
tooth space.
HIGH SPOT
marked with yellow paint
10. Remove shim and discard.
3. Apply JLG Threadlocker P/N 0100019 and torque pivot

bolt to 205 ft. lbs. (280 Nm).
NOTE: Make sure the turntable is properly supported during the
following step. The turntable can swing a few degrees
when the turntable lock is removed if the turntable is not
balanced properly.
4. Remove turntable lock pin.

5. Apply JLG Threadlocker P/N 0100019 and pre-torque
swing drive mounting bolts to 30 ft. lbs. (40 Nm).
Swing Drive Lubrication
Fill Swing Drive Gearbox with 32 oz (0.946 L) 80w90 gear oil
with EP additives. Oil should cover the ring gear. Torque pipe
plug to 23-25 ft.lbs (31- 33 Nm).
FILL PLUG
DRAIN PLUG
6. Tighten jack bolt until pinion is completely snug against
shim and bearing then loosen jack bolt. MAE22610
3121728 3-13
3.12 SWING BEARING Wear Tolerance

Turntable Bearing Mounting Bolt Condition Check 1. From underside of the machine, at rear center, with the
boom fully elevated and fully retracted, as shown in 
NOTE: This check is designed to replace existing bearing bolt Figure 3-12., Swing Bearing Tolerance Measurement
torque checks on JLG Lifts in service. This check must be Location & Boom Placement A, using a magnetic base
performed after first 50 hours of machine operation and dial indicator, measure and record distance between
every 600 hours of machine operation thereafter. If during swing bearing and turntable as shown in Figure 3-11.,
this check any bolts are found to be missing or loose, Swing Bearing Tolerance Measuring Point.
replace missing or loose bolts with new bolts and torque to
2. At the same point, with the boom horizontal and fully
the value specified in the torque chart, after lubricating the
extended, as shown in the Figure 3-12., Swing Bearing
bolt threads with JLG Threadlocker P/N 0100019. After
Tolerance Measurement Location & Boom Placement B,
replacing and retorquing bolt or bolts recheck all existing
using a magnetic base dial indicator, measure and
bolts for looseness.
record distance between swing bearing and turntable as
1. Check frame to bearing. Attach bolts as follows: shown in Figure 3-11., Swing Bearing Tolerance Measur-
ing Point.
a. Elevate fully retracted main boom to 70 degrees (full
elevation). 3. If difference is greater than 0.079 inch (2.00 mm), is
b. At the positions indicated on (See Figure 3-10.). try determined, the swing bearing should be replaced.
and insert the 0.0015 inch (0.0381 mm) feeler gauge 4. If a difference less than 0.079 inch (2.00 mm) is deter-
between the bolt head and hardened washer at the mined, and any of the following conditions exist, the
arrow indicated position. bearing should be removed, disassembled, and
c. Assure that the 0.0015 inch (0.0381 mm) feeler inspected for the following:
gauge will not penetrate under the bolt head to the
bolt shank. a. Metal particles in grease.
d. Swing turntable 90 degrees and check some b. Increased drive power required.
selected bolts are at the new position. c. Noise.
e. Continue rotating turntable at 90 degrees intervals d. Rough rotation.
until a sampling of bolts have been checked in all
5. If bearing inspection shows no defects, reassemble and
quadrants.
return to service.
2. Check the turntable to bearing. Attach bolts as follows:
a. Elevate the fully retracted boom to 70 degrees (full
elevation). THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL
LIFT. IT IS HERE THAT THE STRESSES OF LIFTING ARE CONCENTRATED, AT THE
b. Try and insert the 0.0015" feeler gauge between bolt
CENTER OF ROTATION. BECAUSE OF THIS, PROPER MAINTENANCE OF
head and hardened washer at position shown in 
THESWING BEARING BOLTS IS A MUST FOR SAFE OPERATION.
(See Figure 3-10.)
c. Lower the boom to horizontal and fully extend the
boom.
d. Try and insert the 0.0015" feeler gauge between bolt
head and hardened washer at position shown in
(See Figure 3-10.)
.0015" Feeler Gauge Figure 3-11. Swing Bearing Tolerance Measuring Point
Figure 3-10. Swing Bearing Bolt Feeler Gauge Check
3-14 3121728
BOOM FULLY EXTENDED

HORIZONTAL (ZERO DEGREES)
MEASURING POINT
LEVEL SURFACE
BOOM FULLY
RETRACTED AND ELEVATED
MEASURING POINT
LEVEL
LEVEL SURFACE
SURFACE MAE21740
Figure 3-12. Swing Bearing Tolerance Measurement Location & Boom Placement
3121728 3-15
Swing Bearing Replacement INSTALLATION

1. Using suitable lifting equipment, carefully lower the
REMOVAL swing bearing into position on the frame. Ensure the
1. From Ground Control station, place the boom in a level scribed line of the outer race of the bearing aligns with
position. the scribed line on the frame. If a new swing bearing is
used, ensure that the filler plug fitting is at 90 degrees
from the fore and aft center line of the frame.
NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND/OR BLOCK-
ING. JLG INDUSTRIES RECOMMENDS ALL REMOVED BEARING BOLTS BE DISCARDED
AND REPLACED WITH NEW BOLTS. SINCE THE SWING BEARING IS THE ONLY
2. Adequately secure the boom to the rear of the turntable, STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE, IT IS IMPERATIVE
as shown in Figure 3-14., Swing Bearing Removal - 600S SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS. USE OF GENU-
and Figure 3-15., Swing Bearing Removal - 660SJ. INE JLG HARDWARE IS HIGHLY RECOMMENDED.
3. Using the front lifting eyes in the turntable and a loca-
tion on the boom equidistant from the center of gravity, 2. Apply a light coating of JLG Threadlocker P/N 0100019
as shown in Figure 3-14., Swing Bearing Removal - 600S to the new bearing bolts, and loosely install the bolts
and Figure 3-15., Swing Bearing Removal - 660SJ, secure and washers through the frame and outer race of bear-
the turntable assembly with adequate lifting equip- ing.
ment.
4. From inside turntable, remove mounting hardware
attaching rotary coupling retaining yoke brackets to IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED
turntable. FOR TIGHTENING THE BEARING ATTACHMENT BOLTS, THE TORQUE SETTING
ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE.
3. Refer to the Torque Sequence diagram as shown in Fig-

HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- ure 3-13., Swing Bearing Torque Sequence, Swing Bear-
CONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYS- ing Torque Sequence Clean any residue off the new
TEM. bearing bolts, then apply a light coating of JLG Thread-
locker P/N 0100019 and install the bolts and washers
5. Tag and disconnect hydraulic lines from the fittings on through the frame and outer race of the bearing.
the top of the rotary coupling. Use a suitable container Tighten the bolts to an initial torque of 190 ft. lbs. (260
Nm) w/Loctite.
to retain any residual hydraulic fluid. Immediately cap
lines and ports. 4. Remove the lifting equipment from the bearing.
6. Use a suitable tool to scribe a line on the inner race of 5. Using suitable lifting equipment, carefully position the
the swing bearing and on the underside of the turnta- turntable assembly above the machine frame.
ble. This will aid in aligning the bearing upon installa- 6. Carefully lower the turntable onto the swing bearing,
tion. Remove the bolts and washers which attach the ensuring that the scribed line of the inner race of the
turntable to the bearing inner race. Discard the bolts. bearing aligns with scribed line on the turntable. If a
new swing bearing is used, ensure that the filler plug fit-
7. Use the lifting equipment to carefully lift the complete ting is at 90 degrees from the fore and aft center line of
turntable assembly from the bearing. Ensure that no the turntable.
damage occurs to the turntable, bearing or frame-
mounted components. 7. Clean any residue off the new bearing bolts, then apply a
light coating of JLG Threadlocker P/N 0100019 and
8. Carefully place the turntable on a suitably supported install the bolts and washers through the turntable and
trestle. inner race of the bearing.
9. Use a suitable tool to scribe a line on the outer race of 8. Following the Torque Sequence diagram shown in Fig-
the swing bearing and the frame. This line will aid in ure 3-13., Swing Bearing Torque Sequence, tighten the
aligning the bearing upon installation. Remove the bolts bolts to a torque of 190 ft. lbs. (260 Nm) w/Loctite.
and washers which attach the outer race of the bearing 9. Install the rotary coupling retaining yoke brackets, apply
to the frame. Discard the bolts. Use suitable lifting equip- a light coating of JLG Threadlocker P/N 0100011 to the
ment to remove the bearing from the frame, then move attaching bolts and secure the yoke to the turntable
the bearing to a clean, suitably supported work area. with the mounting hardware.
10. Connect the hydraulic lines to the rotary coupling as
tagged prior to removal.
3-16 3121728
11. Remove the lifting equipment. Swing Bearing Torque Values

12. Unsecure the boom from rear of turntable.
1. Outer Race - 190 ft-lb (260 Nm) w/Loctite.
13. At ground control station, use boom lift control to lower
2. Inner Race - 190 ft-lb (260 Nm) w/Loctite.
boom to stowed position.
3. See Figure 3-13., Swing Bearing Torque Sequence.
14. Using all applicable safety precautions, activate the
hydraulic system and check the swing system for proper
and safe operation.
CHECK INNER AND OUTER SWING BEARING BOLTS FOR MISSING OR LOOSE-
NESS AFTER FIRST 50 HOURS OF OPERATION AND EVERY 600 HOURS THERE-
AFTER.
6 2
10 15
14 6 2 11
10 15
14 11
18 7
18 7
4 4 3 3
8 17
8 17
12 13
16 9
12 1 5 13
16 9
1 5
ORIENT BEARING HIGH SPOT IN THIS LOCATION

(ALIGNED WITH SWING DRIVE).
THE HIGH SPOT WILL BE MARKED WITH A STAMPED
"X" AND YELLOW PAINT IN THE TOOTH SPACE
MAE22580
Figure 3-13. Swing Bearing Torque Sequence
3121728 3-17
3-18
Gross Weight (includes all
components except Chassis):16,100 lbs
Note: CG location may vary slightly

depending on the exact conguration
of the machine.
26" (660.4 mm)

1001215615-D
MAE22630
Figure 3-14. Swing Bearing Removal - 600S
3121728
3121728
Gross Weight (includes all
components except Chassis): 17,300 lbs
Note: CG location may vary slightly

depending on the exact conguration
of the machine.
22.5" (571.5 mm)

MAE24550
Figure 3-15. Swing Bearing Removal - 660SJ
3-19
3.13 ROTARY COUPLING 5. Assemble lip seals (2) in direction shown in Figure 3-16.,
Rotary Coupling
Use the following procedure to install the seal kit.
6. Reassemble O-ring (5).
1. If not already removed, remove axle oscillation valve
from cylinder barrel. The valve spool protrudes into the 7. Heat cap seals (8) in hydraulic oil for 5 minutes at 300° F
barrel and will damage spool and seals if left in place. (149° C).
2. Remove snap ring (1) from end. 8. Assemble cap seals over O-rings
3. Remove center body (6) from housing (7). 9. Reinsert center body in housing (lube with hydraulic oil).
4. Cut off old seals (3, 4, 5, 8). 10. Replace snap ring.
3
4
5,8
5,8
1 MAE22570
Figure 3-16. Rotary Coupling
3-20 3121728
5 7
MAE21600
1. Bolt 3. Nut 5. Washer 7. Rotary Coupling

2. Bolt 4. Nut 6. Mount
Figure 3-17. Rotary Coupling - 2WS
3121728 3-21
5
6
3
MAE21590
1. Bolt 3. Nut 5. Washer 7. Mount

2. Bolt 4. Nut 6. Coupling Assembly
Figure 3-18. Rotary Coupling - 4WS
3-22 3121728
3121728
5,8
1
1 7 2,7 2 7
5 6
1 2
8
2 4 3
8 3 1
2,8
3
1
4,6,8
4 3
2 1
3
4
8 8
MAE21730
Figure 3-19. Rotary Coupling Port Location - 2WS
3-23
3-24
5,10
10 5 1 5
7 1,9 2,8
9 1 7 2 8
5 6
5 4 1 2
4 10 3 7
2 10 7 3
8 9 3
10
4 2 3
10 6 8 4 6 10
1,6,10
MAE21880
Figure 3-20. Rotary Coupling Port Location - 4WS
3121728
5
9
8
10
7
1
3
13
10
11
12
4
10
13
6
MAE21610
1. Housing 6. Circlip 11. Seal

2. Shaft 7. Sensor 12. Wiper
3. Spacer 8. Bolt 13. Seal, Rod
4. Spacer 9. Washer
5. Fitting 10. Ring, Wear
Figure 3-21. Rotary Coupling Assembly
3121728 3-25
Table 3-2. Coupling Port Information Table - 2WS
Operating
Port Port
Outlet Description Pressure
No. Size
PSI (Bar)
1 2 -8 Brake 450 (31)
2 2 -6 2 Speed 450 (31)
3 1 -6 Steer 3000 (207)
4 1 -6 Steer 3000 (207)
5 1 -16 Drive Reverse 4500 (310)
6 1 -16 Drive Forward 4500 (310)
7 1 -8 Axle Release 450 (31)
8 3 -12 Drain 250 (17)
Table 3-3. Coupling Port Information Table - 4WS
Operating
Port Port
Outlet Description Pressure
No. Size
PSI (Bar)
1 2 -8 Brake 450 (31)
2 2 -6 2 Speed 450 (31)
3 1 -6 Steer 3000 (207)
4 1 -6 Steer 3000 (207)
5 2 -6, -16 Drive Reverse 4500 (310)
6 1 -16 Drive Forward 4500 (310)
7 1 -8 Axle Release 450 (31)
8 1 -6 Steer 3000 (207)
9 1 -6 Steer 3000 (207)
10 3 -12 Drain 250 (17)
3-26 3121728
3.14 DEUTZ TD2.9 L4 ENGINE
6
5
3
3
1001186806-K
MAE21800
1. Deutz TD2.9L4 Engine and Pump 3. Hose 5. Battery Cable (-)

2. Hose 4. Bracket 6. Battery Cable (+)
Figure 3-22. Deutz TD2.9 L4 Engine Installation
3121728 3-27
1001186811-G
MAE21810
1. Piston Pump Assembly 2. Deutz TD2.9 L4 Engine Assembly 3. Gear Pump Assembly 4. Exhaust Pipe
Figure 3-23. Deutz TD2.9 L4 Engine and Pumps Sub-Assembly
3-28 3121728
20
33
24
6
31
10
34
9
31
12 30
11
15
29 26 22
13
13
31
21
27
12 1001186812-L
MAE21820
1. Pump Coupling Kit 8. Relay 15. Hose, Radiator 22. Air Filter 29. Bracket
2. Pulley 9. Sensor, Coolant Level 16. Mount 23. Tray 30. Hose
3. Contactor 10. Tank, Surge 17. Deutz TD2.9L4 Engine 24. Radiator Support 31. Hose
4. Adapter, Fan 11. Radiator 18. Bracket, Engine - Rear 25. Plate 32. Alternator Power Harness
5. Adapter 12. Bracket 19. Bracket, Engine - Right 26. Support 33. Bracket
6. Cap, Tank 13. Bracket 20. Restriction Indicator 27. Hose, Radiator 34. Tube
7. Fan 14. Hose 21. Hose 28. Mount, Motor 35. Glow Fuse Harness
Figure 3-24. Deutz TD2.9 L4 Engine Assembly - Sheet 1 of 2
3121728 3-29
1
17
32
35
16
25 A
14
19
2 A
18
7
34
28
23
1001186812-L
MAE21830
Figure 3-25. Deutz TD2.9 L4 Engine Assembly - Sheet 2 of 2
3-30 3121728
NOTE: Refer to engine manufacturer’s manual for detailed oper- Change Engine Oil
ating and maintenance instructions.
1. Allow engine to warm up. Engine oil should reach
Check Oil Level approximately 176° F (80° C).
1. Make sure machine and engine are level and switch 2. Make sure machine and engine are level and switch off
engine OFF before checking oil level. engine.
2. Remove oil dipstick and wipe with clean cloth. 3. Place oil tray under engine.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
with an approved grade and type of oil outlined in
DRAINING.
engine manufacturer’s operator’s manual.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.

DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
MINIMUM OIL
LEVEL LATIONS.
4. Open oil drain valve and drain oil.
5. Close oil drain valve.
6. Pour in new engine oil. Refer to Section 1 for capacity
MAXIMUM OIL and Figure 3-33., Engine Oil Viscosity.
LEVEL
Figure 3-26. Deutz 2.9 T4F Dipstick Markings

5. Replace dipstick until fully seated.
Figure 3-27. Engine Oil Viscosity
3121728 3-31
Change Oil Filter Change Fuel Filters

1. Wipe area around filter to clean any dirt from area.
2. Using a suitable oil filter removal tool, loosen lube oil fil- FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
ter cartridge and spin off.
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYS-
TEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.

2. Disconnect water sensor connector (Pre-filter Only).
3. Remove fuel filter cartridge. Catch any escaping fuel.
3. Catch any escaping oil.

4. Clean any dirt from filter carrier sealing surface.
5. Lightly coat new oil filter rubber gasket with clean oil
6. Screw in new filter by hand until gasket is flush.
7. Hand-tighten filter another half-turn.
4. Clean dirt from filter carrier sealing surface.

5. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
6. Screw in new filter by hand until gasket is flush. Hand-
tighten filter another half-turn.
8. Check oil level.

9. Check oil pressure.
10. Check oil filter cartridge for leaks.
7. Connect water sensor connector (Pre-filter Only).

8. Open fuel shut-off valve.
9. Check for leaks.
3-32 3121728
Table 3-4. Deutz Trouble Codes (TD2.9 L4 Engine)
SPN FMI Error Identification

16 0 No detail information
16 0 BusOff error CAN
No detail information
29 3 Hand throttle idle validation switch; short circuit to battery
29 4 Hand throttle; short circuit to ground
29 2 Plausibility error between sensor and idle switch, Acceleration Pedal Detection. In case of Hand Throttle with Low Idle
Switch, it is the plausibility check between hand throttle and idle switch.
51 5 Intake Throttle Flap, H-Bridge, wiring harness broken at connected actuator
51 6 Intake Throttle Flap, H-Bridge, current above maximum threshold
51 3 Intake Throttle Flap, H-Bridge, short circuit to battery (A02)
51 3 Intake Throttle Flap, H-Bridge, short circuit to battery (A67)
51 4 Intake Throttle Flap, H-Bridge, short circuit to ground (A02)
51 4 Intake Throttle Flap, H-Bridge, short circuit to ground (A67)
51 7 Intake Throttle Flap, H-Bridge, position of actuator not plausible (deviation from set point more than 7%)
51 3 Intake Throttle Flap, H-Bridge, short circuit to battery oder broken wiring harness
51 4 Intake Throttle Flap, H-Bridge, short circuit to ground
91 3 Sensor error accelerator pedal. signal range check high.
91 4 Sensor error accelerator pedal. Signal is below the range.
91 11 Plausibility error between APP1 and APP2 or APP1 and idle switch.
94 3 Sensor error low fuel pressure; signal range check high
94 4 Sensor error low fuel pressure; signal range check low
94 1 Low fuel pressure; warning threshold exceeded
94 1 Low fuel pressure; shut off threshold exceeded
97 3 Sensor error water in fuel; signal range check high
97 4 Sensor error water in fuel; signal range check low.
97 12 Water in fuel level prefilter; maximum value exceeded
98 2 Plausibility Check; No detail information
100 3 Sensor error oil pressure; signal range check high
100 4 Sensor error oil pressure sensor; signal range check low
100 0 High oil pressure; warning threshold exceeded.
100 0 High oil pressure; shut off threshold exceeded
100 1 Low oil pressure; warning threshold exceeded
100 1 Low oil pressure; shut off threshold exceeded
102 2 Charged air pressure above warning threshold.
102 2 Charged air pressure above shut off threshold.
102 2 Pressure downstream charge air cooler, plausibility error
102 1 Pressure downstream charge air cooler, pressure below lower physical threshold
102 3 Pressure downstream charge air cooler, short circuit to battery or open load
102 4 Pressure downstream charge air cooler, short circuit to ground
105 1 Charged Air cooler down stream temperature. 
Temperature below lower physical threshold.
105 3 Electrical error charged air temperature. Signal range check high.(SRC)
3121728 3-33

105 4 Electrical error charged air temperature. Signal range check low.
105 0 Charged air cooler temperature. System reaction initiated. 
High charged air cooler temperature. Warning threshold exceeded.
105 0 High charged air cooler temperature. Shut off threshold exceeded.
105 11 Diagnostic fault check for charged air cooler downstream temperature sensor 
107 3 Sensor error air filter differential pressure; short circuit to battery
107 0 Sensor error air filter differential pressure; short circuit to ground
107 0 Air filter differential pressure; air filter clogged.
108 11 DFC for CAN message
108 3 Sensor error ambient air pressure; signal range check high
108 4 Sensor error ambient air pressure; signal range check low
110 2 Defect fault check for Absolute plausibility test. No detail information
110 0 Physical Range Check high for Coolant temperature
110 1 Physical Range Check low for Coolant temperature.
110 3 Sensor error coolant temperature; signal range check high
110 4 Sensor error coolant temperature; signal range check low
110 0 High coolant temperature; warning threshold exceeded
110 0 Coolant temperature; system reaction initiated
111 1 Coolant level too low
132 1 The air mass flow AFS_dm is greater than or equal to AFS_PhysRng.Min_C
Physical Range Check low for air mass flow sensor. No detail information
157 0 Rail pressure raw value is intermittent. No detail information
157 1 Rail pressure raw value is above maximum offset. No detail information
157 3 Sensor error rail pressure. Sensor voltage above upper limit.
157 4 Sensor error rail pressure. Sensor voltage below lower limit.
164 2 Rail pressure safety function is not executed correctly.
168 3 Sensor error battery voltage; signal range check high.
168 4 Sensor error battery voltage; signal range check low
168 2 High battery voltage; warning threshold exceeded
168 2 High battery voltage; shot off threshold exceeded
168 0 Physical range check high for battery voltage
168 1 Physical range check low for battery voltage
171 0 Environment temperature sensor, temperature above upper physical threshold
171 1 Environment Temperature Physical Range Check low
171 3 Sensor error SCR-System environment temperature;
DPF-System air inlet temperature; signal range check high
171 4 Sensor error SCR-System environment temperature; 
DPF-System air inlet temperature; signal range check low
172 2 Air inlet filter temperature, plausibility error
172 3 Air flow temperature sensor; short circuit to battery or open load.
172 4 Air flow temperature sensor; short circuit to ground
172 1 Air inlet filter sensor out of physical range check
172 0 air temperature within air filter box above maximum physical value
3-34 3121728

174 11 DFC for fuel temperature plausibility check function. No detail information
175 3 Sensor error oil temperature; signal range check high
175 4 Sensor error oil temperature; signal range check low
175 0 High oil temperature; warning threshold exceeded
175 0 High oil temperature; shut off threshold exceeded
175 2 Customer oil temperature: signal unplausible
190 0 Engine speed above warning threshold
Over speed detection in component engine protection
190 0 Engine speed above warning threshold (FOC-Level 1)
190 11 Engine speed above warning threshold (FOC-Level 2)
190 14 Engine speed above warning threshold (Overrun Mode)
190 8 Sensor camshaft speed; disturbed signal
190 12 Sensor camshaft detection; out of range, signal disrupted; no signal
190 2 Offset angle between crank- and camshaft sensor is too large.
190 8 Sensor crankshaft detection; out of range, signal disrupted; disturbed signal
190 12 Speed detection; out of range, signal disrupted Sensor crankshaft speed; no signal
190 14 Camshaft- and Crankshaft speed sensor signal not available on CAN
411 4 Physical range check low for EGR differential pressure
411 0 Delta pressure across venturi in EGR line above physical high limit
411 0 Plausibility Check fault for deviation of desired and actual EGR-mass flow, where the latter is calculated out of EGR Delta
Pressure Sensor
411 3 Sensor error differential pressure Venturiunit (EGR), signal range check low.
411 4 Sensor error differential pressure Venturiunit (EGR), signal range check high.
412 3 Electrical error EGR cooler downstream temperature. Signal range check high.
412 4 electrical error EGR cooler downstream temperature. Signal range check low.
520 9 Timeout Error of CAN-Receive-Frame TSC1TR; control signal
598 2 Plausibility check for Clutch. No detail information
624 5 SVS lamp; open load
624 12 SVS lamp: power stage over temperature
624 3 SVS lamp; short circuit to battery
624 4 SVS lamp; short circuit to ground
630 12 Access error EEPROM memory (delete)
630 12 Access error EEPROM memory (read)
630 12 Access error EEPROM memory (write)
639 14 CAN-Bus 0 “BusOff-Status”
651 5 Injector 1 (in firing order); interruption of electric connection
651 3 Injector 1 (in firing order); short circuit
3121728 3-35

655 4 High side to low side short circuit in the injector 5 (in firing order)
656 4 High side to low side short circuit in the injector 6 (in firing order)
676 11 Cold start device relay error
676 11 Cold start aid relay open load
677 3 Starter relay high side. Short circuit to battery.
677 4 Starter relay high side short circuit to ground.
677 5 Starter relay low side no load error.
677 12 Starter relay power stage over temperature.
677 3 Starter relay low side short circuit to battery.
677 4 Starter relay low side short circuit to ground.
729 5 Cold start aid relay open load
729 12 Cold start aid relay; over temperature error
729 3 Intake Air Heater Device; Short circuit to battery
729 4 Air intake heater; Short circuit to ground error for power stage on CJ945.
898 9 Timeout Error of CAN-Receive-Frame TSC1TE; Set point
975 5 PWM-Signal Fan, Open load or short-circuit ground
975 3 PWM-Signal Fan, short-circuit to plus
975 4 PWM-Signal Fan, open load or short circuit to ground
1079 13 Failure of sensor supply voltage 1.
1109 2 Engine shut off demand ignored
1136 0 Physical range check high for ECU temperature
1176 0 Pressure sensor upstream turbine, Physical Range Check high.
1176 1 Pressure sensor upstream turbine, Physical Range Check low.
1176 3 Pressure sensor upstream turbine, signal range check (SRC) high.
1176 4 Pressure sensor upstream turbine, signal range check (SRC) low.
1180 3 Sensor error exhaust gas temperature upstream turbine; signal range check high
1180 4 Sensor error exhaust gas temperature upstream turbine; signal range check low
1180 0 Physical range check high for exhaust gas temperature upstream turbine
1180 1 Physical range check low for exhaust gas temperature upstream turbine
1188 11 Wastegate actuator; internal error
1188 11 Wastegate actuator; EOL calibration not performed correctly
1188 13 Wastegate actuator calibration deviation too large, re-calibration required
1188 2 Wastegate; status message from ECU missing
1188 7 Wastegate actuator; blocked
1188 11 Wastegate actuator; over temperature (> 135°C)
1188 11 Wastegate actuator; operating voltage error
1188 7 Turbocharger wastegate, mechanical blocking detected.
1188 2 Turbocharger wastegate, CAN Error
3-36 3121728

1188 13 Turbocharger wastegate, EOL calibration error.
1188 12 Turbocharger wastegate, internal electrical error
1188 13 Turbocharger wastegate, learning process aborted.
1188 6 Turbocharger wastegate, current above maximum threshold.
1188 3 Turbocharger wastegate, supply voltage above maximum threshold.
1188 4 Turbocharger wastegate, supply voltage below minimum threshold.
1188 13 Turbocharger wastegate, learning process out of range.
1188 7 Turbocharger wastegate, broken spring detected.
1188 0 Turbocharger wastegate, temperature critical high.
1231 14 CAN-Bus 1 “BusOff-Status”
1235 14 CAN-Bus 2 = CAN_C reports Bus-error (for engines <8L and CV52 it is the engine-CAN@250kbaud) CAN Bus error passive;
warning CAN C - engine CAN
1235 14 CAN-Bus 2 = engine bus “BusOff-Status”
1237 2 Override switch; plausibility error.
1322 12 N/A
1323 12 Too many recognized misfires in cylinder 1 (in firing order)
1323 12 N/A
1323 12 N/A
1323 12 N/A
1323 12 N/A
1323 12 N/A
1346 0 Misfire detection monitoring No detail information
1638 2 Hydraulic oil temperature check for Shut off condition
1639 12 Fan speed sensor; electrical error or signal disturbed or very low fan speed
1639 0 Sensor error fan speed; signal range check high or engine speed respective fan speed too high
1639 1 Sensor error fan speed; signal range check low or fan speed too low
1761 14 DEF tank level; warning threshold exceeded
1761 0 DEF tank, DEF level above upper physical threshold
1761 1 DEF tank, DEF level below lower physical threshold
1761 14 Urea Tank Signal to HMI for indicating the Urea Tank-Level (Urea tank volume ratio low threshold 1)
1761 14 DEF tank, DEF level below first warning threshold
1761 14 DEF tank, DEF level below second warning threshold
1761 2 DEF tank level, plausibility error
1761 14 DEF tank, DEF level below third warning threshold
2634 12 Early opening defect of main relay No detail information
2634 12 DFC for stuck main relay error No detail information
2659 2 Exhaust Gas Recirculation AGS Sensor; signal not plausible
2659 0 Exhaust Gas Recirculation AGS Sensor; Sensed exhaust mass value above maximum physical value
2659 1 Exhaust Gas Recirculation AGS Sensor; Sensed exhaust mass value below minimum physical value
2659 12 Exhaust Gas Recirculation AGS Sensor; plausibility error, AGS sensor has not passed the burn off process
2659 2 Exhaust Gas Recirculation AGS Sensor; Temperature of EGR mass not plausible
2791 12 Actuator EGR Valve; power stage over temperature
2791 7 EGR actuator, actuator blocked
3121728 3-37

2791 2 EGR actuator, CAN error
2791 13 EGR actuator, EOL calibration error
2791 12 EGR Actuator, internal electrical fault
2791 13 EGR actuator, learning process aborted
2791 6 EGR actuator current is above maximum threshold
2791 3 EGR actuator supply voltage is above the maximum threshold
2791 4 EGR actuator supply voltage is below minimum threshold.
2791 13 EGR actuator, learning process out of range
2791 7 EGR actuator, broken spring detected.
2791 16 EGR actuator, temperature high.
2791 0 EGR actuator, temperature critical high
2797 4 Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 0;_IVDiaShCirGndToutBnk_0
2797 4 Injector diagnostic; Short circuit to ground cylinder bank 0
2798 4 Timeout of Short-Circuit Ground Diagnosis Cyl. Bank 1;_IVDiaShCirGndToutBnk_1
2798 4 Injector diagnostic; Short circuit to ground cylinder bank 1
3031 0 DEF tank, DEF temperature in DEF tank is to high.
3031 1 DEF tank, DEF temperature below lower physical threshold
3031 2 Urea tank temperature outside of plausible thresholds
3219 2 DFC SAE J1939 error No detail information
3224 2 DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor (SCR-system upstream cat; DPF-system downstream cat); length of
frame incorrect
3224 9 Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor upstream
3224 2 DLC Error of CAN-Receive-Frame AT1IG1Vol NOX sensor.
3224 9 Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX sensor.
3224 1 DFC for plausibility error Max for NOx sensor upstream of SCR Cat
3226 2 Nox feed back fault detection No detail information
3227 2 DFC SAE J1939 error No detail information
3234 2 DLC Error of CAN-Receive-Frame AT1O1 No detail information
3234 9 Timeout Error of CAN-Receive-Frame AT1OG1; NOX sensor (SCR-system downstream cat; DPF-system downstream cat)
3234 2 DLC Error of CAN-Receive-Frame AT1O1Vol NOX
3234 9 Timeout Error of CAN-Receive-Frame AT1OG1Vol.
3234 11 DFC for plausibility error Min for NOx sensor downstream of SCR Cat.
3241 0 Sensor SCR catalyst upstream temperature too high; plausibility error.
3248 4 Sensor error particle filter downstream temperature; signal range check low
3251 0 Differential pressure DPF maximum value is exceeded
3251 0 Differential pressure sensor across DPF exceeds warning high limit
3251 1 Differential pressure DPF, pressure below lower shutoff threshold.
3251 1 Differential pressure DPF, pressure below lower warning threshold.
3253 2 Differential pressure DPF, plausibility error
3253 3 Electrical error differential pressure B58 (DPF). (signal range check high)
3253 4 Electrical error differential pressure (DPF). signal range check low.
3253 2 Sensor differential pressure (DPF); plausibility error
3361 7 DEF dosing valve blocked (SCR)
3-38 3121728

3361 6 DEF dosing valve; power at the end of injection too high
3361 3 DEF dosing valve; short circuit to battery on low side
3361 3 DEF dosing valve; short circuit to battery or open load on high side
3361 4 Urea dosing valve; short circuit to ground or open load on low side
3361 4 DEF dosing valve; short circuit on high side
3519 12 DEF tank temperature, temperature too high
3519 3 DEF quality sensor, internal temperature sensor short circuit to battery or open load
3519 4 DEF quality sensor, internal temperature sensor short circuit to ground
3519 13 Temperature at UQS invalid
3520 3 DEF quality sensor, short circuit to battery or open load
3520 4 DEF quality sensor, short circuit to ground
3520 2 DEF quality sensor, bad DEF quality detected or no DEF measuring possible.
3520 13 Urea quality at UQS invalid
3532 3 Sensor error DEF tank level; signal range check high
3532 4 Sensor error DEF tank level; signal range check low
3532 3 The DEF Level at UQS out of max. physical range
3532 4 Quality at UQS out of min. physical range
3699 2 Passive regeneration of DPF; plausibility error
DPF differential pressure sensor and a further sensor or actuator CRT system defective
3699 2 Passive regeneration of DPF; DOC error
Temperature sensor us. and ds. DOC simultaneously defect
3699 0 Maximum standstill time reached; oil exchange request ignored
3711 12 Temperature during stand-still main phase too low or too high
3936 14 Standstill request ignored too long.
3936 14 Standstill time based escalation requests Inducement step 2
4171 2 Dynamic temperature check of temp before SCR
4243 11 SCR heater; Pressure line heater error and temperature condition to perform an afterrun (Group error diagnosis heater)
SCR system heater diagnostic reports error; shut off SCR-system
4334 0 Supply module DEF, DEF pressure above upper physical threshold
4334 1 Urea supply module pressure sensor; physical range check low (defect pressure sensor)
4334 0 Urea pump pressure sensor; high signal not plausible
4334 1 Urea pump pressure sensor; low signal not plausible
4334 2 DEF supply module pressure, plausibility error
4341 5 SCR heater relay DEF supply line secondary side; open load
4341 5 SCR heater relay DEF supply line primary side; open load
4341 3 SCR-heater DEF supply line; short circuit to battery
4341 4 SCR-heater DEF supply line; short circuit to ground
4343 11 SCR Monitoring; Pressure stabilization error, general pressure check error (SCR)
4343 5 SCR heater relay DEF pressure line secondary side; open load
4343 5 SCR heater relay DEF pressure line primary side; open load
4343 12 Over Temperature error No detail information
4343 3 SCR heater DEF pressure line; short circuit to battery
4343 4 SCR heater DEF pressure line; short circuit to ground
4345 11 Sensor back flow line pressure (SCR); plausibility error
3121728 3-39

4345 5 SCR heater relay DEF return line secondary side; open load
4345 5 SCR heater relay DEF return line primary side; open load
4345 3 SCR heater DEF return line; short circuit to battery
4345 4 SCR heater DEF return line; short circuit to ground
4360 0 Exhaust temperature upstream SCR-Cat, temperature above upper physical threshold
4360 1 Sensed exhaust temperature before SCR-Cat is < physical low limit
4360 2 Exhaust temperature sensor upstream SCR, plausibility error
4361 2 Signal error for CAN message No detail information
4361 3 Sensor error DEF catalyst exhaust gas temperature upstream; signal range check high
4361 4 Sensor error DEF catalyst exhaust gas temperature upstream; signal range check low
4365 0 DEF tank temperature too high.
4365 2 Tank temperature signal error for CAN message
4365 3 Sensor error urea tank temperature: short circuit to battery
4365 4 Sensor error urea tank temperature; short circuit to ground.
4365 3 DEF quality sensor, tank temperature; Short circuit to battery or open load
4365 4 DEF quality sensor, tank temperature; Short circuit to ground
4366 5 SCR main relay (secondary side): open load
4366 5 SCR main relay (secondary side); Shortcut to battery
4366 5 SCR main relay (secondary side), heat relay (secondary side), heating elements or heating valve short to ground.
4366 5 SCR Tank heating valve secondary side: open load
4366 5 SCR tank heating valve primary side; open load
4366 12 SCR-heater relay urea tank power stage output; over temperature
4366 3 SCR Tank heating valve; short circuit to battery
4366 4 SCR Tank heating valve; short circuit to ground
4374 13 Pressure stabilization error dosing valve (SCR)
4375 5 Urea pump motor; open load
4375 3 Urea pump motor; short circuit to battery
4375 4 Urea pump motor; short circuit to ground
4376 5 SCR reversal valve; open load
4376 12 SCR reversing valve; over temperature
4376 3 SCR reversal valve; short circuit to battery
4376 4 SCR reversing valve; short circuit to ground
4376 5 SCR reverting valve; open load
4376 12 SCR reverting valve; over temperature
4376 4 eSCR reverting valve; short circuit to ground
4765 0 Temperature upstream DOC, temperature above upper shutoff threshold
4765 0 Temperature upstream DOC, temperature above upper warning threshold
4766 0 Temperature downstream DOC, temperature above upper shutoff threshold
4766 0 Temperature downstream DOC, temperature above upper warning threshold
4768 2 Temperature upstream DOC, plausibility error
4768 3 Electrical error exhaust gas temperature upstream (DOC); signal range check high
4768 4 Electrical error exhaust gas temperature upstream (DOC); signal range check low
3-40 3121728

4768 2 Exhaust gas temperature sensors up and downstream DOC are physically swapped
4769 2 Temperature downstream DOC, plausibility error
4769 3 Sensor error exhaust gas temperature downstream (DOC); signal range check high
4769 4 Sensor error exhaust gas temperature downstream (DOC); signal range check low
4769 2 Sensor exhaust gas temperature OxiCat downstream (normal operation); plausibility error
4769 2 Sensor exhaust gas temperature OxiCat downstream (regeneration); plausibility error
5763 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8).
Signal range check high.
5763 7 Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8) not plausible.
5763 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range check high
5763 5 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range check low
5763 3 Position sensor error of actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8).
Signal range check high.
5763 4 Position sensor error actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8).
Signal range check low.
5763 5 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); open load
5763 6 Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over current
5763 3 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to battery
5763 3 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to battery
5763 4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to ground
5763 4 EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short circuit to ground
5763 6 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); Overload by short-circuit
5763 11 Power stage over temperature due to high current.
5763 4 Actuator AGR valve (2.9;3.6) throttle valve (4.1;6.1;7.8); Voltage below threshold.
5763 0 Warning threshold for an internal actuator error exceeded, < 4L EGR.actuator und >4L Air Intake Flap
5763 1 Shut off threshold for an internal actuator error exceeded, < 4L EGR.actuator und >4L Air Intake Flap
520521 5 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); signal range check low.
523008 1 Manipulation control was triggered
523008 2 Timeout error in Manipulation control
523009 9 The pressure relief valve (PRV) has reached the number of allowed activations.
523009 10 Open time of Pressure Relief Valve (PRV) for wear out monitoring had exceeded
523090 2 Engine Brake Pre-Selection switch; Plausibility Error
523211 9 Timeout Error of CAN-Receive-Frame EBC1
523212 9 Timeout Error of CAN-Receive-Frame ComEngPrt; Engine Protection
523213 12 Timeout Error of CAN-Transmit-Frame ERC1 No detail information
523216 9 Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat command, engine command
523240 9 Timeout CAN-message FunModCtl; Function Mode Control
523330 14 Immobilizer status; fuel blocked
523330 14 DFC to block the fuel by Sia No detail information
523330 14 DFC to indicate that TEN-code or UC-code received if ECU is learned.
523330 14 DFC to indicate that no code is received via CAN. No detail information
523330 14 DFC to indicate that wrong code is received. No detail information
523350 4 Injector cylinder-bank 1; short circuit
3121728 3-41

523352 4 Injector cylinder-bank 2; short circuit
523354 12 Injector power stage output defect
523470 2 Pressure relief valve is forced to open, perform pressure increase.
523470 2 Pressure Relief Valve (PRV) forced to open. Performed by pressure increase.
523470 12 Pressure Relief Valve (PRV) forced to open. Shutoff conditions.
523470 12 Pressure Relief Valve (PRV) forced to open. Warning conditions.
523470 14 Open Pressure Relief Valve (PRV)
523470 11 Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range.
523470 11 Rail pressure out of tolerance range.
The PRV can not be opened at this operating point with a pressure shock.
523470 7 Maximum rail pressure exceeded (PRV).
523550 12 Terminal 50 was operated too long
523580 2 Data set variant with the desired number not found Invalid variant data set Identifier error No detail information
523580 11 An error has occurred in the switch over to the desired data set variant in the code word.
Variant data set switching error No detail information
523580 11 The code word could not be read correctly from the EEPROM Variant dataset switching error; No detail information
523602 0 High fan speed; warning threshold exceeded
523602 0 High fan speed; shut off threshold exceeded
523603 9 Timeout Error of CAN-Receive-Frame AMB; Ambient Temperature Sensor
523605 9 Timeout Error of CAN-Receive-Frame TSC1AE; Traction Control
523606 9 Timeout Error of CAN-Receive-Frame TSC1AR; Retarder
523612 12 Internal software error ECU; injection cut off
523612 12 Internal ECU monitoring detection reported error
523612 12 ECU reported internal software error
Internal ECU monitoring detection reported error
523612 12 ECU reported internal software error
523612 12 ECU reported internal software error.
523612 12 Injection system, electrical error injectors
523612 12 Diagnostic fault check to report the accelerator pedal position error
523612 12 Diagnostic fault check to report the engine speed error
523612 12 Error in the plausibility of the injection energizing time
523612 12 Error in the plausibility of the start of energizing angles
523612 12 Diagnostic fault check to report the error due to non plausibility in ZFC
3-42 3121728

523612 12 Diagnosis fault check to report the demand for normal mode due to an error in the PoI2 quantity
523612 12 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off
523612 12 Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor
523612 12 Internal ECU monitoring detection reported error
523612 12 Monitoring of Fuel Quantity Correction
523612 12 Diagnostic fault check to report the plausibility error in rail pressure monitoring
523612 12 Diagnostic fault check to report the error due to torque comparison
523612 12 Diagnosis of curr path limitation forced by ECU monitoring level 2
523612 12 Diagnosis of lead path limitation forced by ECU monitoring level 2
523612 12 Diagnosis of set path limitation forced by ECU monitoring level 2.
523612 3 Reported Over Voltage of Supply
523612 4 Reported Under Voltage of Supply
523612 12 Diagnostic fault check to report WDA active due to errors in query-/response communication
523612 12 Diagnostic fault check to report ABE active due to under voltage detection
523612 12 Diagnostic fault check to report ABE active due to overvoltage detection
523612 12 Diagnostic fault check to report WDA/ABE active due to unknown reason
523612 14 Software reset CPU SWReset_0
523612 12 Internal software error ECU
523612 12 Engine starter, plausibility error of starter release condition
523613 0 Rail pressure metering unit, Positive governor deviation.
523613 0 Rail pressure metering unit, Rail pressure disrupted. Maximum positive deviation of rail pressure exceeded.
523613 0 Rail pressure metering unit, Rail pressure disrupted. Maximum positive deviation of rail pressure in metering unit
exceeded (RailMeUn1).
523613 0 Rail pressure metering unit, Rail pressure below the target range (RailMeUn2)
Rail system leakage detected. (RailMeUn10)
523613 1 Rail pressure metering unit, Minimum rail pressure exceeded (RailMeUn3)
Negative deviation of rail pressure second stage (RailMeUn22)
523613 0 Rail pressure metering unit, Maximum rail pressure exceeded.
523613 2 Rail pressure metering unit, Set point of metering unit in overrun mode not plausible.
523613 0 Set point of metering unit in overrun mode not plausible
523615 5 Metering unit (Fuel-System); open load
523615 12 Metering unit (Fuel-System); power stage over temperature
523615 3 Metering unit (Fuel-System); short circuit to battery high side
523615 4 Metering unit (Fuel-System); short circuit to ground high side
523615 3 Metering unit (Fuel-System); short circuit to battery low side
523615 4 Metering Unit (Fuel-System); short circuit to ground low side
523615 3 Metering unit, short circuit to battery
523615 4 Metering unit, short circuit to ground
523618 3 Gearbox oil temperature; Short circuit to battery or broken harness
523618 4 Gearbox oil temperature; Short circuit to ground
523619 2 Physical range check high for exhaust gas temperature up stream (SCR-CAT)
523632 16 Pump pressure SCR metering unit too high.
3121728 3-43

523632 18 Pump pressure SCR metering unit too low
523632 0 Pressure overload of SCR-System.
523632 1 Pressure build-up error SCR-System.
523632 11 Pump motor not available for actuation
523632 2 Signal error for CAN message No detail information
523632 3 Sensor error urea pump pressure; signal range check high
523632 4 Sensor error urea pump pressure; signal range check low
523633 11 Long term adoption factor below threshold
523633 11 Nox conversion rate insufficient (SCR-Cat defect, bad DEF quality)
523633 11 Nox conversion rate insufficient (SCR-Cat defect, bad DEF quality); temperature range 1
523698 11 Shut off request from supervisory monitoring function
523699 3 Boost pressure control; negative governor deviation below limit
523699 4 learning value too high No detail information
523704 12 Timeout Error of CAN-Transmit-Frame EEC3
523706 12 Timeout Error of CAN-Transmit-Frame FlEco No detail information
523717 12 Timeout Error of CAN-Transmit-Frame AmbCon; Weather environments
523718 5 tank heating valve; open load
523718 12 SCR main relay (primary side); power stage over temperature
523718 3 SCR main relay (primary side); short circuit to battery
523718 4 SCR main relay (primary side); short circuit to ground
523718 5 SCR main relay; open load (only CV56B)
523718 3 SCR main relay; short circuit to battery (only CV56B)
523718 4 SCR main relay; short circuit to ground (only CV56B)
523719 5 SCR heater relay DEF supply module secondary side; open load
523719 5 SCR heater relay DEF supply module primary side; open load
523719 3 SCR heater DEF supply module; short circuit to battery
523719 4 SCR heater DEF supply module; short circuit to ground
523720 2 DEF supply module heater temperature; plausibility error (normal condition).
523720 2 Sensor DEF supply module heater temperature; plausibility error (cold start condition)
523720 8 DEF supply module heater temperature; duty cycle in failure range.
523720 8 DEF supply module heater temperature; duty cycle in invalid range.
523721 2 Sensor DEF supply module temperature; plausibility error (normal condition)
523721 2 Sensor DEF supply module temperature; plausibility error (cold start condition)
523721 11 Urea supply module temperature measurement not available.
523721 8 DEF supply module temperature; duty cycle in failure range.
523721 8 Urea supply module temperature; duty cycle in invalid range.
523722 8 DEF supply module PWM signal; period outside valid range.
523722 8 Detect faulty PWM signal from Supply Module.
523741 14 Engine shut off request through CAN No detail information
523752 0 Plausibility error during Rich to Lean switch over No detail information
523752 0 Monitoring of Nox signal readiness No detail information
523756 14 special pattern for special cases No detail information
3-44 3121728

523766 9 Timeout Error of CAN-Receive-Frame Active TSC1AE
523767 9 Timeout Error of CAN-Receive-Frame Passive TSC1AE
523768 9 Timeout Error of CAN-Receive-Frame Active TSC1AR
523769 9 Timeout Error of CAN-Receive-Frame Passive TSC1AR
523776 9 Timeout Error of CAN-Receive-Frame TSC1TE - active
523777 9 Passive Timeout Error of CAN-Receive-Frame TSC1TE; Set point
523778 9 Timeout Error of CAN-Receive-Frame TSC1TR
523779 9 Passive Timeout Error of CAN-Receive-Frame TSC1TR
523788 12 Timeout Error of CAN-Transmit-Frame TrbCH; Status Waste gate
523788 0 Waste gate plausibility error off CAN transmit message.
523788 0 Timeout Error of CAN-Receive-Frame ComTrbChActr; Wastegate
523793 9 Timeout Error of CAN-Receive-Frame UAA10; AGS sensor service message
523794 9 Timeout Error of CAN-Receive-Frame UAA11; AGS sensor data
523803 9 Timeout error of CAN Receive Message RxEngPres; Status Burner Air Pump
523858 12 Timeout Error of CAN-Transmit-Frame UAA11
523867 12 Timeout Error of CAN-Transmit-Frame UAA1 on CAN 2. Control burner air pump;
523889 3 Over temperature of device driver of pressure control valve No detail information
523891 14 When AirHt_ctDefSRCLoOn_mp is less than AirHt_ctMaxDef_C.
DFC to SRC Low error when heater is On No detail information
523895 13 Check of missing injector adjustment value programming (IMA) injector 1 (in firing order).
523906 5 Electrical fuel pre - supply pump; open load
523906 12 Electrical fuel pre - supply pump. ECU powerstage over temperature.
523906 3 Electrical fuel pre - supply pump; short circuit to battery
523906 4 Electrical fuel pre - supply pump. Short circuit to ground.
523910 14 Air pump doesn't achieve air mass flow setpoint Burner Control - burner air pump
523910 9 Burner Control; Air Pump - CAN Lost Air Pump; CAN communication lost
523910 7 Air pump; CAN communication interrupted no purge function available
523910 12 Air Pump; internal error
523910 0 Air Pump; operating voltage error
523910 6 Burner Control Air Pump; over current Air pump electrically overloaded
523911 0 Burner dosing valve (DV2); over current at the end of the injection phase
523911 12 Burner dosing valve (DV2); power stage over temperature
523911 3 Burner dosing valve (DV2); short circuit to battery
523911 4 Burner dosing valve (DV2); short circuit to ground
3121728 3-45

523911 11 Burner dosing valve (DV2); short circuit high side power stage
523912 2 Burner dosing valve (DV2) downstream pressure sensor; plausibility error
523912 0 Physical range check high for burner dosing valve (DV2) downstream pressure; shut off regeneration
523912 1 Physical range check low for burner dosing valve (DV2) downstream pressure; shut off regeneration. When burner injector
is actuated, the measured pressure does not rise above ca. 1250mbar abs (expected: ca. 2400mbar).
523912 3 Sensor error burner dosing valve (DV2) downstream pressure sensor; signal range check high
523912 4 @ engines < 4l: Throttle valve error, Open Load or Short cut to Battery, blocked valve or wrong control signal for valve.
@ engines with Burner T4i: Pressure Sensor error after valve (DV2), lower limit reached
523913 3 Sensor error glow plug control diagnostic line voltage; signal range check high
523913 4 Sensor error glow plug control diagnostic line voltage; signal range check low
523914 5 Glow plug control; open load water pump control (PWM)
523914 12 Glow plug control; power stage over temperature
523914 3 Glow plug control; short circuit to battery water pump control (PWM)
523914 4 Glow plug control; short circuit to ground water pump control (PWM)
523915 0 HCI dosing valve (DV1); over current at the end of the injection phase
523915 12 HCI dosing valve (DV1); power stage over temperature
523915 3 HCI dosing valve (DV1); short circuit to battery
523915 3 HCI dosing valve (DV1); short circuit to battery high side
523915 4 HCI dosing valve (DV1); short circuit to ground
523915 11 HCI dosing valve (DV1); short circuit high side power stage
523915 7 HCI dosing valve (DV1); blocked open
523916 2 Sensor HCI dosing valve (DV1) downstream pressure; plausibility error
523916 0 Physical range check high for HCI dosing valve (DV1) downstream pressure; shut off regeneration
523916 1 Physical range check low for HCI dosing valve (DV1) downstream pressure; shut off regeneration
523916 3 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check high
523916 4 Sensor error HCI dosing valve (DV1) downstream pressure; signal range check low
523917 3 Sensor error DV1 & DV2 upstream pressure; signal range check high
523917 4 Sensor error DV1 & DV2 upstream pressure; signal range check low
523918 3 Sensor error DV1 & DV2 upstream temperature; signal range check high
523918 4 Sensor error DV1 & DV2 upstream temperature; signal range check low
523919 2 DPF burner air pump pressure sensor, plausibility error
523919 0 DPF burner air pump pressure sensor, pressure above upper shutoff threshold
523919 1 DPF burner air pump pressure sensor, pressure below lower shutoff threshold
523919 3 DPF burner air pump pressure sensor, short circuit to battery or open load
523919 4 DPF burner air pump pressure sensor, short circuit to ground
523919 2 Sensor air pump air pressure; plausibility error
523920 2 Exhaust gas pressure upstream burner, plausibility error
523920 0 Exhaust gas pressure upstream burner, pressure above upper shutoff threshold
523920 3 Exhaust gas pressure upstream burner, short circuit to battery or open load
523920 4 Exhaust gas pressure upstream burner, short circuit to ground
523920 2 Sensor exhaust gas back pressure burner; plausibility error
523921 3 Sensor error burner temperature; signal range check high
523921 4 Sensor error burner temperature; signal range check low
3-46 3121728

523921 0 Burner temperature, temperature above upper shutoff threshold
523921 1 Burner temperature, temperature below lower shutoff threshold
523921 2 Burner temperature sensor; Plausibility Check for burner temperature sensor
Sensor burner temperature; plausibility error
523922 3 Burner shut of valve; short circuit to battery
523922 7 Burner Control; Shut-off Valve - Blocked closed Burner Shut Off Valve; blocked closed
523922 7 Burner Shut Off Valve; blocked open
523922 5 Burner Shut Off Valve; open load
523922 12 Burner Shut Off Valve; power stage over temperature
523922 4 Burner Shut Off Valve; short circuit to ground
523923 3 UB1; Short circuit to battery error of actuator relay 1
523923 4 Short circuit to ground error No detail information
523924 4 UB2; Short circuit to ground actuator relay 2
523925 3 UB3: Short circuit to battery error of actuator relay 3.
523926 4 UB4; Short circuit to ground actuator relay 4.
523927 3 UB5; Short circuit to battery error of actuator relay 5.
523935 12 Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine send messages
523936 12 Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine send messages
523937 9 Timeout DFC for NOxSensGlbReqTx. No detail information
523938 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1IGCVol1.
523939 9 Broadcast Announce Message of the calibration message of the upstream catalytic NOx sensor has failed.
523940 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1IGCVol1
523941 9 Timeout Error (BAM to packet) for CAN-Receive-Frame AT1OGCVol2.
523942 9 Calibration message 1 of the after catalyst NOx sensor has failed.
523943 9 Timeout Error (PCK2PCK) for CAN-Receive-Frame AT1OGCVol2.
523946 0 Zerofuel calibration injector 1 (in firing order); maximum value exceeded
523946 1 Zerofuel calibration injector 1 (in firing order); minimum value exceeded
523953 2 Healing takes place if the condition for error detection is not present.
Air temperature monitoring plausibility check array No detail information
523955 2 Healing takes place if the condition for error detection is not present.
Air temperature monitoring plausibility check array No detail information
523960 0 Physical range check high for EGR cooler downstream temperature.
523960 1 Physical range check low for EGR cooler downstream temperature.
3121728 3-47

523960 0 High exhaust gas temperature EGR cooler downstream; warning threshold exceeded.
523969 11 Fault entry for override control mode. No detail information
523973 14 SCR Tamper detection; derating timer below limit 1
523974 14 SCR Tamper detection; derating timer below limit 2
523975 14 Urea quality; derating timer below limit 1
523976 14 Urea quality; derating timer below limit 2
523977 14 Urea tank level; derating timer below limit 1
523978 14 Urea tank level; derating timer below limit 2
523981 11 SCR plausibility, OBD and diagnosis; Stuck in range check of DEF tank temperature sensor
DEF-tank without heating function (heating phase)
523982 0 Power stage diagnosis disabled; high battery voltage
523982 1 Power stage diagnosis disabled; low battery voltage
523992 9 N/A
523993 9 N/A
523995 13 Check of missing injector adjustment value programming (IMA) injector 7 (in firing order)
523996 13 check of missing injector adjustment value programming (IMA) injector 8 (in firing order)
523997 4 Injector cylinder bank 1 slave; short circuit
523998 4 Injector cylinder bank 2 slave; short circuit
523999 12 Injector power stage output Slave defect
524013 7 Burner Control; burner Flame;
Burner does not start after x trials (burner flame lost detection)
Burner flame unintentional deleted
524013 7 Burner Control; Flame lost max
Burner operation is interrupted too often
524014 1 Air inlet EPV - pressure too low
Air pressure glow plug flush line; below limit
524016 11 Burner Control; HFM - Electrical Fault HFM sensor; electrical fault
524016 2 Burner Control; HFM - Plausibility error1 Amount of air is not plausible to pump speed
524018 14 HMI engine derate service state
DPF wasn't regenerated, power reduction phase 1 (manual regeneration request)
524019 11 Burner Control; Air Line - Blocked Air Pump; air lines blocked
524020 14 Burner Control: power reduction due to low lambda. Engine power; Not enough oxygen for regeneration.
524021 11 Burner Control; Fuel line ShutOff downstream - broken Burner fuel line pipe leak behind Shut Off Valve
524022 14 HMI engine derate stop state
DPF wasn't regenerated, power reduction phase 2 (manual regeneration request)
524024 11 Deviation of the exhaust gas temperature set point to actual value downstream (DOC) too high
3-48 3121728

524025 14 Particulate filter regeneration.
Regeneration after time X is not successful (The error occurs when the regeneration times
(3x) over the max. has been aborted allowed recovery time)
524025 5 DPF system; operating voltage error
524025 14 The standstill-regeneration mode time exceeds the long-limit.
Vehicle was too long or too often in standstill mode. Make oil change and reset counter.
524025 14 The standstill-regeneration mode time exceeds the short-limit.
Vehicle was too long or too often within a short time in standstill mode.
Make oil change and reset counter.
524025 8 Max. launch time for stand still exceeded (60min).
524028 2 CAN message PROEGRActr; plausibility error
524029 2 Timeout Error of CAN-Receive-Frame ComEGRActr - exhaust gas recirculation positioner
524030 7 EGR actuator; internal error
524031 13 EGR actuator, calibration error
524032 2 EGR actuator; status message “EGRCust” is missing
524033 7 EGR actuator; due to overload in Save Mode
524034 5 Disc Separator; open load
524034 12 Disc Separator; power stage over temperature
524034 3 Disc separator; short circuit to battery
524034 4 Disc separator; short circuit to ground
524035 12 Injector diagnostics; time out error in the SPI communication
524036 12 Injector diagnostics Slave; time out error in the SPI communication
524038 9 Timeout error of CAN-Receive-Frame ComMS_Sys1TO (error memory Slave); Master-Slave internal CAN message
524044 9 CAN message ComMS_Sys7 not received from slave
524045 9 Master Slave, Error of message counter CAN receive message ComMSMoFOvR; ComMSMoFOvR1CNT
524046 9 Master-Slave CAN; Error Checksum of CAN-Receive Message
524047 9 Master-Slave CAN; Error of message length of CAN receive message ComMSMoFOvR;_ComMSMoFOvR1DLC
524048 9 Timeout error CAN message ComMSMoFOvR1TO error memory Slave
524052 11 Error memory Slave reports FID MSMonFC2 (collective error)
524052 11 Error memory Slave reports FID MSMonFC3 (collective error)
524052 11 Master ECU and Slave ECU data sets or software are not identical
524057 2 Fuel low pressure pump; error pressure build up
524058 2 Particulate filter; regeneration not successful
524063 5 Relay Urea back flow line heater: broken wiring detected (open load)
Row engine: SCR-back flow line (K29)
V-engine: Master: SCR-suction / back flow line (K32.1) 
Slave: SCR-suction / back flow line (K32.2)
524063 5 SCR main relay not connected
524063 5 SCR heater pressure line; open load
524063 3 SCR heater main relay; short circuit to battery
3121728 3-49

524063 4 SCR heater main relay load side (K31) on heating valve (Y31),
Short cut to ground.
524063 5 Relay Urea suction line: broken wiring detected (open load) Row engine:
SCR suction line (K28)
V-engine: Master: common SCR-suction line (K28) 
Slave: common SCR back flow line (K29)
524063 5 SCR heater supply module; open load
524063 5 SCR heater tank; open load
524063 12 DEF supply module, time for defrosting too long
524063 12 DEF tank, time for defrosting too long
524065 0 Pressure sensor upstream SCR-CAT, pressure above upper physical threshold
524065 1 Pressure sensor upstream SCR-CAT, pressure below lower physical threshold
524065 3 Pressure sensor upstream SCR-CAT; short circuit battery or open load
524065 4 Pressure sensor upstream SCR-CAT; short circuit ground
524065 2 Pressure sensor upstream SCR-CAT, plausibility error
524066 3 SCR measurement heater output stage; short circuit battery or open load
524067 0 DEF supply module, heater temperature above upper physical threshold
524067 1 DEF supply module, heater temperature below lower physical threshold
524067 0 DEF supply module, temperature above upper physical threshold
524067 1 DEF supply module, temperature below lower physical threshold
524067 2 Supply module heater temperature, plausibility error
524067 2 Supply module temperature, plausibility error
524068 2 Master ECU and Slave ECU have been identified as the same types
524069 9 Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO; Master-Slave CAN communication faulty
524070 2 (Upstream NOx-Sensor) Diagnostic Fault Check for invalid upstream NOx value (Sensor self diagnostic DFC set by Deutz-
SW)
NOx-Sensor before SCR-Cat: Invalid upstream NOx value
524071 2 (Downstream NOx-Sensor) Diagnostic Fault Check for invalid downstream lambda value (Sensor self diagnostic DFC set by
Deutz-SW)
524072 2 (Upstream NOx-Sensor) Diagnostic Fault Check for invalid upstream lambda value (Sensor self diagnostic DFC set by
Deutz-SW)
524073 2 (Downstream NOx-Sensor) Diagnostic Fault Check for invalid downstream NOx value (Sensor self diagnostic DFC set by
Deutz-SW)
524074 9 NOx sensor downstream SCR-CAT, sensor internally open load
524074 2 NOx-Sensor after SCR-Cat: Nox-Sensor dew point problem or plausibility problem
524075 11 NOx sensor downstream SCR-CAT, sensor internally short circuit
524076 9 NOx sensor upstream SCR-CAT, sensor internally open line
524076 2 NOx-Sensor before SCR-Cat: Nox-Sensor dew point problem or plausibility problem
524077 11 NOx sensor upstream SCR-CAT, sensor internally short circuit
524078 9 NOx sensor downstream SCR-CAT, lambda value above upper physical threshold
524079 9 NOx sensor downstream SCR-CAT, lambda value below lower physical threshold
524080 9 NOx sensor upstream SCR-CAT, lambda value above upper physical threshold
524081 9 NOx sensor upstream SCR-CAT, lambda value below lower physical threshold
524082 9 (Downstream NOx-Sensor) Diagnostic Fault Check for downstream NOx value over maximum limit (DFC set by Deutz-SW)
524083 9 NOx-Sensor downstream SCR-CAT, NOx value below minimum value.
3-50 3121728

524084 9 NOx-Sensor upstream SCR-CAT, NOx value above maximum value.
524085 9 NOx sensor upstream SCR-CAT, NOx value below lower physical threshold
524087 5 Urea Error Lamp; open load
524087 12 Urea Error Lamp; temperature over limit
524087 3 Urea Error Lamp; short circuit battery
524087 4 Urea Error Lamp; short circuit ground
524096 14 Control of the SCR system; If the start stop counter (EPA-Counter) exceeds the threshold
SCRCtl_ctEngStrtStopThresh_C. This counter will increment only once in each driving cycle in case of an SCR error. If the
counter reaches the threshold, the DFC will be set to inhibit the engine start. Engine will not be started, because of EPA-
Counter
524097 9 Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl
524098 9 Timeout error of CAN-Transmit-Frame ComDPFBrnPT
524099 9 Timeout error of CAN-Transmit-Frame ComDPFC1
524100 9 Timeout error of CAN-Transmit-Frame ComDPFHisDat.
524101 9 Timeout error of CAN-Transmit-Frame ComDPFTstMon
524102 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmpCtl
524103 9 Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
524104 9 Timeout error of CAN-Receive-Frame ComRxDPFCtl.
524105 9 Timeout error of CAN-Transmit-Frame ComEGRMsFlw (EGR Steller)
524106 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1 (EGR actuator)
524107 9 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2 (EGR actuator)
524108 9 Timeout error of CAN-Transmit-Frame ComEGRTVActr (EGR actuator)
524109 9 Timeout error of CAN-Receive-Frame ComRxEGRTVActr (EGR actuator)
524110 9 Timeout error of CAN-Transmit-Frame ComETVActrTO.
524111 9 Timeout error of CAN-Receive-Frame ComRxETVActr
524112 9 Timeout ComIntake Throttle Valve Actr.
524113 9 Timeout error of CAN-Receive-Frame ComRxITVActr
524114 9 Timeout error of CAN-Transmit-Frame A1DOC
524115 9 Timeout error of CAN-Transmit-Frame AT1S
524116 9 Timeout error of CAN-Transmit-Frame SCR2
524117 9 Timeout error of CAN-Transmit-Frame SCR3
524118 9 Timeout error of CAN-Receive-Frame ComRxCM1
524119 9 Timeout error of CAN-Receive-Frame ComRxCustSCR3
524120 9 Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
524121 9 Timeout error of CAN-Receive-Frame ComRxTrbChActr (wastegate actuator)
524122 9 Timeout error of CAN-Receive-Frame ComRxUQSens (Urea quality)
524123 9 Timeout error of CAN-Receive-Frame ComSCRHtCtl
524124 9 Timeout error of CAN-Receive-Frame ComTxAT1IMG
524125 9 Timeout error of CAN-Receive-Frame ComTxTrbChActr (Wastegate actuator)
524132 2 Fuel low pressure upstream fuel low pressure pump not plausible
524132 0 Fuel low pressure upstream fuel low pressure pump, pressure above maximum warning threshold
524132 0 Fuel low pressure upstream fuel low pressure pump, pressure above maximum shut off threshold
524132 1 Fuel low pressure upstream fuel low pressure pump, pressure below minimum shut off threshold
524132 1 Fuel low pressure upstream fuel low pressure pump, pressure below minimum warning threshold
3121728 3-51

524133 2 HMI system; set if restore button blocked
524134 0 DPF, ash load exceeds the shutoff threshold
524134 0 DPF, ash load exceeds the warning threshold
524135 0 DPF, soot load exceeds the shutoff threshold
524135 14 DPF, soot load exceeds the service request threshold
524135 0 DPF, soot load exceeds the warning threshold
524141 7 DEF dosing valve, dosing valve blocked
524147 13 SCR System, pressure build up not possible
524147 7 SCR-System, reverting valve blocked
524147 13 Set together with DFC_SCRCoBldUpLoPres. DFC_SCRCoBldUpLoPresRst is only used for inducement purposes.
It ensures that legal inducement is working correctly.
524149 2 Plausibility error between pressure downstream turbine (PTrbnDs) and ambient air pressure (EnvP)
524149 2 Pressure downstream turbine, plausibility error
524152 2 Urea Quality Sensor; Timeout CAN message
524153 2 Urea tank level & urea tank temperature via CAN bus, timeout of CAN message
524156 9 Timeout error of CAN-Receive-Frame ComRxEBC2.
524157 9 Fan control; time out for fan governing
524159 0 Fan; short circuit battery or open load
524159 1 Fan; short circuit ground
524160 5 Fan; in/outlet valve 1; open load
524160 3 Fan; in/outlet valve 1; short circuit battery
524160 4 Fan; in/outlet valve 1; open load ground
524161 5 Fan; in/outlet valve 2; open load
524161 3 Fan; in/outlet valve 2; short circuit battery
524161 4 Fan; in/outlet valve 2; open load ground
524162 12 Fan; fan control; angle sensor defect
524163 12 Fan; fan control; fan or valve defect
524175 0 SCR-CAT, Nox emissions above maximum threshold
524177 7 SCR System, DEF suction line blocked
524178 7 SCR System, DEF pressure out of range
524189 9 Master / Slave Can disturbed.
524190 14 Inducement level 1 active
524191 14 Inducement level 2 active
524193 8 The standstill-regeneration mode time exceeds the long limit threshold.
Vehicle was too long or too often in standstill mode. Change oil and reset counter.
524194 8 The standstill-regeneration mode time exceeds the short-limit.
Vehicle was too long or too often within a short time in standstill mode.
Change oil and reset counter.
524195 14 Standstill request due to crystallization ignored too long
524196 13 Variant handling, address error
524196 2 Variant handling, Synchronisation error
524202 11 SCR error code in master ECU active.
524203 11 DEF tank level failure is in master ECU active.
524204 11 SCR after run failure is in master ECU active.
3-52 3121728

524205 11 SCR Co2Off failure is in master ECU active.
524206 11 SCR disable DEF dosing failure is in master ECU active.
524230 11 Inducement HW Failure Slave.
524231 11 Inducement SCR Tamp. Slave
524232 11 Inducement DEF Quality in Slave ECU
524239 11 SCR regeneration failure is in slave ECU active.
524248 11 NOX sensor downstream error in slave ECU
524249 11 DEF dosing valve error in slave ECU
524251 11 DEF pressure problems in slave ECU
524252 11 Reverting valve error in slave ECU
524253 11 DEF back flow line heater error on slave ECU
524254 11 Error NOx-Tailpipe emissions exceeded on Slave ECU
524255 11 DEF suction line heater error on slave ECU
524256 11 DEF supply module heater error on slave ECU
524257 11 Error Exhaust pressure upstream SCR on Slave ECU
524258 11 Error Exhaust temperature upstream SCR on Slave ECU
524259 11 DEF pressure line heater error on slave ECU
524260 11 Error Urea pump temperature on Slave ECU
524261 11 Error DEF heater relays on Slave ECU
524267 14 Announcement triggers the Inducement Level 2
3121728 3-53
3.15 DEUTZ D2011L04 ENGINE
4
2
5
4
101186808-K
MAE21760
1. Deutz D2011 Engine 3. Bracket 5. Batter y Cable (-)

2. Fuel Hose 4. Battery Cable (+)
Figure 3-28. Deutz D2011 Engine Installation
3-54 3121728
1001186815-E
MAE21770
1. Piston Pump Assembly 2. Deutz D2011 Engine Assembly 3. Gear Pump Assembly 4. Exhaust Pipe
Figure 3-29. Deutz D2011 Engine and Pumps Sub-Assembly
3121728 3-55
17
20
7 21 18
22
5
22
4
8
10
6
3
1001186816-M
MAE21780
1. Fan 6. Adapter 11. Engine Bracket - Rear 16. Tray 21. Air Filter
2. Relay 7. Clamp, Air Cleaner 12. Engine Bracket - Right 17. Radiator Support 22. Hose
3. Gasket, Air Intake Adapter 8. Indicator, Air Filter Service 13. Fan Adapter 18. Hose 23. Glow Plug Harness
4. Support 9. Deutz D2011 Engine 14. Motor Mount 19. Motor Mount 24. Pump Coupling Kit
5. Bracket 10. Radiator 15. Plate 20. Tube 25. Shim
Figure 3-30. Deutz D2011 Engine Assembly - Sheet 1 of 2
3-56 3121728
23
13 12
25 24
11
2
16
15
19
14
1001186816-M
MAE21790
Figure 3-31. Deutz D2011 Engine Assembly - Sheet 2 of 2
3121728 3-57
NOTE: Refer to engine manufacturer’s manual for detailed operat- Changing Engine Oil
ing and maintenance instructions.
1. Allow engine to warm up. Engine oil should reach
Checking Oil Level approximately 176° F (80° C).
1. Make sure machine and engine are level and switch 2. Make sure machine and engine are level and switch off
engine OFF before checking oil level. engine.
2. Remove oil dipstick and wipe with clean cloth. 3. Place oil tray under engine.
3. Insert dipstick to the stop and remove again.
4. Check oil level. Top oil level as shown in figure below
HOT ENGINE OIL CAN CAUSE BURNS. AVOID CONTACT WITH HOT OIL WHEN
with an approved grade and type of oil outlined in
DRAINING.
engine manufacturer’s operator’s manual.
COLLECT USED OIL IN A CONTAINER SUITABLE FOR DISPOSAL OR RECYCLING.

DISPOSE OF USED ENGINE OIL IN ACCORDANCE WITH ENVIRONMENTAL REGU-
LATIONS.
4. Open oil drain valve and drain oil.
5. Close oil drain valve.
6. Pour in new engine oil. Refer to Section 1 for capacity
and Figure 3-33., Engine Oil Viscosity.
Figure 3-32. Deutz Dipstick Markings

5. Replace dipstick until fully seated.
Figure 3-33. Engine Oil Viscosity
3-58 3121728
Changing Oil Filter 6. Screw in new filter by hand until gasket is flush.

2. Using a suitable oil filter removal tool, loosen lube oil fil-
ter cartridge and spin off.
7. Hand-tighten filter another half-turn.

8. Check oil level.
9. Check oil pressure.
3. Catch any escaping oil. 10. Check oil filter cartridge for leaks.
4. Clean any dirt from filter carrier sealing surface.
Replace Fuel Filter
5. Lightly coat new oil filter rubber gasket with clean oil.
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL
SYSTEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM.

2. Remove fuel filter cartridge. Catch any escaping fuel.
3. Clean dirt from filter carrier sealing surface.
4. Apply light film of oil or diesel fuel to rubber gasket of
new filter cartridge.
5. Screw in new filter by hand until gasket is flush. Hand-
tighten filter another half-turn.
6. Open fuel shut-off valve.
7. Check for leaks.
3121728 3-59
Clean Fuel Strainer 3.16 SPARK ARRESTER CLEANING INSTRUCTIONS

1. Remove cleanout plug in bottom of spark arrester (muf-
fler).
FUEL IS FLAMMABLE AND CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE
2. Without causing deformation (or any type of damage to
NO OPEN FLAMES OR SPARKS ARE IN THE AREA WHEN WORKING ON FUEL SYS-
TEM. DO NOT SMOKE WHEN WORKING ON FUEL SYSTEM. spark arrester) repeatedly tap on arrester near cleanout
plug. This may be enough to begin spark trap drainage.
1. Unscrew hexagonal nut (1). 3. An industrial vacuum cleaner can do a complete job at
this point.
a. Or, IN A SAFE AREA, start engine. Alternate between
low idle and high idle for two to three minutes.
b. Or, operate engine as required by application for
two to three minutes.
4. Install cleanout plug.
3.17 GLOW PLUGS

If glow plug option is enabled in the JLG Control System, glow
plug and indicator lamp will be energized when Power/Emer-
gency Stop switch is pulled on if ambient air temperature is
less than 50° F (10° C) and engine coolant temperature is less
than 140° F (60° C).
This determination occurs one second after the Power/Emer-

2. Remove fuel strainer cover (2). gency Stop switch has been pulled on. Lamp and glow plugs
remain energized for period of time specified by setting in the
3. Clean fuel strainer with diesel fuel and replace as JLG Control System. Engine start is disabled during this period.
needed.
On Deutz engines, glow plugs continue (post glow) after
4. Place seal (3) in position. engine has started three times the machine digit setting.
5. Install fuel strainer cover (2). Tighten screw (1).
6. Check for leaks.
3-60 3121728
Table 3-5. Deutz Trouble Codes (D2011L04 Engine)
FAULT FAULT NO. FAULT LOCALITY/

SPN FMI CAUSE REMARKS HELP
GROUP (IN SERDIA) FAULT DESCRIPTION
Zero error display - No faults 524287 31 No active faults present
Governor in emergency
operation (if sensor 2
available). Emergency
Sensor failure. Distance switch-off (if sensor 2 not
Check distance. Check cable
from gear too far. available or failed).
01 Speed sensor 1 190 8 connection. Check sensor and
Additional fault impulses. Governor in emergency
replace if required.
Cable joint interrupted. operation (with sensor 1)
Emergency switch-off (if
Revolutions/  sensor 1 not available or
speed acquisition failed).
Tacho failed. Additional Check cable connection and Tacho.
Governor in emergency
3 Speed sensor 84 8 fault impulses. Cable Replace if required.
operation.
connection interrupted.
Speed was/is in excess of Check parameter (21). Check speed
Engine stop.
Excess speed switch- limit.e. settings.
4 190 0
off Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator
(impulse on incorrect speed). Check No. of teeth. For vehicles check for possible thrust mode.
07 Charge air pressure 102 2
08 Oil pressure 100 2

Fault at corresponding With failure of the sensor, Check sensor cable. Check sensor
Sensors 09 Coolant temperature 110 2 sensor entry (e.g. short the associated monitoring and replace if required. Check fault
circuit or cable break). function is de-activated. limits for sensor.
10 Charge air temperature 105 2
11 Fuel temperature 174 2
3121728 3-61

Fault message (disappears
Check engine (oil level, oil pump).
Oil pressure below speed- when oil pressure is again
Check oil pressure sensor and
30 Oil pressure warning 100 1 dependent warning line above recovery limit).
cable. Check oil pressure warning
characteristic After a delay time - fill
line characteristic.
limitation.
when coolant temperature
Coolant temperature Coolant temperature has Check coolant. Check coolant
31 110 0 again drops below recovery
warning exceeded warning level. temperature sensor and cable.
level). After a delay time - fill
limitation.
when charge air
Charge air temperature Charge air temperature has Check charge air. Check charge air-
32 105 0 temperature gain drops
warning exceeded warning level. temperature sensor and cable.
Functional fault below recovery level). After
warning a delay time - fill limitation.
Switch input “Low coolant Check coolant level. Check coolant
34 Coolant level warning 111 1 Fault message.
level” is active. level sensor and cable.
revolutions was/is above
(top) revolution speed Check parameters. Check speed
Speed warning (with limit. “Thrust mode” settings.
35 thrust mode S ID 190 14 function is active.
operation). Check PID setting. Check rods. Check actuator and replace if required. Check cable to actuator.
Check speed sensor (impulses on incorrect speed). Check No. of teeth. For vehicles check for
possible thrust mode.
Fuel temperature Fuel-temperature has when fuel temperature Check fuel. Check fuel temperature
36 174 0
warning exceeded warning level. again drops below recovery sensor and cable.
level).
Check charge air. Check charge air-
Charge air temperature Charge air temperature has
42 105 0 Emergency stop temperature sensor and cable.
Functional fault, switch- off exceeded switch-off limit.
Check switch-off limit.
switch-off
Coolant level switch- Switch input “Low coolant Check coolant level. Check coolant
44 111 1 Emergency stop. Start lock.
off level” is active. level sensor and cable.
3-62 3121728

Check actuator, replace if required.
50 Feedback S ID 24 12 Check cable, check fault limits for
Actuator not connected. Emergency switch-off.
“Confirmation”.
Fault in actuator Actuator cannot be
Check actuator, replace if required.
confirmation. operated.
52 Reference feedback S ID 24 13 Check cable, check fault limits for
“Rifeness confirmation”.
Injection pump/actuator
jammed or not connected.
Check actuator/actuator rods /
Control travel Difference between Fault message (disappears
53 DI 23 7 injection pump, replace if
difference nominal/actual control when difference is < 10%).
required. Check actuator cable.
travel is > 10% of the
Actuator
overall control path.
Check actuator and replaced if
required. Check feedback cable.
Check fault limits and reference
No automatic actuator Engine stop / start lock. values of the feedback. Program
Auto calibration
equalization possible. Governor cannot be taken the fault limits for feedback, save
59 BOSCH-EDC pumps S ID 23 13
Incorrect input of the into use. EDC actuator values. Switch ignition off and on
faulty operation
actuator reference values. calibration required. again.Check again. If faulty, inform
DEUTZ-Service and carry out
automatic equalization again. Set
fault limits again.
Digital output 3
Check cable of digital output (cable
60 (Switch-off solenoid, S ID 51 2 Driver level is switched off.
Fault (short circuit / cable break or short circuit).
pin M 2)
break) at digital output.
Digital output 6, pin M
62 S ID 60 2 Fault message.
Hardware  7
inputs/ outputs Excess voltage switch-
63 S ID 51 6
off solenoid
67 Error Hand Setp1 91 11
68 Error CAN Step 1 898 2
CAN-controller for CAN-bus

is faulty. Fault removal
70 CAN-Bus controller S ID 231 12
despite re- initializing Check CAN connection,
continuously not possible Application-dependent. terminating resistor (see Chapter
Overflow in input buffer or 12.4), Check control unit.
Communication CAN interface SAE J
71 S ID 231 9 a transmission cannot be
1939
placed on the bus.
Check CAN connection, cable
Cable break, short
74 S ID 231 14 connection. Check sensor and
circuit or bus-error
replace if required.
3121728 3-63

Fault in parameter
Parameter
programming in the
76 programming (write S ID 253 12
governor fixed value
EEPROM) Switch ignition off and on again.
memory.
Check again. If faulty inform DEUTZ
Constant monitoring of
Service
program memory shows Emergency switch-off.
Memory 77 Cyclic program test S ID 240 12
error (so-called “Flash- engine cannot be started.
test”).
Note values of parameters (3895
Constant monitoring of
and 3896). Switch ignition off and
78 Cyclic RAM test S ID 254 2 working memory shows
on again. Check again. If faulty
error.
inform DEUTZ Service.
Power supply for actuator Fault message (disappears Switch ignition off and on again.
Power supply
80 S ID 254 2 not in the permissible when power again in the Check again. If faulty inform DEUTZ
(Actuator)
range. normal range). Service.
83 Reference voltage 1 S ID 254 2 Fault message (disappears Check voltage supply. Switch
Reference voltage for
when power again in the ignition off and on again. Check
84 Reference voltage 2 S ID 254 2 actuator not in the
normal range). Auxiliary again. If faulty inform DEUTZ
permissible range.
85 Reference voltage 4 S ID 254 2 value 5 V Service.
Control unit
hardware Internal temperature for Fault message (disappears Switch ignition off and on again.
86 Internal temperature 171 12 control unit not in when power again in the Check again. If faulty inform DEUTZ
permissible range. normal range). Service.
when power again in normal
Atmospheric pressure not
87 Atmospheric pressure 108 12 range). Atmospheric
in permissible range.
pressure monitoring
function de-activated.
No data found or checksum
Check data for correct settings.
Parameter fault  of data is faulty (note: fault
Save parameters. Switch ignition
90 (EEPROM retrieval or S ID 253 2 only occurs during setting Engine cannot be started.
off and on again. Check again. If
checksum faulty). of parameter / saving or
faulty inform DEUTZ Service.
reset.).
Program logic Note parameters (3897 and 3898).
Internal calculation fault 
Emergency switch-off. Switch ignition off and on again.
93 Stack overflow S ID 240 2 (so-called “Stack over
Engine cannot be started. Check again. If faulty inform DEUTZ
flow” fault).
Service.
94 Internal fa u lt S ID 254 2
NOTE: SID is equal to 512. To get SPN #, add 512 + number. For example, SID 254 would be 512+254 or an SPN of 766.
3-64 3121728
3.18 FORD ENGINE

9
6
7
8 8
3
2
10
2
3 1001215608-C
MAE21840
1. Hose 3. Battery Cable (+) 5. Ford Engine and Pumps 7. Hose 9. Hose
2. Battery Cable (-) 4. Bracket 6. Bracket 8. Hose 10. Hose
Figure 3-34. Ford MSG425 Engine Installation
3121728 3-65
1001215610-C
MAE21850
1. Piston Pump Assembly 4. Exhaust Insulate 7. Muffler Insulate

2. Gear Pump Assembly 5. Exhaust Insulate 8. Exhaust Pipe
3. Ford Engine Assembly 6. Muffler Insulate 9. Exhaust Insulate
Figure 3-35. Ford Engine and Pumps Sub-Assembly
3-66 3121728
35
12
1
38
35
36
33
19
20
21 16
22 34
15
18
14
32
25
EXHAUST SYSTEM
17
1001215612-D
MAE21860
1. Fuel Hose 4. Support 7. Motor Mount 10. Air Filter 13. Radiator
2. Hose 5. Bracket 8. Bracket 11. Support 14. Exhaust Pipe
3. Strap 6. Hose 9. Bracket 12. Fan 15. Clamp
Figure 3-36. Ford Engine Assembly - Sheet 1 of 2
3121728 3-67
37
1
24
1
38
40
23
7
39
6
5
4 31
1
2
28 27 30
10
26
11
8
13
29
8
1001215612-D
MAE21870
16. Exhaust Pipe 21. Plate 26. Air Intake Pipe 31. Bracket 36. Hose
17. Bracket 22. Support 27. Air Intake Pipe 32. Engine Mount (RH Front) 37. Surge Tank
18. Heat Shield 23. Tray 28. Air Intake Pipe 33. Engine Mount (LH Front) 38. Bracket
19. Adapter 24. Radiator Support 29. Radiator Hose (Lower) 34. Engine Mount (Rear) 39. Restriction Indicator
20. Ford Engine Assembly 25. Mount 30. Radiator Hose (Upper) 35. Heater Hose 40. Hose
Figure 3-37. Ford Engine Assembly - Sheet 2 of 2
3-68 3121728
Table 3-6. Fault Code Cross Reference List (Ford MSG425 Engine)
Original DTC Corresponding

Fault Name
Number DTC (Current)
11 Intake cam / distributor position 11
24 Exhaust cam position 24
111 CL high LPG 1151
112 EGO open/lazy pre-cat 1 134
113 EGO open/lazy pre-cat 2/post-cat 1 154
114 EGO open/lazy post-cat 1 140
115 EGO open/lazy post-cat 2 160
121 CL high gasoline bank1 1155
122 CL low gasoline bank1 1156
124 CL low LPG 1152
125 CL high NG 1153
126 CL low NG 1154
131 CL high gasoline bank2 1157
132 CL low gasoline bank2 1158
133 Gasoline cat monitor 420
134 LPG cat monitor 1165
135 NG cat monitor 1166
136 Gasoline cat monitor 430
141 AL high gasoline bank1 171
142 AL low gasoline bank1 172
143 AL high LPG 1161
144 AL low LPG 1162
145 AL high NG 1163
146 AL low NG 1164
147 AL high gasoline bank2 174
148 AL low gasoline bank2 175
161 Battery Voltage High 563
162 Battery Voltage Low 562
163 AUX analog PD1 high 1515
164 AUX analog PD1 low 1516
165 AUX analog PU3 high 1517
166 AUX analog PU3 low 1518
167 AUX analog PUD1 high 1541
168 AUX analog PUD1 low 1542
181 AUX DIG1 high 1551
182 AUX DIG1 low 1552
3121728 3-69

Fault Name
211 IAT high voltage 113
212 IAT low voltage 112
213 IAT higher than expected 1 111
214 IAT higher than expected 2 127
215 Oil pressure low 524
221 ECT/CHT High Voltage 118
222 ECT/CHT Low Voltage 117
223 CHT higher than expected 1 1521
224 CHT higher than expected 2 1522
225 ECT higher than expected 1 116
226 ECT higher than expected 2 217
231 MAP High Pressure 108
232 MAP Low Voltage 107
234 BP high pressure 2229
235 BP low pressure 129
242 Crank sync noise 336
243 Never crank synced at start 16
244 Cam loss 342
245 Cam sync noise 341
246 Crank loss 337
253 Knock 1 sensor Open 327
254 Knock 1 Excessive Signal 326
255 Knock 2 sensor Open 332
256 Knock 2 Excessive Signal 331
261 FP high voltage 92
262 FP low voltage 91
271 FT Gasoline High Voltage 183
272 FT Gasoline Low Voltage 182
273 FT Gaseaous fuel high voltage 188
274 FT Gaseaous fuel low voltage 187
281 TIP High Voltage 238
282 TIP Low Voltage 237
283 TIP Active 236
301 Emissions/catalyst damaging misfire 301
3-70 3121728

Fault Name
311 Injector Loop Open or Low-side short to Ground 261
312 Injector Coil Shorted 262
351 FPump motor loop open or high-side shorted to ground 628
352 FPump motor high-side shorted to power 629
353 Megajector delivery pressure higher than expected 1171
354 Megajector delivery pressure lower than expected 1172
355 Megajector comm lost 1173
359 Fuel run-out longer than expected 1181
361 Megajector voltage supply high 1174
362 Megajector voltage supply low 1175
363 Megajector internal actuator fault detection 1176
364 Megajector internal circuitry fault detection 1177
365 Megajector internal comm fault detection 1178
411 Primary Loop Open or Low-side Short to Ground 2300
412 Primary Coil Shorted 2301
3121728 3-71

Fault Name
511 FPP1 high voltage 2122
512 FPP1 low voltage 2123
513 FPP1 higher than IVS limit 2115
514 FPP1 lower than IVS limit 2139
515 FPP1 higher than FPP2 2126
516 FPP1 lower than FPP2 2121
517 IVS stuck at-idle, FPP1/2 match 2130
518 IVS stuck off-idle, FPP1/2 match 2131
521 FPP2 high voltage 2128
522 FPP2 low voltage 2127
523 FPP2 higher than IVS limit 2116
524 FPP2 lower than IVS limit 2140
525 FPP1/2 simultaneous voltages out of range 1121
526 FPP1 invalid voltage and FPP2 disagrees with IVS 2120
527 FPP2 invalid voltage and FPP1 disagrees with IVS 2125
528 FPP1/2 do not match each other or the IVS 1122
531 TPS1 high voltage 123
532 TPS1 low voltage 122
533 TPS2 high voltage 223
532 TPS2 low voltage 222
535 TPS1 higher than TPS2 221
536 TPS1 lower than TPS2 121
537 Unable to reach higher TPS 2112
538 Unable to reach lower TPS 2111
539 TPS1/2 simultaneous voltages out of range 2135
545 IVS/Brake/Trans-Park interlock failure 1531
3-72 3121728

Fault Name
551 Max govern speed override 219
552 Fuel rev limit 1111
553 Spark rev limit 1112
611 COP failure 606
612 Invalid interrupt 1616
613 A/D loss 1615
614 RTI 1 loss 1612
615 Flash checksum invalid 601
616 RAM failure 604
631 5VE1 low voltage 642
632 5VE1 high voltage 643
633 5VE2 high voltage 653
634 5VE2 low voltage 652
635 5VE 1/2 simultaneous out-of-range 1611
641 Rx Inactive 1621
642 Rx Noise 1622
643 Invalid Packet Format 1623
644 Shutdown Request 1624/1625
646 CAN Tx failure 1626
647 CAN Rx failure 1627
648 CAN address conflict failure 1628
655 RTI 2 loss 1613
656 RTI 3 loss 1614
711 Relay Control ground short 686
712 Relay Coil Open 685
713 Relay coil short to power 687
714 Fpump relay control ground short 628
715 Fpump relay coil open 627
716 Fpump relay coil short to power 629
721 Start relay control ground short 616
722 Start relay coil open 615
723 Start relay coil short to power 617
724 Buzzer control ground short 1641
725 Buzzer open 1642
726 Buzzer control short to power 1643
731 PWM1-Gauge1 open / ground short 1631
732 PWM1-Gauge1 short to power 1632
733 PWM2-Gauge2 open /ground short 1633
735 PWM3-Gauge3 open / ground short 1635
741 PWM4 open / ground short 1637
3121728 3-73

Fault Name
742 PWM4 short to power 1638
761 MIL control ground short 1644
762 MIL open 650
763 MIL control short to power 1645
771 Tach output ground short 2618
772 Tach output short to power 2619
1182 Fuel impurity level high 1182
1183 Megajector autozero / lock-off failed 1183
1311 Misfire detected 1311
1629 J1939 TSC1 message receipt lost 1629
1630 J1939 ETC message receipt lost 1630
3-74 3121728
Table 3-7. CAN to DTC Cross Reference (Ford MSG425 Engine)
DTC DTC and Description SPN FMI

108 MAP pressure high 106 16
107 MAP voltage low 106 4
118 ECT voltage high 110 3
117 ECT voltage low 110 4
116 ECT higher than expected stage 1 110 15
113 IAT voltage high 105 3
112 IAT voltage low 105 4
2229 BP pressure high 108 0
129 BP pressure low 108 1
563 Vbat voltage high 168 15
562 Vbat voltage low 168 17
643 Sensor supply voltage 1 high 1079 3
642 Sensor supply voltage 1 low 1079 4
123 TPS1 voltage high 51 3
122 TPS1 voltage low 51 4
223 TPS2 voltage high 3673 3
222 TPS2 voltage low 3673 4
221 TPS1-2 higher than expected 51 0
121 TPS1-2 lower than expected 51 1
2122 FPP1 voltage high 91 3
2123 FPP1 voltage low 91 4
2128 FPP2 voltage high 29 3
2127 FPP2 voltage low 29 4
2115 FPP1 higher than IVS 91 0
2139 FPP1 lower than IVS 91 1
2116 FPP2 higher than IVS 29 0
2140 FPP2 lower than IVS 29 1
2126 FPP1-2 higher than expected 91 16
2121 FPP1-2 lower than expected 91 18
524 Oil pressure low 100 1
171 Adaptive-learn gasoline bank1 high 4237 0
172 Adaptive-learn gasoline bank1 low 4237 1
1155 Closed-loop gasoline bank1 high 4236 0
1156 Closed-loop gasoline bank1 low 4236 1
1157 Closed-loop gasoline bank2 high 4238 0
1158 Closed-loop gasoline bank2 low 4238 1
1151 Closed-loop LPG high 4236 0
1152 Closed-loop LPG low 4236 1
1153 Closed-loop NG high 4236 0
1154 Closed-loop NG low 4236 1
174 Adaptive-learn gasoline bank2 high 4239 0
175 Adaptive-learn gasoline bank2 low 4239 1
3121728 3-75

1161 Adaptive-learn LPG high 4237 0
1162 Adaptive-learn LPG low 4237 1
1163 Adaptive-learn NG high 4237 0
1164 Adaptive-learn NG low 4237 1
261 Injector 1 open or short to ground 651 5
262 Injector 1 coil shorted 651 6
2300 Spark coil 1 primary open or short to ground 1268 5
2301 Spark coil 1 primary shorted 1268 6
3-76 3121728

217 ECT higher than expected stage 2 110 0
111 IAT higher than expected stage 1 105 15
127 IAT higher than expected stage 2 105 0
327 Knock1 sensor open or not present 731 4
2112 Unable to reach higher TPS 51 7
2111 Unable to reach lower TPS 51 7
1531 Gov1/2/3 interlock failure 0 31
628 Fuel-pump high-side open or short to ground 1347 5
629 Fuel-pump high-side short to power 1347 6
342 Loss of CAM input signal 723 4
341 CAM input signal noise 723 2
336 CRANK input signal noise 636 2
16 Crank and/or cam could not synchronize during start 636 8
606 Microprocessor failure - COP 629 31
1612 Microprocessor failure - RTI 1 629 31
1615 Microprocessor failure - A/D 629 31
1616 Microprocessor failure - Interrupt 629 31
601 Microprocessor failure - FLASH 628 13
604 Microprocessor failure - RAM 630 12
326 Knock1 excessive or erratic signal 731 2
219 RPM higher than max allowed govern speed 515 15
1111 RPM above fuel rev limit level 515 16
1112 RPM above spark rev limit level 515 0
134 EGO1 open / lazy 3217 5
1521 CHT higher than expected stage 1 110 16
1522 CHT higher than expected stage 2 110 0
1515 AUX analog Pull-Down 1 high voltage 710 3
1516 AUX analog Pull-Down 1 low voltage 710 4
1511 AUX analog Pull-Up 1 high voltage 701 3
1512 AUX analog Pull-Up 1 low voltage 701 4
1621 RS-485 Rx inactive 0 31
1622 RS-485 Rx noise 0 31
1623 RS-485 Rx bad packet format 0 31
1624 RS-485 remote shutdown request 0 31
238 TIP high voltage 102 3
237 TIP low voltage 102 4
3121728 3-77

92 FP high voltage 94 3
91 FP low voltage 94 4
420 Catalyst inactive on gasoline (Bank 1) 3050 11
1165 Catalyst inactive on LPG 3050 11
1166 Catalyst inactive on NG 3050 11
1171 MegaJector delivery pressure higher than expected 520260 0
1172 MegaJector delivery pressure lower than expected 520260 1
1173 MegaJector comm lost 520260 31
1174 MegaJector voltage supply high 520260 3
1175 MegaJector voltage supply low 520260 4
1176 MegaJector internal actuator fault detection 520260 12
1177 MegaJector internal circuitry fault detection 520260 12
1178 MegaJector internal comm fault detection 520260 12
1131 WGP voltage high 1192 3
1132 WGP voltage low 1192 4
234 Boost control overboost failure 102 0
299 Boost control underboost failure 102 1
236 TIP active 102 2
183 FT high voltage 174 3
182 FT low voltage 174 4
524 Oil pressure sender low pressure 100 1
521 Oil pressure sender high pressure 100 0
523 Oil pressure sender high voltage 100 3
522 Oil pressure sender low voltage 100 4
337 Crank signal loss 636 4
1625 J1939 shutdown request 1110 31
1626 CAN-J1939 Tx fault 639 12
1627 CAN-J1939 Rx fault 639 12
508 IAC ground short 520201 6
509 IAC coil open/short 520201 5
686 Power relay ground short 1485 4
685 Power relay coil open 1485 5
687 Power relay coil short to power 1485 3
616 Start relay ground short 1321 4
615 Start relay coil open 1321 5
617 Start relay coil short to power 1321 3
1641 Buzzer control ground short 920 4
1642 Buzzer open 920 5
1643 Buzzer control short to power 920 3
628 Fuel pump relay control ground short 1348 4
627 Fuel pump relay coil open 1348 5
629 Fuel pump relay coil short to power 1348 3
1644 MIL control ground short 1213 4
3-78 3121728

650 MIL open 1213 5
1645 MIL control short to power 1213 3
2618 Tach output ground short 645 4
2619 Tach output short to power 645 3
2130 IVS stuck at-idle, FPP1/2 match 558 5
2131 IVS stuck off-idle, FPP1/2 match 558 6
1121 FPP1/2 simultaneous voltages out-of-range (redundancy lost) 91 31
2120 FPP1 invalid voltage and FPP2 disagrees with IVS (redundancy lost) 520199 11
2125 FPP1/2 do not match each other or IVS (redundancy lost) 520199 11
1122 FPP1/2 do not match each other or IVS (redundancy lost) 520199 11
653 Sensor supply voltage 2 high 1080 3
652 Sensor supply voltage 2 low 1080 4
1611 Sensor supply voltage 1 and 2 out-of-range 1079 31
332 Knock2 sensor open or not present 520197 4
331 Knock2 excessive or erratic signal 520197 2
2135 TPS1/2 simultaneous voltages out-of-range 51 31
2428 EGT temperature high 173 0
1628 J1939 CAN address / engine-number conflict 639 13
1631 PWM1-Gauge1 open / ground short 697 5
1632 PWM1-Gauge1 short to power 697 3
1637 PWM4 open / ground short 700 5
1638 PWM4 short to power 700 3
430 Catalyst inactive on gasoline (Bank 2) 3051 11
1541 AUX analog Pull-Up/Down 1 high voltage 704 3
1542 AUX analog Pull-Up/Down 1 low voltage 704 4
1551 AUX digital 1 high voltage 707 3
1552 AUX digital 1 low voltage 707 4
3121728 3-79

188 Gaseous fuel temperature sender high voltage 3468 3
187 Gaseous fuel temperature sender low voltage 3468 4
1629 J1939 TSC1 message receipt loss 695 9
359 Fuel run-out longer than expected 632 31
1630 J1939 ETC message receipt loss 91 19
502 Roadspeed input loss of signal 84 8
1411 EMWT1 voltage high 441 3
1412 EMWT2 voltage high 442 3
1413 EMWT1 voltage low 441 4
1414 EMWT2 voltage low 442 4
1415 EMWT1 higher than expected stage 1 441 15
1419 ERWT1 voltage high 1385 3
1420 ERWT2 voltage high 1386 3
1421 ERWT1 voltage low 1385 4
1422 ERWT2 voltage low 1386 4
1423 ERWT1 higher than expected stage 1 1385 15
8901 UEGO microprocessor internal fault 3221 31
8902 UEGO heater supply high voltage 3222 3
8903 UEGO heater supply low voltage 3222 4
8904 UEGO cal resistor voltage high 3221 3
8905 UEGO cal resistor voltage low 3221 4
8906 UEGO return voltage shorted high 3056 3
8907 UEGO return voltage shorted low 3056 4
8908 UEGO pump voltage shorted high 3218 3
8909 UEGO pump voltage shorted low 3218 4
8910 UEGO sense cell voltage high 3217 3
8911 UEGO sense cell voltage low 3217 4
8912 UEGO pump voltage at high drive limit 3225 3
8913 UEGO pump voltage at low drive limit 3225 4
8914 UEGO sense cell slow to warm up 3222 10
8915 UEGO pump cell slow to warm up 3225 10
8916 UEGO sense cell impedance high 3222 0
3-80 3121728

8917 UEGO pump cell impedance high 3225 0
8918 UEGO pump cell impedance low 3225 1
1311 Cylinder 1 misfire detected 1323 11
301 Cylinder 1 emissions/catalyst damaging misfire 1323 31
1651 J1939 ETC message receipt loss while in-gear 91 9
1182 Fuel impurity level high 520401 0
3121728 3-81
3.19 COUNTERWEIGHT
If the counterweight has been removed, ensure the retaining
bolts are torqued to the proper value as shown in Figure 3-38.,
Counterweight Bolt Torque.
MAE21750
*Torque the bolts to 346 ft-lb (469 Nm)
Figure 3-38. Counterweight Bolt Torque
3-82 3121728
3.20 GENERATOR Overload Protection

Every 250 hours
Check drive belt tension every 250 hours of operation,. STOP ENGINE WHENEVER CHECKING OR INSPECTING CIRCUIT BREAKER.
The circuit breaker protects generator windings from over-

load. Generator output stops if circuit breaker opens.
If circuit breaker continues to open, check for faulty equip-

ment connected to platform receptacles.
1/2 in.
(13 mm)
Circuit
Breaker
Figure 3-38. Generator Belt Tension
Every 500 hours

Service generator brushes and slip rings every 500 hours of
operation. Hostile environments may require more frequent
service.
Figure 3-41. Generator Circuit Breaker Location
Figure 3-39. Generator Brushes and Slip Rings

Blow out inside of generator every 500 hours of service. If
operating in a hostile environment, clean monthly.
Circuit
Breaker
MAE23780
Figure 3-42. Generator Circuit Breaker Location

(If Equipped with 4000W)
Figure 3-40. Generator Cleaning
3121728 3-83
Inspecting Brushes, Replacing Brushes, and 3. Replace brushes if damaged, or if brush is at or near min-
imum length.
Cleaning Slip Rings
CLEANING SLIP RINGS
INSPECTING BRUSH POSITION
Inspect brush alignment with slip rings. View alignment 1. Visually inspect the slip rings. Under normal use, the
through air vents in stator barrel. Brushes must ride com- rings turn dark brown.
pletely on slip rings. 2. If slip rings are corroded or their surface is uneven,
remove belt to turn shaft by hand for cleaning.
INSPECTING BRUSHES
3. Clean rings with 220 grit emery paper. Remove as little
1. Remove end panel. Inspect wires. material as possible. If rings are deeply pitted and do not
clean up, consult generator factory service.
2. Remove brush holder assembly. Pull brushes from hold-
ers. 4. Reinstall belt, brush holder assembly, and end panel.
Brush Position on Slip Rings
3 2
Acceptable Unacceptable
Note: Brushes must ride completely on slip rings.
1/4 in (6 mm)
or Less - Replace
7/16 in - 1/2 in
2 (11 - 12 mm ) New
1. Brush Holder Assembly

2. Brushes
3. Slip Rings
Figure 3-43. Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
3-84 3121728
SECTION 4. BOOM & PLATFORM

4.1 TRANSPORT POSITION SENSING SYSTEM 4.4 DUAL CAPACITY SYSTEM
The transport position sensing system consists of a boom The dual capacity selection and indicator system consists of a
angle sensor (this sensor is a hall effect sensor with built-in capacity mode toggle switch at the platform control box, a set
redundancy) mounted at the pivot point between the main of redundant proximity sensors to detect boom extension,
boom and tension link. The system uses this sensor to sense if and a main boom angle sensor. The operator selects the mode
the boom is in the position associated with high speed travel. to work in:
The control circuit reads two redundant angular sensor signals 600S: 600 lb (270 kg) unrestricted, 1000 lb (450 kg) restricted
from the boom angle sensor. Above transport angle is recog- 660SJ: 550 lb (250kg) unrestricted, 750 lb (340 kg) restricted. 
nized when one angular sensor signal from the boom angle The light indicator in the platform control box will change to
sensor reads more than 5° greater than horizontal (with match the selected mode, unless there is a system DTC that
respect to the turntable) and resets to within transport posi- forces the machine into the restricted mode. The system uses
tion when both angular sensor signals read less than 3° the boom extension proximity sensors and boom angle sensor
greater than horizontal (with respect to the turntable). The to prevent the platform from entering the unrestricted zone if
position of the articulated jib is not considered. This system is the restricted mode is selected. When the dual capacity switch
used to control the following systems: is in the restricted position, the platform will move but stop at
Beyond Transport - Drive Speed Cutback System the boundaries of the restricted zone. The platform will not be
Drive/Steer – Boom Function Interlock System able to enter the unrestricted zone. When the machine control
Oscillating Axle System system senses the platform is already on the boundaries of the
restricted zone, it only allows the retraction of the boom or lift-
4.2 BEYOND TRANSPORT - DRIVE SPEED CUTBACK ing up of the boom as these movements place the platform
further away from the unrestricted zone. In case the platform
SYSTEM is already inside the restricted zone and the dual capacity
When the boom is positioned beyond the transport position, switch is flipped to the unrestricted position at that time, the
the drive motors are automatically restricted to their maxi- machine will only allow the boom to retract and will only allow
mum displacement position (slow speed). See the Tilt Indica- the boom to lift up, as these movements will bring the plat-
tor System for interaction with the tilt sensor. form towards the restricted zone. When the dual capacity
switch is in the unrestricted position, the platform can go any-
4.3 DRIVE/STEER - BOOM FUNCTION INTERLOCK where within the whole boundaries.
SYSTEM 4.5 PLATFORM LOAD SENSING SYSTEM
The Drive/Steer – Boom Function Interlock System (not appli- The Platform Load Sensing System consists of a single load cell
cable in ANSI markets, standard in CE markets, optional in all mounted within the platform support. This system compares
other markets) uses the Transport Position Sensing System to the capacity mode recognized by the dual capacity system to
sense when the boom is out of the transport position. All con- the measured weight in the platform. When the platform
trols are simultaneously functional when the booms are within capacity is exceeded or when there is a fault in the system, the
the transport position as on the standard machine. When the platform overload indicator will flash, the platform alarm will
boom is beyond the transport position, the control functions sound at the rate of 5 sec on / 2 sec off and all platform func-
are interlocked to prevent simultaneous operation of any tion controls (except auxiliary power) will be disabled. The
boom function with drive/steer. The first function set to be ground controls are unaffected unless configured otherwise in
operated while in this mode, becomes the master function set. the machine setup selection.
In other words, while operating drive/steer functions the
boom functions are inoperable. Likewise, while operating
boom functions drive/steer functions are inoperable.
3121728 4-1
4.6 ELECTRONIC PLATFORM LEVELING 4.7 FUEL LEVEL CUTOUT SYSTEM

The Electronic Platform Leveling System simulates a conven- The Fuel Shutoff System senses when the fuel level is getting
tional master/slave cylinder arrangement by adjusting the lev- low and automatically shuts the engine down before the fuel
eling cylinder stroke based on the boom angle changes tank is emptied. When the fuel level gets below 1.2 gallons,
during the lift operation. The system uses two rotary angle the fault light will flash at the platform controls and the control
sensors (Internally Redundant Hall Effect Sensors), one to mea- system will report fault 0/0 “FUEL LEVEL LOW – ENGINE SHUT-
sure the main boom angle relative to the tension link and one DOWN” on the analyzer. There is an analyzer personality set-
to measure the platform angle relative to the main boom.  ting in the control system to control the machines response to
The first angle sensor is mounted concentric with the pin that this fault. With the “RESTART” setting, the operator will be able
connects the base boom to the tension link. As the boom rises to start the engine and run for 2 minutes. After 2 minutes, the
or lowers the sensor sends a signal to the UGM which deter- engine will shut off and a power cycle will allow the engine to
mines, through an algorithm that considers the boom linkage run for 2 more minutes. With the “ENGINE STOP” setting, the
geometry, the required angle at the second sensor.  machine will remain in this fault mode until the fuel level is
For 600S, that second sensor is mounted concentric with the returned to a level above 1.2 gallons. With the “ONE RESTART”
pin that connects the platform rotator to the fly boom. For setting, the operator will be able to start the engine and run
660SJ, the sensor is mounted with the pin between fly boom for 2 minutes. After 2 minutes, the engine will shut off for a
and jib pivot. As the level cylinder in the fly boom is activated second time and the machine will return to the “Engine Shut-
to adjust the angle between the platform and the fly boom the down” fault mode. The machine will then stay in this mode
angle sensor signal is sent to the UGM. Once the required plat- until the fuel level is returned to a level above 1.2 gallons.
form to fly boom angle (as determined by the UGM based on
the first sensors input) is reached the movement of the level
cylinder is stopped. This leveling system operates like a con-
ventional master/slave cylinder system, meaning that it will
not correct level relative to gravity but maintain the platform
angle relative to gravity as it was manually set by the operator
prior to activation of the lift function.
4-2 3121728
4.8 PLATFORM 5. Remove the bolts and washers securing the support to
the rotator.
Support Removal
1. Disconnect electrical cables from control console.
2. Tag and disconnect the hydraulic lines from the rotator.
Use suitable container to retain any residual hydraulic
fluid. Cap hydraulic lines and ports.
3. Remove the bolts securing the platform to the platform
support, then remove the platform.
MAE17170
6. Using a suitable brass drift and hammer, remove the

rotator shaft, then remove the support from the rotator.
MAE17160
4. Using a suitable lifting device, support the platform sup-

port.
NOTE: The platform support weighs approximately 125 lbs. 

(56.7 kg).
MAE17180
3121728 4-3
Support Installation 3. Torque the nut on the rotator center bolt to 586 ft. lbs.
(795 Nm). Torque the retaining bolts to 40 ft. lbs. 
1. Using a suitable lifting device, support the platform sup- (55 Nm).
port and position it on the rotator.
4. Position the platform on the platform support and
NOTE: The platform support weighs approximately 125 lbs.  install the bolts securing the platform to the platform
(56.7 kg). support.
NOTE: Install the rotator center bolt.
MAE17160
5. Remove tag and reconnect the hydraulic lines to the

rotator.
MAE17180
6. Connect the electrical cables to the platform control
console.
2. Apply Loctite 242 to the bolts and washers securing the
support to the rotator and install the bolts and washers.
MAE17170
4-4 3121728
A, B, D
C, D
A - Torque to 40 ft-lb (55 Nm)
B - Loctite #242
C - Torque to 586 ft-lb (795 Nm)
D - Check torque every 150 hours of operation
E - Torque to 65 ft-lb (88 Nm)
NOTE: If any rotator bolts are replaced, all bolts on the rotator
should be retorqued.
Figure 4-1. Platform Support Torque Values
3121728 4-5
4.9 ROTATOR AND SLAVE CYLINDER Assembly/Disassembly

For detail assembly/disassembly instruction, Refer Rotary
NOTE: Refer Figure 4-2., Removal of Components - Rotator and Actuator Manual (PN 3128848).
Slave Cylinder.
Installation
Removal
600S
600S
1. Support the slave cylinder. Using a suitable brass drift
1. Tag and disconnect hydraulic lines from the rotator. Use and hammer, install pin (3) to the fly boom.
suitable container to retain any residual hydraulic fluid.
Cap hydraulic lines and ports. 2. Support the rotator. Using a suitable brass drift and
hammer, install pin (2) to the fly boom and install the
2. Supporting the rotator, remove hardware from pin (1). rotator.
Using a suitable brass drift and hammer remove pin (1)
from the fly boom. 3. Using a suitable brass drift and hammer, install pin (1) to
the rotator.
3. Remove the hardware from pin (2). Using a suitable
brass drift and hammer, remove pin (2) from the fly 4. Remove tag and reconnect the hydraulic lines to the
boom and remove the rotator. rotator and the slave cylinder.
4. Supporting the slave cylinder, remove the hardware 660SJ

from pin (3). Using a suitable brass drift and hammer
1. Telescope the fly section out approximately 
remove pin (3) from the fly boom.
20 in. (50.8 cm) to gain access to the slave leveling cylin-
660SJ der.
1. Tag and disconnect hydraulic lines from the rotator. Use 2. Support the slave cylinder. Using a suitable brass drift
suitable container to retain any residual hydraulic fluid. and hammer, install pin (4) to the fly boom.
Cap hydraulic lines and ports. 3. Using a suitable brass drift and hammer, install pin (3) to
2. Supporting the rotator, remove hardware from pin (1). the jib assembly.
Using a suitable brass drift and hammer remove pin (1) 4. Support the rotator. Using a suitable brass drift and
from the jib assembly. hammer, install pin (2) to the fly boom and install the
3. Remove the hardware from pin (2). Using a suitable rotator.
brass drift and hammer, remove pin (2) from the jib 5. Using a suitable brass drift and hammer, install pin (1) to
assembly and remove the rotator. the rotator.
4. Telescope the fly section out approximately  6. Remove tag and reconnect the hydraulic lines to the
20 in. (50.8 cm) to gain access to the slave leveling cylin- rotator and the slave cylinder.
der.
5. Remove the hardware from pin (3). Using a suitable
brass drift and hammer remove pin (3) from the jib
assembly.
6. Supporting the slave cylinder, remove the hardware
from pin (4). Using a suitable brass drift and hammer
remove pin (4) from the fly boom.
4-6 3121728
660SJ 3
SLAVE CYLINDER
ROTATOR
600S
3
2
ROTATOR
2 MAE22800
1
Figure 4-2. Removal of Components - Rotator and Slave Cylinder
3121728 4-7
4.10 MAIN BOOM ASSEMBLY 11. Support the boom lift cylinder and remove retaining
bolts, keeper pins, and pins (3 and 4) securing the lift
cylinder and tower link to the boom assembly.
Removal
12. Remove the boom assembly.
NOTE: Refer to Figure 4-3., Boom Assembly Removal and Installa-
13. If required, remove retaining bolt, keeper pin, and pin (5)
tion.
securing tension link to the turntable and place it on an
adequate support.
1. Level the boom and support boom assembly and tower
link with adequate lifting equipment as shown below. NOTE: The tension link weighs approximately 419 lbs. (190 kg).
2. Use a ratchet strap to bind the tower link to boom.
NOTE: The boom alone weighs approximately 2792 lbs. (1269 kg).
Including the powertrack, slave cylinder, rotator, jib, plat-
form and platform support the assembly weighs approxi-
mately 7500 lbs. (3400 kg).
3. Tag and disconnect all electrical connections from the

boom assembly.
4. Tag, disconnect and cap hydraulic lines from telescope
cylinder and boom lift cylinder. Use an adequate con-
tainer to catch any residual hydraulic fluid.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS-

CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM.
5. Tag and disconnect hydraulic lines from boom to the

main control valve. Use an adequate container to catch
any residual hydraulic fluid. Cap or plug all open
hydraulic lines and ports.
6. Remove retaining bolt, keeper pin, and pin (1) securing
the tower link to the turntable.
7. Lift and move forward the boom assembly with tower
link and boom lift cylinder to gain the access to boom
pivot pin (2). Ensure tension link pivot pin is above the
turntable lifting point.
8. Insert an adequate metal rod into the lifting eye holes to
support the tension link.
9. Remove retaining bolt, keeper pin, and pin securing the
main boom pivot pin (2) to the tension link.
10. Remove complete boom assembly and lift cylinder with
tower link and lift cylinder from the machine and place it
on a suitable support.
4-8 3121728
BOOM LIFT
CYLINDER BOOM
BOOM SUPPORT STRAP
SUPPORT STRAP
3
BOOM ASSEMBLY 4 2
TOWER LINK
SUPPORT STRAP TENSION LINK
1 5 TOWER LINK
BOOM
3 SUPPORT STRAP
BOOM ASSEMBLY 4
BOOM
SUPPORT STRAP
TOWER LINK
SUPPORT STRAP
TOWER LINK
5 TENSION LINK
1
MAE24130
Figure 4-3. Boom Assembly Removal and Installation
3121728 4-9
Boom Disassembly 5. Remove the hardware securing spring mounting plate

and spring to the cable block. Remove the spring
1. Tag and disconnect the hoses and electrical harnesses mounting plate and spring from the end of the boom
that run to the platform. Cap or plug all openings. section.
2. Remove hardware securing the cover plate and sheave

blocks on the bottom front of the base boom section.
Remove the cover plate and sheave blocks.
NOTE: Do not allow wire rope to rotate. This may damage the
wire rope. Clamp both threaded ends of wire rope to pre-
vent rotation.
MAE22930
6. Remove hardware securing cable block to boom sec-

3. Clamp both threaded ends of wire rope to prevent tion. Remove cable block.
rotation.
NOTE: Do not clamp on threads. Remove jam nuts and nuts which
secure the wire rope adjustments to the bottom front of the
base boom section.
4. Remove the hardware securing base boom cover plate

and base boom. Remove base boom cover plate from
the end of the boom section.
MAE22940
MAE22920
4-10 3121728
7. Remove hardware securing valve to telescope cylinder. 9. Attach an auxiliary hydraulic power source to the tele-
Remove the valve assembly. scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
MAE22970
MAE22950
10. Pull the mid and fly boom sections from the base boom
section. Use additional lifting device and lifting straps as
8. Remove the four bolts, shims, and block that secure the necessary as the sections are withdrawn. It will be help-
telescope cylinder rod to the boom base section. ful during this step to pull the mid retract cable out from
the front of the boom section as the other sections are
being pulled out. This will prevent the cables from tan-
gling as the sections are withdrawn.
11. Remove the trunnion blocks that secure the telescope

cylinder barrel to the inner mid boom section.
MAE22960
MAE22990
3121728 4-11
12. Remove the hardware that secure rope extend block to 16. Remove spacer and hardware that secure sheave guard
the fly boom section. to the telescope cylinder.
MAE23010
17. Remove the sheave assembly by adjusting the sheave

MAE23020 guard then remove the bracket and cable.
13. Attach a lifting device to the telescope cylinder, pull the
18. Remove the cable retainer plate, cable retainer block,
cylinder along with the extend cables, sheave assembly
bushing and sheave.
and sheave guard out of the fly boom section. Reposi-
tion the lifting device as necessary to balance the cylin-
der.
14. Remove extent block and cable from the telescope cyl-
inder.
15. Remove the pin that secures sheave assembly to tele-
scope cylinder.
MAE23030
19. Remove the top, bottom and side wear pads from the
front mid boom sections.
20. Attach a lifting device to the fly boom section, pull the
fly boom from mid boom.
NOTE: When removing fly boom section from mid boom section,
retract wire rope must be dragged along with fly boom sec-
tion.
MAE23000 21. Remove the top, bottom and side wear pads from the
rear end fly boom sections.
22. Remove the fly boom retract cables from the bottom of
the fly boom sections.
23. Thoroughly clean the boom sections.
4-12 3121728
Assembly 9. Install sheave on the telescope cylinder secure with pin

and bolts.
NOTE: When installing fly section wear pads, install same number
and thickness of shims as were removed during disassem-
bly.
1. Measure inside dimensions of the base and mid sections

to determine the number of shims required for proper
lift.
2. Install side, top and bottom wear pads to the rear end of
fly section; shim evenly to the measurements of the
inside of mid section. Torque the bolts to 40.6 ft. lbs. (55
Nm).
3. Install retract wire ropes into rear end of fly section,
route wire ropes through holes in side of fly boom sec-
tion and pull into slot.
MAE23010
4. Install side, top and bottom wear pads to the rear end of
mid section, shim evenly to the measurements of the 10. Route the cables around the sheave on the cylinder and
inside of mid section. Torque the bolts to 40.6 ft. lbs.(55 install the sheave guard.
Nm).
5. Using Super Lube, lubricate all wear surfaces on the out-
side of fly boom and inside of the mid boom.
6. Slide fly boom section into mid boom section.
7. Install wear pads into the front end of the mid boom
section. Torque the bolts to 40.6 ft. lbs. (55Nm).
8. Apply a thin coat of moly paste lubricant to the inside
diameter of the sheave composite bearings. Install the
fly retract sheaves and bushings while guiding the wire
ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely.
MAE23000
11. Using an adequate lifting device, insert the cylinder and

cables part way into the inner fly boom.
MAE23030
3121728 4-13
12. Install end of the extend cables into the extend rope 17. Insert the mid, fly and Tele cylinder assembly way into
block. the boom base section enough to be able to pull the
outer mid retract cables out through the hole at the bot-
tom front of the boom base section.
18. Install the front lower wear pads into the boom base
section. Torque the bolts to 40.6 ft. lbs. (55 Nm).
19. Push the mid boom assembly the rest of the way into
the boom base section, adjusting the lifting device as
necessary to keep the weight balanced.
20. Install the side and upper wear pads into the boom base
section. Torque the bolts to 40.6 ft. lbs. (55 Nm).
21. Install hardware securing valve to telescope cylinder.
Install the valve assembly. Torque the bolts to 42.8 ft. lbs.
(58 Nm).
MAE23020
13. Install the bolts and washers securing the extend rope
block to the fly boom. Torque the bolts to 40.6 ft. lbs.(55
Nm).
14. Install the cylinder trunnion block and shims that secure
the telescope cylinder barrel to the mid boom section.
Torque the bolts to 40.6 ft. lbs. (55 Nm).
MAE22950
22. Attach an auxiliary hydraulic power source to the tele-

scope cylinder, extend cylinder enough so the trunnion
of Rod out of base boom, turn rod trunnion to horizontal
position. Retract cylinder so the trunnion of rod slide
into the slot on base boom.
MAE22990
15. Turn the trunnion of Rod in a vertical position.
16. Using Super Lube, lubricate all wear surfaces on the

inside of the base section and the outside of the mid
boom.
4-14 3121728
23. Install the four bolts, shims, and bars that secure the 25. Install the hardware securing spring mounting plate and
telescope cylinder rod to the boom base section. Torque spring to the cable block.
the bolts to 40.6 ft. lbs. (55 Nm).
MAE22960
MAE22930
24. Route extend cable through cable block and install the
26. Install base boom cover plate to base boom at the end
cable block on base boom.
of the boom section.
27. Install the cover plate and sheave blocks.
28. Connect the hydraulic hoses to the telescope cylinder as

tagged during removal.
29. Adjust the boom cables. Refer to Section 4.14, Wire Rope
Tensioning Adjustment.
30. Install jam nuts and nuts which secure the wire rope.
MAE22940
3121728 4-15
Installation 9. Lift and move forward the boom and tower link assem-
bly.
NOTE: Refer to Figure 4-3., Boom Assembly Removal and Installa-
10. Remove metal rod from the turntable lifting eye holes
tion.
and level the boom assembly to normal position.
NOTE: The boom alone weighs approximately 2792 lbs. (1269 kg). 11. Install pin, keeper pin, and retaining bolt (1) securing
Including the powertrack, slave cylinder, rotator, jib, plat- tower link to turntable. Apply JLG Threadlocker 
form and platform support the assembly weighs approxi- (PN 0100011) and torque to 346 ft.lbs. (469 Nm).
mately 7500 lbs. (3400 kg).
12. Reconnect all hydraulic lines as tagged during removal.
1. If tension link is removed, insert an adequate metal rod 13. Reconnect all electrical connections to the boom assem-
into the turntable lifting eye holes to support the ten- bly as tagged during removal.
sion link.
14. If necessary, adjust retract and extend cables to the
2. Using an adequate lifting device, position the tension proper torque. Refer to Section 4.14, Wire Rope Tension-
link on turntable so that the pivot holes of tension link ing Adjustment for wire rope torque procedures.
and turntable holes are aligned.
15. Using all applicable safety precautions, raise and extend
NOTE: The tension link weighs approximately 419 lbs. (190 kg). boom fully, then retract and lower boom. Check for
proper operation and hydraulic leaks.
3. Install pin, keeper pin, and retaining bolt (5) securing
tension link to the turntable. Apply JLG Threadlocker 
(PN 0100011) and torque to 346 ft.lbs. (469 Nm).
NOTE: Steps 1, 2, and 3 are only necessary if the tension link has
been removed.
4. Place the tower link with boom lift cylinder on the

proper support.
5. Use an adequate lifting device, lift the boom assembly
and install pin, keeper pin, and retaining bolt (4) secur-
ing the tower link to the boom assembly. Apply JLG
Threadlocker (PN 0100011) and torque to 346 ft.lbs. (469
Nm).
6. Install pin, keeper pin, and retaining bolt (3) securing lift
cylinder rod end pin to main boom assembly. Apply JLG
Threadlocker (PN 0100011) and torque to 346 ft.lbs. (469
Nm).
7. Using an adequate lifting device, lift and position the
boom assembly with tower link and boom lift cylinder
on turntable so that the pivot holes of boom assembly
and tension link are aligned.
8. Install boom pivot pin, keeper pin, and retaining bolt (2),
ensuring that location of hole in pin is aligned with
attach point on tension link.
4-16 3121728
4.11 MAIN BOOM LIFT CYLINDER Installation

1. Using an adequate lifting device, position the lift cylin-
Removal der in tower link in the same manner that it was
removed.
NOTE: Refer to Figure 4-4., Main Boom Lift Cylinder Removal and
Installation. 2. Install trunnion pins (1), hardware and bearings securing
boom lift cylinder to the tower link.
1. Remove main boom assembly with tower link and lift
3. Install main boom assembly with tower link and lift cyl-
cylinder from the machine and place it on a suitable
inder to the turntable. Refer to Section 4.10, Main Boom
support. Refer to Section 4.10, Main Boom Assembly for
Assembly for Install procedure.
removal procedure.
2. Place blocking under the lift cylinder to prevent it from
falling when the attaching hardware is removed.
3. Attach an adequate lifting device and sling to the main
lift cylinder.
NOTE: The Main Lift Cylinder weighs approximately 557 lbs. (253
kg).
4. Remove trunnion pins (1), hardware and bearings (if

necessary) securing boom lift cylinder to the tower link.
5. Carefully lift the cylinder clear of the tower link and
lower to the ground or suitably supported work area.
LIFT CYLINDER
1
TOWER LINK
MAE24200
Figure 4-4. Main Boom Lift Cylinder Removal and Installation
3121728 4-17
4.12 MAIN BOOM POWERTRACK 6. Remove bolts (2) securing push tube on mid boom sec-
tion.
Removal 7. With powertrack support and using all applicable safety
precautions, remove bolts (3) securing rail to the base
1. Disconnect wiring harness from ground control box. boom section. Remove powertrack from boom section.
Installation
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- 1. With powertrack supported and using all applicable
CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. safety precautions, install hardware (3) securing rail to
the base boom.
2. Tag and disconnect hydraulic lines from boom to control
2. With adequate support and lifting device align, place
valve. Use a suitable container for residual hydraulic mid boom push tube on the boom section to get access
fluid. Cap hydraulic lines and ports. to install hardware (2).
3. Remove hydraulic lines and electrical cables from the 3. Install the hardware (1) securing powertrack to fly boom
powertrack. push tube.
4. Using a suitable lifting equipment, adequately support 4. Connect all hydraulic lines and electrical cables to pow-
powertrack weight along entire length. ertrack as tagged during removal.
5. Connect wiring harness to ground control box.

5. Remove bolts (1) securing push tube on fly boom sec-
tion.
2 MAE23040
Figure 4-5. Powertrack Components
4-18 3121728
4.13 WIRE ROPE NOTE: Check groove so that it may be clearly seen if gauge con-
tour matches sheave groove contour.
WIRE ROPE CAN HAVE SHARP EDGES AND CAUSE SERIOUS INJURY. NEVER
HANDLE WIRE ROPE WITH BARE HANDS.
Each day before using machine:
1. Raise main boom approximately horizontal.
2. Extend and retract the boom sections.
3. Check for delayed movement of fly section which indi-

cates loose wire ropes. Figure 4-8. Sheave Groove Wear
7. Ropes passing inspection should be lubricated with wire
Inspection rope lubricant before reassembly.
NOTE: Pictures in this paragraph are samples to show rope

replacement criteria.
Three Month Inspection
1. Remove boom covers and visually (with flashlight)
1. Inspect ropes for broken wires, particularly valley wire inspect the ropes for rust, broken wires, frays, abuse, or
breaks and breaks at end terminations. any signs of abnormalities.
NOTE: Flexing a wire rope can often expose broken wires hidden 2. Check wire rope tension by deflecting wire ropes by
in valleys between strands. hand. Properly tensioned ropes should have little or no
movement.
12 Year or 7000 Hour Replacement

1. Mandatory wire rope and sheave replacement.

Additional inspection required if:
Figure 4-6. Wire Rope Wire Breaks a. Machine is exposed to hostile environment or con-
ditions.
2. Inspect ropes for corrosion.
b. Erratic boom operation or unusual noise exists.
3. Inspect ropes for kinks or abuse. c. Machine is idle for an extended period.
NOTE: A kink is caused by pulling down a loop in a slack line dur- d. Boom is overloaded or sustained a shock load.
ing improper handling, installation, or operation. e. Boom exposed to electrical arc. Wires may be fused
internally.
Additional Replacement Criteria

NOTE: Sheaves and wire rope must be replaced as sets.
1. Rusted or corroded wire ropes.

Figure 4-7. Wire Rope Kink
2. Kinked, “bird caged”, or crushed ropes.
4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)Inspect 3. Ropes at end of adjustment range.
sheaves for condition of flanges. (See Dimension Of 4. Sheaves failing wearout gage inspection.
Sheaves for proper dimension.)
5. Ropes with 6 total broken wires in one rope lay, 3 in one
5. Inspect sheaves with a groove wearout gauge for exces- strand in one rope lay, 1 valley break, or 1 break at any
sive wear. end termination.
3121728 4-19
4.14 WIRE ROPE TENSIONING ADJUSTMENT
Wire Rope Tensioning Procedure

1. Position boom in fully down and retracted position.
Model 600S 660SJ

Dim. A 14.6" (37.1cm) 17" (44cm)
Dim. B 9" (23cm) 9" (23cm)
Figure 4-10. Clamping Wire Ropes
2. Install adjusting nuts (or remove nylon collar locknuts if

re-adjusting) to both retract and extend wire ropes.
3. Torque retract adjusting nuts (platform end) to 15 ft-lb

(20 Nm) alternating between the two wire ropes and
keeping approximately the same amount of thread
beyond the adjusting nut.
4. Repeat torque procedure in step #4 to extend wire ropes

(turntable end).
B A 5. Extend boom 2 - 3 feet using telescope function. Repeat
MAE22850
step #4.
600S 6. Retract boom 1 - 2 feet using telescope function. Do not
bottom out telescope cylinder. Repeat step #5.
B A 7. Extend boom approximately 2 - 3 feet again and check
torque on retract wire ropes.
8. Retract boom without bottoming out telescope cylin-

der. Check torque on extend wire ropes.
NOTE: Step #8 and #9 may need to be repeated to equalize the

torque on all 4 wire ropes.
9. After all wire ropes are properly torqued, install nylon

collar locknuts. Remove all clamping devices and install
MAE22840
all covers and guards. Check boom for proper function.
660SJ
4.15 WIRE ROPE SERVICE INDICATOR
Figure 4-9. Dimensions of Boom Sections
The wire rope service indicator is integrated into the mounting
block that the extension wire ropes mount to at the end of the
base boom. More specifically, the smaller diameter wire rope
mounts to a spring loaded block that also contains a proxy
DO NOT CLAMP ON THREADS OR THREADS MAY BE DAMAGED. sensor. In the event that the rope breaks, the block with the
 proxy sensor is pushed away from the main mounting block
DO NOT ALLOW WIRE ROPE TO ROTATE OR WIRE ROPE MAY BE DAMAGED. through the spring which causes a warning light to be lit in the
CLAMP THREADED ENDS OF WIRE ROPE TO PREVENT ROTATION. platform control box. All boom functions are still operable.
4-20 3121728
4.16 JIB (IF EQUIPPED) Inspection

NOTE: Using a suitable lifting device, support the jib. NOTE: When inspecting pins and bearings Refer to Section 2.5 -
Pins and Composite Bearing Repair Guidelines.
Removal
1. Inspect fly boom pivot pin for wear, scoring, tapering
1. For platform and support removal see Section 4.8 - Plat- and ovality, or other damage. Replace pins as necessary.
form.
2. Inspect fly boom pivot attach points for scoring, taper-
2. Position the articulating jib boom level with ground. ing and ovality, or other damage. Replace pins as neces-
sary.
3. Inspect inner diameter of fly boom pivot bearings for
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DIS- scoring, distortion, wear, or other damage. Replace bear-
CONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM. ings as necessary.
4. Inspect lift cylinder attach pin for wear, scoring, tapering
3. Tag and disconnect hydraulic lines from level cylinder
and ovality, or other damage. Ensure pin surfaces are
and lift cylinder. Use suitable container to retain any
protected prior to installation. Replace pins as neces-
residual hydraulic fluid. Cap hydraulic lines and ports.
sary.
4. Remove mounting hardware from slave leveling cylin-
5. Inspect inner diameter of rotator attach point bearings
der pin (1). Using a suitable brass drift and hammer,
for scoring, distortion, wear, or other damage.
remove the cylinder pin from jib assembly.
6. Inspect all threaded components for damage such as
5. Remove mounting hardware from jib assembly boom
stretching, thread deformation, or twisting. Replace as
pivot pin (2). Using a suitable brass drift and hammer,
necessary.
remove the pivot pin from boom assembly.
7. Inspect structural units of jib boom assembly for bend-
Disassembly ing, cracking, separation of welds, or other damage.
Replace boom sections as necessary.
1. Remove mounting hardware from articulating jib boom
pivot pins (3) and (4). Using a suitable brass drift and
hammer, remove the pins from articulating jib boom
pivot weldment.
2. Remove mounting hardware from rotator support pins
(5) and (6). Using a suitable brass drift and hammer,
remove the pins from rotator support.
3. Remove mounting hardware from lift cylinder pin (7).
Using a suitable brass drift and hammer, remove the cyl-
inder pin from articulating jib boom.
JIB BOOM PIVOT

2 4
JIB
7
1
SLAVE 3
CYLINDER
JIB LIFT
CYLINDER
6
5
MAE17190
3121728 4-21
Assembly 4.17 BOOM CLEANLINESS GUIDELINES

1. Align lift cylinder with attach holes in jib assembly. The following are guidelines for internal boom cleanliness for
Using a soft head mallet, install cylinder pin (7) into jib machines used in excessively dirty environments.
and secure with mounting hardware. 1. JLG recommends use of JLG Hostile Environment Pack-
2. Align rotator support with attach hole in jib assembly. age to keep internal portions of a boom cleaner and
Using a soft head mallet, install rotator support pin (6) help prevent dirt and debris from entering the boom.
into jib and secure with mounting hardware. This package reduces the amount of contamination
which can enter the boom, but does not eliminate the
3. Align bottom tubes with attach holes in rotator support. need for more frequent inspections and maintenance
Using a soft head mallet, install rotator support pin (5) when used in these types of environments.
into jib assembly and secure with mounting hardware.
2. JLG recommends you follow all guidelines for servicing
4. Align jib assembly with attach hole in jib boom pivot your equipment in accordance with instruction in the
weldment. Using a soft head mallet, install rotator sup- JLG Service & Maintenance Manual for your machine.
port pin (4) into jib assembly and secure with mounting Periodic maintenance and inspection is vital to proper
hardware. operation of the machine. Frequency of service and
maintenance must be increased as environment, sever-
5. Align bottom tubes with attach holes in jib boom pivot
ity, and frequency of usage requires.
weldment. Using a soft head mallet, install rotator sup-
port pin (3) into jib boom pivot weldment and secure 3. Debris and contamination inside the boom can cause
with mounting hardware. premature failure of components and should be
removed. Methods to remove debris should always be
Installation done using all applicable safety precautions outlined in
the JLG Operation & Safety Manual and the JLG Service
1. Align jib boom pivot weldment with attach holes in fly & Maintenance Manuals.
boom assembly. Using a soft head mallet, install pivot
pin (2) into fly boom assembly and secure with mount- 4. The first attempt to remove debris from inside the boom
ing hardware. must be to utilize pressurized air to blow the debris
toward the nearest exiting point from the boom. Make
2. Align the slave leveling cylinder with attach holes in jib sure that all debris is removed before operating the
boom pivot weldment. Using a soft head mallet, install machine.
slave leveling cylinder pin (1) into articulating jib boom
pivot weldment and secure with mounting hardware. 5. If pressurized air cannot dislodge debris, then water
with mild solvents applied with a pressure washer can
be used. Wash debris toward the nearest exiting point
JIB BOOM PIVOT
2 4 from the boom. Make sure all debris is removed, no
“puddling” of water has occurred, and boom internal
components are dry before operating machine. Make
JIB
sure you comply with all federal and local laws for dis-
posing of wash water and debris.
7
6. If pressurized air or washing boom does not dislodge
1
3 and remove debris, disassemble boom following
SLAVE
CYLINDER instructions outlined in the JLG Service & Maintenance
Manual to remove debris.
JIB LIFT
CYLINDER
6
5
MAE17190
4-22 3121728
4.18 FOOT SWITCH ADJUSTMENT 4.19 PLATFORM CONTROL ENABLE SYSTEM

Adjust foot switch to operate functions when pedal is at center The platform controls use a time dependant enable circuit to
of travel. Adjust if switch operates within last 1/4 in. (6.35 mm) limit the time availability of “live” or enabled controls. When
of top or bottom travel. the footswitch is depressed, the controls are enabled and the
operator has 7 seconds to operate any control. The controls
will remain enabled as long as the operator continues to use
any function and will remain enabled 7 seconds after the last
ELECTRIC SHOCK OR UNCONTROLLED MACHINE MOVEMENT CAN CAUSE
function has been used. While the controls are “live”, the
DEATH OR SERIOUS INJURY. DISCONNECT INPUT POWER BEFORE PERFORM-
enabled light will be illuminated in the platform display panel.
ING INSTALLATION OR MAINTENANCE.
When the time limit has been reached, the enabled light will
NOTE: For models with two switches, both switches can be inde- turn off and the controls will be disabled. To continue use of
pendently adjusted. the machine the controls must be re-enabled to start the timer
system over again. This is done by releasing all functions, then
1. Remove four socket head cap screws and cover from releasing and re-depressing the footswitch.
foot switch assembly.
2. To increase travel before switch is activated, turn Adjust-
ment Screw clockwise.
3. To decrease travel before switch is activated, turn
Adjustment Screw counter-clockwise.

Figure 4-11. Foot Switch Adjustment

4. Install cover and secure with four socket head caps
crews. Torque to 18-22 in-lb (2-3 Nm).
3121728 4-23
4.20 POWERTRACK MAINTENANCE 2. Repeat step 1 and remove screw from other side of
track. Remove bar/poly roller from powertrack.
Remove Link
NOTE: Hoses shown in powertrack are for example only. Actual
hose and cable arrangements are different.
1. Clamp bar and poly roller tightly so they do not spin

when removing screw. With a small ¼” ratchet and a 
T-20 Torx bit, remove 8-32 x 0.500 screw from one side.
REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT

DAMAGE.
4-24 3121728
3. To remove a link, rivets holding links together must be 5. After grinding it may be necessary to use a center punch
removed. Use a right-angle pneumatic die grinder with with a hammer to remove rivet.
a ¼” ball double cut bur attachment.
NOTE: It may be necessary to loosen fixed end brackets from
machine to move track section enough to disconnect links.
4. insert tool into rolled over end of rivet. Grind out middle
of rivet until rolled over part of rivet falls off. Repeat for
all rivets to be removed.
3121728 4-25
6. Insert flat head screwdriver between links. Twist and pull 7. Remove link from other section of powertrack using
links apart. screwdriver.
4-26 3121728
Install New Link 2. Spread half-shear (female) end of new link and slide cut-
out end of track section into it. Use screwdriver if neces-
1. Squeeze cut-out end of new link into half-shear (female) sary.
end of track section.
3. Round half-shears will not fit properly in cut-outs after

new link is installed.
3121728 4-27
4. Pull moving end over track so new connection is posi- 6. Push pin through center hole. Slide washer on pin.
tioned in curve of powertrack. Round half-shears will
rotate into cut-outs.
7. Install snap ring in groove on pin. Repeat pin installation

steps for all center holes with rivets removed.
5. Parts shown below connect new link to powertrack.
4-28 3121728
NOTE: Make sure snap rings are seated in pin groove and closed 2. Pull up on other end of round bar. Slide new poly roller
properly. on bar.
Correct Incorrect
1. Install new 8-32 x 0.500 self-threading Torx head screw

in end of new aluminum round bar. Torque to 18-20 in-
lb (2-2.25 Nm).
3121728 4-29
3. Install new 8-32 x 0.500 self threading screw on other Replace Fixed End Brackets
side. Torque to 18-20 in-lb (2-2.25 Nm).
REPOSITION CABLES/HOSES. KEEP COVERED DURING GRINDING TO PREVENT

DAMAGE.
1. Remove rivets as shown in link removal instructions.
NOTE: When tightening screws make sure screw head is seated

against link with no space in between link and underside of
screw head.
4-30 3121728
2. Parts used: Bracket Center Pin and Center Pin Snap Ring. Replace Moving End Brackets
3. Take new bracket and install bracket center pin and

snap ring. Repeat on other bracket if replacing it.
REPOSITION CABLES AND HOSES. KEEP COVERED DURING GRINDING TO PRE-

VENT DAMAGE.
1. Remove existing pins and center rivet. Remove rivet as

shown in link removal instructions on page 4-20. Repeat
on other bracket if replaced.
NOTE: Ensure snap rings are seated in pin groove and closed
properly.
Correct Incorrect
3121728 4-31
2. Install center pin with snap ring in new bracket. NOTE: Ensure snap rings are seated in pin groove and closed
properly.
Correct Incorrect
3. Install radius pins and snap rings in original locations. 1. Make sure both brackets rotate correctly.
Repeat with other moving end if replaced.
4-32 3121728
4.21 SKYGUARD 3. Disengage the SkyGuard sensor, release controls, recycle

the foot switch, make sure normal operation available.
SkyGuard is a protective device that protects against Sus-
In Ground Mode:
tained Involuntary Operation (SIO). SkyGuard is offered in
three different configurations. The first is a passive system Operation will be allowed regardless of SkyGuard sensor acti-
which is a fixed bolt on rail. The second and third configura- vation. 
tion utilizes a bolted on bar with a sensor. When the sensor is
activated, SkyGuard stops all functions in use at the time and
reverses some of the functions. The third configuration offers a IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &
flashing blue beacon which flashes when the sensor is acti- “BOTH” IS SELECTED.
vated. In Platform Mode:
Operation NOTE: Machine will treat Soft Touch/SkyGuard override switch as

if it is a Soft Touch and SkyGuard switch.
Skyguard is used to provide enhanced control panel protec-
tion. When the SkyGuard sensor is activated, functions that 1. In an area free of obstructions, from platform controls
were in use at the time of actuation will reverse or cutout. test the SkyGuard feature by operating the telescopic
Refer Table 4-1, “SkyGuard Function Table,” on page 34for out functions and engaging the SkyGuard sensor, tele-
functions. scopic out function will be stopped, soft touch indicator
light will flash at 3HZ, the horn will be turned on until
the SkyGuard sensor and footswitch is disengaged.
2. With SkyGuard sensor engaged, press and hold the yel-
low “Override Soft Touch” button and then operate a
function switch or joystick to check if the operation can
be resumed.
3. Disengage the SkyGuard sensor, release controls, recycle
the foot switch, make sure normal operation is available. 
In Ground Mode:
Operation will be allowed regardless of SkyGuard switch acti-
vation.
IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &

Figure 4-12. Skyguard “SOFT TOUCH” IS SELECTED.
Machine will treat the Soft Touch/SkyGuard override switch as
if it is a Soft Touch switch.
Functional Test
IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE & IF SKYGUARD SYSTEM IS INSTALLED ON MACHINE &
“SKYGUARD” IS SELECTED IN MACHINE SET UP. “NONE” IS SELECTED.
In Platform Mode: Skyguard sensor status will be ignored. No function cutout or
reversal will be implemented.
1. In an area free of obstructions, from the platform con-
trols test the SkyGuard feature by operating the tele-
scope out functions and engaging (and holding) the
SkyGuard sensor. Telescope function will be stopped
and telescope in function will be activated for a short
duration. Soft touch indicator light will flash at 3HZ,
horn will be turned on, until the SkyGuard sensor and
footswitch is disengaged.
2. With SkyGuard sensor engaged, press and hold 

the yellow “Override Soft Touch” button and then oper-
ate a function switch or joystick to check if the operation
can be resumed.
3121728 4-33
Diagnostic & Troubleshooting 2. If machine operation is not available:


If you are experiencing a problem that is not described here, Help menu or diagnostics menu is to be used to collect
see your authorized dealer for service. the fault information.
Depending on configuration, diagnostics menu 
will read:
1. Check the configuration under the menu “MACHINE
SETUP  STOUCH/SKYGUARD” according to the actual Diagnostics->System->Skyguard switch
system installed on machine. Make sure recommended
configuration described is selected. Diagnostics->System->STOUCH OR SG
 Pressing to engage the SkyGuard sensor will change the
If SkyGuard does Not Function with sensor engaged. switch or relay to open/close status. 

If the switch status states “Closed” regardless of sensor
AUTHORIZED TECHNICIAN OR OPERATOR IS REQUIRED TO CONDUCT AN OPER- activation status:
ATION CHECK OF SKYGUARD SENSOR DAILY. Power or ground wire is not making good contact and/
or may be loose or broken.
Help menu or diagnostics menu is to be used to collect
the fault information. Both relays failed (low probability).
Depending on configurations, diagnostics menu  If the switch status is in disagreement, then one relay
will read: may have failed or one relay isn't inserted into the
holder correctly. This may also be noticed since machine
Diagnostics->System->Skyguard switch will not be able to be operated.
Diagnostics->System->STOUCH OR SG
Pressing to engage the SkyGuard sensor will change the Switch disagreement fault (2563) and SkyGuard switch
switch or relay to open/close status.  activation fault (0039) will be shown under 
 Help menu.
If the switch status stays in “Open” while the actual Sky-
Guard sensor is pressed, then the SkyGuard sensor may
have failed, it needs to be changed immediately.
Table 4-1. SkyGuard Function Table
Main Main Tele Main Tele Main Drive Forward Drive Reverse Basket Basket Jib
Lift In Out Swing Level Rotate Lift
DOS DOS DOS DOS
Enabled Not Enabled Not
Enabled Enabled
R C R R R C* R R C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* Disregard when boom is in line and driving forward with or without steering and no other function active
Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.
4-34 3121728
4.22 BOLT ON FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The bolt on fall arrest system is designed to provide a lanyard
attach point while allowing the operator to access areas out- GAP
GAPSHOWING:
SHOWING:
side the platform. Exit/Enter the platform through the gate INCORRECT
INCORRECT
area only. The system is designed for use by one person.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs. (408
kg).
NO GAP:
External Fall Arrest System capacity is 310 lb (140 kg) - one (1) NO GAP: CORRECT
CORRECT
person maximum.
Do not move the platform during use of the external fall arrest
system.
DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM.

BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.
Figure 4-13. Bolt On Fall Arrest Cable Tension
• Fittings & Brackets: Ensure all fittings are tight and there are
IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTH- no signs of fractures. Inspect brackets for any damage.
ERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLAT- • Attachment Ring: No cracks or signs of wear are accept-
FORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO THE able. Any signs of corrosion requires replacement.
SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
• Attaching Hardware: Inspect all attaching hardware to
THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND ensure there are no missing components and hardware is
CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE properly tightened.
PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.
• Platform Rails: No visible damage is acceptable.
Inspection Before Use Installation

The external fall arrest system must be inspected before each 1. Install the retaining hardware (bolts, nuts, and washers)
use of the aerial work platform. Replace components if there and secure the brackets to the platform rail. Tighten the
are any signs of wear or damage. nuts but do not torque them yet.
Before each use, perform a visual inspection of the following BOLT
components:
WASHER
WASHER
NUT
2. Attach the fall arrest cable to the right hand bracket

Using the attaching bolt and nut. Orient the bolt as
3121728 4-35
shown below. Do not tighten the nut so cable can still ent at the outside diameter of the washers. Ensure the
rotate. cable has not rotated during tightening.
BOLT
NUT
6. Tighten the first jam nut against the retaining nut to

keep the nut from loosening. Tighten the remaining jam
nut against the first jam nut.
3. Install the Attachment Ring onto the cable.
7. Torque the nuts and bolts securing the brackets to 15
4. Without twisting the fall arrest cable, pull it thru the left ft.lbs. (20 Nm).
hand bracket and mark the top of the swaged cable end.
Install the fall arrest cable through the left hand bracket
and secure it using the belleville washers, washer, retain-
ing nut, and jam nuts. Orient the hardware as shown
below and with the belleville washers so the gap is pres-
ent at the outside diameter of the washers. install the
nuts onto the cable finger tight so the mark on the cable
does not move.
WASHER
BELLEVILLE
NUT WASHER
JAM NUT
5. Use the two jam nuts to prevent the cable from rotating
while the nut is tightened. Tighten the nut until the bel-
leville washers are fully compressed and no gap is pres-
4-36 3121728
7
1,2,3,4
5
1. Belleville Washer
2. Washer
6 3. Hex Nut
4. Jam Nut
5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal
Figure 4-14. Bolt On Fall Arrest System
3121728 4-37
NOTES:
4-38 3121728
SECTION 5. BASIC HYDRAULICS INFORMATION & SCHEMATICS
5.1 LUBRICATING O-RINGS IN THE HYDRAULIC 2. Holding the fitting over the hydraulic oil container,
brush an even film of oil around the entire o-ring in the
SYSTEM fitting, making sure the entire o-ring is completely satu-
rated.
When assembling connectors in the hydraulic that use o-ring
fittings, it is necessary to lubricate all fittings with hydraulic oil
prior to assembly. To lubricate the fittings, use one of the fol-
lowing procedures.
NOTE: All O-ring fittings must be pre-lubricated with hydraulic oil

prior to assembly.
Cup and Brush

The following is needed to correctly oil the o-ring in this man-
ner:
3. Turn the o-ring on the other side of the fitting and
• Small container for hydraulic oil repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
• Small paint brush
1. Hold the fitting in one hand while using the brush with
the other hand to dip into the container. Remove excess
hydraulic oil from the brush so an even film of oil is
applied on the o-ring.
3121728 5-1
Dip Method Spray Method

NOTE: This method works best with Face Seal o-rings, but will This method requires a pump or trigger spray bottle.
work for all o-ring fitting types.
1. Fill the spray bottle with hydraulic oil.
The following is needed to correctly oil the o-ring in this man- 2. Hold the fitting over suitable catch can.
ner:
3. Spray entire o-ring surface with a medium coat of oil.
• A small leak proof container
• Sponge cut to fit inside container
• A small amount of hydraulic oil to saturate sponge.
1. Place sponge inside container and add hydraulic oil to

the sponge until fully saturated.
2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and drip
from the bottom of the fitting. This should signify an
even coating of oil on the fitting.
Brush-on Method
This method requires a sealed bottle brush.
1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
invert the bottle so the brush end is in the downward
position.
3. Brush hydraulic oil on the entire o-ring, applying an
even coat of oil.
3. O-ring Boss type fittings will require more pressure in

able to immerse more of the fitting into the saturated
sponge. This will also cause more oil to be dispersed
from the sponge.
5-2 3121728
5.2 HYDRAULIC CYLINDERS
600S
3
3
4
2 660SJ
MAE22100
1. Main Lift Cylinder 3. Platform Level Cylinder 5. Steer Cylinder

2. Telescope Cylinder 4. Jib Lift Cylinder 6. Axle Lockout Cylinder
Figure 5-1. Hydraulic Cylinder Locations
3121728 5-3
Main Lift Cylinder

DISASSEMBLY
NOTE: Refer to Figure 5-4. Main Lift Cylinder.
CONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A

CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to

cylinder port block fitting.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER

SLIGHTLY TO AVOID TRAPPING PRESSURE.
5
2. Operate hydraulic power source and extend cylinder.
Shut down and disconnect power source. Adequately
support cylinder rod, if applicable.
Figure 5-2. Cylinder Head Removal
3. If applicable, remove cartridge-type counterbalance
valve and fittings from cylinder port block. Discard O-
rings.
4. Place cylinder barrel in a suitable holding fixture. Tap PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
around outside of cylinder head retainer with a suitable USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
hammer to break thread-locking compound.
6. Clamp barrel securely. Pull rod assembly and cylinder
head from barrel.

7. Protect cylinder rod from damage and clamp in a vise or

holding fixture as close to piston as possible.

Figure 5-1. Cylinder Barrel Support
5. Unscrew cylinder head (5) with pin-face spanner

wrench.
5-4 3121728
9
10** 14
13
11***
12****
7 4
26
24
27
15
26
16
17
18
19
3
20
21
22
6
25
23
5*
* Torque 1106 ft-lb (1500 Nm)

** Torque 25-20 ft-lb (34-28 Nm) 8
*** Torque 33-36 ft-lb (45-50 Nm)
1001184500-I
**** Torque 33-40 ft-lb (45-55 Nm) MAE21930
1. Barrel 7. Setscrew 12. Solenoid Valve 18. Backup Ring 24. O-Ring
2. Rod 8. Bushing 13. Plug 19. Bearing Ring 25. O-Ring
3. Head 9. Solenoid Valve 14. Orifice 20. Seal 26. Bearing Ring
4. Piston 10. Check Valve 15. Spacer 21. Bearing Ring 27. Seal
5. Collar 11. Pressure Compensator 16. Wire 22. Wiper
6. Ring Valve 17. O-Ring 23. O-Ring
Figure 5-4. Main Lift Cylinder
3121728 5-5
14. Remove and discard retaining ring (16), wiper (22),

bearing ring (19), rod seal (20), and ring (21) from cylin-
REMOVE SEALS USING A BRASS OR PLASTIC PICK ONLY. DO NOT USE A KNIFE, der head (3).
SHARP OBJECT, OR SCREW DRIVER. NOTE SEAL ORIENTATION BEFORE REMOV-
25
ING FOR PROPER INSTALLATION.
8. Loosen setscrew (7) in piston (4).

9. Screw piston counter-clockwise and remove from rod.
3
10. Remove and discard O-ring (24), bearing rings (26) and
seal (27).
27
20
19
7 22
21
16
26 17
26 18 MAE22310
24 Figure 5-6. Cylinder Head Disassembly
4
CLEANING AND INSPECTION
1. Clean parts thoroughly with approved cleaning solvent.

MAE22300
Figure 5-5. Piston Disassembly 2. Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
11. Remove rod from holding fixture. or equivalent. Replace rod if necessary.
12. Remove cylinder head assembly (3) from rod (2). 3. Inspect threaded portion of rod for excessive damage.
13. Remove and discard O-ring (17), back-up ring (18), and  Dress threads as necessary.
O-ring (25) from cylinder head.
4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress

threads as necessary.
6. Inspect piston surface for damage, scoring, or distortion.

Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress

8. Inspect seal and O-ring grooves in piston for burrs and

sharp edges. Dress surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring or

other damage, and for ovality and tapering. Replace as
necessary.
10. Inspect threaded portion of head for damage. Dress

5-6 3121728
11. Inspect seal and O-ring grooves in head for burrs and ASSEMBLY
sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring,
damage, ovality, and tapering. Replace as necessary. INCORRECT SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
C YLINDER OPERATION. ENSURE ALL PISTON SEALS ARE CORREC TLY
13. If applicable, inspect rod and barrel bearings for signs of
INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL
correct excessive wear or damage. Replace as necessary.
ORIENTATION.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
etc. to facilitate bearing installation. NOTE: Use proper cylinder seal kit for cylinder assembly. See your
b. Inspect steel bushing for wear or other damage. If JLG Parts Manual.
steel bushing is worn or damaged, rod/barrel must 
be replaced. Apply a light film of hydraulic oil to all components before
assembly.
c. Lubricate inside of the steel bushing with WD40
prior to bearing installation. 1. Support rod in holding fixture.
NOTE: Lubrication is not required with nickel plated pins and 2. Install retaining ring (16), bearing ring (19), seal (20), and
bearings. Install pin in composite bushing dry. wiper (22) inside cylinder head (3).
d. Press composite bushing into barrel or rod bushing 3. Install O-ring (17), backup ring (18), and O-ring (19) on
with correct size arbor. cylinder head.
4. Slide cylinder head assembly on rod (2) to rod end. Do

not dislodge or damage seals.

25

3

Figure 5-7. Composite Bushing Installation

14. Inspect travel limiting collar or spacer for burrs and 20
sharp edges. If necessary, dress inside diameter surface 19
with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
22
16. Inspect oil ports for blockage or presence of dirt or other 21
foreign material. Repair as necessary. 16
17
17. If applicable, inspect piston rings for cracks or other
18 MAE22310
damage. Replace as necessary.
Figure 5-8. Cylinder Head Assembly
3121728 5-7
5. Install two seals (27) and O-rings (24) on piston. 12. Apply anti-seize to cylinder head (5) threads. Screw in
cylinder head. Torque to 1106 ft-lb (1500 Nm). Adjust
6. Apply loctite 243 (Loxeal 55-03) to piston threads. Install
cylinder head so screw hole is aligned between cylinder
piston on rod. Torque to 1475 ft-lb (2000 Nm).
head and barrel. Secure cylinder head gland using
7. Install setscrew (7). washer ring and socket head bolts.
27
26
26
24
5
MAE22300
Figure 5-9. Piston Assembly
Figure 5-10. Cylinder Head Installation

8. Carefully install piston on cylinder rod. Do not damage
or dislodge O-ring and back-up rings.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL

SURFACES. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD,
AND PISTON.
9. Clamp barrel clamped securely and support rod. Insert

piston end into barrel cylinder. Do not damage or dis-
lodge piston loading O-ring and seal ring.
10. Remove cylinder rod from holding fixture.
11. Place cylinder barrel in suitable holding fixture.
5-8 3121728
Telescope Cylinder 5. Mark cylinder head (3) and barrel (13) with center punch
marks (A) for later realignment. Remove eight cylinder
DISASSEMBLY head cap screws (9).
NOTE: Refer to Figure 5-14. Telescope Cylinder.




3. If applicable, remove cartridge-type counterbalance Figure 5-12. Marking Cylinder for Alignment
rings.
head from barrel.



Figure 5-13. Cylinder Rod Support
3121728 5-9
11
1*
2
17
8 16
17
5
20
11 20 19
13
4
12
18
14
15
3
6
9
22
21
4
12
10 10A
7
10E
10C
10D 10B
*Torque to 9 ft-lb (12 Nm) 1001175850 -D

MAE21950
1. Bolt 6. Ring 10 A. Cartridge 11. Barrel 16. Seal 21. Wiper

2. Bushing 7. Cap screw 10 B. Cartridge 12. Rod 17. Wear Ring 22. Seal
3. Head 8. Cap screw 10 C. Cartridge 13. Spacer 18. Wear Ring
4. Plug 9. Cap screw 10 D. Seal 14. O-Ring 19. O-Ring
5. Piston 10. Valve Assembly 10 E. Roll Pin 15. Backup Ring 20. Seal
Figure 5-14. Telescope Cylinder
5-10 3121728
8. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress
similar holding fixture as close to piston as possible. threads as necessary.
9. Loosen and remove nut attaching piston to rod. Remove 8. Inspect seal and O-ring grooves in piston for burrs and
piston. sharp edges. Dress surfaces as necessary.
10. Loosen and remove cap screw(s), if applicable, attaching 9. Inspect cylinder head inside diameter for scoring or
tapered bushing to piston. other damage, and for ovality and tapering. Replace as
11. Insert cap screw(s) in threaded holes in outer piece of necessary.
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
12. Remove tapered bushing from piston.
11. Inspect seal and O-ring grooves in head for burrs and
13. Screw piston counter-clockwise by hand and remove sharp edges. Dress applicable surfaces as necessary.
from cylinder rod.
damage, ovality, and tapering. Replace as necessary.


etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
be replaced.

prior to bearing installation.

NOTE: Lubrication is not required with nickel plated pins and

bearings. Install pin in composite bushing dry.
Figure 5-15. Tapered Bushing Removal
14. Remove and discard piston O-rings, seal rings, and d. Press composite bushing into barrel or rod bushing
backup rings. with correct size arbor.
15. Remove piston spacer, if applicable, from rod.

16. Remove rod from holding fixture. Remove cylinder head

gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.


2. Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite Figure 5-16. Composite Bushing Installation
or equivalent. Replace rod if necessary.
14. Inspect travel limiting collar or spacer for burrs and
3. Inspect threaded portion of rod for excessive damage.
sharp edges. If necessary, dress inside diameter surface
Dress threads as necessary.
or other damage. Check inside diameter for tapering or 15. If applicable, inspect port block fittings and holding
ovality. Replace if necessary. valve. Replace as necessary.
5. Inspect threaded portion of barrel for damage. Dress 16. Inspect oil ports for blockage or presence of dirt or other
threads as necessary. foreign material. Repair as necessary.
6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other
Dress piston surface or replace piston as necessary. damage. Replace as necessary.
3121728 5-11
ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your
JLG Parts Manual.

Apply a light film of hydraulic oil to all components before
assembly.
1. Use seal tool to install new rod seal into applicable cylin-
der head gland groove.
Figure 5-19. Wiper Seal Installation

3. Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-17. Rod Seal Installation
IMPROPER SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER

CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION.
2. Use a soft mallet to tap new wiper seal into applicable Figure 5-20. Head Seal Kit Installation
cylinder head gland groove. Install new wear ring in
4. Install washer ring on rod. Carefully install head gland
applicable cylinder head gland groove.
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5. Carefully slide piston spacer on rod.
Figure 5-18. Poly-Pak Piston Seal Installation
5-12 3121728
6. If applicable, place new O-ring and back-up rings in 11. Remove cylinder rod from holding fixture.
inner piston diameter groove.
12. Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)
13. Position cylinder barrel in a suitable holding fixture.

AND PISTON.

15. Continue pushing rod into barrel until cylinder head
Figure 5-21. Piston Seal Kit Installation gland can be inserted into barrel cylinder.
7. Using suitable protection, clamp cylinder rod in a vise or 16. Secure cylinder head gland using washer ring and
similar holding fixture as close to piston as possible. socket head bolts.
8. Carefully thread piston on cylinder rod hand tight,

Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9. Thread piston onto rod until it aligns with spacer end

and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts

when rebuilding slave, lift, and telescope cylinders.
10. Install bolts in tapered bushing using loctite #242

Figure 5-23. Rod Assembly Installation

Figure 5-22. Tapered Bushing Installation
3121728 5-13
Platform Level (Slave) Cylinder 5. Unscrew cylinder head with hook spanner wrench.
DISASSEMBLY
NOTE: Refer to Figure 5-27. Platform Level (Slave) Cylinder - 600S
and Figure 5-28. Platform Level (Slave) Cylinder - 660SJ.



Figure 5-25. Marking Cylinder for Alignment
3. If applicable, remove cartridge-type counterbalance PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
valve and fittings from cylinder port block. Discard O- USE EXTREME CARE WHEN REMOVING CYLINDER ROD, HEAD, AND PISTON.
rings.
4. Place cylinder barrel in a suitable holding fixture. Tap 6. Clamp barrel securely. Pull rod assembly and cylinder
around outside of cylinder head retainer with a suitable head from barrel.
hammer to break thread-locking compound. 7. Protect cylinder rod from damage and clamp in a vise or

5-14 3121728
16
2
16
5
4
3**
7
6
8
11
10
9
18
21*
19
12***
17 13
17 14
15
17
17 20*
16
17
1 16
* Torque 50 - 55 ft-lb (68 - 75 Nm)
** Torque 564.3 - 689.7 ft-lb (765 - 935 Nm)
1001184954 -C
*** Torque 240.3 - 293.7 ft-lb (325 - 398 Nm) MAE21910
1. Barrel 7. Back-up Ring 13. Piston Seal 19. O-Ring

2. Rod 8. Bearing 14. O-Ring 20. Counterbalance Valve
3. Head 9. O-Ring 15. Nut 21. Counterbalance Valve
4. Wiper 10. Back-up Ring 16. Bearing
5. Retaining Ring 11. O-Ring 17. Plug
6. Rod Seal 12. Piston 18. Spacer
Figure 5-27. Platform Level (Slave) Cylinder - 600S
3121728 5-15
17 17
5
4
3**
7
6
8
10 16
9 15
11
19
14
21*
12***
13
18 14
18
18
20*
18
17
18
1 17
* Torque 50 - 55 ft-lb (68 - 75 Nm)
** Torque 673.2 - 822.8 ft-lb (912 - 1115 Nm)
1001184957-C
*** Torque 673.2 - 822.8 ft-lb (912 - 1115 Nm) MAE21920
1. Barrel 7. Back-up Ring 13. Piston Seal 19. Spacer

2. Rod 8. Bearing 14. O-Ring 20. Counterbalance Valve
3. Head 9. O-Ring 15. Ball 21. Counterbalance Valve
4. Wiper 10. Back-up Ring 16. Setscrew
5. Retaining Ring 11. O-Ring 17. Bearing
6. Rod Seal 12. Piston 18. Plug
Figure 5-28. Platform Level (Slave) Cylinder - 660SJ
5-16 3121728
8. Loosen setscrew (16) retaining ball (15) in piston (12). CLEANING AND INSPECTION
9. Screw piston counter-clockwise and remove from rod. 1. Clean parts thoroughly with approved cleaning solvent.
10. Remove and discard O-ring (14) and seal (13). 2. Inspect cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite

or other damage. Check inside diameter for tapering or

ovality. Replace if necessary.
6. Inspect piston surface for damage, scoring, or distortion.
Dress piston surface or replace piston as necessary.
7. Inspect threaded portion of piston for damage. Dress
8. Inspect seal and O-ring grooves in piston for burrs and
sharp edges. Dress surfaces as necessary.
Figure 5-29. Piston Disassembly 9. Inspect cylinder head inside diameter for scoring or
11. Remove rod from holding fixture. other damage, and for ovality and tapering. Replace as
necessary.
12. Remove cylinder head assembly (3) from rod (2).
13. Remove and discard O-ring (9), back-up ring (10), and threads as necessary.
O-ring (11) from cylinder head.
14. Remove and discard retaining ring (5), wiper (4), dry sharp edges. Dress applicable surfaces as necessary.
bearing (8), rod seal (7), and back-up ring (6) from cylin-
der head (3). 12. Inspect cylinder head outside diameter for scoring,



be replaced.


Figure 5-30. Cylinder Head Disassembly
3121728 5-17
d. Press composite bushing into barrel or rod bushing

with correct size arbor.



15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
16. Inspect oil ports for blockage or presence of dirt or other

Figure 5-32. Cylinder Head Seal Installation
foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or other

damage. Replace as necessary.

ASSEMBLY

INCORRECT SEAL INSTALLATION CAN CAUSE CYLINDER LEAKS AND IMPROPER
C YLINDER OPERATION. ENSURE ALL PISTON SEALS ARE CORREC TLY

INSTALLED. REFER TO CROSS SECTION ILLUSTRATIONS FOR CORRECT SEAL
ORIENTATION.

NOTE: Use correct cylinder seal kit for cylinder assembly. See your


assembly.
1. Support rod in holding fixture.
2. Install back-up ring (6), rod seal (7), and dry bearing (8)
in cylinder head (3).
3. Install wiper (4) and retaining ring (5) in cylinder head.
4. Install O-ring (11) on cylinder head.
5. Install backup ring (10) and O-ring (9) on cylinder head.
6. Slide cylinder head assembly on rod (2) to rod end. Do

not dislodge or damage seals.
5-18 3121728
7. Install O-ring (14) in piston (12). 11. Position cylinder barrel in a suitable holding fixture.
8. Install seal (16) on piston.
9. Apply JLG thread locking compound (P/N 0100011) to INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
piston threads. Install piston on rod. USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
10. Install ball (15) and setscrew (16).
12. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge seal.
13. Remove cylinder rod from holding fixture.

14. Place cylinder barrel in suitable holding fixture.
INSERTING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL SURFACES.
USE EXTREME CARE WHEN INSTALLING CYLINDER ROD, HEAD, AND PISTON.
15. Clamp barrel securely and support rod. Insert piston end
into barrel cylinder. Do not damage or dislodge piston
O-rings and backup ring.
16. Continue pushing rod into barrel. Screw in cylinder
head.
Figure 5-34. Piston Seal Installation

Figure 5-36. Cylinder Head Installation

Figure 5-35. Piston Assembly
3121728 5-19
Jib Lift Cylinder (660SJ Only) 5. Mark cylinder head (1) and barrel (2) with center punch
marks (3) for later realignment. Remove eight cylinder
DISASSEMBLY head cap screws (4).
NOTE: Refer to Figure 5-40. Jib Lift Cylinder Assembly(660SJ).
CCONTAMINATION MAY DAMAGE EQUIPMENT. DISASSEMBLE CYLINDER ON A




3. If applicable, remove cartridge-type counterbalance Figure 5-38. Marking Cylinder for Alignment
rings.
head from barrel.



5-20 3121728
1A
6*
1A
8
1 8
8 6* 23**
11
1617 10
17
16
9
15
20 14
12
14
18 15
22 19
21 5
3
4
5A *50 - 55 ft-lb (68 - 75 Nm)

**5 ft-lb (9 Nm)
1001231956-A
5A MAE23720
1. Barrel 5. Rod 9. O-Ring Plug 14. Seal 19. Wiper

1a. Bushing 5a. Bushing 10. Piston 15. Lock Ring 20. Wear Ring
2. Head 6. Cartridge Valve 11. Tapered Bushing 16. O-Ring 21. Wiper
3. Ring Washer 7. Not Used 12. Spacer 17. Back-Up Ring 22. Wear Ring
4. Capscrew 8. O-Ring Plug 13. Not Used 18. Rod Seal 23. Bolt
Figure 5-40. Jib Lift Cylinder Assembly(660SJ)
3121728 5-21
8. Using suitable protection, clamp cylinder rod in a vise or 7. Inspect threaded portion of piston for damage. Dress
similar holding fixture as close to piston as possible. threads as necessary.
9. Loosen and remove nut attaching piston to rod. Remove 8. Inspect seal and O-ring grooves in piston for burrs and
piston. sharp edges. Dress surfaces as necessary.
10. Loosen and remove cap screw(s), if applicable, attaching 9. Inspect cylinder head inside diameter for scoring or
tapered bushing to piston. other damage, and for ovality and tapering. Replace as
11. Insert cap screw(s) in threaded holes in outer piece of necessary.
tapered bushing. Progressively tighten cap screw(s) until
bushing is loose on piston.
12. Remove tapered bushing from piston.
13. Screw piston counter-clockwise by hand and remove sharp edges. Dress applicable surfaces as necessary.
from cylinder rod.


be replaced.



Figure 5-41. Tapered Bushing Removal
14. Remove and discard piston O-rings, seal rings, and d. Press composite bushing into barrel or rod bushing
backup rings. with correct size arbor.
15. Remove piston spacer, if applicable, from rod.

16. Remove rod from holding fixture. Remove cylinder head

gland and retainer plate, if applicable. Discard O-rings,
back-up rings, rod seals, and wiper seals.


other damage. If necessary, dress rod with Scotch Brite Figure 5-42. Composite Bushing Installation
or other damage. Check inside diameter for tapering or 15. If applicable, inspect port block fittings and holding
ovality. Replace if necessary. valve. Replace as necessary.
5. Inspect threaded portion of barrel for damage. Dress 16. Inspect oil ports for blockage or presence of dirt or other
threads as necessary. foreign material. Repair as necessary.
6. Inspect piston surface for damage, scoring, or distortion. 17. If applicable, inspect piston rings for cracks or other
Dress piston surface or replace piston as necessary. damage. Replace as necessary.
5-22 3121728
ASSEMBLY
NOTE: Use proper cylinder seal kit for cylinder assembly. See your

assembly.
1. Use seal tool to install new rod seal into applicable cylin-
der head gland groove.
Figure 5-45. Wiper Seal Installation

3. Place new O-ring and back-up seal in applicable outside
diameter groove of cylinder head.
Figure 5-43. Rod Seal Installation

CYLINDER OPERATION. ENSURE ‘POLY-PAK’ PISTON SEALS ARE PROPERLY
INSTALLED. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
TATION.
2. Use a soft mallet to tap new wiper seal into applicable Figure 5-46. Head Seal Kit Installation
cylinder head gland groove. Install new wear ring in
4. Install washer ring on rod. Carefully install head gland
applicable cylinder head gland groove.
on rod. Do not damage or dislodge wiper and rod seals.
Push head along rod to rod end, as applicable.
5. Carefully slide piston spacer on rod.
Figure 5-44. Poly-Pak Piston Seal Installation
3121728 5-23
6. If applicable, place new O-ring and back-up rings in 11. Remove cylinder rod from holding fixture.
inner piston diameter groove.
12. Place new guide locks and seals in applicable outside
diameter grooves of cylinder piston. (See Figure 2-28.
Piston Seal Kit Installation.)

AND PISTON.

15. Continue pushing rod into barrel until cylinder head
Figure 5-47. Piston Seal Kit Installation gland can be inserted into barrel cylinder.
7. Using suitable protection, clamp cylinder rod in a vise or 16. Secure cylinder head gland using washer ring and
similar holding fixture as close to piston as possible. socket head bolts.
8. Carefully thread piston on cylinder rod hand tight,

Ensure O-ring and back-up rings are not damaged or
dislodged.
NOTE: Piston and mating end of rod must be free of oil when
installing tapered bushing.
9. Thread piston onto rod until it aligns with spacer end

and install tapered bushing.
NOTE: Apply LOCTITE #242 or equivalent to tapered bushing bolts

when rebuilding slave, lift, and telescope cylinders.
10. Install bolts in tapered bushing using loctite #242

Figure 5-49. Rod Assembly Installation

Figure 5-48. Tapered Bushing Installation
5-24 3121728
Steer Cylinder 5. Unscrew Spanner Nut (12) with hook spanner.
DISASSEMBLY
NOTE: Refer to Figure 5-53. Steer Cylinder Assembly.



Figure 5-51. Removing Spanner Nut
PULLING ROD OFF-CENTER CAN DAMAGE PISTON AND CYLINDER BARREL
3. Place cylinder barrel in a suitable holding fixture. Tap SURFACES. USE EXTREME CARE WHEN REMOVING CYLINDER ROD AND PIS-
around outside of cylinder head retainer with a suitable TON.
6. Clamp barrel securely. Apply pressure to rod pulling
device and carefully withdraw complete rod assembly
from cylinder barrel.


4. Remove burrs and contamination from cylinder before
disassembly.
3121728 5-25
14
6
2
2
4
1* 10
4
13
8
9
12**
11
14
* Torque 155 - 180 ft-lb (210 - 244 Nm)

** Torque 57- 63 ft-lb (77 - 85 Nm) 1001181792-E
MAE21940
1. Piston 5. Rod 9. Ring 13. Wiper

2. Wear Ring 6. Barrel 10. Ring 14. Bearing
3. Piston Seal 7. Head 11. Rod Seal
4. Setscrew 8. O-Ring 12. Nut
Figure 5-53. Steer Cylinder Assembly
5-26 3121728
7. Remove two Seals (2) and O-Ring (3) from Piston (1). CLEANING AND INSPECTION
8. Loosen two Setscrews (4) in Piston (1). Unscrew and 1. Clean all parts in an approved cleaning solvent.
remove Piston (1) from Rod (5) with strap wrench.
other damage. If necessary, dress rod with Scotch Brite™
3. Inspect inner surface of cylinder barrel tube for scoring,

tapering, ovality, or other damage. Replace if necessary.


5. Inspect piston surface for damage and scoring and for
distortion. Inspect seal and O-ring grooves in piston for
burrs and sharp edges. Dress piston surfaces or replace
rod assembly as necessary.
6. Inspect rod bushings for excessive wear or damage.
Replace as necessary.
Figure 5-54. Piston Seal and Wear Ring a. Thoroughly clean rod bushing of burrs, dirt, etc.
9. Remove Cylinder Head (7) from Rod (5). b. Inspect rod bushing for wear or other damage. If rod
bushing is worn or damaged, rod must be replaced.
10. Remove O-Ring (8), O-Ring (10), and Backup Ring (9)
from Cylinder Head (7). c. Lubricate inside of rod bushing with WD40 before
11. Remove Wiper (13) and Rod Seal (11). Do not damage installing composite bushing.
cylinder head groove. d. Press composite bushing in rod bushing using cor-
12. Remove Spanner Nut (12) from Rod (5). rect size arbor.
NOTE: Pin is installed in composite bushing dry. Lubrication is not

required with nickel plated pins and bearings.

7. Inspect cylinder head inside diameter for scoring, taper-

ing, ovality, or other damage. Replace as necessary.

8. Inspect threads, and seal and O-Ring grooves in head for
burrs, sharp edges, and other damage. Dress surfaces as
necessary.
9. Inspect oil ports for blockage or contamination. Repair

Figure 5-55. Cylinder Head Disassembly as necessary.
3121728 5-27
ASSEMBLY 5. Install wear ring (2) in piston groove.
NOTE: Apply a light film of hydraulic oil to all components before 6. Install seal (3) in piston groove.
assembly. 7. Install setscrew (4) to piston.


CYLINDER OPERATION.

2. Install Spanner Nut (3) on Rod (5).
3. Install Rod Seal (11) and Wiper (13) in Cylinder Head (7).
4. Install O-Ring (8), Backup Ring (9), and O-Ring (10).

Figure 5-58. Piston Seal and Wear Ring

SURFACES. USE EXTREME CARE INSTALLING CYLINDER ROD AND PISTON.
8. Insert Rod Assembly in Barrel (1).

9. Apply Locking Primer and Loctite 242 (or equivalent) to
threads of Spanner Nut (3). Tighten spanner nut (3) with
hook spanner to 57- 63 ft-lb (77 - 85 Nm).

Figure 5-59. Spanner Nut Torque
5-28 3121728
Axle Lockout Cylinder ASSEMBLY

Refer to Figure 5-60. Axle Lockout Cylinder.
NOTE: Refer to Figure 5-60. Axle Lockout Cylinder.
1. Install two new wear rings (6) and rod seal (7) in piston
DISASSEMBLY bore grooves. Make sure they are not twisted.
2. Install new wiper (8) in housing.
3. Lubricate piston bore with clean hydraulic fluid.
INSERTING PISTON OFF-CENTER CAN DAMAGE PISTON AND PISTON BORE

SURFACES. USE EXTREME CARE WHEN INSTALLING PISTON.
PISTON CAN FALL OUT OF HOUSING AND CAUSE INJURY OR DAMAGE TO
EQUIPMENT. BE CAREFUL WHEN REMOVING AXLE CYLINDER. OPENING BLEED 4. Install piston (1) in bore and push to top of bore.
VALVE CAN CAUSE PISTON TO FALL OUT OF HOUSING.
5. Install check valve (5). Torque to 22 - 24 ft-lb (30 - 33 Nm).
1. Open bleed valve (3). Rotate piston (1) and remove from 6. Bleed system.
housing (4).
2. Remove wiper (8). Do not scratch housing bore.
3. Remove two wear rings (6) and rod seal (7) from grooves
in piston bore. Do not scratch housing bore.
4. Remove check valve (5), if required.
5. Inspect bore and piston for scoring, pitting, or excessive
wear.
6. Remove minor surface blemishes with wet 2000-grit
sandpaper. Pitting requires replacement of housing or
piston.
7. Clean all parts with approved solvent and dry with com-
pressed air
3121728 5-29
2
5
3*
* Torque to 22 - 24 ft-lb (30 - 33 Nm)

1001219040-A
MAE21900
1. Rod 4. Barrel 7. Seal

2. Plug 5. Cartridge Valve 8. Wiper
3. Bleed Valve 6. Ring
Figure 5-60. Axle Lockout Cylinder
5-30 3121728
5.3 HYDRAULIC PUMP (GEAR) Assembly/Disassembly

For detail assembly/disassembly procedure, contact local JLG
Removal or JLG dealer for information.
Installation
ENSURE THE PRESSURE IS PROPERLY RELIEVED FROM THE HYDRAULIC SYS-
TEM BEFORE PROCEEDING TO REMOVAL OF THE PUMP MOTOR.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
1. Disconnect the hydraulic hoses from inlet and outlet
SURFACE IN A DIRT FREE WORK AREA.
ports of the gear pump.
1. Check for gear teeth on shaft for scoring, pitting taper-
ing and damage. If damaged need to be replaced with a
CAP ALL THE HYDRAULIC HOSES TO PREVENT ENTRAPPING OF THE DUST AND new assembly completely.
DIRT INTO IT.
2. Apply thin film of spline grease on the gear shaft.
2. Remove bolts and washers secured on the gear pump. 3. Carefully insert the shaft into the piston pump and
secure the pump using two bolts and washers. Apply
3. Carefully dislodge the gear pump shaft from the piston loctite 242 to end of bolts. Torque bolts to 20-24 ft.lbs
pump assembly. (27-33 Nm).
4. Carefully place the gear pump on the clean working sur- 4. Remove cap from the hydraulic hoses and re-connect to
face. their original locations.
WASHER
BOLT
GEAR PUMP
WASHER
BOLT
MAE23060
Figure 5-61. Hydraulic Pump Installation
3121728 5-31
5.4 VARIABLE PUMP Assembly/Disassembly

For detail assembly/disassembly instruction, Refer Variable
Removal
Pump Manual (PN XXXXXX).
Installation
ENSURE THE PRESSURE IS PROPERLY RELIEVED FROM THE HYDRAULIC SYS-
TEM BEFORE PROCEEDING TO REMOVAL OF THE PUMP MOTOR.
1. Disconnect the hydraulic hoses from inlet and outlet DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
ports of the variable pump. SURFACE IN A DIRT FREE WORK AREA.
1. Check for gear teeth on shaft for scoring, pitting taper-

CAP ALL THE HYDRAULIC HOSES TO PREVENT ENTRAPPING OF THE DUST AND ing and damage. If damaged need to be replaced with a
DIRT INTO IT. new assembly completely.
2. Remove bolts and washers secured on the variable 2. Apply thin film of spline grease on the gear shaft.
pump.
3. Carefully insert the shaft into the engine and secure the
3. Carefully dislodge the variable pump shaft from the pump using two bolts and washers. Apply loctite 242 to
engine assembly. end of bolts. Torque bolts to 46-56 ft.lbs (62-76 Nm).
4. Carefully place the variable pump on the clean working 4. Remove cap from the hydraulic hoses and re-connect to
surface. their original locations.
WASHER
BOLT
VARIABLE PUMP
WASHER
BOLT MAE23050
Figure 5-62. Variable Pump Installation
5-32 3121728
5.5 MAIN VALVE BLOCK PRESSURE SETTING 2 Wheel Steer, Relief Valves
PROCEDURE 1. Install a pressure gauge at port MJ of the main control
valve capable of reading pressures up to 3000 psi 
Refer to Figure 5-63. Main Control Valve Block (2WS) and  (207 bar).
Figure 5-64. Main Control Valve Block (4WS).
2. Activate wheel steer left and right.
3. Adjust front steer relief valves (4, 5) to 1800 ± 50 psi 

COLD TEMPERATURES HAVE A SIGNIFICANT IMPACT ON PRESSURE READINGS. (124 ± 3.5 bar) in both directions. Turn adjuster clock-
JLG INDUSTRIES INC. RECOMMENDS OPERATING THE MACHINE UNTIL THE wise to increase pressure or counterclockwise to
HYDRAULIC SYSTEM HAS WARMED TO NORMAL OPERATING TEMPERATURES decrease pressure.
PRIOR TO CHECKING PRESSURES. JLG INDUSTRIES INC. ALSO RECOMMENDS
THE USE OF A CALIBRATED GAUGE. PRESSURE READINGS ARE ACCEPTABLE IF 4 Wheel Steer, Front & Rear Steering Relief Valves
THEY ARE WITHIN ± 5% OF SPECIFIED PRESSURES.
1. Install a pressure gauge at port MJ of the main control
Load Sense Compensator (345 bar).
1. Install a pressure gauge at port MP1 of the main control 2. Activate wheel steer left and right.
valve capable of reading pressures up to 1000 psi  3. Adjust front steer relief valves (6, 7) to 2450 - 2500 psi
(70 bar). (169 - 172.5 bar) in both directions. Turn adjuster clock-
wise to increase pressure or counterclockwise to
2. Start the Engine. decrease pressure.
3. Adjust Load Sense Compensator (1) to 450 - 500 psi 
(31 - 34.5 bar). Turn adjuster clockwise to increase or Rear Axle Relief Valves
counterclockwise to decrease pressure.
valve.
Main Relief Valve
2. To check or set the rear steer reliefs, remove the wires
1. Install a pressure gauge at port MP1 of the main control from the front axle steer directional valve. Select either
valve capable of reading pressures up to 5000 psi  crab OR coordinated steer. Only the rear axle will steer.
(345 bar). 3. Activate steer left to the end of stroke, set relief, and rear
steer right to the end of stroke and set relief.
2. Activate telescope in and hold.
4. Adjust rear steer relief valve (8, 9) to 2350 psi (162 bar).
3. Adjust main relief valve (2) to 3350 - 3400 psi  Turn adjuster clockwise to increase or counterclockwise
(231 - 234.5 bar). Turn adjuster clockwise to increase or to decrease pressure.
counterclockwise to decrease pressure.
NOTE: There must be difference of 100 psi between the front and
4. If the pressure will not rise to 3350 psi, the load sense rear axle relief valves. The front must be higher than the
relief valve will have to increase. Locate the load sense rear.
relief valve. Increase this setting by 1 turn clockwise. Go
back to the main relief valve and increase until the cor-
Turntable Swing Relief Valve
rect pressure is achieved.
Load Sense Relief Valve valve.
2. The turntable should be locked in place with the turnta-

ble lock pin. Activate swing right.
(345 bar). 3. Adjust Relief Valve (10) to 1700 - 1750 psi 
(117 - 12.5 bar).
2. Activate telescope in and hold.
4. One adjustment will take care of both directions. Swing
3. Adjust load sense relief valve (3) to 3200 - 3250 psi  left will be approximately 50 psi - 100 psi (3.5 bar - 7 bar)
(220.6 - 224.1 bar). Turn adjuster clockwise to increase or lower. Turn adjuster clockwise to increase pressure or
counterclockwise to decrease pressure. counterclockwise to decrease pressure.
3121728 5-33
MP1
MJ
5
4
1
10 2
3 MAE22290
Figure 5-63. Main Control Valve Block (2WS)
5-34 3121728
9
8
6
MAE22280
Figure 5-64. Main Control Valve Block (4WS)
3121728 5-35
5.6 PLATFORM VALVE BLOCK PRESSURE SETTING Platform Jib Down Relief Valve
PROCEDURE 1. Install a pressure gauge at port M5-6 of the platform
control valve capable of reading pressures up to 
Refer to Figure 5-65. Platform Control Valve Block.
5000 psi (345 bar).
Main High Pressure Relief Valve 2. Activate jib down to the end of stroke and hold.
1. Install a pressure gauge at port MP1 of the platform con- 3. Adjust Relief Valve (13) to 1600 - 1650 psi 
trol valve capable of reading pressures up to 5000 psi (110 - 113.5 bar).
(345 bar).
4. This one adjustment will take care of jib up and down.
2. Activate platform right or left to the end of stroke and Jib up will automatically be approximately 
hold. 50 - 100 psi (3.5 - 7 bar) higher than jib down. Turn
adjuster clockwise to increase pressure or counterclock-
3. Adjust Relief Valve (11) to 2950 - 3000 psi  wise to decrease pressure.
(204.5 - 207 bar). Turn adjuster clockwise to increase
pressure or counterclockwise to decrease pressure.
Low Pressure Relief Valve

1. Install a pressure gauge at port MP1 of the platform con-
trol valve capable of reading pressures up to 5000 psi
(345 bar).
2. To check or set this adjustment locate the dump direc-
tional valve (16) at the platform manifold (12). Flip the
wires between the two solenoid coils. After the relief has
been set, flip the wires back to their original place.
3. Activate rotate right or left to the end of stroke.
4. Adjust Relief Valve (12) to 2200 ± 50 psi (152 ± 3.5 bar).
Turn adjuster clockwise to increase pressure or counter-
clockwise to decrease pressure.
5-36 3121728
11
12
14
15
16
14
15
11
12
13
MAE22130
11. Main High Pressure Relief Valve 13. Jib Relief Valve 15. High Pressure Relief Solenoid
12. Low Pressure Relief Valve 14. Low Pressure Relief Solenoid 16. Dump Directional Valve
Figure 5-65. Platform Control Valve Block
3121728 5-37
10
14 16
11
15 1
3
5
2
7
17 6
12
13
8 11
11
4 18
19
19
9
MAE22120
1. Flow/Pressure Control Valve 8. Relief Valve 15. Solenoid Valve

2. Relief Valve 9. Flow/Pressure Control Valve 16. Solenoid Valve
3. Relief Valve 10. Relief Valve 17. Solenoid Valve
4. Solenoid Valve 11. Relief Valve 18. Solenoid Valve
5. Load Sense Valve 12. Pressure Compensator Valve 19. Check Valve
6. Check Valve 13. Pressure Compensator Valve
7. Solenoid Valve 14. Solenoid Valve
Figure 5-66. Main Control Valve (2WS)
5-38 3121728
19 4
11
17
9
16
14
15
6
20
7
9
13
12
18
2 MAE22110
1. Flow/Pressure Control Valve 8. Relief Valve 15. Solenoid Valve

2. Relief Valve 9. Flow/Pressure Control Valve 16. Solenoid Valve
3. Relief Valve 10. Relief Valve 17. Solenoid Valve
4. Solenoid Valve 11. Relief Valve 18. Check Valve
5. Load Sense Valve 12. Pressure Compensator Valve 19. Solenoid Valve
6. Solenoid Valve 13. Pressure Compensator Valve 20. Check Valve
7. Solenoid Valve 14. Solenoid Valve
Figure 5-67. Main Control Valve (4WS)
3121728 5-39
25 - 30
(33 - 40.7)
40 - 45 121 - 132
40 - 45 (54 - 61)
(54 - 61) (164 -178)
25 - 30 40 - 45
(33 - 40.7) (54 - 61)
6.5 (8.8)
30 - 35
(40 - 47.45)
60 - 70
(81 - 95)
25 - 30 30 - 35
25 - 30 25 - 30 (40 - 47)
(33 - 40.7)
(33 - 40.7) (33 - 40.7)
A A A 25 - 30
(33 - 40.7)
B B B
30 - 35
(40 - 47) 6.5 (8.8)
30 - 35
(40 - 47) 1001190169-F
NOTE: All values are in Foot-Pounds (Nm) MAE23700
Figure 5-68. Main Control Valve Torque Values (2WS) - Sheet 1 of 3
5-40 3121728
6.5 (8.8)
40 - 49
(54 - 66)
29 - 38
(39 - 51)
25 - 30
(33 - 40.7)
4 (5)
6.5 (8.8) 25 - 30 44 (59.6) 44 (59.9)
(33 - 40.7)
6.5 (8.8)
6.5 (8.8)
39 (52)
6.5 (8.8)
1001190169-F
MAE23730
NOTE : All values are in Foot-Pounds (Nm)
3121728 5-41
22.2 (30)
29 - 38
(39 - 51)
25 - 30
(33 - 40.7)
25 - 30
(33 - 40.7)
1001190169-F
NOTE : All values are in Foot-Pounds (Nm) MAE23740
5-42 3121728
25 - 30
(33 - 40.7) 40 - 45 30 - 35
40 - 45 (54 - 61) 6.5 (8.8)
(54 - 61) (40 - 47)
30 - 35
(40 - 47)
25 - 30
(33 - 40.7)
29 - 38
(39 - 51)
25 - 30
(33 - 40)
25 - 30 25 - 30 121.7 - 132.8
29 - 38 29 - 38 60 - 70
(33 - 40.7) (33 - 40.7) (165 - 180)
(39 - 51) (39 - 51) (81 - 94)
S2 S2
A A
B
S1 S1
B
25 - 30
(33 - 40.7)
6.5 (8.8)
30 - 35 30 - 35 25 - 30
(40 - 47.45) (40 - 47.45) (33 - 40.7)
1001190326-F
NOTE : All values are in Foot-Pounds (Nm) MAE23710
3121728 5-43
6.5 (8.8) 25 - 30
(33- 40.7)
25 - 30
(33- 40.7)
40 - 49
(54 - 66)
25 - 30
(33- 40.7)
25 - 38 25 - 30 25 - 38 25 - 30
(33- 51) (33- 40.7) (33- 51) (33- 40.7)
39 (52) 4 (5) 4 (5)

44 (59) 44 (59)
25 - 30
6.5 (8.8) (33 - 40)
6.5 (8.8)
6.5 (8.8)
6.5 (8.8)
1001190326-F
MAE23750
5-44 3121728
22.2 (30)
1001190326-F
MAE23760
3121728 5-45
40.5 - 44.3
(52 - 60) 29 - 38
(39 - 51)
28.8 - 37.6
(39 - 50)
40.5 - 44.3
(54 - 60)
25 - 30
(33 - 40.7)
25 - 30
34 - 38 (33 - 40.7)
(46 - 51) 25 - 30 25 - 30
(33 - 40.7) (33 - 40.7)
25 - 30
(33 - 40.7)
S1
MP1
MP5-6
25 - 30
25 - 30 (33 - 30.7)
(33 - 30.7)
1001190286-D
MAE23770
Figure 5-74. Platform Valve Torque Values
5-46 3121728
3121728 5-47
5.7 HYDRAULIC SCHEMATICS
ACTUATOR
Figure 5-75. 2-Wheel Steer (2WS) without Jib Hydraulic Schematic - Sheet 1 of 2
5-48 3121728
SHEET 1
3121728 5-49
Figure 5-77. 2-Wheel Steer (2WS) with Jib Hydraulic Schematic - Sheet 1 of 2
5-50 3121728
SHEET 2
3121728 5-51
SHEET 3
5-52 3121728
SHEET 3
3121728 5-53
SHEET 4
5-54 3121728
SHEET 4
3121728 5-55
SHEET 5
Figure 5-83. 4-Wheel Drive (4WD) Hydraulic Schematic - Sheet 1 of 2
5-56 3121728
SHEET 5
3121728 5-57
SHEET 6
5-58 3121728
SHEET 6
3121728 5-59
8 7 6 5 4
H H
HYDRAULIC OIL COOLER

(OPTIONAL)
G G
DRIVE PUMP CONTROL

CURRENT AT C1 = FLOW AT PORT "A", M4
CURRENT AT C2 = FLOW AT PORT "B", M5
C1
C2
DRIVE PUMP:
DISPLACEMENT: 46CC (2.8CU.IN/REV)
CHARGE PUMP: 13.9CC (0.65 CU.IN/REV)
DISPLACEMENT
F F
E D
F00A F00B
E E
M1
M4
3625 PSI M5
ENGINE
D D
350 PSI
L2
M2
L1
3625 psi
HYDRAULIC
COOLER
B
20 PSI
C C
PORT #8 2WS
PORT #10 SWIVEL
4WS
B B
A A
SHEET 7 1001188898-C
8 7 6 5 4
MAE21260
Figure 5-87. Hydraulic Oil Cooler Schematic
5-60 3121728
SECTION 6. JLG CONTROL SYSTEM
6.1 JLG CONTROL SYSTEM ANALYZER KIT speed, and max.-speed for all boom, drive, and steering func-
tions.
INSTRUCTIONS Upper lift, swing, and drive are controlled by individual joy-
sticks. Steering is controlled by a rocker switch built in the top
of the drive joystick. To activate Drive, Lift, and Swing; pull up
WHEN INSTALLING A NEW GROUND MODULE CONTROLLER IT IS NECESSARY the slide lock on the joystick and move the handle in the
TO PROGRAM THE CONTROLLER FOR PROPER MACHINE CONFIGURATION, desired direction.
INCLUDING OPTIONS. The control system provides voltage output to the valves and
pump, as programmed, for smooth operation and maximum
cycle time. Ground control speeds for all boom functions can
also be programmed in the control system.
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF
PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/ The JLG Control System controller has a built in LED to indicate
ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM any faults. The system stores recent faults which may be
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 accessed for troubleshooting. Optional equipment includes a
CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS soft touch system, head and tail lights, and ground alarm.
ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME PERI- These options may be added later but must be programmed
ODS TO AVOID HEAVY SATURATION. into the control system when installed.
The Control System may be accessed with a custom designed,
The JLG designed Control System is a 12 volt based motor con- direct connect hand held analyzer or wireless adapter using an
trol unit installed on the boom lift. app on your Android or iPhone/iPad device. The analyzer or
The JLG Control System has reduced the need for exposed ter- wireless output displays two lines of information at a time, by
minal strips, diodes and trimpots and provides simplicity in scrolling through the program.
viewing and adjusting the various personality settings for Each module has a label with JLG part number and a serial number
smooth control of: acceleration, deceleration, creep, min containing a date code.
menu:
Analyzer Display HELP:PRESS ENTER
Escape Key Enter Key

To return home or access ESC ENTER Stores and selects Top Level, Sub Level,
previous menu and item menus
Up & Down Arrow Keys Left & Right Arrow Keys

Value Selector Used to move between Top Level, Sub
Level, and item menus
Figure 6-1. Hand Held Analyzer
3121728 6-1
Connect JLG Control System Analyzer Using Analyzer

1. Connect the four pin end of the cable supplied with the With the machine power on and the analyzer connected prop-
analyzer, to the motor controller module located in the erly, the analyzer will display the following:
platform box or at the power module and connect the
remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of the cable;
the cable cannot be connected backwards.
2. Power up the Control System by turning the lower key to MENU:

HELP: PRESS
the platform or ground position and pulling both 
emergency stop buttons on.
ESC ENTER
MAE19060
MENU:
HELP:PRESS ENTER
Move between top level menu items using 
RIGHT and LEFT arrow keys. To select a dis-
played menu item, press ENTER . To cancel a selected
menu item press ESC . Scroll using right and left arrow
keys to select a different menu item.
Top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
OPERATOR ACCESS
PERSONALITIES
MACHINE SETUP
CALIBRATIONS
6-2 3121728
If you press ENTER , at the HELP: PRESS ENTER display, Pressing ENTER with any of the above displayed menus,
and a fault is present, the analyzer display will scroll the fault displays additional sub-menus within the selected menu. In
across the screen. If there was no fault detected, the display some cases, such as DRIVE, the next level is the parameter or
will read: HELP: EVERYTHING OK. If powered up at the information to be changed. Refer to the flow chart for what
ground station, the display shows: GROUND OK. menus are available within the top level menus. You may only
view the personality settings for selected menus while in
access level 2. Remember, you may always cancel a selected
If ENTER is pressed again, the display moves to the fol-
lowing display: menu item by pressing the ESCAPE key.
Changing Access Level

When analyzer is first connected, you will be in access level 2
HELP: which enables you to only view most settings which cannot be
1: startup (2/1) changed until you enter a password to advance to a lower
level. This ensures that a setting cannot be accidentally
altered. To change access level, the correct password must be
ESC ENTER entered. To enter password, scroll to ACCESS LEVEL menu. For
example:
MENU:
OPERATOR
ESC ENTER
MAE19060
LOGGED HELP
1: STARTUP (2/1)
At this point, the analyzer will display the last fault the system
has seen, if any are present. You may scroll through the fault
logs to view what the last 25 faults were. Use the right and left
arrow keys to scroll through the fault logs. To return to the
MAE19060
beginning, press ESC two times. STARTUP (2/1) indi-
cates a power up. ACCESS LEVEL:
CODE 00000
When a top level menu is selected, a new set of menu items
may be offered: for example:
DRIVE
BOOM
ENGINE
SYSTEM
OPER CONTROLS
PLATFORM LOAD
CAN STATISTICS
CALIBRATION DATA
DATALOG
VERSIONS
3121728 6-3
Adjust Parameters
Press ENTER to select the ACCESS LEVEL menu. Once you have gained access to level 1, and a personality item
Using the UP or DOWN arrow keys, enter first is selected, press the UP or DOWN arrow keys to
digit of the password, 3. adjust its value, for example:
Then using the RIGHT arrow key, position cursor right

one space to enter the second digit of the password.
drive
ACCE l 1.0s
Use the UP or DOWN arrow key to enter the sec-
ond digit of the password which is 33271.
ESC ENTER
When correct password is displayed, press ENTER . The

access level displays the following if password was entered
correctly:
MENU:
SERVICE ACCESS
ESC ENTER
MAE19060
DRIVE:
ACCEL 1.0S
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if the UP
arrow is pressed at maximum value or decrease if the
DOWN arrow is pressed at minimum value for any per-

sonality. If value does not change when pressing up and down
arrows, check access level is at access level 1.
MAE19060
MENU: 
SERVICE ACCESS
Repeat above steps if correct access level is not displayed or
you can not adjust personality settings.
6-4 3121728
Machine Setup There is a setting that JLG strongly recommends that you do
not change. This setting is so noted below:
ELEVATION CUTBACK
When a machine digit item is selected, press UP or
DOWN arrow keys to adjust its value, for example: CHANGING ELEVATION CUTBACK SETTING MAY ADVERSELY AFFECT PERFOR-
MANCE OF YOUR MACHINE.
AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF

ground alarm: PRESSURE-WASHING IS USED TO WASH AREAS CONTAINING ELECTRICAL/
2 = drive ELECTRONIC COMPONENTS, JLG INDUSTRIES INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES
(30.5CM) FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-
ESC ENTER
NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND FOR BRIEF TIME
PERIODS TO AVOID HEAVY SATURATION.
Level Vehicle Description
DO NOT LEVEL VEHICLE EXCEPT ON A LEVEL SURFACE.
MAE19060 level vehicle

yes:Enter, no:esc
GROUND ALARM:
2 = DRIVE ESC ENTER
The effect of the machine digit value is displayed along with

its value. The above display would be selected if the machine
was equipped with a ground alarm and you wanted it to
sound when driving. There are certain settings allowed to
install optional features or select the machine model.
When selection the machine model to match the size of the
machine, the personality settings will all default to the factory
recommended setting.
NOTE: Refer to Personality Ranges/Defaults for the recommended
factory settings.
NOTE: Password 33271 allows access to level 1 to change MAE19060

machine personality settings.
LEVEL VEHICLE
YES:ENTER, NO:ESC
Not available at password level 2. ENTER confirms vehi-

cle is currently level, and zeroes the tilt sensor measurements.
3121728 6-5
Table 6-1. Analyzer Abbreviations Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING ABBREVIATION MEANING
ACCEL ACCELERATE GND GROUND
ACT ACTIVE GRN GREEN
A/D ANALOG DIGITAL CONVERTER COUNT GM GROUND MODULE
AMB. AMBIENT H HOURS
ANG ANGLE HW HARDWARE
AUX AUXILIARY HWFS HARDWARE FAILSAFE
BCS BOOM CONTROL SYSTEM I IN or CURRENT
BM BOOM LENGTH ANGLE MODULE JOY JOYSTICK
BLAM BOOM LENGTH ANGLE MODULE L LEFT
BR BROKEN LB POUND
BSK BASKET LEN LENGTH
CAL CALIBRATION LIM LIMIT
CL CLOSED LT LEFT
CM CHASSIS MODULE LVL LEVEL
CNTL CONTROL M MINUTES
CNTRL CONTROL MIN MINIMUM
C/O CUT OUT MAX MAXIMUM
CONT(S) CONTRACTOR(S) M MAIN
COOR COORDINATED MN MAIN
CRK PT CRACK POINT NO NORMALLY OPEN or NO
CRP CREEP NC NORMALLY CLOSED
CUT CUTOUT O OUT
CYL CYLINDER O/C OPEN CIRCUIT
DECEL DECELERATE OP OPEN
D DOWN O/R OVERRIDE or OUTRIGGER
DN DOWN O//R OVERRIDE
DWN DOWN OSC OSCILLATING
DEG. DEGREE OVRD OVERRIDE
DOS DRIVE ORIENTATION SYSTEM P PLATFORM
DRV DRIVE P PRESSURE
E ERROR PCV PROPORTIONAL CONTROL VALVE
E&T ELEVATED & TILTED PLAT PLATFORM
ELEV ELEVATION PLT PLATFORM
ENG ENGINE PM PLATFORM MODULE
EXT EXTEND POT POTENTIOMETER
F FRONT PRES PRESSURE
FL FLOW PRS PRESSURE
FNT FRONT PT POINT
FOR FORWARD R REAR or RIGHT
FWD FORWARD REV REVERSE or REVISION
FSW FOOT SWITCH RET RETRACT
FUNC FUNCTION ROT. ROTATE
G GROUND RT RIGHT
6-6 3121728
Table 6-1. Analyzer Abbreviations

ABBREVIATION MEANING
S/C SHORT CIRCUIT
SEL SELECTOR
SN SERIAL NUMBER
SPD SPEED
STOW STOWED
STOWD STOWED
SW SWITCH or SOFTWARE
TELE TELESCOPE
TEMP TEMPERATURE
TORQ. TORQUE
TRN TRANSPORT
T/T TURNTABLE
T TOWER
TURNTBL TURNTABLE
TWR TOWER
U UPPER or UP
V VOLT
VER VERSION
VLV VALVE
WIT WITNESS
YEL YELLOW
3121728 6-7
ANALYZER MENU
STRUCTURE
MENU: HELP: (001)

HELP: PRESS ENTER SYSTEM OK
LOG: *(XXXXX)
X: XXXXXXXXXXXX
MENU: DIAGNOSTICS: DIAGNOSTICS : TO

DIAGNOSTICS DRIVE / STEER BOOM FUNCTIONS DIAGNOSTICS :
ENGINE
DRIVE DEMAND SWING DEMAND

FORWARD XXX % LEFT XXX %
DRIVE OUTPUT SWING OUTPUT

FORWARD XXX % LEFT XXX%
DRIVE OUT mA SWING OUTPUT mA

FORWARD XXXXmA LEFT XXXXmA
DRIVE FDBK Ma STEER TYPE SWING FDBK mA TELE OUTPUT

XXXXmA NORMAL XXXXmA OUT XXX%
STEER DEMAND BRAKES STATUS TWR LIFT DEMAND TELE OUTPUT mA

LEFT XXX% LOCKED UP XXX% OUT XXXXmA
STEER OUTPUT TRACTION LOCK TWR LIFT OUTPUT TELE FDBK mA FLW CNTRL OUT mA
LEFT XXX% OUTPUT OFF UP XXX% XXXXmA XXXXmA
LT TRACK DEMAND 2WD OUTPUT TWR LIFT OUT mA JIB LIFT DEMAND FLW CNTRL FBK mA
FORWARD XXX % OFF UP XXXXmA UP XXX% XXXXmA
LT TRACK OUTPUT 2SPEED OUTPUT TWR LIFT FDBK mA JIB LIFT OUTPUT LF PRS REL OUTPT
FORWARD XXX% OFF XXXXmA UP XXX% OFF
LT TRACK OUT mA DRIVE MODE TWR LIFT DN AUX PLAT LVL DEMAND MAIN DUMP
FORWARD XXXmA MID ENGINE OFF UP XXX% OUTPUT OFF
LT TRACK FDBK mA DRV ORIENT TT SW LIFT DEMAND PLAT LVL OUTPUT STEER DUMP OUTPT
FORWARD XXXmA CLOSED UP XXX% UP XXX% OFF
RT TRACK DEMAND DRV ORIENT MODE LIFT OUTPUT PLAT LVL OUT mA TELE IN DUMP
FORWARD XXX% INLINE UP XXX% UP XXXXmA OFF
RT TRACK OUTPUT DRV ORIENT STATE LIFT OUTPUT mA PLAT LVL UP FDBK TELE OUT DUMP
FORWARD XXX % REQUIRED UP XXXXmA XXXXmA OFF
RT TRACK OUT mA DRV ORNT OVR SW LIFT FDBK mA PLAT LVL DN FDBK FUNCTION SPEED
FORWARD XXXmA CLOSED XXXXmA XXXXmA SETTING: XXX%
TO RT TRACK FDBK mA CRIBBING MODE SW LIFT DN AUX PLAT ROT DEMAND CREEP SW
FORWARD XXXmA CLOSED OFF LEFT XXX% CLOSED
MENU :
SYSTEM TEST
DRV/ST JS ENABLE CRIBBING MODE TELE DEMAND PLAT ROT OUTPUT CREEP MODE
CLOSED DISABLED OUT XXX% LEFT XXX% OFF
MAE23430
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depending
upon machine configuration and software versions.
Figure 6-2. Analyzer Software - Sheet 1 of 13
6-8 3121728
FROM DIAGNOSTICS : DIAGNOSTICS : TO

DIAGNOSTICS : DIAGNOSTICS :
ENGINE SYSTEM
BOOM FUNCTIONS OPER CONTROLS
OPERATING STATE UGM BATTERY

STOPPED XX. XV
GLOW PLUG PLATFORM MODULE

NOT ACTIVE BATTERY : XX. XV
COOLANT TEMP UGM TEMP PLATFORM ANGLE : SWING SW 2

XXXC XXXC XXX . XDEG OPEN
ENGINE OIL PRESS PLATFORM SELECT PLAT ANGLE 1 RAW OSC AXLE SW 1
XXXKPA KEYSWITCH : OPEN XX. X% OPEN
FUEL SELECTION GROUND SELECT PLAT ANGLE 2 RAW OSC AXLE SW 2

STATUS : GAS KEYSWITCH : OPEN XX. X% OPEN
FUEL PRESS STATION CONTROL ELEVATION MODE OSC AXLE

XXXKPA GROUND NOT ABOVE LOCKED
AMBIENT TEMP FOOTSWITCH INPUT TELE CUTBACK SW TRANSPORT MODE H&T LIGHTS OUT
XXXC GROUND : OPEN OPEN IN TRANSPORT OFF
FUEL LEVEL FOOTSWITCH INPUT TELE RETRAC SW 1 CREEP SW SOFT TOUCH INPUT
FULL PLATFORM : OPEN OPEN CLOSED OPEN
ALLOWED STARTER BOOM ANGLE TELE RETRAC SW 2 CREEP MODE SKYGUARD INPUTS
CRANK TIME : XXXs XX. XDEG OPEN OFF OPEN
ENGINE SPEED BOOM ANGLE 1 RAW TELE RETRACT SW CHASSIS TILT SKYGUARD INPUT 1
ACTUAL : XXXXRPM XXXXCOUNTS OPEN XXX . XDEG OPEN
ENGINE SPEED BOOM ANGLE 2 RAW RETRACTED MODE CHASSIS TILT SKYGUARD INPUT 2
TARGET : XXXXRPM XXXXCOUNTS NOT RETRACTED X- AXIS : XXX .XDEG OPEN
FUEL ACTUATOR BOOM ELEV SW 1 CAPACITY SW 1 CHASSIS TILT AMBIENT TEMP

OUTPUT : XXXXmA OPEN OPEN Y- AXIS : XXX .XDEG XXXX
FUEL ACTUATOR BOOM ELEV SW 2 CAPACITY SW 2 GENSET / WELDER SW LOW TEPERATURE

FDBK : XXXXmA OPEN OPEN OPEN CUTOUT: ACTIVE
THROTTLE OUTPUT BOOM ELEV SW CAPACITY MODE GENSET ENABLE MSSO

OFF OPEN RESTRICTED OUTPUT : OFF INACTIVE
TOWER ELEV SW SWING SW 1 H&T LIGHTS SW WIRE ROPE

OPEN OPEN OPEN SWITCH : CLOSED
MAE23440
3121728 6-9
FROM : TO
DIAGNOSTICS : DIAGNOSTICS
TO
DIAGNOSTICS : DIAGNOSTICS :
OPER CONTROLS PLATFORM LOAD
OPER CONTROLS CAN STATISTICS
JOYSTICK DRIVE PLATFORM LOAD

FORWARD XXX % STATE : OK
JOYSTICK STEER LIFT DN SW PLATFORM LOAD

LEFT XXX % OPEN ACTUAL : XXXXKG
JOYSTICK SWING TELE IN SW PLATFORM LOAD 2

LEFT XXX % OPEN GROSS : XXXXKG
JOYSTICK LIFT TELE OUT SW PLATFORM LOAD 2

UP XXX % OPEN OFFSET : XXXKG
DRV ORNT OVR SW JIB LIFT UP SW PLATFORM LOAD 2

OPEN OPEN OFFSET 1 : XXXKG
FUEL SELECT SW JIB LIFT DN SW H&T LIGHTS SW PLATFORM LOAD 2

OPEN OPEN OPEN OFFSET 2 : XXXKG
START SWITCH PLAT LEVEL UP SW GENSET / WELDER SW PLATFORM LOAD 2

OPEN OPEN OPEN ACCESSORY XXXKG
APU DESCENT SW PLAT LEVEL DN SW SG OVERRIDE SW PLATFORM LOAD 2

OPEN OPEN OPEN UNRSTRICT XXXXKG
AUX DESCENT SW PLAT ROT LEFT SW ST OVERRIDE SW PLATFORM LOAD 2

OPEN OPEN OPEN RSTRICT XXXXKG
SWING LEFT SW PLAT ROT RGHT SW SG/ ST OVRRIDE SW PLATFORM LOAD 2

OPEN OPEN OPEN CELL 1: XXXKG
SWING RIGHT SW MAX SPEED SW MSSO SW PLATFORM LOAD 2

OPEN OPEN OPEN CELL 2 : XXXKG
TOWER LIFT UP SW MAX TORQUE SW CAPACITY SW PLATFORM LOAD 2

OPEN OPEN OPEN CELL 3 : XXXKG
TOWER LIFT DN SW CREEP SW STEER CRAB SW PLATFORM LOAD 2

OPEN CLOSED OPEN CELL 4 : XXXKG
LIFT UP SW HORN SW STEER COORD SW PLATFORM LOAD 2

OPEN OPEN OPEN RAW 1: XXXXKG
PLATFORM LOAD 2
RAW 2 : XXXXKG
MAE23460
6-10 3121728
FROM DIAGNOSTICS : 2 DIAGNOSTICS : 2

TO
DIAGNOSTICS DIAGNOSTICS :
PLATFORM LOAD CAN STATISTICS CALIBRATION DATA DATALOG
CAN 1 STATISTICS 2 UGM TILT 1 X 2
RX / SEC : XXXXX XXXX COUNTS
CAN 1STATISTICS 2 UGM TILT 1 Y 2
TX / SEC : XXXXX XXXX COUNTS
CAN 1 STATISTICS 2 UGM TILT 2 X 2
BUS OFF : XXXXX XXXX COUNTS
CAN 1 STATISTICS 2 UGM TILT 2 Y 2
PASSIVE : XXXXX XXXX COUNTS
CAN 1 STATISTICS 2 TILT X 2

MSG ERROR : XXXXX XX . X DEG
CAN 2 STATISTICS 2 TILT Y 2
RX / SEC : XXXXX XX . X DEG
CAN 2 STATISTICS 2
TX /SEC : XXXXX
CAN 2 STATISTICS 2
BUS OFF : XXXXX
CAN 2 STATISITICS 2
PASSIVE : XXXXX
CAN 2 STATISTICS 2
MSG ERROR : XXXXX

MAE23470
3121728 6-11
FROM DIAGNOSTICS : TO
DIAGNOSTICS : DIAGNOSTICS:
CALIBRATION DATA DATALOG
VERSIONS
DATALOG TIME
ON XXXH XXM
DATALOG TIME DATALOG TIME DATALOG CYCLES

ENGINE XXXH XXM LEVEL XXXH XXM TELE IN XXXXX

ENABLD XXXH XXM ROTATE XXXH XXM TELE OUT XXXXX

AUX XXXH XXM GEN XXXH XXM JIB UP XXXXX
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOG CYCLES

DRIVE XXXH XXM DRVE FWD XXXXX JIB DOWN XXXXX BOOM TR XXXXX

DRV MS XXXH XXM DRVE REV XXXXX LEVEL UP XXXXX BOOM UP XXXXX

DRV MT XXXH XXM STEER LT XXXXX LEVEL DN XXXXX TOWER UP XXXXX

DRV ME XXXH XXM STEER RT XXXXX ROT LEFT XXXXX TELE TR XXXXX

STEER XXXH XXM SWING LT XXXXX ROT RIGHT XXXXX DUAL CAP XXXXX
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOG : MAX

SWING XXXH XXM SWING RT XXXXX UGM ON XXXXX UGM TEMP XXXX
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOGl : MIN

TOWER XXXH XXM TOWER UP XXXXX GND OPS XXXXX UGM TEMP XXXX
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOG : MAX

LIFT XXXH XXM TOWER DN XXXXX PLAT OPS XXXXX UGM VOLT XXXV
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOG : MACHINE

TELE XXXH XXM LIFT UP XXXXX AUX OPS XXXXX RENTAL XXXH XXM
DATALOG TIME DATALOG CYCLES DATALOG CYCLES DATALOG : ERASE 2 CLEAR RENTAL : 2
JIB XXXH XXM LIFT DN XXXXX GEN ON XXXXX MACHINE RENTAL ? YES : ENTER , NO: ESC
MAE23480
6-12 3121728
FROM DIAGNOSTICS :
DIAGNOSTICS :
DATALOG VERSIONS
UGM
SOFTWARD XX . XX
UGM
CNST DATA XX . XX
UGM
HARDWARD REV XX
UGM
S / N XXXXXX
UGM
P / N XX - XXXXXX - XX
PLATFORM MODULE
SOFTWARE XX . XX
PLATFORM MODULE
HARDWARE REV XX
PLATFORM MODULE
S / N XXXXXX
LSS MODULE
SOFTWARE XX . XX
LSS MODULE
HARDWARE REV XX
TCU MODULE
SOFTWARE XX . XX
TCU MODULE
HARDWARE REV XX
TCU MODULE
S / N XXXXXX
GROUND DISPLAY
SOFTWARE XX . XX
ANALYZER
ANALYZER XX . XX
MAE23490
NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be avail-
able depending upon machine configuration and software versions.
3121728 6-13
FROM
MENU
DIAGNOSCTICS
MENU : SYSTEM TEST :

SYSTEM TEST ACTIVATE ?
MENU : ACCESS LEVEL :

OPERATOR ACCESS CODE XXXXX
TO
MENU : PERSONALITIES : PERSONALITIES :
PERSONALITIES
PERSONALITIES DRIVE LEFT TRACK RIGHT TRACK
DRIVE LEFT TRACK

ACCEL XXXXmA /S ACCEL X . XS
DRIVE MAX SPEED LEFT TRACK

ACCEL XXXXmA / S DECEL X . XS
TO
MACHINE SETUP
DRIVE DRIVE TO STOP LEFT TRACK

DECEL XXXXmA / S DECEL XXXXmA /S FWD MIN XXXXmA
DRIVE MAX SPEED DRIVE ME / MT LEFT TRACK

DECEL XXXXmA / S MIN XXXXmA FWD MAX XXXXmA
DRIVE DRIVE MAX TORQUE LEFT TRACK

MIN XXXXxmA MAX XXXXmA FWD ELV XXXXmA
DRIVE MAX SPEED DRIVE MID ENGINE LEFT TRACK

MIN XXXXxmA MAX XXXXmA FWD CREEP XXXXmA
DRIVE DRIVE MT ELEV LEFT TRACK

MAX XXXXxmA MAX XXXXmA REV MIN XXXXmA
DRIVE MAX SPEED DRIVE ME ELEV LEFT TRACK

MAX XXXXmA MAX XXXXmA REV MAX XXXXmA
DRIVE ME / MT DRIVE MAX TORQUE LEFT TRACK

ACCEL XXXXmA /S CREEP XXXXmA REV ELV XXXXmA
DRIVE ME / MT DRIVE MID ENGINE LEFT TRACK

DECEL XXXXmA /S CREEP XXXXmA REV CREEP XXXXmA
MAE23500
6-14 3121728
FROM
PERSONALITIES
LEFT TRACK
PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : TO

PERSONALITIES
RIGHT TRACK SWING TOWER LIFT LIFT TELESCOPE
RIGHT TRACK SWING TOWER LIFT LIFT

ACCEL X . XS ACCEL X . Xs ACCEL X. Xs ACCEL X . Xs

DECEL X . XS DECEL X . Xs DECEL X . Xs DECEL X . Xs

FWD MIN XXXXmA LEFT MIN XXXXmA UP MIN XXXXma UP MIN XXXXmA

FWD MAX XXXXmA LEFT MAX XXXXmA UP MAX XXXXmA UP MAX XXXXmA

FWD ELV XXXXmA LT CREEP XXXXmA UP CREEP XXXXmA UP CREEP XXXXmA

FWD CREEP XXXXmA RIGHT MIN XXXXmA DOWN MIN XXXXmA DOWN MIN XXXXmA

REV MIN XXXXmA RIGHT MAX XXXXmA DOWN MAX XXXXmA DOWN MAX XXXXmA

REV MAX XXXXmA RT CREEP XXXXmA DN CREEP XXXXmA DN CREEP XXXXmA
RIGHT TRACK TOWER LIFT LIFT

REV ELV XXXXmA DN SOFT XXXXmA DN SOFT XXXXmA
RIGHT TRACK LIFT

REV CREEP XXXXmA UP SOFT XXXXmA
MAE23520
3121728 6-15
FROM PERSONALITIES : PERSONALITIES : PERSONALITIES : PERSONALITIES : TO

PERSONALITIES PERSONALITIES
TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE GROUND MODE
LIFT
TELESCOPE JIB LIFT PLATFORM LEVEL PLATFORM ROTATE

ACCEL X . Xs ACCEL X . Xs ACCEL X . Xs ACCEL X . Xs

DECEL X . Xs DECEL X . Xs DECEL X . Xs DECEL X . Xs

IN MIN XXXmA UP MIN XXXXmA UP MIN XXXXmA LEFT MIN XXXXmA

IN MAX XXXXmA UP MAX XXXXmA UP MAX XXXXmA LEFT MAX XXXXmA

IN CREEP XXXmA UP CREEP XXXXmA UP CREEP XXXXmA LT CREEP XXXXmA

IN CUTBK XXXmA UP CUTBK XXXmA DOWN MIN XXXXmA RIGHT MIN XXXXmA

OUT MIN XXXmA DOWN MIN XXX % DOWN MAX XXXXmA RIGHT MAX XXXXmA

OUT MAX XXXXmA DOWN MAX XXX % DN CREEP XXXXmA RT CREEP XXXXmA
TELESCOPE JIB LIFT

OUT CREEP XXXmA DOWN CREEP XXX %
TELESCOPE JIB LIFT

OUT CUTBK XXXmA DN CUTBK XXXmA MAE23530
6-16 3121728
FROM PERSONALITIES : PERSONALITIES : 2 PERSONALITIES : PERSONALITIES : PERSONALITIES :

PERSONALITIES
GROUND MODE ENGINE RPM ALARM / HORN TEMPERATURE CUT PLATFORM LOAD
GROUND MODE
GROUND MODE ENGINE RPM 2 HORN VOLUME LOW TEPERATURE PLATFORM OVRLD
SWING LT XXXXmA GEN SET XXXXRPM XXX % CUTOUT SET : XXXC XXXX
GROUND MODE ALARM VOLUME PLATFORM OVRLD

SWING RT XXXXmA XXX % RESTRICT XXXX
GROUND MODE
TOWER UP XXXXmA
GROUND MODE
TWR DOWN XXXXmA
GROUND MODE
LIFT UP XXXXmA
GROUND MODE
LIFT DOWN XXXXmA
GROUND MODE
TELE IN XXXXmA
GROUND MODE
TELE OUT XXXXmA
GROUND MODE
JIB UP XXXXmA
GROUND MODE
JIB DOWN XXX %
GROUND MODE
PLTLVL UP XXXXmA
GROUND MODE
PLTLVL DN XXXXmA
GROUND MODE
PLT ROT XXXXmA MAE23540
3121728 6-17
FROM
MENU
PERSONALITY
MENU : MODEL MARKET ENGINE STARTER LOCKOUT

MACHINE SETUP 600 S ANSI USA KUBOTA D 1105 DISABLED
ENGINE SHUTDOWN FUEL CUTOUT TILT JIB 4 WHEEL STEER

ENABLED ONE RESTART 5 DEGREES YES NO
SOFT TOUCH SKYGUARD GEN SET / WELDER GEN SET CUTOUT H & T LIGHTS
NO YES BELT DRIVE MOTION ENABLED NO
CABLE SWITCH LOAD SYSTEM FUNCTION CUTOUT GROUND ALARM DRIVE TYPE
NO NO NO NO 4WD
DISPLAY UNITS CLEARSKY CRIBBING OPTION ALERT BEACON TEMP CUTOUT

IMPERIAL NO NO OFF FOR CREEP NO
PLAT LVL OVR CUT DUAL CAPACITY ALARM/ HORN TELE CUTBACK FUEL LEVEL WATER IN FUEL
NO NO COMBINDED NO NONE SESNOR YES
MAE23550
6-18 3121728
FROM
MENU:
MACHINE SETUP
2 2 2 2 TO
MENU : CALIBRATIONS : CALIBRATIONS : CALIBRATIONS :
CALIBRATIONS
CALIBRATIONS TILT SENSOR BOOM ANGLE LEVEL UP CRKPT
LEVEL DN CRKPT
TILT SENSOR : 2 BOOM ANGLE : 2 LEVEL UP CRKPT : 2

CALIBRATE ? CALIBRATE ? CALIBRATE ?

BOOM IN - LINE ? TILT NOT CAL XXXXmA

CALIBRATING LEVEL VEHICLE ? CAL COMPLETE

SWING 180 & ENTER BOOM IN - LINE ? CAL FAILED
TILT SENSOR : 2 BOOM ANGLE : 2

SWING 180 ? BOOM DN TO STOP

CALIBRATING CALIBRATING

LEVEL VEHICLE ? BOOM DOWN ?

CAL COMPLETE SENSOR TOO LOW

CAL FAILED BOOM UP TO STOP
BOOM ANGLE : 2
CALIBRATING
BOOM ANGLE : 2
BOOM UP ?
BOOM ANGLE : 2
SENSOR TOO HIGH
BOOM ANGLE : 2
CAL COMPLETE
BOOM ANGLE : 2
CAL FAILED MAE23560
3121728 6-19
TO CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATIONS : 2 CALIBRATIONS : 2

CALIBRATIONS
LEVEL DN CRKPT LEVEL DN CRKPT PLATFORM ANGLE LOAD SENSING MSSO
LEVEL DN CRKPT : 2 PLATFORM ANGLE : 2 LOAD SENSING : 2 MSSO RESET 2

CAKUBRATE ? CALIBRATE ? CALIBRATE ? CONFIRM ?
LEVEL DN CRKPT : 2 PLATFORM ANGLE : 2 LOAD SENSING : 2

XXXXmA LVL UP TO STOP PLATFORM EMPTY ?

CAL COMPLETE CALIBRATING ACCESSORY XXXKGS

CAL FAILED PLT LVL UP ? CALIBRATING
PLATFORM ANGLE : 2 LOAD SENSING : 2

LVL DN TO STOP SKY GLAZIER ? NO

CALIBRATING PIPE RACKS ? NO

PLT LVL DN ? UNRSTRICT XXXKGS

CAL COMPLETE RSTRICT XXXKGS

CAL FAILED CAL COMPLETE
LOAD SENSING : 2
CAL FAILED MAE23570
6-20 3121728
PLATFORM CONTROL
MODULE
GROUND CONTROL
MODULE
MAE22740
Figure 6-15. Control Module Locations
3121728 6-21
J8
J1
J7
J12
J2
J3 J4
1001187200B
MAE21440
Figure 6-16. Ground Control Module Pin Connections
6-22 3121728
Connector Pin Function Type Connector Pin Function Type

UNUSED (PROPORTIONAL FUEL RACK 1 STEER DUMP VALVE DIGITAL OUTPUT
1 DIGITAL OUTPUT 2 UNUSED (ALARM OUTPUT) DIGITAL OUTPUT
ACTUATOR)
2 OSCILLATING AXLE VALVE #2 DIGITAL OUTPUT 3 PLATFORM DUMP VALVE #1 DIGITAL OUTPUT
3 DRIVE FORWARD VALVE DIGITAL OUTPUT 4 MAIN TELESCOPE IN VALVE DIGITAL OUTPUT
4 UNUSED (GROUND) GROUND INPUT 5 PLATFORM LEVEL UP VALVE DIGITAL OUTPUT
5 UNUSED GROUND INPUT 6 FUEL SENSOR GROUND GROUND INPUT
6 DRIVE REVERSE VALVE DIGITAL OUTPUT 7 PLATFORM LEVEL DOWN VALVE DIGITAL OUTPUT
7 OSCILLATING AXLE VALVE #1 DIGITAL OUTPUT 8 FRONT STEER RIGHT VALVE DIGITAL OUTPUT
8 UNUSED (GROUND) GROUND INPUT 9 TOWER LIFT DOWN VALVE DIGITAL OUTPUT
9 MSSO SWITCH GROUND GROUND INPUT 10 PLATFORM ROTATE LEFT VALVE DIGITAL OUTPUT
10 ECU POWER DIGITAL OUTPUT 11 MAIN LIFT UP VALVE DIGITAL OUTPUT
11 ENGINE START RELAY DIGITAL OUTPUT 12 JIB LIFT UP VALVE DIGITAL OUTPUT
12 ENGINE GLOW PLUGS DIGITAL OUTPUT 13 MAIN DUMP VALVE DIGITAL OUTPUT
13 APU ENABLE RELAY DIGITAL OUTPUT 14 MAIN TELESCOPE VALVES GROUND GROUND INPUT
UNUSED (ENGINE COOLANT UNUSED (TOWER TELESCOPE OUT
14 ANALOG INPUT 15 DIGITAL OUTPUT
TEMPERATURE SENSOR) VALVE)
UNUSED 16 MAIN TELESCOPE OUT VALVE DIGITAL OUTPUT
15 ANALOG INPUT UNUSED (PLATFORM ROTATE / JIB
(ENGINE OIL PRESSURE SENSOR) 17 GROUND INPUT
16 UNUSED (ENGINE SPEED SENSOR) FREQUENCY INPUT J2 LIFT VALVE GROUND)
UNUSED 18 STEER DUMP VALVE GROUND GROUND INPUT
17 GROUND INPUT (Gray) 19 FRONT LEFT STEER VALVE DIGITAL OUTPUT
J1 (ENGINE SPEED SENSOR GROUND)
(Natural) 18 UNUSED (ENGINE GROUND) GROUND INPUT 20 TOWER LIFT UP VALVE DIGITAL OUTPUT
19 UNUSED GROUND INPUT 21 AUX MAIN LIFT DOWN VALVE DIGITAL OUTPUT
20 2 SPEED VALVE DIGITAL OUTPUT 22 MAIN LIFT DOWN VALVE DIGITAL OUTPUT
21 UNUSED DIGITAL INPUT AUX TOWER LIFT DOWN /
23 DIGITAL OUTPUT
22 GENERATOR ENABLE RELAY DIGITAL OUTPUT PLATFORM DUMP VALVE #2
23 BRAKE VALVE DIGITAL OUTPUT 24 UNUSED (CONFIGURATION #2) DIGITAL INPUT
24 UNUSED N/C N/C 25 FUEL SENSOR ANALOG INPUT
UNUSED 26 HEAD / TAIL LIGHT ENABLE RELAY DIGITAL OUTPUT
25 SERIAL I/O 27 GROUND ALARM DIGITAL OUTPUT
(RESERVED FOR RS-485 HIGH)
UNUSED 28 STEER VALVES GROUND GROUND INPUT
26 SERIAL I/O 29 GROUND ALARM GROUND GROUND INPUT
(RESERVED FOR RS-485 LOW)
30 MAIN DUMP VALVE GROUND GROUND INPUT
27 BRAKE / 2 SPEED VALVE GROUND GROUND INPUT
FLOW CONTROL VALVE / TELESCOPE
28 ANALYZER POWER VOLTAGE OUTPUT 31 DIGITAL OUTPUT
29 ANALYZER RS-232 RX SERIAL INPUT FLOW CONTROL VALVE
30 ANALYZER RS-232 TX SERIAL OUTPUT 32 REAR STEER RIGHT VALVE DIGITAL OUTPUT
31 ANALYZER GROUND GROUND INPUT 33 REAR STEER LEFT VALVE DIGITAL OUTPUT
32 ALTERNATOR EXCITATION DIGITAL OUTPUT 34 SWING LEFT VALVE DIGITAL OUTPUT
33 UNUSED (RS-485 GROUND) GROUND INPUT 35 SWING RIGHT VALVE DIGITAL OUTPUT
UNUSED
34 DIGITAL INPUT
(TELESCOPE RETRACTED SWITCH #2)
35 CAPACITY LENGTH SWITCH #2 DIGITAL INPUT Connector Pin Function Type
1 UNUSED FREQUENCY INPUT
2 UNUSED FREQUENCY INPUT
Connector Pin Function Type 3 CAN2 HIGH SERIAL I/O
J12 4 CAN2 LOW SERIAL I/O
1 MODULE GROUND GROUND OUTPUT
(RED) 5 CAN2 SHIELD GROUND INPUT
2 MODULE POWER VBAT INPUT
J8 6 CAN2 TERMINATOR TERM I/O
(Black) 3 GROUND TO PLATFORM MODULE GROUND INPUT 7 CAN2 TERMINATOR TERM I/O
8 MSSO SWITCH DIGITAL INPUT
4 POWER TO PLATFORM MODULE VBAT OUTPUT
3121728 6-23
Connector Pin Function Type

ENGINE HIGH COOLANT
Connector Pin Function Type 28 DIGITAL OUTPUT
TEMPERATURE INDICATOR
1 DRIVE VALVES CURRENT FEEDBACK GROUND INPUT
ENGINE LOW OIL PRESSURE
AUX DOWN VALVES CURRENT 29 DIGITAL OUTPUT
2 GROUND INPUT INDICATOR
FEEDBACK J4 30 MAIN TELESCOPE OUT SWITCH DIGITAL INPUT
3 CABLE BREAK SWITCH GROUND GROUND INPUT (Blue) 31 INDICATORS GROUND GROUND INPUT
4 SWING VALVES CURRENT FEEDBACK GROUND INPUT
32 INDICATORS GROUND GROUND INPUT
TOWER LIFT VALVES CURRENT
5 GROUND INPUT 33 MAIN LIFT DOWN SWITCH DIGITAL INPUT
FEEDBACK 34 SWING LEFT SWITCH DIGITAL INPUT
FLOW CONTROL / TELESCOPE FLOW 35 SWING RIGHT SWITCH DIGITAL INPUT
J3 6 CONTROL VALVES CURRENT GROUND INPUT
(Black) FEEDBACK
7 GROUND ALARM POWER VBAT OUTPUT Connector Pin Function Type
8 BROKEN CABLE SWITCH DIGITAL INPUT 1 PLATFORM EMS DIGITAL INPUT
9 CRIBBING ENABLE SWITCH DIGITAL INPUT 2 PLATFORM MODE DIGITAL INPUT
10 UNUSED DIGITAL INPUT 3 GROUND MODE DIGITAL INPUT
11 UNUSED (CONFIGURATION #1) DIGITAL INPUT 4 BOOM ANGLE SENSOR #1 ANALOG INPUT
12 UNUSED VOLTAGE OUTPUT 5 UNUSED (ENGINE SPEED SENSOR) VOLTAGE OUTPUT
13 UNUSED ANALOG INPUT 6 CAN1 TERMINATOR TERM I/O
MAIN LIFT VALVES CURRENT 7 BOOM ANGLE SENSOR #2 ANALOG INPUT
14 GROUND INPUT
FEEDBACK 8 UNUSED ANALOG INPUT
9 BOOM ANGLE SENSOR GROUND GROUND INPUT
10 TILT SENSOR GROUND GROUND INPUT
11 TOWER ELEVATION SWITCH DIGITAL INPUT
Connector Pin Function Type
12 OSCILLATING AXLE SWITCH #1 D IGITAL IN PUT
1 CRIBBING ENGAGED INDICATOR DIGITAL OUTPUT
13 CAN1 HIGH SERIAL I/O
2 SYSTEM DISTRESS INDICATOR DIGITAL OUTPUT
GROUND MODE POWER TO
3 GLOWPLUG INDICATOR DIGITAL OUTPUT 14 DIGITAL INPUT
4 ENGINE START SWITCH DIGITAL INPUT PLATFORM
5 PLATFORM LEVEL DOWN SWITCH DIGITAL INPUT 15 FOOTSWITCH DIGITAL INPUT
6 PLATFORM ROTATE LEFT SWITCH DIGITAL INPUT 16 BOOM ANGLE SENSOR POWER VOLTAGE OUTPUT
7 MAIN TELESCOPE IN SWITCH DIGITAL INPUT 17 CAN1 TERMINATOR TERM I/O
8 JIB LIFT DOWN SWITCH DIGITAL INPUT J7 18 CAN1 SHIELD GROUND INPUT
9 UNUSED (JIB LEFT SWITCH) DIGITAL INPUT (Black) 19 IGNITION RELAY GROUND GROUND INPUT
10 TOWER LIFT UP SWITCH DIGITAL INPUT 20 OSCILLATING AXLE SWITCH #2 ANALOG INPUT
UNUSED 21 TELESCOPE RETRACTED SWITCH #1 DIGITAL INPUT
11 DIGITAL INPUT 22 UNUSED DIGITAL INPUT
(TOWER TELESCOPE IN SWITCH)
23 CAPACITY LENGTH SWITCH #1 DIGITAL INPUT
12 UNUSED DIGITAL OUTPUT
24 CAN1 LOW SERIAL I/O
13 LOW FUEL INDICATOR DIGITAL OUTPUT
25 GROUND DISPLAY GROUND GROUND INPUT
14 PLATFORM OVERLOADED INDICATOR DIGITAL OUTPUT
J4 26 UNUSED VOLTAGE OUTPUT
15 UNUSED (UMS INDICATOR) DIGITAL OUTPUT
(Blue) 27 UNUSED VOLTAGE OUTPUT
AUXILIARY POWER / FUNCTION
16 DIGITAL INPUT TELESCOPE RETRACTED SWITCH
ENABLE 28 GROUND INPUT
GROUND
17 PLATFORM LEVEL UP SWITCH DIGITAL INPUT
29 GROUND DISPLAY POWER VBAT OUTPUT
18 PLATFORM ROTATE RIGHT SWITCH DIGITAL INPUT
30 UNUSED VBAT OUTPUT
19 JIB LIFT UP SWITCH DIGITAL INPUT
31 CABLE BREAK SWITCH POWER VBAT OUTPUT
20 UNUSED (JIB RIGHT SWITCH) DIGITAL INPUT
32 TRANSPORT SWITCHES POWER VBAT OUTPUT
21 TOWER LIFT DOWN SWITCH DIGITAL INPUT
TELESCOPE RETRACTED SWITCH
UNUSED 33 VBAT OUTPUT
22 DIGITAL INPUT POWER
(TOWER TELESCOPE OUT SWITCH)
34 TILT SENSOR POWER VBAT OUTPUT
23 MAIN LIFT UP SWITCH DIGITAL INPUT
35 DOS SWITCH DIGITAL INPUT
24 UNUSED VBAT OUTPUT
25 SWITCHES POWER VBAT OUTPUT
BATTERY LOW / NOT CHARGING
26 DIGITAL OUTPUT
INDICATOR
6-24 3121728
3121728 6-25
J5
J2
J8
J6
J7
J1
1001185726A
MAE21470
Figure 6-17. Platform Control Module Pin Connections
6-26 3121728
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

1 UNUSED HS DIGITAL INPUT 1 UNUSED HS DIGITAL INPUT
2 UNUSED HS DIGITAL INPUT 2 UNUSED HS DIGITAL INPUT
3 UNUSED HS DIGITAL INPUT 3 UNUSED BATTERY VOLTAGE
4 UNUSED HS DIGITAL INPUT DRIVE ORIENTATION SYSTEM
5 MAIN TELESCOPE IN HS DIGITAL INPUT 4 HS DIGITAL INPUT
OVERRIDE SWITCH
6 MAIN TELESCOPE OUT HS DIGITAL INPUT 5 UNUSED HS DIGITAL INPUT
7 PLATFORM ROTATE RIGHT HS DIGITAL INPUT 6 CHASSIS TILTED INDICATOR LAMP OUTPUT
8 PLATFORM ROTATE LEFT HS DIGITAL INPUT 7 FUNCTION ENABLE INDICATOR LAMP OUTPUT
9 PLATFORM LEVEL UP HS DIGITAL INPUT VEHICLE SYSTEM DISTRESS
10 PLATFORM LEVEL DOWN HS DIGITAL INPUT 8 LAMP OUTPUT
INDICATOR
11 JIB UP HS DIGITAL INPUT 9 CREEP SPEED INDICATOR LAMP OUTPUT
12 JIB DOWN HS DIGITAL INPUT 10 BROKEN CABLE INDICATOR LAMP OUTPUT
SPEED PUMP POTENTIOMETER 11 PLATFORM OVERLOADED INDICATOR LAMP OUTPUT
13 GROUND
GROUND 12 LOW CAPACITY INDICATOR LAMP OUTPUT
14 ENGINE START HS DIGITAL INPUT 13 HIGH CAPACITY INDICATOR LAMP OUTPUT
15 AUXILIARY POWER HS DIGITAL INPUT DRIVE ORIENTATION SYSTEM
16 UNUSED HS DIGITAL INPUT 14 LAMP OUTPUT
INDICATOR
J1 17 UNUSED HS DIGITAL INPUT 15 GENERATOR ON INDICATOR LAMP OUTPUT
18 SWITCH POWER BATTERY VOLTAGE J2 16 SOFT TOUCH TRIGGERED INDICATOR LAMP OUTPUT
(NATURAL) 19 UNUSED HS DIGITAL INPUT (BLUE) 17 GLOW PLUG ENGAGED INDICATOR LAMP OUTPUT
20 SOFT TOUCH SWITCH HS DIGITAL INPUT 18 LAMP RETURN GROUND
21 CAPACITY SELECT SWITCH HS DIGITAL INPUT 19 UNUSED LAMP OUTPUT
22 UNUSED HS DIGITAL INPUT 20 UNUSED LAMP OUTPUT
23 SKYGUARD INPUT #2 HS DIGITAL INPUT 21 LOW FUEL INDICATOR LAMP OUTPUT
24 UNUSED HS DIGITAL INPUT 22 1/4 FUEL LEVEL INDICATOR LAMP OUTPUT
25 PLATFORM ANGLE 1 SIGNAL HS DIGITAL INPUT 23 3/4 FUEL LEVEL INDICATOR LAMP OUTPUT
26 PLATFORM ANGLE 2 SIGNAL HS DIGITAL INPUT 24 1/2 FUEL LEVEL INDICATOR LAMP OUTPUT
27 TWO SPEED VALVE (HIGH ENGINE) HS DIGITAL INPUT 25 FUEL LEVEL INDICATORS RETURN GROUND
28 TORQUE MODE HS DIGITAL INPUT 26 ANALYZER POWER ANALYZER POWER
29 SOFT TOUCH OVERRIDE HS DIGITAL INPUT 27 ANALYZER GROUND ANALYZER GROUND
30 HEAD/TAIL LIGHT HS DIGITAL INPUT 28 ANALYZER RX ANALYZER RX
31 HORN HS DIGITAL INPUT 29 ANALYZER TX ANALYZER TX
32 CREEP MODE HS DIGITAL INPUT 30 UNUSED LAMP OUTPUT
33 DUAL-FUEL SELECT HS DIGITAL INPUT 31 UNUSED DIGITAL OUTPUT
SPEED PUMP POTENTIOMETER +7 REFERENCE 32 LSS POWER BATTERY VOLTAGE
34
REFERENCE VOLTAGE VOLTAGE 33 OPTION POWER BATTERY VOLTAGE
35 SPEED PUMP POTENTIOMETER ANALOG INPUT 34 SOFT TOUCH POWER BATTERY VOLTAGE
35 FULL FUEL LEVEL INDICATOR LAMP OUTPUT
3121728 6-27
CONNECTOR PIN ASSIGNMENT FUNCTION CONNECTOR PIN ASSIGNMENT FUNCTION

LIFT / SWING JOYSTICK SUPPLY 1 GROUND MODE GROUND MODE
1 SUPPLY VOLTAGE 2 PLATFORM EMS PLATFORM EMS
VOLTAGE
2 LIFT CENTER TAP ANALOG INPUT 3 PLATFORM EMS TO GROUND MODULE PLATFORM MODE
3 LIFT SIGNAL ANALOG INPUT FOOTSWITCH (FUNCTION ENABLE
J5 4 BATTERY VOLTAGE
4 SWING SIGNAL ANALOG INPUT SWITCH) POWER
(NATURAL)
5 SWING CENTER TAP ANALOG INPUT 5 PLATFORM ROTATE LEFT ME DIGITAL OUTPUT
6 NOT CONNECTED ANALOG INPUT 6 PLATFORM ROTATE RIGHT ME DIGITAL OUTPUT
7 LIFT / SWING JOYSTICK RETURN GROUND 7 SKYGUARD POWER BATTERY VOLTAGE
8 SPARE PIN BLANK 8 FOOTSWITCH SIGNAL DIGITAL INPUT
9 GENERATOR ON SIGNAL DIGITAL INPUT
+7 REFERENCE
10 UNUSED
CONNECTOR PIN ASSIGNMENT FUNCTION VOLTAGE
DRIVE / STEER JOYSTICK SUPPLY +5V REFERENCE
1 SUPPLY VOLTAGE 11 PLATFORM ANGLE SENSOR SUPPLY
VOLTAGE VOLTAGE
2 DRIVE CENTER TAP ANALOG INPUT +5V REFERENCE
12 UNUSED
3 DRIVE SIGNAL ANALOG INPUT VOLTAGE
J6 4 STEER SIGNAL ANALOG INPUT 13 UNUSED ANALOG INPUT
(BLACK) 14 PLATFORM ANGLE SENSOR GROUND GROUND
5 STEER LEFT ANALOG INPUT J7 15 PLATFORM LEVEL UP HS DIGITAL OUTPUT
6 STEER RIGHT ANALOG INPUT (BLACK) 16 PLATFORM LEVEL DOWN HS DIGITAL OUTPUT
7 DRIVE / STEER JOYSTICK RETURN GROUND 17 UNUSED HS DIGITAL INPUT
8 SPARE PIN BLANK 18 SKYGUARD INPUT 1 SWITCH HS DIGITAL INPUT
19 PLATFORM ALARM LAMP OUTPUT
20 ALARM RETURN GROUND
21 SKYGUARD GROUND GROUND
22 LSS GROUND GROUND
23 UNUSED ANALOG INPUT
25 JIB UP ME DIGITAL OUTPUT
26 JIB DOWN ME DIGITAL OUTPUT
27 UNUSED ME DIGITAL OUTPUT
28 UNUSED ME DIGITAL OUTPUT
29 OPTIONAL VALVES GROUND RETURN GROUND
30 CAN LOW CAN LOW
31 CAN HIGH CAN HIGH
32 UNUSED CAN SHIELD
33 UNUSED GROUND
34 UNUSED GROUND
35 UNUSED ANALOG INPUT
6-28 3121728
Table 6-2. Machine Configuration Programming Information
Default
Configuration Digit Number Description
Number
NOTE: Machine configuration must be completed before any personality settings can be changed. Changing personality set-
tings first and then changing the model number of the machine configuration will cause personality settings to return to
default
MODEL NUMBER: 0 No Model Visible only on a Non-Configured UGM

1 1 600S 1
1 ANSI USA 1
2 ANSI EXPORT
3 CSA
MARKET:
4 CE
2
5 AUSTRALIA
6 JAPAN
7 GB
1 DEUTZ EMR2: (Tier 4i) 1

ENGINE:
2 DEUTZ EMR4: (Tier 4f)
3
3 FORD DUAL FUEL
FLYWHEEL TEETH:
1 98 TEETH: 98 flywheel teeth. 1
4*
* This menu item is not visible
GLOW PLUG: 1 NO GLOW PLUGS: No glow plugs installed.

2
5* 2 IN-CYLINDER: Glow plugs installed in each cylinder.
* This menu item is not visible.
1 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start 1
can be attempted at any time during pre-glow.
STARTER LOCKOUT:
6*
2 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permit-
ted until pre-glow is finished.
* Only visible for Engine Selection = Deutz EMR2 or Deutz EMR4.
1 DISABLED: No engine shutdown.

ENGINE SHUTDOWN:
7
2 ENABLED: Shutdown engine for high coolant temperature fault or low oil pressure fault 2
3121728 6-29
Default
Number
1 ONE RESTART: One restart with limited run time when near Empty.
FUEL CUTOUT: 2 ENGINE STOP: No starting permitted when near Empty.
8* 3 NONE
4 RESTART: Restarts allowed with limited run time when near Empty 4
* Only visible for Engine Selection = Deutz EMR2 or Deutz EMR4.
1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees
and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out
and main lift up.
5 4 DEG + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also disallows tower lift up, drive, telescope out and lift up.
TILT:
9
6 3 DEG + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3
degrees and above elevation; also disallows tower lift up, drive, telescope out and lift up.
7 5 DEG + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted 7
more than 5 degrees and above elevation; also reduces drive speed to creep when drive
reversal is allowed, drive is disallowed otherwise.
8 4 DEG + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4
degrees and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is
disallowed otherwise.
9 3 DEG + DRV CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3
degrees and above elevation; also reduces drive speed to creep when drive reversal is allowed, drive is
disallowed otherwise.
* Certain market selections will limit tilt options and alter default setting.
Note: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation.
JIB: 1 NO: No Jib installed. 1

10 2 YES: Jib installed which has up and down movements only.
6-30 3121728
Default
Number
4 WHEEL STEER: 1 NO: 4 Wheel Steer not installed. 1

11* 2 YES: 4 Wheel Steer installed.
* Only visible for 600S.
SOFT TOUCH: 1 NO: No Soft Touch system installed. 1

12 2 YES: Soft Touch system installed.
SKYGUARD: 1 NO: No SkyGuard system installed.

2
13 2 SKYGUARD: SkyGuard system only installed.
GEN SET/WELDER: 1 NO: No generator installed. 1

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

16 2 YES: Head and tail lights installed.
1 NO: No load sensor installed. 1
2 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
LOAD SYSTEM:
17* 3 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).
4 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), platform alarm beeps (5
sec ON, 2 sec OFF).
* Only visible under certain market selections.

* Certain market selections will limit load system options or alter default setting.
3121728 6-31
Default
Number
1 NO: No drive cutout. 1

FUNCTION CUTOUT:
2 BOOM CUTOUT: Boom function cutout while driving above elevation.
18*
3 DRIVE CUTOUT: Drive cutout above elevation.

* Certain market selections will limit function cutout options or alter default setting.
1 NO: No ground alarm installed.

GROUND ALARM: 2 DRIVE: Travel alarm sounds when the drive function is active (Option).
19 3 DESCENT: Descent alarm sounds when lift down is active (Option).
4 MOTION: Motion alarm sounds when any function is active (Option). 4
DRIVE TYPE: 1 4 WD: Four wheel drive. 1

20* 2 2WD: Two wheel drive.
* This menu item is not visible
DISPLAY UNITS: 1 METRIC: Celsius, Kilograms, KiloPascal.

21* 2 IMPERIAL: Fahrenheit, Pounds, Pounds/in2 2
* Certain market selections will alter default setting.
CLEARSKY: 1 NO: ClearSky (Telematics) system not installed. 1

22 2 YES: ClearSky (Telematics) system installed.
CRIBBING OPTION: 1 NO: Cribbing Option is disabled. 1

23* 2 YES: Cribbing Option is enabled.
* Certain market selections will limit cribbing options.
ALERT BECON: 1 OFF FOR CREEP 1

24 2 IN CREEP 20FPM
TEMP CUTOUT: 1 NO: No Low Temp Cutout system installed 1

25* 2 YES: Low Temp Cutout system installed
* Certain market selections will temp cutout options.
6-32 3121728
Default
Number
PLAT LVL OVR CUT: 1 NO: Platform Level functions above elevation 1
26 2 YES: Platform Level does not function above elevation
DUAL CAPACITY: 1 NO: No Dual Capacity system installed.

27* 2 YES: Dual Capacity system installed. 2
* Only visible for 600S.
ALARM / HORN: 1 SEPARATE: Ambient alarm installed.

28 2 COMBINED: Single Horn / Alarm installed. 2
WATER IN FUELSENSOR: 1 NO: Water in Fuel Sensor not installed. 1

29* 2 YES: Water in Fuel Sensor installed.

* Only visible for Engine Selection = Deutz EMR4.
1001198686 - C
3121728 6-33
Table 6-3. Machine Configuration Programming Settings Table 6-3. Machine Configuration Programming Settings
ANSI Export
ANSI Export
Australia
ANSI USA
Australia
ANSI USA
Japan
Japan
CSA
600S
GB
CE
CSA
600S
GB
CE
Model Number 1 1 1 1 1 1 1 Load System 1 1 1 X X 1 X
Market 1 2 3 4 5 6 7 2 2 2 X 2 2 2
Engine 1 1 1 1 1 1 1 3 3 3 X 3 3 3
2 2 2 2 2 2 2 4 4 4 4 X 4 4
3 3 3 3 3 3 3 Function Cutout 1 1 1 X 1 1 1
Flywheel Teeth X X X X X X X X 2 2 2 2 2 2
Glow Plug 2 2 2 2 2 2 2 3 3 3 X 3 3 3
Starter Lockout 1 1 1 1 1 1 1 Ground Alarm 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
Engine Shutdown 1 1 1 1 1 1 1 3 3 3 3 3 3 3
2 2 2 2 2 2 2 4 4 4 4 4 4 4
Fuel Cutout 1 1 1 1 1 1 1 Drive Type 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
X X X X X X X Display Units 1 1 1 1 1 1 1
4 4 4 4 4 4 4 2 2 2 2 2 2 2
Tilt 1 1 1 1 1 1 1 Clearsky 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 Cribbing Option 1 X X X X X X
4 4 4 4 4 4 4 2 X X X X X X
5 5 5 5 5 5 5 Alert Beacon 1 1 1 1 1 1 1
6 6 6 6 6 6 6 2 2 2 2 2 2 2
7 7 7 7 7 7 7 Temp Cutout X 1 X 1 X X 1
8 8 8 8 8 8 8 X 2 X 2 X X 2
9 9 9 9 9 9 9 PLAT LVL OVR CUT 1 1 1 1 1 1 1
4 Wheel Steer 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 Dual Capacity 1 1 1 1 1 1 1
Jib 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 ALARM / HORN 1 1 1 1 1 1 1
SOFT TOUCH 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 Water in Fuel Sensor X 1 X X X X 1
SKYGUARD 1 1 1 1 1 1 1 X 2 X X X X 2
2 2 2 2 2 2 2 BOLD BLUE text indicates the default setting. Plain text indicates another available
selection. RED ITALIC text indicates the default when option is factory installed. SHADED
Gen Set / Welder 1 1 1 1 1 1 1
CELLS indicate hidden menu or selection.
2 2 2 2 2 2 2 1001198686 - C
Gen Set Cutout 1 1 1 1 1 1 1

2 2 2 2 2 2 2
Head & Tail lights 1 1 1 1 1 1 1
2 2 2 2 2 2 2
6-34 3121728
Table 6-4. Machine Configuration Programming Settings Table 6-4. Machine Configuration Programming Settings
ANSI Export
ANSI Export
Australia
ANSI USA
Australia
ANSI USA
Japan
Japan
CSA
660SJ
GB
CE
CSA
660SJ
GB
CE
Model Number 1 1 1 1 1 1 1 Load System 1 1 1 X X 1 X
Market 1 2 3 4 5 6 7 2 2 2 X 2 2 2
Engine 1 1 1 1 1 1 1 3 3 3 X 3 3 3
2 2 2 2 2 2 2 4 4 4 4 X 4 4
3 3 3 3 3 3 3 Function Cutout 1 1 1 X 1 1 1
Flywheel Teeth X X X X X X X X 2 2 2 2 2 2
Glow Plug 2 2 2 2 2 2 2 3 3 3 X 3 3 3
Starter Lockout 1 1 1 1 1 1 1 Ground Alarm 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
Engine Shutdown 1 1 1 1 1 1 1 3 3 3 3 3 3 3
2 2 2 2 2 2 2 4 4 4 4 4 4 4
Fuel Cutout 1 1 1 1 1 1 1 Drive Type 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
X X X X X X X Display Units 1 1 1 1 1 1 1
4 4 4 4 4 4 4 2 2 2 2 2 2 2
Tilt 1 1 1 1 1 1 1 Clearsky 1 1 1 1 1 1 1
2 2 2 2 2 2 2 2 2 2 2 2 2 2
3 3 3 3 3 3 3 Cribbing Option 1 X X X X X X
4 4 4 4 4 4 4 2 X X X X X X
5 5 5 5 5 5 5 Alert Beacon 1 1 1 1 1 1 1
6 6 6 6 6 6 6 2 2 2 2 2 2 2
7 7 7 7 7 7 7 Temp Cutout X 1 X 1 X X 1
8 8 8 8 8 8 8 X 2 X 2 X X 2
9 9 9 9 9 9 9 PLAT LVL OVR CUT 1 1 1 1 1 1 1
4 Wheel Steer 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 Dual Capacity 1 1 1 1 1 1 1
Jib 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 ALARM / HORN 1 1 1 1 1 1 1
SOFT TOUCH 1 1 1 1 1 1 1 2 2 2 2 2 2 2
2 2 2 2 2 2 2 Water in Fuel Sensor X 1 X X X X 1
SKYGUARD 1 1 1 1 1 1 1 X 2 X X X X 2
2 2 2 2 2 2 2 BOLD BLUE text indicates the default setting. Plain text indicates another available
selection. RED ITALIC text indicates the default when option is factory installed. SHADED
Gen Set / Welder 1 1 1 1 1 1 1
CELLS indicate hidden menu or selection.
2 2 2 2 2 2 2 1001198686 - C
Gen Set Cutout 1 1 1 1 1 1 1

2 2 2 2 2 2 2
Head & Tail lights 1 1 1 1 1 1 1
2 2 2 2 2 2 2
3121728 6-35
6.2 MACHINE PERSONALITY SETTINGS AND SWING: Boom at full elevation, Telescope retracted. Swing
Right until over rear axle or end stop (if equipped). Swing Left
FUNCTION SPEED 360° or end stop (if equipped), record time. Swing Right 360°
or end stop (if equipped), record time. Turn Platform Speed
Test Notes Control Knob fully counterclockwise to enter Creep mode;
Creep light on Panel must be energized. Verify that machine
1. Personality settings can be adjusted anywhere within
will swing left and right. Return Knob to fully clockwise.
the adjustment range for optimum machine perfor-
mance. MAIN LIFT: Main Lift in stowed position, Telescope Retracted.
Main Lift Up, record time. Main Lift Down, record time. Turn
2. Stop watch should be started with the function move- Platform Speed Control Knob fully counterclockwise to enter
ment, not with actuation of the joystick or switch. Creep mode; Creep light on Panel must be energized. Verify
3. Drive speeds should be set to the values below regard- that machine will Lift Up and Down. Return Knob to fully
less of the tire size. clockwise.
4. All speed tests are run from the platform, these speeds TELESCOPE: Main Lift at full elevation, Telescope Retracted.
do not reflect the ground control operation. Telescope Out, record time.Telescope In, record time. Turn
Platform Speed Control Knob fully counterclockwise to enter
5. The Platform Speed Control knob must be at full speed Creep mode; Creep light on Panel must be energized. Verify
(turned clockwise completely) unless noted. that machine will Telescope In and Out. Return Knob to fully
6. Some flow control functions may not work with the Plat- clockwise.
form Speed Control knob clicked into the creep posi- JIB LIFT: Platform level and centered with the boom. Jib Lift
tion. Down until stop. Jib Lift Up, record time.Jib Lift Down, record
time. Turn Platform Speed Control Knob fully counterclock-
7. Functional speeds may vary due to cold thick hydraulic
wise to enter Creep mode; Creep light on Panel must be ener-
oil. Test should be run with the oil temperature above
gized. Verify that machine will Jib Lift Up and Down. Return
38° C (100° F).
Knob to fully clockwise.
Machine Orientation When Setting Function PLATFORM ROTATE: Platform level, Rotate Platform Right
Speeds until stop. Platform Left, record time. Platform Right, record
time. Turn Platform Speed Control Knob fully counterclock-
DRIVE (Below Elevation): Test should be done on a smooth, wise to enter Creep mode; Creep light on Panel must be ener-
level surface. The Drive Select Switch should be in the “Max gized. Verify that machine will Platform Rotate Left and Right.
Speed” position. Start approximately 25 ft (7.6m) from starting Return Knob to fully clockwise.
point so the unit is at a maximum speed when starting the
NOTE: When the platform speed control knob is turned fully coun-
test. Results should be recorded for a 200ft (61m) course. Drive
terclockwise. The platform rotate may not work, this is
forward, “High Speed”, record time.
acceptable.
DRIVE (Above Elevation): Test should be done on a smooth,
level surface. The Drive Select Switch should be in the “Max
Speed” position, the boom should be > 10° above horizontal
to ensure the drive is operating in Max Torque mode. Results
should be recorded for a 15.2m (50ft) course. Drive forward,
record time. Drive Reverse, record time. Turn Platform Speed
Control Knob fully counterclockwise to enter Creep mode;
Creep light on Panel must be energized. Verify that machine
will Drive Forward and Reverse. Return Knob to fully clockwise.












6-36 3121728
Table 6-5. Machine Personality Settings and Function Speed
MODEL MODEL TIME RANGE

FUNCTION ADJUSTMENT RANGES
DEFAULTS (IN SECONDS)
DRIVE
Accel 25 – 2000 mA/s 500 mA/s
Decel 25 – 2000 mA/s 925 mA/s
Max Speed
MIn 250 – 1000 mA 625 mA
Max 250 – 1400 mA 1550 mA 35 to 39
Drive to Stop Decel 25 – 2000 mA/s 725 mA/s
Max Torque Elevated Max 250 – 1200 mA 950 mA 85 to 97
Mid Engine Elevated Max 250 – 1200 mA 1050 mA 85 to 97
Max Torque Creep 250 – 1200 mA 850 mA
Mid Engine Creep 250 – 1200 mA 950 mA
SWING
Accel 0.0 to 3.0 s 3.0 s
Decel 0.0 to 2.0 s 1.6 s
Min 250 to 1000 mA 430 mA
LEFT Max 250 to 1000 mA 875 mA 79 to 99
Creep 250 to 1000 mA 675 mA
Min 250 to 1000 mA 430 mA
RIGHT Max 250 to 1000 mA 900 mA 79 to 99
LIFT
Accel 0.0 to 3.0 s 2.5 s
Decel 0.0 to 2.0 s 1.2 s
Min 250 to 1500 mA 525 mA
UP Max 250 to 1500 mA 1400 mA 55 to 75
Creep 250 to 1500 mA 1000 mA
Min 250 to 1300 mA 700 mA
DOWN Max 250 to 1300 mA 1200 mA 55 to 75
Creep 250 to 1300 mA 1000 mA
Soft Down 250 to 1500 mA 900 mA
Soft Down 250 to 1300 mA 850 mA
TELESCOPE
Accel 0.0 to 3.0 s 0.7 s
Decel 0.0 to 2.0 s 0.5 s
Min 250 to 1200 mA 420 mA
IN Max 250 to 1200 mA 1000 mA 40 to 50
3121728 6-37
Table 6-5. Machine Personality Settings and Function Speed
MODEL MODEL TIME RANGE

FUNCTION ADJUSTMENT RANGES
DEFAULTS (IN SECONDS)
Min 250 to 1200 mA 480 mA
OUT Max 250 to 1200 mA 1050 mA 42 to 52
JIB LIFT
Accel 0.0 to 3.0 s 3.0 s
Decel 0.0 to 2.0 s 0.8 s
Min 10 to 50% 27%
UP Max 10 to 50% 41% 25 to 32
Creep 10 to 50% 34%
Min 10 to 50% 27%
DOWN Max 10 to 50% 40% 22 to 28
Creep 10 to 50% 35%
Up Cutback 10 to 50% 33%
Down Cutback 10 to 50% 33%
PLATFORM LEVEL
Accel 0.0 to 3.0 s 0.0 s
Decel 0.0 to 2.0 s 0.0 s
Min 250 to 1500 mA 800 mA
UP Max 250 to 1500 mA 1300 mA
Creep 250 to 1500 mA 1100 mA
Min 250 to 1500 mA 850 mA
DOWN Max 250 to 1500 mA 1400 mA
Creep 250 to 1500 mA 1250 mA
GROUND MODE
Left 250 to 1000 mA 670 mA
SWING
Right 250 to 1000 mA 895 mA
Up 250 to 1500 mA 1395 mA
Lift
Down 250 to 1300 mA 1195 mA
In 250 to 1200 mA 995 mA
Telescope
Out 250 to 1200 mA 1045 mA
Up 10 to 50% 40%
JIB
Down 10 to 50% 39%
Up 250 to 1500 mA 1295 mA
Platform
Down 250 to 1500 mA 1395 mA
1001198722-D
6-38 3121728
6.3 CANBUS COMMUNICATIONS Platform Level: The GROUND MODULE stores default values
and handles interlocks. The PLATFORM MODULE reads sensors
CANbus: CAN (Control Area Network) is a two wire differential mounted on the platform assembly and controls Level Up /
serial link between the Platform and Ground Modules provid- Down valves to maintain setpoint sent from the GROUND
ing bi-directional communications. MODULE.
Two-wire: One wire (red) is driven high (5v) and the other low Steer: The GROUND MODULE stores crack points, and sends
(black) (0v) to send a signal. Both wires “float” (2.5v) when no desired drive direction, steering mode, and axle extend/retract
signal is being sent.  commands. The PLATFORM MODULE reports steering switch
 position to the GROUND MODULE.
Differential: Any electrical line noise can affect the high or the Drive: The GROUND MODULE stores crack points and sends
low wires but never both, so communications is not corrupted.  commands for each drive pump. (Command is computed from
 drive joystick input, interlocks, wheel angle, etc).
Serial Link: Messages are being sent bit by bit along the wires;
the high bus speed allow all modules to be constantly Lift, Tele, & Swing: The GROUND MODULE stores default val-
updated around 20 times per second. Typical traffic is 300 - ues, and handles interlocks and calibration information. Lift,
500 messages per second.  Telescope, and Swing commands depend on interlocks
 through out the machine. Boom angle, length, and swing are
A complete CANbus circuit is approximately 60 ohms, which controlled by the GROUND MODULE
can be verified at the “T” fitting inside the ground station. Indi-
vidual circuits are approximately 120 ohms.
The GROUND MODULE (UGM) is the master system controller.
Most functions are dispatched and coordinated from this
module. The PLATFORM MODULE handles sub-tasks. All char-
acterized information (values) are stored in the ground mod-
ule (i.e., Personalities or Calibrations).
Interlocks: Any device that sends an electrical input. (For an
example a limit switch, proximity switch, etc;).
3121728 6-39
6.4 SYSTEM TEST 4. Pull out the Emergency Stop switch and Start the
engine.
The Control System Incorporates a built-in system test to
check the system components and functions. To use this func-
tion, use the following procedures.
Test from the Platform

1. Position the Platform/Ground select switch to the Plat-
form position.
5. The analyzer screen should read:
HELP:
PRESS ENTER
MAE23330
2. Plug the analyzer into the connector at the base of the ESC ENTER
platform control box.
MAE19060
6. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
MAE15680
vate the system test; hit Enter again to activate.
7. Follow the flow path in Figure 6-18., System Test Flow
3. Before proceeding, ensure that the switches on the plat- Chart - Platform Tests (Sheet 1 of 2) & Figure 6-19., Sys-
form console are in the following positions: tem Test Flow Chart - Platform Tests (Sheet 2 of 2) and
go through the component tests. Hit the ESC key during
a. Drive speed dial is in the slow position. (Turtle Icon)
any part of the test to return to the main menu without
b. Function speed potentiometer out of creep mode completing all tests or wait until all tests are complete.
switch. During the TEST ALL INPUTS sequence, the analyzer
c. Generator (if equipped) switched to the off position. allows control switches to be operated and shows if they
are closed (CL) or open (OP).
d. Head and Tail lights (if equipped) switched to the off
position.
6-40 3121728
OPERATOR ACCESS
TEST INPUTS
FLOW CTRL VALVE CHECK DRIVE

SPEED CHECK PLAT DOWN DRIVE MAX SPEED
STEER DUMP VALVE CHECK DRIVE CHECK STEER

DRIVE FOR VALVE DRIVE MID ENG
JOYSTICK 2W SWTICH
BYPASS DUMP CHECK STEER
VALVE DRIVE REV VALVE JOYSTICK CHECK HORN DRIVE MAX TORQ
BRAKE VALVE FRONT RGHT CHECK LIFT CHECK START

STEER VALVE DRIVE MID ENG
JOYSTICK SWITCH
FRONT LEFT CHECK SWING
STEER VALVE CHECK AUX POWER STEER CRAB
JOYSTICK
SWING LEFT VALVE CHECK SPEED CHECK FUEL STEER 2W
POT SELECT
SWING RGHT VALVE CHECK CREEP CHECK HEADLIGHT STEER COORD
SW SWITCH
CHECK SWING
LIFT UP VALVE CHECK GEN SET STEER 2W
LEFT
CHECK SWING CHECK CAPACITY
LIFT DN VALVE CL PLATFORM UP
RIGHT SWITCH
AUX LIFT DN VALVE CHECK LIFT UP CHECK TURNTBL OP PLATFORM UP
OVRD
TELE OUT VALVE CHECK LIFT DOWN CHECK SKYGUARD CL PLATFORM
OVRD DOWN
TELE IN VALVE CHECK TELE IN CHECK SOFT OP PLATFORM
TOUCH OVRD DOWN
TELE IN DMP VLV CHECK TELE OUT CHECK SG/ST LIFT JOYSTICK TO
OVRD UP MAX
PLAT DMP 1 VLV CHECK JIB UP LIFT JOYSTICK TO
CHECK SKYGUARD DOWN MAX
PLAT DMP 2 VLV SWING JOYSTICK
CHECK JIB DOWN
TO LEFT MAX
JIB UP VALVE CHECK PLAT UP SWING JOYSTICK
TO RIGHT MAX
JIB DN VALVE CHECK PLAT LEFT CREEP SWITCH
CCW
PLATFRM LT VALVE CREEP SWITCH
CHECK PLAT RIGHT
CW
PLATFRM RT VLE
FUNC SPD TO MAX
PLATFORM UP VLE
FUNC SPD TO MIN
PLATFORM DN VLE
CL HORN
HEAD/TAIL LIGHTS
OP HORN
GEN SET
CL PLATFORM LEFT
OSC AXLE
1 VALVE OP PLATFORM LEFT
OSC AXLE
2 VALVE
GLOWPLUGS
MAE22790
Figure 6-18. System Test Flow Chart - Platform Tests (Sheet 1 of 2)
3121728 6-41
TEST INDICATORS
CL PLATFORM CL HEADLIGHT FUEL FULL LAMP ON

RIGHT SWITCH
OP PLATFORM OP HEADLIGHT SOFT TOUCH
RIGHT SWITCH LAMP ON
CL JIB UP CL GENSET FUEL 3/4 LAMP ON
OP JIB UP OP GENSET SKYGUARD LAMP ON
CL JIB DOWN CL CAPACITY FUEL 1/2 LAMP ON
OP JIB DOWN OP CAPACITY ST/SG LAMP ON
CL TELE IN CL SOFT TOUCH FUEL 1/4 LAMP ON

OVR
OP TELE IN OP SOFT TOUCH PLAT. ALARM ON
OVR
CL TELE OUT CL SKYGUARD OVR ENABLE LAMP ON
OP TELE OUT OP SKYGUARD OVR HORN ON
CL START SWITCH CL ST/SG OVR CREEP LAMP ON
OP START SWITCH OP ST/SG OVR TEST COMPLETE
ENGAGE GLWPLUG LAMP ON

CL AUX POWER
SKYGUARD
RELEASE
OP AUX POWER
SKYGUARD
CL DRIVE ORIENT DISTRESS LAMP ON
OP DRIVE ORIENT
DRIVE JOYSTICK
TILT LAMP ON
TO FORWARD MAX
DRIVE JOYSTICK
TO BACK MAX
STEER TO LEFT WIRE ROPE
MAX LAMP ON
STEER TO RIGHT
MAX
UNRESTRICTED
LAMP ON
RESTRICTED
LAMP ON
OVRLOAD LAMP ON
DRIVE ORIENTATION
LAMP ON
GEN. LAMP ON
MAE22910
Figure 6-19. System Test Flow Chart - Platform Tests (Sheet 2 of 2)
6-42 3121728
Test from the Ground Station 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE23330
MAE23330 4. The analyzer screen should read:
2. Plug the analyzer into the connector inside the Ground

control box.
HELP:
PRESS ENTER
ESC ENTER
MAE23320
MAE19060
5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

The analyzer will prompt you asking if you want to acti-
vate the system test; hit Enter again to activate.
6. Follow the flow path in Figure 6-20., System Test Flow

Chart - Ground Station Tests and go through the compo-
nent tests. Hit the ESC key during any part of the test to
return to the main menu without completing all tests or
wait until all tests are complete. During the TEST ALL
INPUTS sequence, the analyzer allows control switches
to be operated and shows if they are closed (CL) or open
(OP).
3121728 6-43
6-44
OPERATOR ACCESS
TEST INPUTS TEST INDICATORS

CL PLATFORM LEFT NO CHARGE

TELE OUT VALVE CL SWING RIGHT
LAMP ON
TELE IN VALVE OP SWING RIGHT OP PLATFORM LEFT
STEER DUMP CL SWING LEFT CL PLATFORM RGHT FUEL LOW LAMP ON

TELE IN DMP VLV
VALVE
BYPASS DUMP OP SWING LEFT OP PLATFORM RGHT
VALVE PLAT DMP 1 VLV
BRAKE VALVE CL LIFT UP CL PLATFORM UP GLOWPLUG

PLAT DMP 2 VLV LAMP ON
DRIVE FOR VALVE OP LIFT UP OP PLATFORM UP
JIB UP VALVE
DRIVE REV VALVE CL LIFT DOWN

CHECK ENGINE
JIB DN VALVE CL PLATFORM DWN LAMP ON
FRONT RIGHT
STEER VALVE PLATFRM LT VALVE OP LIFT DOWN OP PLATFORM DWN
FRONT LEFT
STEER VALVE PLATFRM RT VLE CL TELE OUT CL START SWITCH DISTRESS LAMP ON
SWING LEFT VALVE OP TELE OUT

PLATFORM UP VLE OP START SWITCH
SWING RGHT VALVE CL TELE IN CL APU SWITCH CRIBBING ENABLED

PLATFORM DN VLE
LAMP ON
LIFT UP VALVE OP APU SWITCH
HEAD/TAIL LIGHTS OP TELE IN
LIFT DN VALVE CL JIB UP CL FUNC ENABLE OVERLOAD

GEN SET
LAMP ON
AUX LIFT DN VALVE OP JIB UP OP FUNC ENABLE
OSC AXLE 1 VALVE
TEST COMPLETE
OSC AXLE 2 VAVLE CL JIB DOWN CL MSSO SWITCH
GLOWPLUGS OP JIB DOWN OP MSSO SWITCH
MAE22780
Figure 6-20. System Test Flow Chart - Ground Station Tests
3121728
6.5 SYSTEM TEST MESSAGES

Table 6-6. System Test Messages
Message Displayed on Message Displayed on
Description
Analyzer Analyzer
RUNNING Initial display when system test is run while running certain “critical” checks are made
CHECK GROUND/ PLATFORM SELECT The analyzer must be connected to the active control station to run the system test
BATTERY VOLTAGE TOO LOW The system test may not run properly with battery voltage below 11V
BATTERY VOLTAGE TOO HIGH The system test may not operate properly with the battery voltage above 16V
CHECK CAN WIRING The system test will not operate properly unless the CAN bus is functional
ENGINE RUNNING? The LOSS OF ENGINE SPEED SENSOR fault 4322 is active or CANBUS FAILURE – ENGINE CONN-
TROLLER fault 666 is active
HIGH TILT ANGLE The CHASSIS TILT SENSOR OUT OF RANGE fault 814 is active
HOT ENGINE The HIGH ENGINE TEMP fault 438 is active
OPEN FOOTSWITCH In platform mode, the footswitch must be open at the start of the test
CLOSE FOOTSWITCH In platform mode, the operator must close the footswitch when this message is displayed
BAD FOOTSWITCH The two footswitch signals are not changing together, probably because one is open circuit. Check
footswitch and wiring
OPEN FOOTSWITCH In platform mode, the operator must open the footswitch when this message is displayed
PLATFORM OVERLOADED Load Sensing is configured and the ground module considers the platform to be overloaded
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized;
checks are made for open- and short- circuit valve coils
NOTE: In platform mode, the footswitch must be closed
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if
TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT
AXLES=NO. Four wheel steer valves are not tested if 4WS=NO
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING
Problems that can be reported include below messages
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning correctly. Check valve
wiring. Check ground alarm & hour meter wiring
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-circuited. Check valve
wiring
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wiring
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its 
“normal” position; function switches should be open, cutout switches should be closed, joysticks
should be in neutral
In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are
reported
In ground mode any non-neutral ground switches is reported; any active cutouts are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep
to maximum
Problems that can be reported include below messages
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick
3121728 6-45
Table 6-6. System Test Messages

Message Displayed on Message Displayed on
Description
Analyzer Analyzer
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for confir-
mation that the lamp is lit
ENTER must be pressed or clicked to continue the test
NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked
NOTE: Platform Lamps are only tested in platform mode
NOTE: The GM overload lamp and 500# capacity lamp are not tested
NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine
digit
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for con-
firmation that the alarm is sounding
ENTER must be pressed or clicked to continue the test
NOTE: The platform alarm and the horn are only tested in platform mode
NOTE: The ground alarm is not tested if GROUND ALARM = NO
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends
If ENTER is pressed or clicked, each operator input is prompted for in turn
In platform mode every platform switch and joystick is tested
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not
tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are
not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed
OPEN XXXXXXX The named switch should be opened
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction
PUMP POT TO MAX The pump pot should be turned to maximum
PUMP POT TO MIN The pump pot should be turned to minimum
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short
between two inputs
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and
should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu
6-46 3121728
6.6 MACHINE DIAGNOSTICS PARAMETERS

Table 6-7. Machine Diagnostics Parameters
Diagnostics Submenu Parameter Parameter Value

(Displayed on Analyzer (Displayed on (Displayed on Description
1st Line) Analyzer 1st Line) Analyzer 2nd Line)
DRIVE/STEER DRIVE DEMAND FORWARD/REVERSE XXX% Direction and command percentage of Drive as reported by PM
DRIVE OUTPUT FORWARD/REVERSE XXX% Direction and current output percentage
DRIVE OUT mA FORWARD/REVERSE XXXXmA Direction and current output command
DRIVE FDBK mA XXXXmA Current feedback measurement
STEER DEMAND LEFT/RIGHT XXX% Direction and command percentage of Steer as reported by PM.
STEER OUPTUT LEFT/RIGHT XXX% Direction and PWM output percentage
STEER TYPE NORMAL/CRAB/COORDINATED Steer Type Status (MACHINE SETUP → 4 WHEEL STEER = YES)
BRAKES STATUS LOCKED/RELEASED Status of Brake Valve output
2SPEED OUTPUT ON/OFF Status of 2 Speed Valve output (600S)
DRIVE MODE MAX SPEED/MAX TORQUE/MID Drive Mode Status
ENGINE
DRV ORIENT TT SW OPEN /CLOSED State of DOS Switch (600S)
DRV ORIENT MODE INLINE/SWUNG DOS state
DRV ORIENT STATE CONFIRMED/REQUIRED InLine and DOS Active = Confirmed
DRV ORNT OVR SW CLOSED/OPEN State of Drive Orientation Override Switch
CRIBBING MODE SW CLOSED/OPEN State of Cribbing Mode Switch; only displayed 
if MACHINE SETUP → CRIBBING = YES
CRIBBING MODE DISBLED/ENABLED Reflects state of Cribbing Mode Switch; only displayed if MACHINE
SETUP → CRIBBING = YES
BOOM FUNCTIONS SWING DEMAND LEFT/RIGHT XXX% Direction and percentage of input command from Swing Joystick or
Ground%
SWING OUTPUT LEFT/RIGHT XXX% Direction and current output percentage
SWING OUTPUT mA LEFT/RIGHT XXXXmA Direction and current output command
SWING FDBK mA XXXXmA Current feedback measurement
LIFT DEMAND UP/DOWN XXX% Direction and percentage of Lift input command
LIFT OUTPUT UP/DOWN XXX% Direction and current output percentage
LIFT OUTPUT mA UP/DOWN XXXXmA Direction and current output command
LIFT FDBK mA XXXXmA Current feedback measurement
LIFT DN AUX ON/OFF Status of Aux Lift Down (600S)
TELE DEMAND IN/OUT XXX%/CREEP Direction and percentage of input command (or CREEP if selected)
from Function Speed Pot or Ground%
TELE OUTPUT IN/OUT XXX% Direction and current output percentage for Flow Control Valve
mapped to Tele Personalities
TELE OUTPUT mA IN/OUT XXXXmA Direction and current output command (600S)
TELE FDBK mA XXXXmA Current feedback measurement (600S)
3121728 6-47

JIB LIFT DEMAND UP/DOWN XXX%/CREEP Direction and percentage of input command (or CREEP if selected)
from Function Speed Pot or Ground%; only displayed 
if MACHINE SETUP → JIB = YES
JIB LIFT OUTPUT UP/DOWN XXX% For Up, direction and current output percentage for Flow Control
mapped to Jib Lift Up Personality range; for Down, direction and
PWM output percentage; only displayed 
if MACHINE SETUP → JIB = YES
PLAT LVL DEMAND UP/DOWN XXX%/CREEP Direction and percentage of input command (or CREEP if selected)
from Function Speed Pot or Ground% (600S)
PLAT LVL OUTPUT UP/DOWN XXX% Direction and current output percentage for Flow Control mapped to
Platform Level Personality range (600S)
PLAT LVL OUT mA UP/DOWN XXXXmA Direction and current output command (600S)
PLAT LVL UP FDBK XXXXmA Platform Level Up Current feedback measurement (600S)
PLAT LVL DN FDBK XXXXmA Platform Level Down Current feedback measurement (600S)
PLAT ROT DEMAND LEFT/RIGHT XXX%/CREEP Direction and percentage of input command (or CREEP if selected)
from Function Speed Pot or Ground% (600S)
PLAT ROT OUTPUT LEFT/RIGHT XXX% Direction and current output percentage for Flow Control mapped to
Platform Rotate Personality range; for 600S value = 0% or 100%
LF PRS REL OUTPT ON/OFF Status of Low Flow Pressure Release Valve;
Only display if Low Flow Pressure Release is Configured
MAIN DUMP OUTPUT ON/OFF Status of Main Dump Valve
TELE IN DUMP ON/OFF Status of Telescope In Dump Valve (600S)
FUNCTION SPEED SETTING: XXX% Displays the percentage demand from the Function Speed Potenti-
ometer.
CREEP SW OPEN/CLOSED Status of Creep Switch Input
CREEP MODE ON/OFF Displays status of Creep Mode
ENGINE OPERATING STATE STOPPED/CRANKING/ Displays Engine State
STARTING/RUNNING
GLOW PLUG NOT ACTIVE/ACTIVE Display diagnostic if glow plugs configured: MACHINE SETUP →
GLOW PLUG ≠ NO GLOW PLUGS
COOLANT TEMP XXXC/XXXF Degrees F or C displayed depending on Machine Setup Configuration
ENGINE OIL PRESS XXXXPSI/XXXXKPA If Ford read > 10 PSI display OK, else LOW
If Deutz, display transmitted value
FUEL SELECTION STATUS GAS/LP MACHINE SETUP → ENGINE = FORD DUAL FUEL
FUEL PRESS XXXXPSI/XXXXKPA MACHINE SETUP → ENGINE = EMR 4
AMBIENT TEMP XXXC/XXXF
FUEL LEVEL FULL; ¾; ½; ¼; LOW; EMPTY; OK; MACHINE SETUP → FUEL LEVEL ≠ NONE
ERROR
ENGINE SPEED ACTUAL XXXXRPM RPM read from speed sensor if engine = over CAN2 for Deutz, 
Ford Dual Fuel
6-48 3121728

ENGINE SPEED TARGET XXXXRPM UGM - commanded Target RPM
SYSTEM UGM BATTERY XX.XV UGM measured battery voltage
PLATFORM MODULE BATTERY XX.XV PM measured battery voltage
UGM TEMP XXXC/XXXF UGM on-board temperature measurement
PLATFORM SELECT KEYSWITCH: OPEN Displays whether Platform Keyswitch position is being selected
KEYSWITCH: CLOSED
GROUND SELECT KEYSWITCH: OPEN Displays whether Ground Keyswitch position is being selected
KEYSWITCH: CLOSED
STATION CONTROL GROUND/PLATFORM Displays Active control station per System Mode definition
FOOTSWITCH INPUT GROUND: OPEN State of Footswitch input at UGM
GROUND: CLOSED
FOOTSWITCH INPUT PLATFORM: OPEN State of Footswitch input at PM (closed when footswitch not acti-
PLATFORM: CLOSED vated)
PLATFORM ANGLE: XXX.XDEG Platform Angle with respect to Chassis (600S)
PLAT ANGLE 1 RAW XX.X% Platform Angle sensor #1 raw PWM% (600S)
PLAT ANGLE 2 RAW XX.X% Platform Angle sensor #2 raw PWM% (600S)
ELEVATION MODE ABOVE/NOT ABOVE Elevation State
CAPACITY MODE RESTRICTED/UNRESTRICTED/ERROR Dual Capacity State; Dual Capacity is configured
TRANSPORT MODE IN TRANSPORT/OUT OF TRANSPORT Transport Position
CREEP SW OPEN/CLOSED Status of Creep Switch Input
CREEP MODE ON/OFF Displays status of Creep Mode
CHASSIS TILT XX.XDEG Combined X/Y Absolute Angle
CHASSIS TILT X-AXIS: XX.XDEG X Angle with respect to sign
CHASSIS TILT Y-AXIS: XX.XDEG Y Angle with respect to sign
GENSET/WELDER SW OPEN/CLOSED Platform Generator Enable switch; only displayed 
if MACHINE SETUP → GEN SET/WELDER ≠ NO
GENSET ENABLE OUTPUT: ON/OFF UGM Generator Relay Enable output; only displayed 
if MACHINE SETUP → GEN SET/WELDER ≠ NO
H&T LIGHTS SW OPEN/CLOSED Only displayed if in Platform Mode and 
MACHINE SETUP → H&T LIGHTS = YES
H&T LIGHTS OUT ON/OFF UGM Nite Brite Relay Enable output; only displayed if in Platform
Mode and MACHINE SETUP → H&T LIGHTS = YES
SOFT TOUCH INPUT OPEN/CLOSED State of Soft Touch Platform Input (J1-20); closed when active;
only displayed if in Platform Mode and MACHINE SETUP → SOFT
TOUCH = YES.
SKYGUARD INPUTS OPEN/CLOSED/DISAGREE SkyGuard Input #1 (PLT J7-18) AND SkyGuard Input #2 (PLT J1-23)
state; only displayed if in Platform Mode and 
MACHINE SETUP → SKYGUARD = YES.
3121728 6-49

SKYGUARD INPUT 1 OPEN/CLOSED State of SkyGuard Platform Input #1 (J7-18); relay NC contacts –
closed when active; only displayed if in Platform Mode and 
SKYGUARD INPUT 2 OPEN/CLOSED State of SkyGuard Platform Input #2 (J1-23); relay NC contacts –
closed when active; only displayed if in Platform Mode and 
AMBIENT TEMP XXXC/XXXF Ambient Temperature sensor reading;
Only displayed if MACHINE SETUP → TEMP CUTOUT = YES
LOW TEMPERATURE CUTOUT: ACTIVE/INACTIVE/FAULTY Status of Low Temperature Cutout;
Only displayed if MACHINE SETUP → TEMP CUTOUT = YES
MSSO ACTIVE/INACTIVE Status of MSSO;
Only displayed if MACHINE SETUP → MARKET = CE
WIRE ROPE SWITCH: OPEN/CLOSED State of Wire Rope Service Switch input (J3-8);
closed when active; MACHINE SETUP → CABLE SWITCH = YES
OPER CONTROLS JOYSTICK DRIVE FORWARD/REVERSE XXX% Drive Joystick drive direction and command percentage as reported
from PM; only displayed if in Platform Mode
JOYSTICK STEER LEFT/RIGHT XXX% Drive Joystick steer direction and percentage command as reported
from PM; only displayed if in Platform Mode
JOYSTICK SWING LEFT/RIGHT XXX% Lift/Swing Joystick Swing direction and percentage command as
reported from PM; only displayed if in Platform Mode
JOYSTICK LIFT UP/DOWN XXX% Lift/Swing Joystick Lift direction and percentage command as
reported from PM; only displayed if in Platform Mode
DRV ORNT OVR SW CLOSED/OPEN State of Drive Orientation Override Switch if in Platform Mode
FUEL SELECT SW OPEN/CLOSED Status of Platform Toggle Switch Input if in Platform Mode and
MACHINE SETUP → ENGINE = FORD DUAL FUEL
START SWITCH OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
SWING LEFT SW OPEN/CLOSED Status of Ground Toggle Switch Input if in Ground Mode
SWING RIGHT SW OPEN/CLOSED Status of Ground Toggle Switch Input if in Ground Mode
LIFT UP SW OPEN/CLOSED Status of Ground Toggle Switch Input if in Ground Mode
LIFT DN SW OPEN/CLOSED Status of Ground Toggle Switch Input if in Ground Mode
TELE IN SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
TELE OUT SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
6-50 3121728

JIB LIFT UP SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input; only displayed if
MACHINE SETUP→ JIB = YES
JIB LIFT DN SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input; only displayed if
MACHINE SETUP → JIB = YES
PLAT LEVEL UP SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
PLAT LEVEL DN SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
PLAT ROT LEFT SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
PLAT ROT RGHT SW OPEN/CLOSED Status of Ground/Platform Toggle Switch Input
MAX SPEED SW OPEN/CLOSED Status of Platform Toggle Switch Input;
only displayed if in Platform Mode
MAX TORQUE SW OPEN/CLOSED Status of Platform Toggle Switch Input; 
CREEP SW OPEN/CLOSED Status of Creep Switch Input; only displayed if in Platform Mode
HORN SW OPEN/CLOSED Status of Platform Switch Input;
H&T LIGHT SW OPEN/CLOSED Status of Platform Toggle Switch Input; only displayed if in Platform
Mode and MACHINE SETUP → H&T LIGHTS = YES
GENSET/WELDER SW OPEN/CLOSED Status of Platform Toggle Switch Input; only displayed if MACHINE
SETUP → GEN SET/WELDER ≠ NO
SG OVERRIDE SW OPEN/CLOSED Status of Platform SkyGuard Override Switch Input; only displayed if
in Platform Mode MACHINE SETUP → SOFT TOUCH = NO and
MACHINE SETUP → SKYGUARD = YES
ST OVERRIDE SW OPEN/CLOSED Status of Platform SkyGuard Override Switch Input; only displayed if
in Platform Mode and MACHINE SETUP → SOFT TOUCH = YES and
MACHINE SETUP → SKYGUARD = NO
SG/ST OVRIDE SW OPEN/CLOSED Status of Platform SkyGuard Override Switch Input; only displayed if
in Platform Mode and MACHINE SETUP → SOFT TOUCH = YES and
MACHINE SETUP → SKYGUARD = YES
MSSO SW OPEN/CLOSED Status of Ground MSSO Switch Input; only displayed if MACHINE
SETUP → MARKET = CE
CAPACITY SW OPEN/CLOSED Status of Platform Dual Capacity Switch Input; only displayed if Dual
Capacity is configured
STEER CRAB SW OPEN/CLOSED Status of the Crab Steer Select Switch Input (MACHINE SETUP → 4
WHEEL STEER = YES)
STEER COORD SW OPEN/CLOSED Status of the Coordinated Steer Select Switch Input (MACHINE SETUP
→ 4 WHEEL STEER = YES)
3121728 6-51

PLATFORM LOAD (DIS- PLATFORM LOAD STATE: OK/OVERLOAD LSS Status
PLAY ONLY IF MACHINE PLATFORM LOAD ACTUAL: XXXXLBS Platform Load??? if Platform Load == Unhealthy
SETUP → 2
PLATFORM LOAD GROSS: XXXXLBS If 4-Cell LSS;
LOAD SYSTEM ≠ NO)
Combined weight of all cells (accounting for sign)
If 1-Cell LSS;
Platform Gross used to calculate Platform Load
??? if (Platform Gross 1 == Unhealthy and Platform Gross 2 ==
Unhealthy)
PLATFORM LOAD2 OFFSET: XXXLBS If 4-Cell LSS;
Stored Platform Empty weight
PLATFORM LOAD2 OFFSET 1: XXXLBS If 1-Cell LSS;
Stored Unloaded Platform Weight of Strain Gauge 1
??? if DTC 825 is active
PLATFORM LOAD2 OFFSET 2: XXXLBS If 1-Cell LSS;
Stored Unloaded Platform Weight of Strain Gauge 2
PLATFORM LOAD2 ACCESSORY XXXLBS Stored Accessory weight;
PLATFORM LOAD2 UNRSTRICT XXXLBS Stored Unrestricted Rated Load;
PLATFORM LOAD2 RSTRICT XXXXLBS If Dual Capacity is Configured;
Stored Restricted Rated Load;
PLATFORM LOAD2 CELL 1: XXXLBS If 4-Cell LSS; Gross weight reading of Cell 1
PLATFORM LOAD2 RAW 1: XXXXLBS If 1-Cell LSS; Platform Gross 1;

??? if Platform Gross 1 == Unhealthy
PLATFORM LOAD2 RAW 2: XXXXLBS If 1-Cell LSS; Platform Gross 2;
??? if Platform Gross 2 == Unhealthy
6-52 3121728

CAN STATISTICS2 CAN 1 STATISTICS RX/SEC: XXX

CAN 1 STATISTICS TX/SEC: XXX
CAN 1 STATISTICS BUS OFF: XXX
CAN 1 STATISTICS PASSIVE: XXX
CAN 1 STATISTICS MSG ERROR: XXXX
CAN 2 STATISTICS RX/SEC: XXX
CAN 2 STATISTICS TX/SEC: XXX
CAN 2 STATISTICS BUS OFF: XXX
CAN 2 STATISTICS PASSIVE: XXX
CAN 2 STATISTICS MSG ERROR: XXXX
3121728 6-53

DEBUG UGM I/O2 DEBUG DIAG DIG IN J1-21 HIGH/LOW Left and Right arrow keys scroll through the inputs. 1st Line = DIG IN
DIGITAL INPUTS DIG IN J1-34 HIGH/LOW JX.XX and 2nd Line displays measurement value
DIG IN J1-35 HIGH/LOW
6-54 3121728

DEBUG DIAG DIG OUT J1-2 ON/OFF Left and Right arrow keys scroll through the inputs. 1st Line = DIG
DIGITAL OUTPUTS DIG OUT J1-7 ON/OFF OUT JX.XX and 2nd Line displays output value
DIG OUT J1-11 ON/OFF
DIG OUT J2-2 ON/OFF
DIG OUT J2-3 ON/OFF
DIG OUT J2-4 ON/OFF
DIG OUT J2-5 ON/OFF
DIG OUT J2-7 ON/OFF
DIG OUT J4-1 ON/OFF
DIG OUT J4-2 ON/OFF
DIG OUT J4-3 ON/OFF
DIG OUT CS1GC ON/OFF1
DIG OUT CS2GC ON/OFF1
DIG OUT LED ON/OFF
DIG OUT TP11
3121728 6-55

DEBUG DIAG PWM J1-1
PWM OUTPUTS XXX.XX% XXXHZ
PWM J1-3
XXX.XX% XXXHZ
PWM J1-6
XXX.XX% XXXHZ
PWM J1-10
XXX.XX% XXXHZ
PWM J1-20
XXX.XX% XXXHZ
PWM J1-22
XXX.XX% XXXHZ
PWM J2-8
XXX.XX% XXXHZ
PWM J2-9
XXX.XX% XXXHZ
PWM J2-11
XXX.XX% XXXHZ
PWM J2-19
XXX.XX% XXXHZ
PWM J2-20
XXX.XX% XXXHZ
PWM J2-22
XXX.XX% XXXHZ
PWM J2-26
XXX.XX% XXXHZ
PWM J2-27
XXX.XX% XXXHZ
PWM J2-31
XXX.XX% XXXHZ
PWM J2-34
XXX.XX% XXXHZ
PWM J2-35
XXX.XX% XXXHZ
FET J3-1
XXX.XX% XXXHZ
FET J3-2
XXX.XX% XXXHZ
FET J3-4
XXX.XX% XXXHZ
FET J3-5
XXX.XX% XXXHZ
FET J3-6
XXX.XX% XXXHZ
6-56 3121728

FET J3-14
XXX.XX% XXXHZ
PWM J4-12
XXX.XX% XXXHZ
ANALOG INPUTS ADC J1-01 FB XXXX1 Left and Right arrow keys scroll through the inputs. 1st Line = ADC
ADC J1-01 IS XXXX1 JX.XX and 2nd Line displays raw A/D counts XXXX of measurement
ADC J1-02 FB XXXX1
ADC J1-03 FB XXXX1
ADC J1-06 FB XXXX1
ADC J1-07 FB XXXX1
ADC J1-10 FB XXXX1
ADC J1-11 FB XXXX1
ADC J1-12 FB XXXX1
ADC J1-13 FB XXXX1
ADC J1-14 XXXX
ADC J1-15 XXXX
ADC J1-20 FB XXXX1
ADC J1-22 FB XXXX1
ADC J1-23 FB XXXX1
ADC J2-01 FB XXXX1
ADC J2-02 FB XXXX1
ADC J2-03 FB XXXX1
ADC J2-04 FB XXXX1
ADC J2-05 FB XXXX1
ADC J2-07 FB XXXX1
ADC J2-08 FB XXXX1
ADC J2-09 FB XXXX1
ADC J2-10 FB XXXX1
ADC J2-11 FB XXXX1
ADC J2-12 FB XXXX1
ADC J2-13 FB XXXX1
ADC J2-15 FB XXXX1
ADC J2-16 FB XXXX1
ADC J2-19 FB XXXX1
ADC J2-20 FB XXXX1
ADC J2-22 FB XXXX1
ADC J2-23 FB XXXX1
ADC J2-25 XXXX
ADC J2-26 FB XXXX1
ADC J2-27 FB XXXX1
ADC J2-31 FB XXXX1
ADC J2-32 FB XXXX1
ADC J2-33 FB XXXX1
3121728 6-57

ADC J2-34 FB XXXX1
ADC J2-35 FB XXXX1
ADC J3-01 IS XXXX1
ADC J3-02 IS XXXX1
ADC J3-04 IS XXXX1
ADC J3-05 IS XXXX1
ADC J3-06 IS XXXX1
ADC J3-13 XXXX
ADC J3-14 IS XXXX1
ADC J4-12 FB XXXX1
ADC J7-2 XXXX
ADC J7-04 XXXX
ADC J7-07 XXXX
ADC J7-08 XXXX
ADC J7-20 XXXX
ADC J8-02 XXXX
ADC AMBIENT XXXX1
ADC VOFCS XXXX1
FREQUENCY INPUTS FREQ IN J1-16 XXXXX HZ Left and Right arrow keys scroll through the inputs. 1st Line = FREQ
FREQ IN J12-1 XXXXX HZ IN JX.XX and 2nd Line displays frequency of measurement XXXXX Hz
FREQ IN J12-2 XXXXX HZ
DATALOG DATALOG TIME ON XXXXH XXM *Controller On time
DATALOG TIME ENGINE XXXXH XXM *Engine Running time
DATALOG TIME ENABLD XXXXH XXM *Combined time for Machine Enabled in Platform Mode while ENGINE
RUNNING + any function active while in Ground Mode (excludes APU/
Emergency Descent)
DATALOG TIME AUX XXXXH XXM Auxiliary Power/Emergency Descent Active time
DATALOG TIME DRIVE XXXXH XXM Drive Forward + Reverse time
DATALOG TIME DRV MS XXXXH XXM Max Speed Drive Forward + Reverse time
DATALOG TIME DRV MT XXXXH XXM Max Torque Drive Forward + Reverse time
DATALOG TIME DRV ME XXXXH XXM Mid Engine Drive Forward + Reverse time
DATALOG TIME DRV CP XXXXH XXM Creep Drive Forward + Reverse time
DATALOG TIME STEER XXXXH XXM Steer Left + Right time
DATALOG TIME SWING XXXXH XXM Swing Left + Right time
DATALOG TIME LIFT XXXXH XXM Lift Up + Down time
DATALOG TIME TELE XXXXH XXM Tele In + Out time
DATALOG TIME JIB XXXXH XXM Jib Lift Up + Down time (MACHINE SETUP → JIB = YES)
DATALOG TIME LEVEL XXXXH XXM Platform Level Up + Down time
DATALOG TIME ROTATE XXXXH XXM Platform Rotate Left + Right time
DATALOG TIME GEN XXXXH XXM *Generator Enable Relay on time
6-58 3121728

For time logging of functions with 30-second resolution, the first 15 seconds of function run time shall be logged as a ½ minute increment and there
after every 30 seconds of run time shall be logged as a ½ minute increment. *The functions annotated with an asterisk in the description are function
timers with 60-second resolution, for which the timer in the rule above is doubled.
DATALOG CYCLES DRVE FWD XXXXXXX Number of times Drive Forward is commanded
DATALOG CYCLES DRVE REV XXXXXXX Number of times Drive Reverse is commanded
DATALOG CYCLES STEER LT XXXXXXXX Number of times Steer Left Output is commanded
DATALOG CYCLES STEER RT XXXXXXXX Number of times Steer Right Output is commanded
DATALOG CYCLES SWING LT XXXXXXX Number of times Swing Left output is commanded
DATALOG CYCLES SWING RT XXXXXXX Number of times Swing Right output is commanded
DATALOG CYCLES LIFT UP XXXXXXX Number of times Lift Up output is commanded
DATALOG CYCLES LIFT DN XXXXXXX Number of times Lift Down output is commanded
DATALOG CYCLES TELE IN XXXXXXX Number of times Tele In output is commanded
DATALOG CYCLES TELE OUT XXXXXXX Number of times Tele Out output is commanded
DATALOG CYCLES JIB UP XXXXXXX Number of times Jib Lift Up is commanded (MACHINE SETUP → JIB =
YES)
DATALOG CYCLES JIB DOWN XXXXXXX Number of times Jib Lift Down is commanded (MACHINE SETUP→ JIB
= YES)
DATALOG CYCLES LEVEL UP XXXXXXX Number of times Level Up is commanded
DATALOG CYCLES LEVEL DN XXXXXXX Number of times Level Down is commanded
DATALOG CYCLES ROT LEFT XXXXXXX Number of times Rotate Left is commanded
DATALOG CYCLES ROT RGHT XXXXXXX Number of times Rotate Right is commanded
DATALOG CYCLES UGM ON XXXXXXX Number of times Power is applied
DATALOG CYCLES GND OPS XXXXXXX Number of times machine is in Ground Mode and any function is active
(excludes APU/Emergency Descent)
DATALOG CYCLES PLAT OPS XXXXXXX Number of times machine is Enabled from Platform Station (excludes
APU/Emergency Descent)
DATALOG CYCLES AUX OPS XXXXXXX Number of times machine Auxiliary Power/Emergency Descent is
Enabled
DATALOG CYCLES GEN ON XXXXXXX Number of times Generator Enable Relay is turned On; information
logged and stored only if machine configured for generator.
DATALOG CYCLES BOOM TR XXXXXXX Number of times the Boom transitions from Below Elevation to Above
Elevation
DATALOG CYCLES DUAL CAP XXXXXXX Number of times the Boom transitions from Restricted to Unrestricted
mode (Dual Capacity is configured)
Cycle counter shall increment up to a limit of 1,000,000, except Steer shall have a limit of 2,000,000 per direction.
DATALOG: MAX UGM TEMP XXXC/ Hottest Temp observed by UGM
UGM TEMP XXXF
DATALOG: MIN UGM TEMP XXXC/ Coldest Temp observed by UGM
UGM TEMP XXXF
3121728 6-59

DATALOG: MAX UGM VOLT XX.XV Maximum input voltage observed by UGM
DATALOG: MACHINE RENTAL XXXXH XXM *Stores Machine hours since last memory clear
2 MACHINE RENTAL? Erases stored machine rental hours
DATALOG: ERASE
VERSIONS: UGM SOFTWARE PX.X
UGM CNST DATA PX.X
UGM HARDWARE REV X
UGM S/N XXXXXX
UGM P/N XXXXXXXXXX
PLATFORM MODULE SOFTWARE PX.X
PLATFORM MODULE HARDWARE REV X
PLATFORM MODULE S/N XXXXXX
LSS MODULE SOFTWARE PX.X Displayed on if LSS is configured (4-Cell LSS)
LSS MODULE HARDWARE REV X Display if LSS is configured (4-Cell LSS)
TCU MODULE SOFTWARE X.Xx Displayed on if TCU is configured
TCU MODULE HARDWARE REV X Displayed on if TCU is configured
TCU MODULE S/N XXXXXX Displayed on if TCU is configured
ANALYZER ANALYZER vX.X
6-60 3121728
6.7 CALIBRATING TILT SENSOR 4. Plug the analyzer into the connector inside the Ground
control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE-
FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE.

1. Use the following procedure to calibrate the tilt sensor.
2. Before the tilt sensor can be calibrated, the following
conditions must be met:
a. Steering previously calibrated.
b. Wheels straight.
c. Turntable centered.
d. Boom fully retracted.
e. Boom angle is less than 45°. 5. Pull out the Emergency Stop switch and Start the
f. Machine on firm, level ground. engine.

form position.
MAE17820
MAE23330
3121728 6-61
6. The analyzer screen should read: 11. Using the arrow keys, navigate to the Tilt Sensor calibra-
tion as shown below and press ENTER .
HELP:
PRESS ENTER
TILT SENSOR:
ESC ENTER CALIBRATE?
ESC ENTER
MAE19060
7. Use the arrow button to reach ACCESS LEVEL. Hit Enter. MAE19060
8. Enter the Access Code, 33271.
9. Use the right Arrow key to reach CALIBRATIONS. Hit

Enter.
10. Using the arrow keys, navigate to Calibrations Menu as
shown below and press ENTER .
MENU:
CALIBRATION
ESC ENTER
MAE19060
6-62 3121728
12. UGM will confirm the position of the boom, then the 13. When the sensor is calibrated in that position, the screen
screen will read: will read:
TILT SENSOR: TILT SENSOR:

BOOM IN LINE? SWING 180 &
ESC ENTER ESC ENTER
MAE19060 MAE19060
14. Swing the machine 180 degrees, making sure the boom
is centered and in the transport position, and 
TILT SENSOR: ENTER . The screen will read:

CALIBRATING...
ESC ENTER
TILT SENSOR:
SWING 180?
ESC ENTER
MAE19060
MAE19060
3121728 6-63
TILT SENSOR:
CALIBRAT-
ESC ENTER
MAE19060
15. When the calibration is complete the screen will read as

shown below. Return the machine to the travel position.
TILT SENSOR:
CAL COMPLETE
ESC ENTER
MAE19060
6-64 3121728
6.8 CALIBRATING BOOM ANGLE 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE17820
MAE23330
2. Plug the analyzer into the connector at the base of the HELP
Ground control box.
PRESS ENTER
ESC ENTER
MAE23320
MAE19060
5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.

Enter.
3121728 6-65
8. Use arrow keys to reach BOOM ANGLE. The Screen will 10. UGM will confirm the tilt sensor calibration. The screen
read: will read.
CALIBRATIONS: BOOM ANGLE:

BOOM TILT NOT CAL
ESC ENTER ESC ENTER
MAE19060 MAE19060
9. Hit Enter. The screen will read. 11. Hit Enter. The screen will read.
BOOM ANGLE: BOOM ANGLE:

CALIBRATE? LEVEL VEhicle
ESC ENTER ESC ENTER
MAE19060 MAE19060
6-66 3121728
12. UGM will confirm the Boom In-Line position. The screen 14. When the sensor is calibrated at lower position of the
will read: boom. The screen will read:
BOOM ANGLE: BOOM ANGLE:

boom in line CALIBRATING....
ESC ENTER ESC ENTER
MAE19060 MAE19060
13. Hit Enter. The Screen will read: 15. UGM will confirm the position of the boom. Press Enter.
The screen will read:
BOOM ANGLE:
boom DN to BOOM ANGLE:
Boom Up?
ESC ENTER
ESC ENTER
MAE19060
MAE19060
3121728 6-67
16. After few seconds. The screen will read:
BOOM ANGLE:
CAL COM-
ESC ENTER
MAE19060
17. Hit ESC twice to go back to CALIBRATIONS.
6-68 3121728
6.9 CALIBRATING LEVEL UP CRKPT 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE17820
MAE23330
HELP:
PRESS ENTER
2. Plug the analyzer into the connector at the base of the
Ground control box.
ESC ENTER
MAE23320
MAE19060
5. Use the arrow button to reach ACCESS LEVEL. Hit Enter.

Enter.
3121728 6-69
8. Use the arrow keys to reach LEVEL UP CRKPT. The screen 10. UGM shall set the Level Up Crackpoint default value. The
will read. screen will read:
Calibration: LEVEL UP CRKPT

LEVEL UP XXXXmA
ESC ENTER ESC ENTER
MAE19060 MAE19060
9. Hit Enter. The screen will read. 11. After few seconds. The screen will read:
LEVEL UP CRKPT: LEVEL UP CRKPT:

CALIBRATE? CAL COM-
ESC ENTER ESC ENTER
MAE19060 MAE19060
6-70 3121728
6.10 CALIBRATING LEVEL DOWN CRKPT 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE17820
MAE23330
HELP:
PRESS ENTER
Ground control box.
ESC ENTER
MAE23320 MAE19060
5. Use the arrow button to reach ACCESS LEVEL. Hit Enter.

Enter.
3121728 6-71
8. Use the arrow keys to reach LEVEL DOWN CRKPT. The 10. UGM shall set the Level Down Crackpoint default value.
screen will read. The screen will read:
Calibration: LEVEL down

LEVEL DOWN CRKPT
ESC ENTER ESC ENTER
MAE19060 MAE19060
9. Hit Enter. The screen will read. 11. After few seconds. The screen will read:
LEVEL down LEVEL down

CRKPT: CRKPT:
ESC ENTER ESC ENTER
MAE19060 MAE19060
6-72 3121728
6.11 CALIBRATING PLATFORM ANGLE SENSOR 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE17820
MAE23330
HELP
2. Plug the analyzer into the connector at the base of the PRESS ENTER
Ground control box.
ESC ENTER
MAE23320
MAE19060

Enter.
3121728 6-73
8. Use the arrow keys to reach PLATFORM ANGLE. The 10. Hit Enter. The screen will read:
screen will read.
PLATFORM
Calibration: ANGLE:
PLATFORM
ESC ENTER
ESC ENTER
MAE19060
MAE19060
11. Hit Enter. The screen will read:

PLATFORM
PLATFORM ANGLE:
ANGLE:
ESC ENTER
ESC ENTER
MAE19060
MAE19060
6-74 3121728
12. UGM will confirm Platform Angle Max sensor readings. 14. After few seconds. The screen will read:
PLATFORM
PLATFORM ANGLE:
ANGLE:
ESC ENTER
ESC ENTER
MAE19060
MAE19060
15. UGM will confirm Platform Angle Min sensor readings.

13. Hit Enter. The screen will read: The screen will read:
PLATFORM PLATFORM
ANGLE: ANGLE:
ESC ENTER ESC ENTER
MAE19060 MAE19060
3121728 6-75
16. After few seconds. The screen will read:
PLATFORM
ANGLE:
ESC ENTER
MAE19060
6-76 3121728
6.12 CALIBRATING LOAD SENSING 3. Pull out the Emergency Stop switch and Start the
engine.
NOTE: Calibration sub-menu LOAD SENSING is visible only if
MACHINE SET-UP sub-menu LOAD SYSTEM is selected to
YES.

form position.
MAE17820
HELP
PRESS ENTER
MAE23330
ESC ENTER
MAE19060

MAE15680 Enter.
3121728 6-77
8. Use the arrow keys to reach LOAD SENSING. The screen 10. Hit Enter. The screen will read:
will read.
load sensing:
Calibration: calibrate?
steer sensor
ESC ENTER
ESC ENTER
MAE19060
MAE19060

9. Hit Enter. The screen will read.
load sensing:
Calibration: PLATFORM
load sensing
ESC ENTER
ESC ENTER
MAE19060
MAE19060
6-78 3121728
12. UGM will set the Accessary Weight default value. Press 14. UGM will set the Glazier default value. Press Enter. The
Enter. The screen will read.: screen will read:
load sensing: load sensing:

ACCESSORY XXX- SKY GLAZIER? X
ESC ENTER ESC ENTER
MAE19060 MAE19060
13. Hit Enter. The screen will read: 15. UGM will set the Pipe Racks default value. Press Enter.
load sensing:
CALIBRAT- load sensing:
PIPE RACKS? X
ESC ENTER
ESC ENTER
MAE19060
MAE19060
3121728 6-79
16. UGM will set the Unrestricted Rated Load. Press Enter. 18. After few seconds, the screen will read:
load sensing:
load sensing: CAL COM-
UNRSTRICT XXX-
ESC ENTER
ESC ENTER
MAE19060
MAE19060
17. UGM will set the Restricted Rated Load. Press Enter. The
screen will read:
load sensing:
RSTRICT XXXXLBS
ESC ENTER
MAE19060
6-80 3121728
6.13 CALIBRATING MSSO 3. Pull out the Emergency Stop switch and Start the
engine.
form position.
MAE17820
MAE23330
HELP
PRESS ENTER
ESC ENTER
MAE19060
MAE15680 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter.
Enter.
3121728 6-81
8. Use the arrow keys to reach MSSO. The screen will read:
CALIBRATIOn:
MSSO
ESC ENTER
MAE19060
MSSO reset
Confirm?
ESC ENTER
MAE19060
6-82 3121728
6.14 LSS SYSTEM

The JLG-designed Load Sensing System (LSS) measures plat- THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR MORE
form load via a sensor mounted in the platform support struc- OFTHE FOLLOWING CONDITIONS OCCUR:
ture. If the actual platform load exceeds the selected Rated
Load, the following will occur: a. LSS Sensor removal or replacement
b. Addition or removal of certain platform mounted
1. The Overload Visual Warning Indicator will
accessories. (Refer to Calibration)
flash at the selected control position (plat-
form or ground). c. Platform is removed, replaced, repaired or shows
evidence of impact.
2. The Platform and Ground Alarms will sound
5 seconds On, and 2 seconds Off.
3. All normal movement will be prevented from the plat- THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFICATION
form control position (optional - ground control func- NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. REFER TO TEST-
tions may be prevented). ING & EVALUATION.
4. Further movement is permitted by:
All calibration procedures are menu driven through the use of
a. Removing the excess platform load until actual plat- a JLG Analyzer.
form load is less than Rated Load.
b. Operation of the overriding emergency system
(Auxiliary Power Unit).
c. By an authorized person at the ground control posi-
tion (optional - ground control functions may be
prevented).
3121728 6-83
Diagnostic Menu
Press the LEFT and RIGHT Arrow keys to view the
The Diagnostic Menu is another troubleshooting tool for the
displays and select the various sub-menus. To access a sub-
Load Sensing System. Sensor and status information is pre-
menu, press the ENTER key. Once in a sub-menu, press the
sented in real-time for the technician. Several sub-menus exist
to organize the data.
LEFT and RIGHT Arrow keys to view the various
displays (just like a Top Level menu). To exit a sub-menu, press
To access the Diagnostic Menu, use the LEFT and
the ESC key.
RIGHT Arrow keys to select DIAGNOSTICS from the Top
Table 6-8, Diagnostic Menu Descriptions details the structure
of the Diagnostic Menu, and describes the meaning of each
Level Menu. Press the ENTER key to view the menu. piece of information presented.
Table 6-8. Diagnostic Menu Descriptions
Diagnostics Menu Parameter (Displayed on Parameter Value

Description
(Displayed on Analyzer 1st Line) Analyzer 2nd Line) (Displayed on Analyzer 2nd Line)
PLATFORM LOAD STATE: OK / OVERLOAD LSS Status.
PLATFORM LOAD ACTUAL: XXX.X KG Calibrated weight of the platform.
??? if Platform Load is Unhealthy**.
PLATFORM LOAD (service*) GROSS: XXX.X KG Gross weight of the platform.
??? if both Cells are Unhealthy**.
PLATFORM LOAD (service*) OFFSET 1: XXX.X KG Stored offset weight of Cell 1.
??? if LSS is not calibrated.
PLATFORM LOAD (service*) OFFSET 2: XXX.X KG Stored offset weight of Cell 1.
PLATFORM LOAD (service*) ACCESSORY XXX.X KG Stored accessory weight.
PLATFORM LOAD (service*) UNRESTRICT XXX.X KG UGM will set Unrestricted Rated Load as defined by
Machine Configuration.
PLATFORM LOAD (service*) RESTRICT XXX.X KG UGM will set Restricted Rated Load as defined by Machine
Configuration.
PLATFORM LOAD (service*) RAW 1: XXX.X KG Gross value from Cell 1.
??? if Unhealthy**.
PLATFORM LOAD (service*) RAW 2: XXX.X KG Gross value from Cell 2.
??? if Unhealthy**.
* Indicates only visible in service view mode
** Typically indicates a DTC is active
6-84 3121728
Calibration Procedure
5. Press the ENTER key to view the menu. Upon
1. Remove everything from the platform, except perma-
entry to the Calibration Menu, the JLG Control System
nently fixed JLG Accessories, to allow the Load Sensing
will link to the Analyzer and the screen will read:
System to record its’ weight during calibration. This
includes all tools, debris, and customer-installed devices.
2. Plug the JLG Analyzer into the Machine at the Ground
Station and enter Service Access Password 33271.
3. The platform should be approximately level for calibra- CALIBRATIONS
LOAD SENSING
tion. Level the platform from ground control (if neces-
sary) to within +/- 5°.
4. To access the Calibration Menu, use the LEFT and RIGHT ESC ENTER
Arrow keys to select CALIBRATION from the Top Level

Menu. The screen will read:
MENU:
CALIBRATIONS
ESC ENTER
MAE19060
6. Press Enter . The Screen will read:
LOAD SENSING
CALIBRATE?
MAE19060
ESC ENTER
NOTE: The Calibration Menu is not available in OPERATOR
ACCESS.
MAE19060
NOTE: Calibration will auto fail if LSS DTC's are active (443, 444,
4479, 4480, 663, 821, 822, 823, 824, 8218, 8222 -> 8238,
991, 992, 993, 994 or 99285).

3121728 6-85
NOTE: Accessory weight will reset to 0 lbs. each time the machine
is re-calibrated and will need to be re-entered.
Pressing the ESC key after starting calibration and
before calibration is complete will display the CAL FAILED
NOTE: The Accessory weight will be temporarily stored in the Con-
message. This will not disturb the prior calibration infor-
trol System until calibration has been completed success-
mation.
fully.
Refer to Table 6-9, Accessory Weights. Use the up and down

7. Press ENTER . The analyzer screen will read: analyzer keys to enter the accessory weight(s) (in lbs). When all
the accessory weights are entered, press ENTER . The

screen will read:
LOAD SENSING
PLATFORM
ESC ENTER LOAD SENSING

CALIBRATING...
ESC ENTER
MAE19060
MAE19060
8. If the platform is empty, press ENTER . The screen
will read:
Table 6-9. Accessory Weights
Accessory Weight
SkyWelder (stick welder) 70 lb. (32 kg)
LOAD SENSING SkyWelder Prep Prep only = 15 lb. (7 kg)
ACCESSORY XXX-
Full install = 70 lb. (32 kg)
SkyCutter (plasma cutter) 70 lb. (32 kg)
ESC ENTER
SkyCutter / SkyWelder Combo 140 lb. (64 kg)
Fire Extinguisher 45 lb. (20 kg)
Overhead SoftTouch 80 lb. (36 kg)
Work Surface 20 lb. (9 kg)
NOTE: Not all Accessories are available on every JLG model.
Some Accessory combinations are prohibited due to
excessive weight and/or load restriction. If any installed
JLG Accessories are labeled with weight decals but are
not listed in the table above, include their weight when
entering the ACC WEIGHT value.
MAE19060
6-86 3121728
9. The control system will calculate the load cell readings 11. Use the analyzer keys to select N for no or Y for yes. Press
and ensure it is greater than 130 lbs. (59 kg), but less
than 575 lbs.(261 kg). 
ENTER . The screen will read:

If the platform weight is not within the allowed range,
the calibration attempt will be unsuccessful and the
Analyzer will show the following:
LOAD SENSING
PIPE RACKS? N
LOAD SENSING ESC ENTER

CAL FAILED
ESC ENTER
MAE19060
MAE19060
10. Press ENTER . The control system will ask for

installed accessories. The screen will show the following:
LOAD SENSING
SKY GLAZIER? N
ESC ENTER
MAE19060
3121728 6-87
12. Use the analyzer keys to select N for no or Y for yes. Press
Table 6-11. Pipe Rack Capacity Reductions
ENTER . The control system will default to an esti-
mate of unrestricted capacity, which can be adjusted if PLATFORM OVRLD
Capacity PLATFORM OVRLD
necessary. Refer to Table 6-10, SkyGlazier Capacity RESTRICT
Reductions and Table 6-11, Pipe Rack Capacity Reduc- 500 lb. (227 kg) 400 lb (181 kg) N/A
tions. The screen will read: 550 lb. (250 kg) 450 lb (204 kg) N/A
600 lb. (272 kg) 500 lb (227 kg) N/A
750 lb. (340 kg) N/A 650 lb (295 kg)
1000 lb. (454 kg) N/A 900 lb (408 kg)
PLATFORM OVRLD: NOTE: If both SkyGlazier and Pipe Racks are configured, capac-
UNRSTRICT XXXLBS
ity will be the lower of the two values.
ESC ENTER
13. Press ENTER . The following screen will be dis-

played for restricted capacity, which can be adjusted if
necessary. Refer to Table 6-10, SkyGlazier Capacity
Reductions and Table 6-11, Pipe Rack Capacity Reduc-
tions.
PLATFORM OVRLD:
RSTRICT XXXLBS
MAE19060
ESC ENTER
Table 6-10. SkyGlazier Capacity Reductions
PLATFORM OVRLD
Capacity PLATFORM OVRLD
RESTRICT
500 lb. (227 kg) 400 lb. (181 kg) N/A
550 lb. (250 kg) 400 lb. (181 kg) N/A
600 lb. (272 kg) 400 lb. (181 kg) N/A
750 lb. (340 kg) N/A 590 lb. (268 kg)
1000 lb. (454 kg) N/A 750 lb. (340 kg)
NOTE: If both SkyGlazier and Pipe Racks are configured, capac-
ity will be the lower of the two values.
MAE19060
6-88 3121728
14. Press ENTER . If calibration is successful, the screen

will read:
LOAD SENSING:
CAL COMPLETE
ESC ENTER
MAE19060
3121728 6-89
Testing & Evaluation 6. Confirm Control System Capacity Indication (optional

for vehicles with Dual Capacity Ratings). For vehicles
Refer to Troubleshooting if the Load Sensing System fails to equipped with a Capacity Select switch on the Platform
meet these guidelines. Console Box, it is necessary to examine an additional
interface between the Load Sensing System and the
1. Connect the JLG Analyzer.
Control System. Using the keyswitch, select Platform
2. Level the Platform. The platform should be approxi- Mode and power-up. If necessary, put the boom in the
mately level for analysis, or the guidelines below will not transport position (completely stowed) and center the
be applicable. Level the platform from Ground Control Jib Plus (if equipped). Place the Capacity Select switch in
(if necessary) to within ±5 degrees. the unrestricted position and ensure that the proper
indicator illuminates on the Platform Console Box. Plug
3. Observe the Empty Platform Weight. Proceed to the
the JLG Analyzer into the Analyzer connection and pro-
DIAGNOSTICS, PLTLOAD sub-menu and observe the
ceed to the DIAGNOSTICS, SYSTEM submenu. Ensure
measured platform load. All tools, debris, and customer
that the CAPACITY displays indicate OFF. Place the
installed devices shall be removed during evaluation.
Capacity Select switch in the unrestricted position (if so
Ideally, the PLTLOAD should be zero but can vary ±15lbs
equipped) and ensure that the proper indicator illumi-
(± 7kg). Further, the reading should be stable and
nates on the Platform Console Box (but does not flash).
should not vary by more than ±2lbs (±1kg) (unless there
For vehicles with unrestricted capacity, ensure that the
is heavy influence from wind or vibration).
unrestricted CAPACITY display indicates ON but the
4. Use the Technician’s Weight to Evaluate. The technician restricted CAPACITY indicates OFF. For vehicles with
should enter the platform and record the PLTLOAD read- restricted capacity, ensure that the unrestricted CAPAC-
ing while standing in the center of the platform. ITY display indicates OFF but the restricted CAPACITY
indicates ON.
5. Confirm Control System Warnings and Interlocks. Using
the keyswitch, select Platform Mode and power-up. 7. Confirm Load Sensing System Performance with Cali-
Start the vehicle’s engine and ensure that all controls are brated Weights. Operate the vehicle from Ground Con-
functional and the Load Sensing System’s Overload trol and place the boom in the transport position (fully
Visual and Audible Warnings are not active. Simulate an stowed) for safety. Plug the JLG Analyzer into the control
Overload by unplugging the Shear Beam Load Cell. The system connection and proceed to the DIAGNOSTICS,
Overload Visual Warning should flash, and the Audible PLTLOAD display. Place 500lbs (230kg) in the platform
Warning (at Platform and Ground) should sound for 5 and ensure that PLTLOAD is with ±5% of the actual
seconds On, and 2 seconds Off. With the engine run- weight. For Dual Capacity vehicles, do the same for the
ning, all control should be prevented. Cycle the Platform alternate capacity (unrestricted or restricted).
EMS to stop the engine and then power-up again. The
Overload Visual and Audible Warning should continue.
Confirm that controls are responsive when using the
Auxiliary Power Unit for emergency movement. Recon-
nect the Load Cell. The Overload Visual and Audible
Warnings should cease and normal control function
should return. Switch the vehicle’s keyswitch to Ground
Mode and repeat the above procedure. The Overload
Visual Warning at the Ground Controls should flash, and
the Audible Warning (at Platform and Ground) should
sound for 5 seconds On, 2 seconds Off. However, the
controls should remain functional when using the
engine and the Auxiliary Power Unit (if the Control Sys-
tem’s MACHINE SETUP, LOAD is set to “2=CUTOUT PLT”. If
set to “3=CUTOUT ALL”, then Ground Controls will be
prevented when using the engine as in the platform).
6-90 3121728
Troubleshooting
The following tables are furnished to provide possible resolu-
tions for common difficulties. Difficulties are classified as Gen-
eral, Calibration, Measurement Performance, and Host System
Functionality.
Table 6-12. LSS Troubleshooting Chart
Difficulty Possible Resolution

Empty Platform Weight (DIAGNOSTICS, PLAT- The LSS System is unable to properly measure the platform weight.
FORM LOAD) is not within ±15lbs (±7kg) of zero. 1. The Load Cell is not properly plugged into the LSS Harness. It is possible poor electrical contact is made.
or
Platform Load readings (DIAGNOTICS, PLTLOAD) 2. Wiring leading to the Load Cell is damaged. Carefully inspect sensor wiring where it passes through cable clamps for signs of
are unstable by more than ±2lbs (±1kg) (without damage. Inspect wiring where damage to the channel is apparent.
the influence of vibration or wind).
or 3. The Load Cell was not assembled properly during installation. Examine the sensor’s reading using the JLG Analyzer. Proceed to
There are large variations in Platform Load (DIAG- the DIAGNOSTICS, CELL, LOAD displays and determine if the readings are reasonable. It is often helpful to apply slight downward pres-
NOSTICS, PLTLOAD) based on the location of the sure above the sensor and observe that its output increases (increasing force measurement; decreasing means the sensor is mounted
load. Tolerance to variations is 20lbs for an evalua- upside-down).
tion using the technician’s weight, and +5% of
Rated Load when using calibrated weights. 4. The Load Cell is contaminated by debris or moisture. Examine the sensor’s reading using the JLG Analyzer. Proceed to the DIAG-
NOSTICS, CELL, LOAD displays and determine if the readings are reasonable and stable (not changing by more than ±2lbs (±1kg)
(without the influence of vibration or wind). Lack of measurement stability is a key indication of contamination. Unplug the connector
and inspect for dirt or moisture. Look carefully into the female connector on the sensor’s cordset for evidence of contamination. Debris
should be brushed away with a soft bristle brush (do not introduce any cleaners as they will leave conductive residue). Moisture should
be allowed to evaporate or accelerated with a heat-gun (use low heat and be carefully to not melt connector materials). Moisture
intrusion into the molded portion of the connector (capillary action into the wire bundle) or the Shear Beam Load Cell itself will require
replacement of the sensor.
5. The Load Cell has been mechanically damaged. If the Load Cell is physically deformed or has damage to the cover it should be
replaced immediately. It is also possible to have invisible mechanical damage resulting from an extreme overload (>6000lbs
[>2722kg]).
The Visual and Audible Overload Warnings fail The Control System is failing to regard the overload signal from the LSS System, or the signal is shorted.
to sound when platform is loaded beyond Rated
Load, or when simulated by unplugging the Load 1. The Load Sensing System must be enabled within the Control System. Plug the JLG Analyzer into the Control System, enter the
Cell. Controls remain functional at Platform and Access Level 1 password (33271), and examine the MACHINE SETUP, LOAD sub-menu. The selection “2=CUTOUT PLT” should be dis-
Ground Control positions. played (platform controls prevented during overload, ground controls remain operational). In country- or customer-specific circum-
stance, the selection “3=CUTOUT ALL” is used (platform and ground controls prevented during overload).
The Ground Audible Warning fails to sound, but The Ground Alarm is missing or improperly installed. Verify that the device is mounted. Verify wiring from the Main Terminal Box and
the Platform Audible Warning sounds properly. Ground Module.
Controls remain functional at the Ground Control The JLG Control System is configured to prevent platform controls only in the event of overload. Alternately, the Host Control System
position during an overload, or when simulated can be configured to prevent ground and platform controls for country- or customer specific circumstances. Using the JLG Analyzer,
by unplugging the Load Cell. The Controls at the enter the Access Level 1 password (33271). Proceed to the MACHINE SETUP, LOAD sub-menu. Set this parameter to “2=CUTOUT PLT”
Platform Control position are prevented when to prevent platform controls in the event of overload. Set this parameter to “3=CUTOUT ALL” to prevent platform and ground controls
using the engine, but not when using the Auxiliary in the event of overload.
Power Unit.
3121728 6-91
6.15 MACHINE FAULT CODES

Table 6-13. Diagnostic Trouble Codes
Fault Condition/Trigger
Conditions Required for Movement
DTC Help Message (For configurable items, fault applies only if configured. All listed
and/or to Clear Fault
conditions to be met unless stated otherwise)
Machine is in Platform Mode;
001 EVERYTHING OK
The UGM determines no problems exist
Machine is in Ground Mode;
002 GROUND MODE OK
The UGM determines no problems exist
RUNNING AT CUTBACK – OUT OF
0010 Machine is in the Out of Transport position Machine is not in the Out of Transport position
TRANSPORT POSITION
Any of the following Platform inputs become active after power up, but
before Machine Enabled:
Drive joystick is not in the neutral position
Steer;
0011 FSW OPEN Controls initialized
Lift and/or Swing joystick is not in the neutral position;
Telescope;
Platform Level;
Platform Rotate;
Jib Lift (if MACHINE SETUP → JIB = YES)
RUNNING AT CREEP - CREEP
0012 Platform Creep switch input = HIGH; Platform Creep switch input = Low
SWITCH OPEN
DTC 0013 is not active
RUNNING AT CREEP - TILTED AND
0013 The Boom is Above Elevation; Not all of the trigger conditions are met
ABOVE ELEVATION
Machine chassis is considered Tilted
MACHINE SETUP → LOAD SYSTEM ≠ NO;
Load System is the 1-Cell LSS;
LOAD SENSOR READING UNDER UGM determines that the Platform Load < -50 lbs. for  UGM determines that the Platform 
0015
WEIGHT 2 seconds; Load >= -50 lbs. for 5 seconds
Do not report if DTC (0030, 825 or 8211) is active or if Platform Load ==
Unhealthy
FUEL LEVEL LOW – ENGINE MACHINE SETUP → FUEL LEVEL ≠ NONE;
0031 Power Cycled
SHUTDOWN Engine Shutdown has occurred due to Fuel Level = EMPTY condition.
Auxiliary Power/Emergency Descent Mode is
0035 APU ACTIVE Auxiliary Power/Emergency Descent Mode is active
not active
6-92 3121728
(Jumper Configuration Status = 0)} and Jumper Configuration 
Status < 2]);
Any of the following Ground inputs become active after power up, but
FUNCTION PREVENTED - FUNCTION before Machine Enabled:
0036 SELECTED BEFORE GROUND Lift; Controls initialized
ENABLE Swing;
Telescope;
Platform Level;
Platform Rotate;
MACHINE SETUP → SKYGUARD = YES;
SKYGUARD ACTIVE – FUNCTIONS
0039 Machine is in Platform Mode; Not all of the trigger conditions are met
CUTOUT
SkyGuard Enabled
UGM Ground Mode input J7-3 input = High;
212 KEYSWITCH FAULTY (J7-3 input = LOW) or (J7-2 input = LOW)
UGM Platform Mode input J7-2 input = High
The ground footswitch input and platform footswitch input have been
213 FSW FAULTY Power Cycled
both HIGH or both LOW for greater than or equal to 1 second
FUNCTION PROBLEM - HORN Machine is in Platform Mode;
221 The Horn switch input = Low
PERMANENTLY SELECTED The Horn switch input = High at Startup
The Steer Left switch input = Low;
FUNCTION PROBLEM - STEER LEFT Machine is in Platform Mode;
224 Steer Left and Right and full Drive speed
PERMANENTLY SELECTED The Steer Left switch input = High at Startup
permitted after controls are initialized
The Steer Right switch input = Low;
FUNCTION PROBLEM - STEER RIGHT Machine is in Platform Mode;
225 Steer Left and Right and full Drive speed
PERMANENTLY SELECTED The Steer Right switch input = High at Startup
The Steer Left switch input = Low;
The Steer Left switch input = High;
The Steer Right switch input = Low;
227 STEER SWITCHES FAULTY The Steer Right switch input = High;
Steer and full Drive speed permitted after
(detectable in Platform or Ground mode)
controls are initialized
2211 FSW INTERLOCK TRIPPED The Footswitch is active for more than seven seconds with no Drive, Steer, The footswitch is released
or Boom commands
If triggered by the Drive joystick not being in
the neutral position at Startup, then (Drive
joystick is returned to its neutral position) and
(Drive and Steer permitted after controls
The UGM detects one of the following conditions:
DRIVE LOCKED - JOYSTICK MOVED initialized)
2212 Drive joystick is not in the neutral position at Startup;
BEFORE FOOTSWITCH
Drive joystick is not in the neutral position when Footswitch becomes
If triggered by the Drive joystick not being in
active or while DTC 2213, 2221 or 2223 is active
the neutral position when Footswitch
becomes active or while DTC 2213, 2221 or
2223, then controls initialized
3121728 6-93
STEER LOCKED - SELECTED BEFORE
2213 A Steer input is active when Footswitch becomes active or while DTC 2212, Controls initialized
FOOTSWITCH
2221 or 2223 is active
The PM detects that the Drive or Steer joystick signal voltage > 8.1V and
2216 D/S JOY. OUT OF RANGE HIGH The PM no longer reports the fault
reports the fault to the UGM.
The PM detects that the drive/steer center tap
The PM detects that the Drive or Steer center tap voltage is not between
2217 D/S JOY. CENTER TAP BAD voltage is between 3.31 and 3.75 volts and no
3.31 volts and 3.75 volts and reports the fault to the UGM
longer reports the fault to the UGM
The PM detects that the Lift and Swing joystick
The PM detects that the Lift or Swing joystick signal voltage > 8.1V and
2219 L/S JOY. OUT OF RANGE HIGH signal voltage is < 8.1V and no longer reports
reports the fault to the UGM.
the fault to the UGM
The PM detects that the lift/swing center tap
The PM detects that the Lift or Swing center tap voltage is not between
2220 L/S JOY. CENTER TAP BAD voltage is between 3.31 and 3.75 volts and no
3.31 volts and 3.75 volts and reports the fault to the UGM
longer reports the fault to the UGM
If triggered by the Lift and/or Swing joystick
not being in the neutral position at Startup,
then (Lift and/or Swing joystick is returned to
its neutral position) and (Lift and Swing
LIFT/SWING LOCKED - JOYSTICK permitted after controls initialized)
2221 Lift and/or Swing joystick is not in the neutral position at Startup;
MOVED BEFORE FOOTSWITCH
Lift and/or Swing joystick is not in the neutral position when Footswitch
If triggered by the Lift and/or Swing joystick is
becomes active or while DTC 2212, 2213 or 2223 is active
not in the neutral position when Footswitch
becomes active or while DTC 2212, 2213 or
2223 is active, then controls initialized
2222 WAITING FOR FSW TO BE OPEN Controls initialized
Footswitch is active at Start Up
Any of the following Platform inputs are active when Footswitch becomes
active or while DTC 2212, 2213 or 2221 is active:
FUNCTION SWITCHES LOCKED - Tower Lift;
2223 Controls initialized
SELECTED BEFORE ENABLE Telescope;
Platform Level;
Platform Rotate;
The engine is stopped;
FOOTSWITCH SELECTED BEFORE
2224 Startup time has expired; The Platform Engine Start switch input = Low;
START
The Footswitch is active before the Platform Engine Start switch input =
High
FUNCTION PROBLEM - PLATFORM The Platform Rotate Left switch input = Low;
2247 ROTATE LEFT PERMANENTLY Platform Rotate Left and Right permitted after
The Platform Rotate Left switch input = High at Startup
SELECTED controls are initialized
6-94 3121728
FUNCTION PROBLEM - PLATFORM The Platform Rotate Right switch input = Low;
2248 ROTATE RIGHT PERMANENTLY Platform Rotate Left and Right permitted after
The Platform Rotate Right switch input = High at Startup
Machine is in Platform Mode; The Jib Lift Up switch input = Low;
FUNCTION PROBLEM - JIB LIFT UP
2249 MACHINE SETUP → JIB = YES; Jib Lift Up and Down permitted after controls
PERMANENTLY SELECTED
The Jib Lift Up switch input = High at Startup are initialized
Machine is in Platform Mode; The Jib Lift Down switch input = Low;
FUNCTION PROBLEM - JIB LIFT
DOWN PERMANENTLY SELECTED
The Jib Lift Down switch input = High at Startup are initialized
The Telescope In switch input = Low;
FUNCTION PROBLEM - TELESCOPE Machine is in Platform Mode;
2251 Telescope permitted after controls are
IN PERMANENTLY SELECTED The Telescope In switch input = High at Startup
initialized
The Telescope Out switch input = Low;
FUNCTION PROBLEM - TELESCOPE Machine is in Platform Mode;
2252 Telescope permitted after controls are
OUT PERMANENTLY SELECTED The Telescope Out switch input = High at Startup
initialized
The Platform Level Up switch input = Low;
FUNCTION PROBLEM - PLATFORM Machine is in Platform Mode;
2262 Platform Level Up and Down permitted after
LEVEL UP PERMANENTLY SELECTED The Platform Level Up switch input = High at Startup
FUNCTION PROBLEM - PLATFORM The Platform Level Down switch input = Low;
2263 LEVEL DOWN PERMANENTLY Platform Level Up and Down permitted after
The Platform Level Down switch input = High at Startup
FUNCTION PROBLEM - DOS
2264 OVERRIDE PERMANENTLY The DOS Override switch input = Low
The DOS Override switch input = High at Startup
SELECTED
[(MACHINE SETUP → SKYGUARD = YES) or (MACHINE SETUP → SOFT
FUNCTION PROBLEM - SOFT TOUCH
TOUCH = YES)]; The Soft Touch / SkyGuard Override switch
2286 / SKYGUARD OVERRIDE
Machine is in Platform Mode; input = Low
The Soft Touch / SkyGuard Override switch input = High at Startup
PLATFORM ANGLE SENSOR - NOT
2287 The Platform Angle Sensor has not been calibrated Platform angle sensor calibrated
CALIBRATED
The UGM detects the following conditions:
The UGM detects < 1 deg change of Platform Angle;
Platform Level Up or Platform Level Down output value ≥ Creep output
PLATFORM ANGLE SENSOR - NOT value;
2289 Power Cycled
RESPONDING Platform Level Up or Platform Level Down has been active longer than 5
seconds;
Platform Angle < (Platform Angle Max -1.5 deg);
Platform Angle > (Platform Angle Min ± 1.5 deg);
The UGM detects that Platform Angle Sensor #1 and Platform Angle Sensor
PLATFORM ANGLE SENSOR
2290 #2 readings disagree ≥ 2.5 deg for longer than 5 seconds; Power Cycled
DISAGREEMENT
Do not report if DTC 2287 is active
3121728 6-95
PLATFORM ANGLE SENSOR - OUT The UGM detects that Platform Angle Sensor #1 < 5% or Platform Angle
2295 Power Cycled
OF RANGE HIGH Sensor #2 signal voltage > 95%.
PLATFORM ANGLE SENSOR - OUT The UGM detects that Platform Angle Sensor #1 > 95% or Platform Angle
2296 Power Cycled
OF RANGE LOW Sensor #2 signal voltage < 5%.
PLATFORM ANGLE SENSOR – The UGM detects that Platform Angle Sensor #1 or Platform Angle Sensor
2297 Power Cycled
FREQUENCY OUT OF RANGE #2 signal frequency is not within 100Hz +/- 5Hz
The UGM detects one of the following conditions (continuous monitoring):
The machine is in Ground Mode and both direction inputs of the following
boom controls are engaged at the same time: Engine Start/Aux, Telescope,
None of the boom controls that trigger this
FUNCTION SWITCHES FAULTY - Platform Level, Platform Rotate, Jib Lift, Tower Lift, Lift, or Swing.
234 fault have both of their direction inputs
CHECK DIAGNOSTICS/BOOM The machine is in Platform Mode and both direction inputs of the
engaged at the same time
following boom controls are engaged at the same time: Engine Start/Aux,
Telescope, Platform Level, Platform Rotate, Jib Lift (MACHINE SETUP →
JIB = YES)
The machine is in Ground Mode and the engine is stopped and the ground
The applicable APU/Auxiliary Descent switch is
APU/Function Enable switch becomes engaged while a Ground control
FUNCTION SWITCHES LOCKED - disengaged or all applicable control inputs
235 input is already engaged.
SELECTED BEFORE AUX POWER become disengaged or the engine state
The machine is in Platform Mode and the engine is stopped and the
becomes ENGINE RUNNING
platform APU/Auxiliary Descent switch becomes engaged while a Platform
control input is already engaged.
The machine is in Ground Mode and the engine is stopped and any
configured boom control is already engaged and the ground start switch
FUNCTION SWITCHES LOCKED - changes from not engaged to engaged The selected station’s start switch is no longer
236
SELECTED BEFORE START SWITCH The machine is in Platform Mode and the engine is stopped and any drive/ engaged
steer or configured boom control is already engaged and the footswitch is
not engaged and the platform start switch changes from not engaged to
engaged
START SWITCH LOCKED - SELECTED The start switch for the selected station is engaged during the UGM startup The selected station’s start switch is no longer
237
BEFORE KEYSWITCH sequence engaged
FUNCTION PROBLEM - GROUND (Jumper Configuration Status = 0)} and Jumper Configuration 
ENABLE PERMANENTLY SELECTED Status < 2]);
The Ground Enable switch input = High at Startup
BOOM ANGLE SENSOR – NOT
2343 The Boom Angle Sensor has not been calibrated Boom angle sensor calibrated
CALIBRATED
BOOM ANGLE SENSOR - OUT OF The UGM detects that Boom Angle Sensor #1 < 0.5V or Boom Angle Sensor
2344 Power Cycled
RANGE HIGH #2 signal voltage > 4.5V.
BOOM ANGLE SENSOR - OUT OF The UGM detects that Boom Angle Sensor #1 > 4.5V or Boom Angle Sensor
2345 Power Cycled
RANGE LOW #2 signal voltage < 0.5V.
6-96 3121728
The UGM detects < 1 deg change of Boom Angle;
BOOM ANGLE SENSOR – NOT Main Lift Up or Main Lift Down output value ≥ Creep output value;
2346 Power Cycled
RESPONDING Main Lift Up or Main Lift Down has been active longer than 5 seconds;
Boom Angle < (Boom Angle Max -1.5 deg);
Boom Angle > (Boom Angle Min ± 1.5 deg);
Machine is in Ground Mode; The Jib Lift Up switch input = Low;
FUNCTION PROBLEM - JIB LIFT UP
The Jib Lift Up switch input = High at Startup are initialized
Machine is in Ground Mode; The Jib Lift Down switch input = Low;
FUNCTION PROBLEM - JIB LIFT
DOWN PERMANENTLY SELECTED
The Jib Lift Down switch input = High at Startup are initialized
The Swing Left switch input = Low;
FUNCTION PROBLEM - SWING LEFT Machine is in Ground Mode;
2372 Swing Left and Right permitted after controls
PERMANENTLY SELECTED The Swing Left switch input = High at Startup
are initialized
The Swing Left switch input = Low;
FUNCTION PROBLEM - SWING Machine is in Ground Mode;
2373 Swing Left and Right permitted after controls
RIGHT PERMANENTLY SELECTED The Swing Right switch input = High at Startup
are initialized
The UGM detects that Boom Angle Sensor #1 and Boom Angle Sensor #2
BOOM ANGLE SENSOR
2396 readings disagree ≥ 2.5 deg for longer than 5 seconds; Power Cycled
DISAGREEMENT
Do not report if DTC 2343 is active
The Lift Up switch input = Low;
FUNCTION PROBLEM - LIFT UP Machine is in Ground Mode;
23107 Lift Up and Down permitted after controls are
PERMANENTLY SELECTED The Lift Up switch input = High at Startup
initialized
The Lift Down switch input = Low;
FUNCTION PROBLEM - LIFT DOWN Machine is in Ground Mode;
23108 Lift Up and Down permitted after controls are
PERMANENTLY SELECTED The Lift Down switch input = High at Startup
initialized
The Telescope In switch input = Low;
FUNCTION PROBLEM - TELESCOPE Machine is in Ground Mode;
23109 Telescope In and Out permitted after controls
IN PERMANENTLY SELECTED The Telescope In switch input = High at Startup
are initialized
The Telescope Out switch input = Low;
FUNCTION PROBLEM - TELESCOPE Machine is in Ground Mode;
23110 Telescope In and Out permitted after controls
OUT PERMANENTLY SELECTED The Telescope Out switch input = High at Startup
are initialized
The Platform Level Up switch input = Low;
FUNCTION PROBLEM - PLATFORM Machine is in Ground Mode;
23111 Platform Level Up and Down permitted after
LEVEL UP PERMANENTLY SELECTED The Platform Level Up switch input = High at Startup
FUNCTION PROBLEM - PLATFORM The Platform Level Down switch input = Low;
23112 LEVEL DOWN PERMANENTLY Platform Level Up and Down permitted after
The Platform Level Down switch input = High at Startup
FUNCTION PROBLEM - PLATFORM The Platform Rotate Left switch input = Low;
23113 ROTATE LEFT PERMANENTLY Platform Rotate Left and Right permitted after
The Platform Rotate Left switch input = High at Startup
3121728 6-97
FUNCTION PROBLEM - PLATFORM The Platform Rotate Right switch input = Low;
23114 ROTATE RIGHT PERMANENTLY Platform Rotate Left and Right permitted after
The Platform Rotate Right switch input = High at Startup
TELESCOPE RETRACT SWITCHES - Telescope Retracted Switch #1 and Telescope Retracted Switch #2 readings
23154 Power Cycled
DISAGREEMENT disagree for longer than 5 seconds;
Telescope In or Telescope Out output value ≥ Creep output value
FUNCTION PROBLEM – MSSO
23163 The MSSO switch input = Low at Startup Power Cycled
Fault shall be retentive through Power Cycled;
BOOM ANGLE SENSOR - SINGLE
23170 Single point Boom Angle calibration is successfully completed Can be reset if CALIBRATIONS → BOOM ANGLE
POINT CALIBRATION PERFORMED
is successfully completed
Dual Capacity is configured;
CAPACITY LENGTH SWITCHES -
23173 Capacity Length Switch #1 and Capacity Length Switch #2 readings Power Cycled
DISAGREEMENT
disagree for longer than 5 seconds;
Telescope In or Telescope Out output value ≥ Creep output value
BOOM ANGLE SENSOR – ANGLE The UGM detects a Boom Angle ≥ (Boom Angle Max + 1.5 deg);
23239 Can be reset by performing a Boom Angle
OUT OF RANGE HIGH Do not report if Boom Angle == Unhealthy
Sensor Calibration
BOOM ANGLE SENSOR - ANGLE OUT The UGM detects a Boom Angle < (Boom Angle Min - 1.5 deg);
23240 Can be reset by performing a Boom Angle
OF RANGE LOW Do not report if Boom Angle == Unhealthy
Sensor Calibration
MACHINE SETUP → TEMP CUTOUT = YES; Ambient Temperature sensor reading > -50C;
AMBIENT TEMPERATURE SENSOR –
241 Ambient Temperature sensor reading ≤ -50C; Full Speed permitted after controls are
OUT OF RANGE LOW
Do not report if DTC 6657 is active initialized
MACHINE SETUP → TEMP CUTOUT = YES; Ambient Temperature sensor reading < 85C;
AMBIENT TEMPERATURE SENSOR –
242 Ambient Temperature sensor reading ≥ 85C; Full Speed permitted after controls are
OUT OF RANGE HIGH
Do not report if DTC 6657 is active initialized
MODEL CHANGED – HYDRAULICS
259 The MACHINE SETUP → MODEL NUMBER is changed using the analyzer Power Cycled
SUSPENDED – CYCLE EMS
MACHINE SETUP → GEN SET = BELT DRIVE;
MACHINE SETUP → GEN SET CUTOUT = MOTION CUTOUT;
GENERATOR MOTION CUTOUT
2513 The platform Generator Switch is engaged Not all of the trigger conditions are met
ACTIVE
Footswitch State = Depressed
The machine is in Platform mode
MACHINE SETUP → FUNCTION CUTOUT = BOOM CUTOUT;
Drive or Steer is already engaged;
BOOM PREVENTED – DRIVE The boom is Above Elevation
2514 Not all of the trigger conditions are met
SELECTED The operator is attempting to activate one of the boom functions
DTC 2514 supercedes DTC 2518 if drive/steer and boom functions are both
active when machine transitions from Below Elevation to Above Elevation.
6-98 3121728
MACHINE SETUP → FUNCTION CUTOUT = DRIVE CUTOUT
DRIVE PREVENTED – ABOVE
2516 The boom is Above Elevation Not all of the trigger conditions are met
ELEVATION
The operator is attempting to activate Drive or Steer
MACHINE SETUP → FUNCTION CUTOUT = DRIVE CUT E&T
DRIVE PREVENTED – TILTED & The boom is Above Elevation
ABOVE ELEVATION The chassis is considered Tilted
The operator is attempting to activate Drive or Steer
MACHINE SETUP → FUNCTION CUTOUT = BOOM CUTOUT
DRIVE PREVENTED – BOOM The boom is Above Elevation
SELECTED Any boom function is already active
The operator attempts to activate Drive or Steer
Chassis Tilt is > 1.8 degrees and either the boom is above 55 degrees main Boom lifted below 55 degrees and/or the
DRIVE PREVENTED - TILTED &
2519 boom angle and/or the boom is telescoped out beyond the drive disable boom retracted to inside the drive disable
EXTENDED OR HIGH ANGLE
switches.(Dual Cap Prox.) length switches. (Dual Cap)
2548 SYSTEM TEST MODE ACTIVE UGM determines that System Test Mode is active Power Cycle
MACHINE SETUP → SOFT TOUCH = YES;
DRIVE & BOOM PREVENTED - SOFT
2549 Machine is in Platform Mode; Not all of the trigger conditions are met
TOUCH ACTIVE
Soft Touch State = Enabled
MACHINE SETUP → SKYGUARD = YES;
[{SkyGuard inputs (Platform Module J7-18 =
SKYGUARD SWITCH – Machine is in Platform Mode;
2563 High) and (Platform Module J1-23 = High)}
DISAGREEMENT [(SkyGuard input #1 Platform Module J7-18) ≠ (SkyGuard input #2
and (Footswitch State = Not Depressed)]
Platform Module J1-23)] > 160ms
Low Temperature Cutout = Inactive;
TEMPERATURE CUTOUT ACTIVE –
2568 Low Temperature Cutout = Active Full Speed permitted after controls are
AMBIENT TEMPERATURE TOO LOW
initialized
Platform Level Override Cutout = Enabled;
The Platform Level Up or Down switch input = High;
PLATFORM LEVEL PREVENTED – Footswitch is active
ABOVE ELEVATION
If 600S:
Auto Platform Level = Enabled
RUNNING AT CREEP – PLATFORM
2587 Platform Leveled Under State = Set Platform Leveled Under State = Cleared
LEVELED UNDER
331 BRAKE – SHORT TO BATTERY The UGM detects a short to battery at this output Power Cycled
332 BRAKE – OPEN CIRCUIT The UGM detects an open circuit at this output Power Cycled
The UGM no longer detects open circuit;
334 LIFT UP VALVE – OPEN CIRCUIT The UGM detects an open circuit at this output Full speed Lift Up and Down permitted after
336 LIFT DOWN VALVE – OPEN CIRCUIT The UGM detects an open circuit at this output Full speed Lift Up and Lift Down permitted
after controls are initialized
3121728 6-99
GROUND ALARM – SHORT TO MACHINE SETUP → ALARM / HORN = SEPARATE;
3311 Power Cycled
BATTERY The UGM detects a short to battery on J2-2
MAIN DUMP VALVE – SHORT TO
3358 The UGM detects a short to ground at this output Power Cycled
GROUND
MAIN DUMP VALVE – OPEN
3359 The UGM detects an open circuit at this output Power Cycled
CIRCUIT
MAIN DUMP VALVE – SHORT TO
3360 The UGM detects a short to battery at this output Power Cycled
BATTERY
3361 BRAKE – SHORT TO GROUND The UGM detects a short to ground at this output Power Cycled
START SOLENOID – SHORT TO
3362 UGM detects a short to ground at this output Power Cycled
GROUND
UGM detects an open circuit at this output; if MACHINE SETUP → ENGINE
= FORD DUAL FUEL only evaluate until first Start is attempted for each
3363 START SOLENOID – OPEN CIRCUIT Power Cycled
power cycle due to possibility of ECU opening ground solenoid return path
to disable Start and causing erroneous diagnostics.
START SOLENOID – SHORT TO
3364 UGM detects a short to battery at this output Power Cycled
BATTERY
STEER DUMP VALVE – SHORT TO
GROUND
STEER DUMP VALVE – OPEN
CIRCUIT
STEER DUMP VALVE – SHORT TO
BATTERY
TWO SPEED VALVE - SHORT TO
GROUND
3369 TWO SPEED VALVE - OPEN CIRCUIT The UGM detects an open circuit at this output Power Cycled
TWO SPEED VALVE - SHORT TO
BATTERY
GROUND ALARM – SHORT TO MACHINE SETUP → ALARM / HORN = SEPARATE;
3371 Power Cycled
GROUND The UGM detects a short to ground on J2-2
MACHINE SETUP → ALARM / HORN = SEPARATE;
3372 GROUND ALARM – OPEN CIRCUIT Power Cycled
The UGM detects an open circuit on J2-2
GEN SET/WELDER – SHORT TO MACHINE SETUP → GEN SET = BELT DRIVE and the UGM detects a short to
3373 Power Cycled
GROUND ground at this output
MACHINE SETUP → GEN SET = BELT DRIVE and the UGM detect an open
3374 GEN SET/WELDER – OPEN CIRCUIT Power Cycled
circuit at this output
GEN SET/WELDER – SHORT TO MACHINE SETUP → GEN SET = BELT DRIVE and the UGM detects a short to
3375 Power Cycled
BATTERY battery at this output
HEAD TAIL LIGHT – SHORT TO MACHINE SETUP → H & T LIGHTS =YES and the UGM detects a short to
3376 Power Cycled
GROUND ground at this output
6-100 3121728
MACHINE SETUP → H & T LIGHTS =YES and the UGM detects an open
3377 HEAD TAIL LIGHT – OPEN CIRCUIT Power Cycled
circuit at this output
HEAD TAIL LIGHT – SHORT TO MACHINE SETUP → H & T LIGHTS =YES and the UGM detects a short to
3378 Power Cycled
BATTERY battery at this output
PLATFORM LEVEL UP VALVE –
SHORT TO BATTERY
PLATFORM LEVEL UP OVERRIDE DTC 662 is active;
3385 Power Cycled
VALVE - SHORT TO GROUND The UGM detects a short to ground at this output
3386 Power Cycled
VALVE - OPEN CIRCUIT The UGM detects an open circuit at this output
3387 Power Cycled
VALVE - SHORT TO BATTERY The UGM detects a short to battery at this output
PLATFORM DOWN OVERRIDE – DTC 662 is active;
3391 Power Cycled
SHORT TO GROUND The UGM detects a short to ground at this output
3392 Power Cycled
OPEN CIRCUIT The UGM detects an open circuit at this output
3393 Power Cycled
SHORT TO BATTERY The UGM detects a short to battery at this output
SWING RIGHT VALVE – SHORT TO
GROUND
SWING RIGHT VALVE – OPEN
33119 The UGM detects an open circuit at this output Full speed Swing Left and Right permitted
CIRCUIT
SWING LEFT VALVE – SHORT TO
GROUND
33182 LIFT VALVES – SHORT TO BATTERY The UGM detects a short to battery at either the Lift Up or Lift Down valve Power Cycled
TELESCOPE OUT VALVE – OPEN
33186 The UGM detects an open circuit at this output Full speed Telescope In and Out permitted
CIRCUIT
TELESCOPE VALVES – SHORT TO
33187 The UGM detects a short to battery at either the Tele In or Tele Out valve. Power Cycled
BATTERY
TELESCOPE OUT VALVE – SHORT TO
GROUND
Telescope Out permitted after controls are
TELESCOPE IN VALVE – OPEN
33189 The UGM detects an open circuit at this output initialized;
CIRCUIT
Full speed Telescope In permitted after
TELESCOPE IN VALVE – SHORT TO
GROUND
33208 HORN – SHORT TO BATTERY The UGM detects a short to battery on J2-27 Power Cycled
3121728 6-101
33276 APU PUMP RELAY - OPEN CIRCUIT The UGM detects an open circuit at this output Power Cycled
APU PUMP RELAY - SHORT TO
BATTERY
APU PUMP RELAY - SHORT TO
GROUND
MACHINE SETUP → ENGINE ≠ DEUTZ EMR4, FORD DUAL FUEL;
33279 GLOWPLUG – OPEN CIRCUIT MACHINE SETUP → GLOW PLUG ≠ NO; Power Cycled
The UGM detects an open circuit at this output
33280 GLOWPLUG – SHORT TO BATTERY MACHINE SETUP → GLOW PLUG ≠ NO; Power Cycled
The UGM detects a short to battery at this output
33281 GLOWPLUG – SHORT TO GROUND MACHINE SETUP → GLOW PLUG ≠ NO; Power Cycled
The UGM detects a short to ground at this output
The Engine State = ENGINE RUNNING;
The UGM commanded current > 250mA;
LIFT – CURRENT FEEDBACK
33287 The difference between the commanded current and the measured Power Cycled
READING TOO LOW
feedback current > [the larger of (125mA) or (15% of the commanded
function Max)] for longer than 1 second
TELESCOPE – CURRENT FEEDBACK
READING TOO LOW
SWING LEFT VALVE – OPEN
33295 The UGM detects an open circuit at this output Full speed Swing Left and Right permitted
CIRCUIT
The UGM detects an open circuit at this output The UGM no longer detects open circuit;
DRIVE FORWARD VALVE – OPEN
33317 Full speed Drive Forward and Reverse
CIRCUIT
DRIVE VALVES – SHORT TO The UGM detects a short to battery at either the Drive Forward or Drive
33318 Power Cycled
BATTERY Reverse valve.
DRIVE FORWARD VALVE – SHORT
TO GROUND
DRIVE REVERSE VALVE – OPEN
33320 The UGM detects an open circuit at this output Full speed Drive Forward and Reverse
CIRCUIT
DRIVE REVERSE VALVE – SHORT TO
GROUND
6-102 3121728
DRIVE – CURRENT FEEDBACK
READING TOO LOW
LIFT UP VALVE – SHORT TO
GROUND
LIFT DOWN VALVE – SHORT TO
GROUND
DRIVE – LOSS OF CURRENT Measured feedback current < 225mA while PWM output > 40% for a
33410 Power Cycled
FEEDBACK period of 100ms.
SWING VALVES – SHORT TO The UGM detects a short to battery at either the Swing Right or Swing Left
33412 Power Cycled
BATTERY valve
SWING – CURRENT FEEDBACK
READING TOO LOW
LIFT – CURRENT FEEDBACK Measured feedback current < 225mA while PWM output > 40% for a
33417 Power Cycled
READING LOST period of 100ms.
SWING – CURRENT FEEDBACK Measured feedback current < 225mA while PWM output > 40% for a
33418 Power Cycled
TELESCOPE – CURRENT FEEDBACK Measured feedback current < 225mA while PWM output > 40% for a
33443 Power Cycled
AUXILIARY LIFT DOWN VALVE -
SHORT TO GROUND
33538 The UGM detects an open circuit at this output The UGM no longer detects open circuit
OPEN CIRCUIT
SHORT TO BATTERY
OSCILLATING AXLE #1 VALVE -
SHORT TO GROUND
OPEN CIRCUIT
SHORT TO BATTERY
SHORT TO GROUND
OPEN CIRCUIT
3121728 6-103
SHORT TO BATTERY
AUXILIARY VALVES - SHORT TO The UGM detects a short to battery at either the Aux Lift Down or Aux
33567 Power Cycled
BATTERY Tower Lift Down valve
AUXILIARY - CURRENT FEEDBACK Measured feedback current < 225mA while output is active for a period of
33568 Power Cycled
READING LOST 100ms.
ECM PULL DOWN RESISTOR - OPEN MACHINE SETUP → ENGINE = DEUTZ EMR4;
33575 Power Cycled
CIRCUIT Pull down resister not detected
PLATFORM DUMP 1 VALVE - SHORT
TO BATTERY
TO GROUND
PLATFORM DUMP 1 VALVE - OPEN
CIRCUIT
TO BATTERY
TO GROUND
PLATFORM DUMP 2 VALVE - OPEN
CIRCUIT
TELESCOPE IN DUMP VALVE -
SHORT TO BATTERY
TELESCOPE IN DUMP VALVE -
SHORT TO GROUND
TELESCOPE IN DUMP VALVE - OPEN
CIRCUIT
BYPASS DUMP VALVE – SHORT TO
BATTERY
BYPASS DUMP VALVE – SHORT TO
GROUND
BYPASS DUMP VALVE – OPEN
CIRCUIT
PLATFORM LEVEL UP VALVE -
SHORT TO GROUND
PLATFORM LEVEL UP VALVE -
344 SHORT TO BATTERY OR OPEN The UGM detects a short to battery or an open circuit at this output Power Cycled
CIRCUIT
PLATFORM LEVEL DOWN VALVE -
SHORT TO GROUND
6-104 3121728
PLATFORM LEVEL DOWN VALVE -
348 SHORT TO BATTERY OR OPEN The UGM detects a short to battery or an open circuit at this output Power Cycled
CIRCUIT
The PM no longer detects open circuit;
PLATFORM ROTATE LEFT VALVE –
349 The PM detects an open circuit at this output and reports it to the UGM Full speed Platform Rotate Right and Left
OPEN CIRCUIT
3410 The PM detects a short to battery at this output and reports it to the UGM Power Cycled
SHORT TO BATTERY
3411 The PM detects a short to ground at this output and reports it to the UGM Power Cycled
SHORT TO GROUND
PLATFORM ROTATE RIGHT VALVE –
3412 The PM detects an open circuit at this output and reports it to the UGM Full speed Platform Rotate Right and Left
OPEN CIRCUIT
3413 The PM detects a short to battery at this output and reports it to the UGM Power Cycled
SHORT TO BATTERY
3414 The PM detects a short to ground at this output and reports it to the UGM Power Cycled
SHORT TO GROUND
3415 JIB LIFT UP VALVE – OPEN CIRCUIT Full speed Jib Lift Up and Down permitted
The PM detects an open circuit at this output and reports it to the UGM
JIB LIFT UP VALVE – SHORT TO MACHINE SETUP → JIB = YES
3416 Power Cycled
BATTERY The PM detects a short to battery at this output and reports it to the UGM
JIB LIFT UP VALVE – SHORT TO MACHINE SETUP → JIB = YES
3417 Power Cycled
GROUND The PM detects a short to ground at this output and reports it to the UGM
Jib Lift Up permitted after controls are
JIB LIFT DOWN VALVE – OPEN MACHINE SETUP → JIB = YES
3418 initialized
CIRCUIT The PM detects an open circuit at this output and reports it to the UGM
Full speed Jib Lift Down permitted after
JIB LIFT DOWN VALVE – SHORT TO MACHINE SETUP → JIB = YES
3419 Power Cycled
BATTERY The PM detects a short to battery at this output and reports it to the UGM
JIB LIFT DOWN VALVE – SHORT TO The PM detects a short to ground at this output and reports it to the UGM;
3420 Power Cycled
GROUND detection occurs for PWM output approximately ≤ 15% or for STG
condition.
MACHINE SETUP → FUEL LEVEL = SENSOR;
FUEL SENSOR - SHORT TO BATTERY
431 UGM fuel sensor analog input J2-25 detects a voltage higher than 2.50 Power Cycled
OR OPEN CIRCUIT
volts (A/D > 512)
MACHINE SETUP → FUEL LEVEL = SENSOR;
432 FUEL SENSOR - SHORT TO GROUND UGM fuel sensor analog input J2-25 detects a voltage less than or equal to Power Cycled
0.3 volts (A/D < 61)
3121728 6-105
An engine with a CAN engine controller is configured in MACHINE SETUP
437 ENGINE TROUBLE CODE Power Cycled
The engine controller reports a J1939 fault
An engine with a CAN engine controller is not configured in MACHINE
SETUP:
- The Engine State = ENGINE RUNNING > 10 seconds
- The coolant temperature is greater than or equal to the
configured engines max allowed temperature.
438 HIGH ENGINE TEMP - The maximum allowed temperature > 110ºC. Power Cycled
An engine with a CAN engine controller is configured in MACHINE SETUP:
- ECM transmits a J1939 DM1 message for an engine coolant
high temperature critical fault (SPN:FMI 110:0) on CAN2 or
uses the J1939 Transport Protocol every one second to send
this information if multiple engine faults exist.
The Engine State = ENGINE RUNNING > 10 seconds and UGM system
4310 NO ALTERNATOR OUTPUT UGM system voltage > 11.7 volts
voltage < 11.5 volts for 10 seconds
An engine with a CAN engine controller is not configured in MACHINE
SETUP
- The Engine State = ENGINE RUNNING > 10 seconds
- The engine oil pressure is LOW 
(debounce 3s).
4311 LOW OIL PRESSURE Power Cycled
- ECM transmits a J1939 DM1 message for an engine oil low
pressure critical fault (SPN:FMI 100:1) on CAN2 or uses the
J1939 Transport Protocol every one second to send this
information if multiple engine faults exist.
MACHINE SETUP → ENGINE = DEUTZ EMR4;
ECM transmits a J1939 DM1 message for an engine coolant low level fault
4334 ENGINE COOLANT – LOW LEVEL Power Cycled
(SPN:FMI 111:1) on CAN2 or uses the J1939 Transport Protocol every one
second to send this information if multiple engine faults exist.
MACHINE SETUP → ENGINE = DEUTZ EMR4;
ECM transmits a J1939 DM1 message for a water in fuel fault (SPN 97) on
4375 WATER IN FUEL Power Cycled
CAN2 or uses the J1939 Transport Protocol every one second to send this
information if multiple engine faults exist.
The UGM detects that its supply voltage is less than 9 volts
BATTERY VOLTAGE TOO LOW –
441 Engine State ≠ ENGINE CRANKING Voltage is greater than 9.25 volts
SYSTEM SHUTDOWN
Auxiliary Power/Emergency Descent Mode is not active
BATTERY VOLTAGE TOO HIGH –
442 The UGM detects that its supply voltage > 16.0 volts Power Cycled
SYSTEM SHUTDOWN
443 LSS BATTERY VOLTAGE TOO HIGH Not all of the trigger conditions are met
The UGM determines that the LSS reports supply voltage > 16.0V
6-106 3121728
Engine State ≠ ENGINE CRANKING or ENGINE STARTING;
Auxiliary Power/Emergency Descent Mode is not active;
If Load System is the 4-Cell LSS;

444 LSS BATTERY VOLTAGE TOO LOW Not all of the trigger conditions are met
The UGM determines that the LSS reports supply voltage < 9.0V

The UGM determines that the LSS reports supply voltage < 8.0V or the LSS
Supply Voltage reports Out of Range Low Error
The UGM detects that its supply voltage < 11 volts for 5 seconds.
Engine State ≠ ENGINE CRANKING
445 BATTERY VOLTAGE LOW Voltage is greater than 11.25 volts
Auxiliary Power/Emergency Descent Mode is not active
Glow Plugs are not energized
ENGINE START FAILED - TOO MANY MACHINE SETUP → ENGINE = FORD DUAL FUEL;
4434 Power Cycled
ATTEMPTS Cumulative Crank Time > 24 seconds
LSS BATTERY VOLTAGE -
4479 Load System is the 1-Cell LSS; Power Cycled
INITIALIZATION ERROR
LSS Supply Voltage reports Initialization Error
LSS BATTERY VOLTAGE - NOT
CALIBRATED
LSS Supply Voltage reports Not Calibrated Error
CANBUS FAILURE – PLATFORM
662 UGM does not receive any CAN messages from the PM in 250ms CAN messages are received from the PM
MODULE
MACHINE SETUP → LOAD SYSTEM ≠ NO;
UGM does not receive any CAN messages from the LSS module in 250ms;
CANBUS FAILURE – LOAD SENSING
SYSTEM MODULE
Engine State ≠ (ENGINE CRANKING or ENGINE STARTING) > 2 seconds;
CAN messages are received from the engine
controller;
CANBUS FAILURE – ENGINE UGM shall require re-activation of Footswitch
666 No CAN messages are received from the engine controller for more than
CONTROLLER (Platform Mode) or Ground Enable (Ground
250ms
Mode) to enable functions and resume
operation.
CANBUS FAILURE – EXCESSIVE More than 22 error frames per second for 4 seconds or more than 500 Buss
6613 Power Cycled
CANBUS ERRORS Off conditions since last power cycle.
MACHINE SETUP → CLEARSKY = YES
6622 CANBUS FAILURE – TCU MODULE No CAN2 messages are received from the TCU module for more than 30 Not all of the trigger conditions are met
seconds
CANBUS FAILURE – CHASSIS TILT UGM does not receive any CAN messages from the Chassis Tile Sensor in CAN messages are received from the Chassis
6635
SENSOR 250ms tilt Sensor and controls are initialized
3121728 6-107
CANBUS FAILURE - GROUND UGM does not receive any CAN messages from the Ground Display in CAN messages are received from the Ground
6651
DISPLAY 250ms Display
MACHINE SETUP → TEMP CUTOUT = YES;
CANBUS FAILURE – TEMPERATURE CAN messages are received from the Ambient
6657 UGM does not receive any CAN messages from the Ambient Temperature
SENSOR Temperature sensor
sensor in 250ms
REMOTE CONTRACT MANAGEMENT
MACHINE SETUP → CLEARSKY = YES
681 OVERRIDE – ALL FUNCTIONS IN Cleared by ClearSky TCU
Value set by ClearSky TCU
CREEP
The UGM detects one of the follow conditions:
CHASSIS TILT SENSOR NOT The tilt sensor has not been calibrated;
813 Tilt sensor calibrated
CALIBRATED For 600S the Tilt Sensor source Address is 0xC0;
For 600S the Tilt Sensor Serial number does not match
Fault CHASSIS TILT SENSOR NOT CALIBRATED (813) is not present and Tilt
CHASSIS TILT SENSOR OUT OF sensor measurement > 19º for 4 seconds (internal tilt sensor based
814 Not all of the trigger conditions are met.
RANGE machines) or > 35º (external tilt sensor based machines) Not to be
reported during Tilt Sensor calibration.
The X axis or Y axis raw readings change by < ±0.05º in 5 second;
818 TILT SENSOR STAGNANT Power Cycled
Drive Forward or Drive Reverse output value is ≥ Creep output value;
Do not report if DTC 6635, 813 or 814 are active
CHASSIS TILT SENSOR - SINGLE
8112 Single point Chassis Tilt calibration is successfully completed Can be reset if CALIBRATIONS → TILT SENSOR
POINT CALIBRATION PERFORMED
is successfully completed
821 LSS CELL #1 ERROR Load System is the 4-Cell LSS; Not all of the trigger conditions are met
The UGM detects that LSS is reporting error with Cell #1
The UGM detects that LSS is reporting error with Cell #4.
6-108 3121728
MACHINE SETUP → LOAD SYSTEM ≠ NO

The load sensor has not been calibrated, or
825 LSS HAS NOT BEEN CALIBRATED DTC 992 (LSS EEPROM ERROR) is active, or Not all of the trigger conditions are met
DTC 9977 (LSS CORRUPT EEPROM) is active

The LSS serial number does not match
RUNNING AT CREEP – PLATFORM Refer to Table 7-1 for trigger conditions and machine response
OVERLOADED requirements
LIFT UP & TELE OUT PREVENTED – Refer to Table 7-1 for trigger conditions and machine response
PLATFORM OVERLOADED requirements
FUNCTIONS CUTOUT – PLATFORM Refer to Table 7-1 for trigger conditions and machine response
OVERLOADED requirements

The load sensor has been calibrated and Gross Platform Weight < (0.5 *
Empty Platform Weight);

Not all of the trigger conditions are met
UGM determines that the Platform Load < (-1.5 * Unloaded Platform
8211 LSS READING UNDER WEIGHT
Weight);
Power Cycled
Drive Forward / Reverse or Lift Up output value is ≥ Creep output value;
Platform Load is < -50 lbs. for the first 5 seconds of command;
Do not report if DTC (0030 or 825) is active or if Platform Load ==

Unhealthy
The UGM detects that (Platform Load 1 and Platform Load 2 disagree by 50
lbs. for longer than 3 seconds) or (that Platform Gross 1 and Platform Gross Power Cycled or CALIBRATIONS LOAD SENSING
8218 LSS SENSOR DISAGREEMENT
2 disagree by 200 lbs. for longer than 3 seconds); is successfully completed
Do not report if (DTC 8222 or 8223) is active or if Platform Load ==
Unhealthy, Platform Gross 1= = Unhealthy or Platform Gross 2= =
Unhealthy
8222 LSS STRAIN GAUGE 1 - STAGNANT Load System is the 1-Cell LSS; Power Cycled
Strain Gauge 1 raw reading does change value for 5 seconds;
Do not report if Platform Gross 1= = Unhealthy
3121728 6-109
8223 LSS STRAIN GAUGE 2 - STAGNANT Load System is the 1-Cell LSS; Power Cycled
Strain Gauge 2 raw reading does change value for 5 seconds;
Do not report if DTC Platform Gross 2= = Unhealthy
LSS STRAIN GAUGE 1 - OUT OF
RANGE LOW
Strain Gauge 1 reports an Out of Range Low error
RANGE LOW
Strain Gauge 2 reports an Out of Range Low error
RANGE HIGH
Strain Gauge 1 reports an Out of Range High error
RANGE HIGH
Strain Gauge 2 reports an Out of Range High error
LSS STRAIN GAUGE 1 - Engine State ≠ (ENGINE CRANKING or ENGINE STARTING) > 2 seconds;
8228 Power Cycled
INITIALIZATION ERROR Load System is the 1-Cell LSS;
Strain Gauge 1 reports an Initialization error
LSS STRAIN GAUGE 2 - Engine State ≠ (ENGINE CRANKING or ENGINE STARTING) > 2 seconds;
8229 Power Cycled
INITIALIZATION ERROR Load System is the 1-Cell LSS;
Strain Gauge 2 reports an Initialization error
LSS STRAIN GAUGE 1 - NOT
CALIBRATED
Strain Gauge 1 reports a Not Calibrated error
CALIBRATED
Strain Gauge 2 reports a Not Calibrated error
LSS STRAIN GAUGE 1 - SENSOR
DEFECT
Strain Gauge 1 reports a Sensor Defect error
LSS STRAIN GAUGE 2 - SENSOR
DEFECT
Strain Gauge 2 reports a Sensor Defect error
INSTALLED
Strain Gauge 1 reports a Not Installed error
6-110 3121728
INSTALLED
Strain Gauge 2 reports a Not Installed error
8236 LSS NOT DETECTING CHANGE Drive Forward / Reverse or Lift Up output value is ≥ Creep output value; Power Cycled
Platform Load does not change (peak to peak) by more than 1 lbs. within
the first 5 seconds of the command;
Do not report if Platform Load == Unhealthy
8237 LSS STRAIN GAUGE 1 - A/D DEFECT Load System is the 1-Cell LSS; Power Cycled
Strain Gauge 1 reports a A/D Defect error
8238 LSS STRAIN GAUGE 2 - A/D DEFECT Load System is the 1-Cell LSS; Power Cycled
Strain Gauge 2 reports a A/D Defect error
Electronic Platform Level = Enabled;
Auxiliary Power/Emergency Decent Mode is not active
{(Electronic Platform Level Up output value is active) and [(Platform Angle
<(Platform Angle Max - 1.5 deg)]} or {(Electronic Platform Level Down
PLATFORM LEVELING SYSTEM
8318 output value is active) and [(Platform Angle < (Platform Angle Max - 1.5 Power Cycled
TIMEOUT
deg)]}
[(Platform Angle >= Platform Angle Setpoint +5 deg) or 
(Platform Angle <= Platform Angle Setpoint -5 deg)] for longer than
2000ms
FRONT LEFT STEER VALVE – OPEN
CIRCUIT
FRONT LEFT STEER VALVE – SHORT
TO BATTERY
FRONT LEFT STEER VALVE – SHORT
TO GROUND
FRONT RIGHT STEER VALVE – OPEN
CIRCUIT
FRONT RIGHT STEER VALVE –
SHORT TO BATTERY
FRONT RIGHT STEER VALVE –
SHORT TO GROUND
REAR LEFT STEER VALVE - OPEN
CIRCUIT
REAR LEFT STEER VALVE - SHORT
TO BATTERY
3121728 6-111
REAR LEFT STEER VALVE - SHORT
TO GROUND
REAR RIGHT STEER VALVE - OPEN
CIRCUIT
REAR RIGHT STEER VALVE - SHORT
TO BATTERY
REAR RIGHT STEER VALVE - SHORT
TO GROUND
MACHINE SAFETY SYSTEM Can be reset only with an Analyzer via the
873 MSSO = Active
OVERRIDE OCCURRED CALIBRATIONS → MSSO → MSSO RESET
menu
MACHINE SETUP → CABLE SWITCH = YES;
876 WIRE ROPE SERVICE REQUIRED Power Cycled
Wire Rope Service = Enabled
991 LSS WATCHDOG RESET Power Cycled
UGM detects LSS report of an anomaly exists that has caused a WatchDog
Timer reset.
992 LSS EEPROM ERROR Load System is the 4-Cell LSS; Power Cycled
UGM detects LSS report of an anomaly that exists in the LSS EEPROM
LSS INTERNAL ERROR – PIN
EXCITATION
UGM detects LSS report of improper excitation voltage
LSS INTERNAL ERROR – DRDY Load System is the 4-Cell LSS;
994 Power Cycled
MISSING FROM A/D UGM detects LSS report of an anomaly that exists in the LSS A/D converter
operations.
EEPROM FAILURE - CHECK ALL
998 The UGM has detected an anomaly in EEPROM Power Cycled
SETTINGS
The UGM software version type is ‘P’
FUNCTIONS LOCKED OUT - The UGM has received valid version information from the PM
9910 PLATFORM MODULE SOFTWARE The PM software version type is ‘P’ Not all of the trigger conditions are met
VERSION IMPROPER The UGM software major version number does not match the major
version number of the platform software
FUNCTION LOCKED OUT - LSS
9911 MODULE SOFTWARE VERSION Power Cycled
The UGM determines that the LSS software version is not compatible with
IMPROPER
existing code
CHASSIS TILT SENSOR NOT GAIN The tilt sensor gain calibration values recorded to flash memory during
9915 Valid values are present
CALIBRATED Phoenix International’s manufacturing test are not present
6-112 3121728
PLATFORM SENSOR REF VOLTAGE The PM detects that its reference voltage is out of range and reports the
9920 Power Cycled
OUT OF RANGE fault to the UGM
The engine is not running
The engine is not cranking
The UGM footswitch input J7-15 is LOW
GROUND MODULE FAILURE:HIGH
9921 The machine is in Platform Mode Power Cycled
SIDE DRIVER CUTOUT FAULTY
The Main Dump output J2-13 is detected as HIGH via the analog feedback
300ms after it is attempted to be activated during the one time startup
test of the UGM hardware shutoff circuitry
PLATFORM MODULE FAILURE: The PM detects that its V(low) FET has failed and reports this fault to the
9922 Power Cycled
HWFS CODE 1 UGM
FUNCTIONS LOCKED OUT - The machine is powered up and no model has been selected yet in the
9924 Power Cycled
MACHINE NOT CONFIGURED MACHINE SETUP menu
The UGM detects one of the following conditions when software type is ‘P’
or ‘B’:
The Version Verification Word #1 or the Version Verification Word #2
values located in the constant data sector of flash memory (found on A different application code or constant data
GROUND MODULE CONSTANT DATA constant data spreadsheet tab pstConstantDataVersion) do not match the version is programmed so that the values
9927
UPDATE REQUIRED values located in the code area of flash memory match
The Version Major value located in the constant data sector of flash Power Cycled
memory (found on constant data spreadsheet tab
pstConstantDataVersion) does not match the value located in the code
area of flash memory
One or more of the current feedback gains that are calculated and written
CURRENT FEEDBACK GAINS OUT OF
9944 to flash memory during the PIC manufacturing test process are detected as Power Cycled
RANGE
being out of range
The current feedback gains checksum that is calculated and written to
CURRENT FEEDBACK CALIBRATION
9945 flash memory during the PIC manufacturing test process is detected as Power Cycled
CHECKSUM INCORRECT
being incorrect
MACHINE CONFIGURATION OUT OF UGM has detected an anomaly in EEPROM with regard to the Machine Power Cycled and EEPROM data in associated
9949
RANGE – CHECK ALL SETTINGS Setup configuration. area is changed
and one of the following conditions:
UGM determines LSS-stored values for Unloaded weight in Indirect
9977 LSS CORRUPT EEPROM Power Cycled
0x100≠ 0x108 or
UGM determines LSS-stored values for Accessory weight in Indirect
0x102≠ 0x10A
UGM determines LSS-stored checksum1 (0x10F) ≠ checksum 2 (0x107)
FUNCTIONS LOCKED OUT - GROUND Ground software has been installed on a UGM with a ST10F274 processor
9979 MODULE SOFTWARE VERSION (Hardware Rev < 6), which does not have guaranteed flash storage in the Power Cycled
IMPROPER sector where Constant Data is written.
3121728 6-113
GROUND MODULE VLOW FET VLow FET determined to be failed because all Digital Inputs are high; UGM
9986 Power Cycled
FAILURE unable to read high-sensing inputs.
LSS - FACTORY CALIBRATION
ERROR
LSS reports an Error Status (other than 0,1,2,8,30,31)
6-114 3121728
SECTION 7. BASIC ELECTRICAL INFORMATION & ELECTRICAL SCHEMATICS

7.1 GENERAL Polarity
Getting a negative Voltage or current reading when expecting
This section contains basic electrical information and  a positive reading frequently means the leads are reversed.
schematics for locating and correcting most electrical prob- Check what reading is expected, location of the signal and
lems. If a problem develops which is not presented in this sec- leads are correctly connected to the device under test. Also
tion or corrected by listed corrective actions, obtain check the lead on the “COM” port goes to the ground or nega-
technically qualified guidance before proceeding with any tive side of the signal and lead on the other port goes to the
positive side of the signal.
additional maintenance.
NOTE: Some procedures/connectors shown in this section may Scale

not apply to all models. M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
7.2 MULTIMETER BASICS m = milli = (Displayed Number) / 1,000
A wide variety of multimeters or Volt Ohm Meters (VOM) can μ = micro = (Displayed Number) / 1,000,000
be used for troubleshooting your equipment. This section
Example: 1.2 kW = 1200 W
shows diagrams of a common, digital VOM configured for sev- Example: 50 mA = 0.05 A
eral different circuit measurements. Instructions for your VOM
may vary. Please consult the meter operator’s manual for more Voltage Measurement
information.
Grounding
“Grounding the meter” means to take the black lead (which is
connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the Voltage source.
Backprobing
To “backprobe” means to take the measurement by accessing
a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining cir-
cuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around
the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors.
Whenever possible insert probes into the side of the connec-
tor such that the test also checks both terminals of the con-
nection. It is possible to inspect a connection within a closed
connector by backprobing both sides of a connector terminal
and measuring resistance. Do this after giving each wire a gen-
Figure 7-1. Voltage Measurement (DC)
tle pull to ensure the wires are still attached to the contact and
contacts are seated in the connector. • If meter is not auto ranging, set it to the correct range (See
multimeter’s operation manual)
Min/Max • Use firm contact with meter leads
Use of the “Min/Max” recording feature of some meters can

help when taking measurements of intermittent conditions
while alone. For example, you can read voltage applied to a
solenoid when it is only operational while a switch, far from
the solenoid and meter, is held down.
3121728 7-1
Resistance Measurement Continuity Measurement
Figure 7-3. Continuity Measurement

• Some meters require a separate button press to enable
audible continuity testing
• Circuit power must be turned OFF before testing continu-
ity
Figure 7-2. Resistance Measurement
• Disconnect component from circuit before testing
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance) • Use firm contact with meter leads
• Circuit power must be turned OFF before testing resistance • First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating conti-
• Disconnect component from circuit before testing nuity
• If meter is not auto ranging, set it to the correct range (See
multimeter’s operation manual)
• Use firm contact with meter leads
7-2 3121728
Current Measurement 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO

ELECTRICAL CONNECTIONS
NOTE: This section is not applicable for battery terminals.
JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-
RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.
NOTE: Do NOT apply dielectric grease to the following connec-

tions:
• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,
• Deutz EMR 2 ECM connection.
Silicone Dielectric Compound must be used on all electrical
connections except for those mentioned above for the follow-
ing reasons:
• To prevent oxidation at mechanical joint between male
and female pins.
• To prevent electrical malfunction caused by low level con-
ductivity between pins when wet.
Figure 7-4. Current Measurement (DC)
Use the following procedure to apply Silicone Dielectric Com-
• Set up meter for expected current range pound to the electrical connectors. This procedure applies to
all plug connections not enclosed in a box. Silicone grease
• Be sure to connect meter leads to correct jacks for selected should not be applied to connectors with external seals.
current range
1. To prevent oxidation, silicone grease must be packed
• If meter is not auto ranging, set it to correct range (See completely around male and female pins on the inside
multi meter’s operation manual) of the connector prior to assembly. This is most easily
• Use firm contact with meter leads achieved by using a syringe.
NOTE: Over a period of time, oxidation increases electrical resis-
tance at the connection, eventually causing circuit failure.
2. To prevent shorting, silicone grease must be packed

around each wire where they enter the outside of the
connector housing. Also, silicone grease must be
applied at the joint where the male and female connec-
tors come together. Any other joints (around strain
reliefs, etc.) where water could enter the connector
should also be sealed.
NOTE: This condition is especially common when machines are
pressure washed since the washing solution is much more
conductive than water.
3121728 7-3
3. Anderson connectors for battery boxes and battery Deutsch HD, DT, DTM, DRC Series
chargers should have silicone grease applied to contacts
The Deutsch connector system is commonly used for harsh
only. environments. Follow installation instructions.
NOTE: Curing-type sealants can also be used to prevent shorting

and would be less messy, but make future pin removal diffi-
cult.
When applied to electrical connections, dielectric grease helps

prevent corrosion of electrical contacts and improper conduc-
tivity between contacts from moisture intrusion. Open and
sealed connectors benefit from application of dielectric
grease.
Dielectric grease shall be applied to all electrical connectors at

the time of connection (except those noted under Exclusions).
Installation of Dielectric Grease

Figure 7-6. Deutsch Connector
Before following these instructions, refer to excluded connec-
tor types (See Exclusions below).
AMP Seal
1. Use dielectric grease in a tube for larger connection
The AMP Seal connector system is used on Control ADE 
points or apply with a syringe for small connectors.
Platform and Ground Modules.
2. Apply dielectric grease to plug/male connector housing Apply dielectric grease to the plug/male connector housing
which typically contains sockets contact/female  which typically contains socket contacts/female terminals. If
terminals. trapped air prevents the connector from latching, pierce one
of the unused wire seals. After assembly, install a seal plug (JLG
3. Leave a thin layer of dielectric grease on the face of the #4460905) in that location to prevent moisture ingress.
connector.
Note that seal plugs may be installed by the wire harness man-
4. Assemble connector system immediately to prevent ufacturer if an unused wire seal becomes compromised (wire
inserted in the wrong cavity during assembly and the cor-
moisture or dust contamination.
rected).
5. Pierce one of the unused wire seals before assembly if
the connector system tends to trap air (i.e. AMP Seal)
and then install a seal plug.

Figure 7-7. Application to plug/male connector
housing
Figure 7-5. Applying Dielectric Grease
7-4 3121728
DIN Connectors
This connector is typically used on hydraulic valves. Follow
manufacturer installation instructions.
Figure 7-10. DIN Connector
Exclusions
A limited number of connectors do not benefit from dielectric
Figure 7-8. Use of Seal Plugs
grease, or may be permanently damaged by application.
Dielectric grease may not be required in properly sealed
enclosures.
AMP Mate-N-Lok
Follow manufacturer installation instructions.
Figure 7-9. AMP Mate-N-Lok Connector
3121728 7-5
BRAD HARRISON/PHOENIX CONTACT M12 ENGINE CONTROL UNIT CONNECTORS

The connector uses gold contact material to resist corrosion Many times, these types of connectors use back-seals for mois-
and an o-ring seal for moisture integrity. If dielectric grease is ture integrity. However, the low-force contacts cannot displace
mistakenly applied to this connector system, the low-force dielectric grease and create electrical contact. It is possible to
contacts cannot displace the grease to achieve electrical con- use solvents (i.e. contact cleaner or mineral spirits) for the
tact. Once contaminated, there is no practical way to remove removal of improperly applied dielectric grease. The EMR4
the dielectric grease (replacement of female contacts engine control module from Deutz employs this connector
required). system (for example).
7-6 3121728
7.4 AMP CONNECTOR 2. Pull back on the contact wire with a force of 1 or 2 lbs. to
be sure the retention fingers are holding the contact
Assembly (See Figure 7-13.).
Check to be sure the wedge lock is in the open, or as-shipped,

position (See Figure 7-11.). Proceed as follows:
Figure 7-11. Connector Assembly Figure 1
1. To insert a contact, push it straight into the appropriate

circuit cavity as far as it will go (See Figure 7-13.).
Figure 7-12. AMP Connector
3121728 7-7
3. After all required contacts have been inserted, the 4. Slide the wedge lock into the housing until it is flush
wedge lock must be closed to its locked position. with the housing (See Figure 7-15.).
Release the locking latches by squeezing them inward
(See Figure 7-14.).
7-8 3121728
Figure 7-16. Connector Disassembly
Disassembly Service - Voltage Reading

5. Insert a 4.8 mm (3/16”) wide screwdriver blade between
the mating seal and one of the red wedge lock tabs.
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
6. Pry open the wedge lock to the open position.
It has been common practice in electrical troubleshooting to
7. While rotating the wire back and forth over a half turn probe wires by piercing the insulation with a sharp point. This
(1/4 turn in each direction), gently pull the wire until the practice should be discouraged when dealing with the
contact is removed. AMPSEAL plug assembly, or any other sealed connector sys-
tem. The resulting pinholes in the insulation will allow mois-
NOTE: The wedge lock should never be removed from the housing
ture to invade the system by traveling along the wire strands.
for insertion or removal of the contacts.
This nullifies the effectiveness of the connector seals and
could result in system failure.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating
end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp
point such as an ice pick.
















3121728 7-9
Figure 7-17. Connector Installation
7-10 3121728
7.5 DEUTSCH CONNECTORS DT/DTP Series Disassembly
DT/DTP Series Assembly
A B
A B
C
C D
Figure 7-19. DT/DTP Contact Removal
Figure 7-18. DT/DTP Contact Installation
5. Remove wedgelock using needlenose pliers or a hook
1. Grasp crimped contact about 25mm behind the contact shaped wire to pull wedge straight out.
barrel.
6. To remove the contacts, gently pull wire backwards,
2. Hold connector with rear grommet facing you. while at the same time releasing the locking finger by
moving it away from the contact with a screwdriver.
3. Push contact straight into connector grommet until a
click is felt. A slight tug will confirm that it is properly 7. Hold the rear seal in place, as removing the contact may
locked in place. displace the seal.
4. Once all contacts are in place, insert wedgelock with
arrow pointing toward exterior locking mechanism. The
wedgelock will snap into place. Rectangular wedges are
not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
3121728 7-11
HD30/HDP20 Series Assembly HD30/HDP20 Series Disassembly
A B A B
C
C
Figure 7-20. HD/HDP Contact Installation Figure 7-22. HD/HDP Contact Removal
8. Grasp contact about 25mm behind the contact crimp

11. With rear insert toward you, snap appropriate size
barrel.
extractor tool over the wire of contact to be removed.
9. Hold connector with rear grommet facing you.
12. Slide tool along into the insert cavity until it engages
10. Push contact straight into connector grommet until a contact and resistance is felt.
positive stop is felt. A slight tug will confirm that it is
13. Pull contact-wire assembly out of connector.
properly locked in place.
Figure 7-23. HD/HDP Unlocking Contacts

Figure 7-21. HD/HDP Locking Contacts Into Position
NOTE: Do Not twist or insert tool at an angle.
NOTE: For unused wire cavities, insert sealing plugs for full envi-
ronmental sealing.
7-12 3121728
7.6 TELEMATICS GATEWAY

Personnel using machines equipped with an optional telemat-
ics gateway will be able to view the following data through
their telematics device:
JLG LABEL DESCRIPTION UNIT
Engine Speed Actual engine speed. RPM
Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is equipped with DEF tank.
DEF Tank Level (If Equipped) • 0% = Empty Percentage (%)
• 100% = Full
• 00 - No Machine Faults
JLG Machine Faults: • 01 - Active Machine Fault

Bit
Active / Not-Active • 10 - Error
• 11 - Not available
Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters
Total Idle Hours Total time of engine operation during idle conditions. Seconds
Total Engine Hours Total time of engine operation. Seconds
Total Fuel Used Total amount of fuel used during vehicle operation. Liters
Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour
Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel limit switch is present, the fuel
level will indicate “full” until the switch opens, which will then indicate 10% fuel remaining.
Fuel Level Percentage (%)
When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel storage containers. When Fuel
Level 2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.
DM1 Engine Faults Shows actual engine fault codes. N/A
3121728 7-13
GATEWAY MODULE
DIAGNOSTICS PLUG
TELEMATICS-READY PLUG
Telematics-Ready (TCU) Plug

The telematics-ready (TCU) plug is a standard 12-pin Deutsch
connector. Pin-out locations are shown below:
12 1 - BATTERY
11 2 - GROUND
CAN-LO 2 - 10 3
CAN-HI 2 - 9 4 - IGNITION
8 5
7 6
7-14 3121728
3121728
MS1619-3 MS1619-1
MS1619-2
X1609
MS1620-1
S1614
MS1618-2
S1615
MS1620-3
MS1620-2
MS1618-3
CO1613-J2
CO1613-J1
X1606
Figure 7-24. Telematics Gateway Harness - Sheet 1 of 3
7-15
X1609 (TCU) MS1620-3 (CAN-T 2)

CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
1 RED 1-0 BAT 16 AWG GXL X1606 (B) A YEL CANH2 18 AWG GXL CO1613-J2 (10)
2 BLK 0-0 GND 16 AWG GXL S1615 (1) B GRN CANL2 18 AWG GXL CO1613-J2 (9)
4 ORN 2-0 IGN 16 AWG GXL S1614 (1)

S1614
9 GRN CANL2 18 AWG GXL MS1619-2 (B)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
10 YEL CANH2 18 AWG GXL MS1619-2 (A)
1 ORN 2-0 IGN 16 AWG GXL X1609 (4)
MS1619-2 (CAN-T 2) 2 ORN 2-1 IGN 16 AWG GXL X1606 (H)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)
A YEL CANH2 18 AWG GXL X1609 (10)
B GRN CANL2 18 AWG GXL X1609 (9)

S1615
MS1619-3 (CAN-T 2) 1 BLK 0-0 GND 16 AWG GXL X1609 (2)
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 2 BLK 0-1 GND 16 AWG GXL X1606 (A)
A YEL CANH2 18 AWG GXL MS1620-2 (A) 2 BLK 0-2 GND 16 AWG GXL CO1613-J1 (11)
B GRN CANL2 18 AWG GXL MS1620-2 (B)
MS1618-2 (CAN-T 1)
CO1613-J1 (GATEWAY 1)
A YEL CANH1 18 AWG GXL CO1613-J1 (10)
9 GRN CAN1 18 AWG GXL MS1618-2 (B)
B GRN CANL1 18 AWG GXL CO1613-J1 (9)
11 BLK 0-2 GND 16 AWG GXL S1615 (2) MS1618-3 (CAN-T 1)

12 ORN 2-2 IGN 16 AWG GXL S1614 (2) CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO
A YEL CANH1 18 AWG GXL X1606 (C)

CO1613-J2 (GATEWAY 2)
B GRN CANL1 18 AWG GXL X1606 (D)
9 GRN CANL2 18 AWG GXL MS1620-3 (B) X1606 (DIAG)

A BLK 0-1 GND 16 AWG GXL S1615 (2)

MS1620-2 (CAN-T 2)
B RED 1-0 BAT 16 AWG GXL X1609 (1)
C YEL CANH1 18 AWG GXL MS1618-3 (A)
A YEL CANH2 18 AWG GXL MS1619-3 (A)
D GRN CANL1 18 AWG GXL MS1618-3 (B)
B GRN CANL2 18 AWG GXL MS1619-3 (B)
H ORN 2-1 IGN 16 AWG GXL S1614 (2)
7-16 3121728
FROM TO
WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN
CAN L2 GRN 18 AWG 1151 GXL MS1619-3 B MS1620-2 B
CAN L2 GRN 18 AWG 151 GXL X1609 9 MS1619-2 B
CAN L1 GRN 18 AWG 157 GXL MS1618-2 B CO1613-J1 9
CAN L2 GRN 18 AWG 225 GXL MS1620-3 B CO1613-J2 9
CAN L1 GRN 18 AWG 1076 GXL MS1618-3 B X1606 D
CAN H2 YEL 18 AWG 155 GXL X1609 10 MS1619-2 A
CAN H2 YEL 18 AWG 233 GXL MS1620-3 A CO1613-J2 10
CAN H1 YEL 18 AWG 157 GXL MS1618-2 A CO1613-J1 10
CAN H2 YEL 18 AWG 1150 GXL MS1619-3 A MS1620-2 A
CAN H1 YEL 18 AWG 1079 GXL MS1618-3 A X1606 C
0-0 GND BLK 16 AWG 1006 GXL X1609 2 S1615 1
0-1 GND BLK 16 AWG 1145 GXL X1606 A S1615 2
0-2 GND BLK 16 AWG 223 GXL CO1613-J1 11 S1615 2
1-0 BAT RED 16 AWG 2150 GXL X1609 1 X1606 B
2-0 IGN ORN 16 AWG 939 GXL X1609 4 S1614 1
2-1 IGN ORN 16 AWG 1212 GXL S1614 2 X1606 H
2-2 IGN ORN 16 AWG 287 GXL CO1613-J1 12 S1614 2
3121728 7-17
7.7 WIRING HARNESS Table 7-1. Wiring Harness Connector Labels
Component Category Label

Connector Labels
Audible Alarms AH
Connectors between harnesses are identified by the prefix “X”
and a sequentially assigned number. An optional suffix (letters Horns
& numbers) may be added when multiple terminations occur Battery Batteries BT
at one device or when there are optional connections. Battery Terminals
Examples: Control Module Ground CO
X25 connects to X25 in another harness. LSS
Platform
X65A, X65B connect to different portions of one device
Engine Alternator EC
X163 connects to X163A in ANSI and X163B in CE machines
Cold Start
Controller
Component Labels
Every component on the vehicle has a unique identification. A Coolant Temp
standard prefix letter is assigned according to the table below, Fuel Pump
followed by a unique sequential number. An optional suffix Fuel Solenoid
(letters & numbers) may be added when multiple terminations
Glow Plugs
occur at one device.
Oil Pressure
Terminals that are not loaded into connectors are considered
Starter
independent components and labeled in the same fashion.
Fuse & CB Fuse FC Fuse FC
Fusible Link FC
Circuit Breaker CB
Gauge & Display Board GD
Cluster
Hour meter
LMI
Speedometer
Inline Resistor R
Diode D
Joystick & Steering Electronic JS
Hydraulic
Lights Dome LB
Headlights
Simple
Taillights
Membrane Panel MP
Miscellaneous Radio MS
Speakers
Splice Blocks
T-Connectors
7-18 3121728
Table 7-1. Wiring Harness Connector Labels
Component Category Label

Other Switches Disconnect SW
EMS
Foot
HVAC WH
Key SW
Park brake
Pump pot
Push
Shifter
Turn signal
Relay 5 Pin RL
4 Pin
Contactor
Power module
Rocker Switch SW
Sensor Angle SN
Fuel
Length
Limit
Load
Pressure
Proximity
Speed
Temperature
Terminals Pins T
Sockets
Male Blades
Female Blades
Rings
Forks
Toggle Switch DPDT SW
DPST
SPDT
SPST
Special
Valves Simple HV
Suppression
Examples:
T67 is a ring terminal connected during installation.
CO1-J3 is the J3 connector for a UGM control module.
EC9 is a glow plug supplied with the engine
3121728 7-19
7-20
SHEET 2 SHEET 3 SHEET 4 SHEET 5
RL737
RL736 SG RELAY #1 SW719-2
SG RELAY #2 SOFT TOUCH/
SKYGUARD
SW709
LEVEL SW719-1 SW707
X738 SOFT TOUCH/ MAIN TELE
SG SNSR SKYGUARD
SW727 SW726-2
FUEL SELECT SW708 HEAD AND TAIL LIGHTS
PLATFORM SW718
IP740 SW724 JIB LIFT SW726-1
X729 ROTATE
18 OHM ENGINE HEAD AND
ANALYZER
CO01-J7 SPEED SW711-2 TAIL LIGHTS
HORN
BLACK AH712+ SW728
MS16 SW751
ALARM SW711-1 DRIVE
CO01-J8 STEER
HORN ORIENTATION
7.8 WIRING HARNESS CONNECTOR LABEL DIAGRAMS
AH712- SELECT
OVERRIDE
X652A ALARM
X305A SW733
S783 S782 DUAL CAPACITY
S653
GD725-J2
S663 S664
SW731 SW710
PUMP POT START AUX
X103B
GD725-J3 GD725-J1 LB543+
CO01-J2 X303A SKYGUARD
S654 BLUE GD725-J4

WARNING
SW715-2B LB543-
X687 CO01-J1 SKYGUARD WARNING
SINGLE CELL LSS NATURAL E STOP
SW715-1B
E STOP 1001196222-F
MAE20740
Figure 7-27. Platform Box Harness - Sheet 1 of 6
3121728
3121728 7-21
MS16
7-22
X652A
S663
X305A S653
X103B
X687
S654
1001196222-F
MAE20750
3121728
X652A S654
CONN WIRE CONN WIRE
WIRE LABEL GAUGE JACKET TO WIRE LABEL GAUGE JACKET TO
POS COLOR POS COLOR
1 BLK 000-10-34 OPTION GND 18 AWG GXL S664 (1) 1 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL X652A (5)
2 2 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL CO01-J7 (16)
3 WHT 4-15 PLAT DUMP 1 18 AWG GXL X103B (13) 2 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL X103B (7)
4 WHT 4-8 PLAT LEVEL UP 18 AWG GXL S653 (1)
5 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL S654 (1)
6 S663
7 WIRE
8 WHT 4-88 PLAT ANGLE SEN 1 18 AWG GXL CO01-J1 (25) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
9 WHT 4-89 PLAT ANGLE SEN 2 18 AWG GXL CO01-J1 (26) 1 WHT 1-90 SG POWER 18 AWG GXL CO01-J7 (7)
10 WHT 4-125 PLAT ANGLE SEN 5V 18 AWG GXL CO01-J7 (11) 1 WHT P2 18 AWG GXL IP740 (2)
11 2 WHT 1-38 GEN IGN SWITCH 18 AWG GXL X305A (2)
12 WHT 4-16 PLAT DUMP 2 18 AWG GXL X103B (15) 2 WHT P9 18 AWG GXL RL737 (30)
13 WHT 1-41 PLAT ROTATE LEFT 18 AWG GXL CO01-J7 (5)
14 WHT 1-42 PLAT ROTATE RIGHT 18 AWG GXL CO01-J7 (6)
15 WHT 1-36 JIB UP 18 AWG GXL CO01-J7 (25)
16 WHT 1-43 JIB DOWN 18 AWG GXL CO01-J7 (26) X687
17 CONN WIRE WIRE
GAUGE JACKET TO
18 POS COLOR LABEL
19 1
20 2 WHT LSS PWR 20 AWG CABLE S782 (2)
21 BLK 000-40-90 PLAT SEN GND 18 AWG GXL CO01-J7 (14) 3 BLU LSS GND 20 AWG CABLE S783 (2)
4 BLK CAN1 HI 20 AWG CABLE MS16 (10)
5 GRY CAN1 LO 20 AWG CABLE MS16 (7)
MS16
CONN WIRE
WIRE LABEL GAUGE JACKET TO X103B
POS COLOR
1 YEL CAN 20 AWG J1939 CABLE CO01-J7 (31) CONN WIRE
WIRE LABEL GAUGE JACKET TO
2 YEL CAN 20 AWG J1939 CABLE X103B (3) POS COLOR
3 YEL CAN 20 AWG J1939 CABLE X303A (8) 1
4 GRN CAN 20 AWG J1939 CABLE CO01-J7 (30) 2 GRN CAN 20 AWG J1939 CABLE MS16 (5)
5 GRN CAN 20 AWG J1939 CABLE X103B (2) 3 YEL CAN 20 AWG J1939 CABLE MS16 (2)
6 GRN CAN 20 AWG J1939 CABLE X303A (9) 4 WHT 1-44 EMS 18 AWG GXL CO01-J7 (3)
7 GRY CAN1 LO 20 AWG CABLE X687 (5) 5 WHT 4-8 PLAT LEVEL UP 18 AWG GXL S653 (2)
8 6
9 7 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL S654 (2)
10 BLK CAN1 HI 20 AWG CABLE X687 (4) 8
11 9 WHT 1-62 EMS B+ 18 AWG GXL SW715-1 (1B)
12 10
11 WHT 1-37 GROUND MODE 18 AWG GXL CO01-J7 (1)
12 WHT 1-1 12 AWG GXL CO01-J8 (2)
13 WHT 4-15 PLAT DUMP 1 18 AWG GXL X652A (3)
X305A 14
CONN WIRE 15 WHT 4-16 PLAT DUMP 2 18 AWG GXL X652A (12)
POS COLOR 16 BLK 000-10-14 GND 12 AWG GXL CO01-J8 (1)
1 WHT 1-35 GENERATOR SWITCH 18 AWG GXL CO01-J7 (9) 17
2 WHT 1-38 GEN IGN SWITCH 18 AWG GXL S663 (2) 18
3 19
4 WHT 1-39 FOOT SW DISENGAGED 18 AWG GXL CO01-J7 (8)
5 WHT 1-40 FOOT SW 18 AWG GXL CO01-J7 (4)
6
7
8
9 WHT 1-85 ST POWER 18 AWG GXL CO01-J2 (34)
10
11
12 WHT 1-91 ST SWITCH 18 AWG GXL CO01-J1 (20)
13
14 WHT 1-551 18 AWG GXL X305A (15)
15 WHT 1-551 18 AWG GXL X305A (14)
S653
CONN WIRE
POS COLOR
1 WHT 4-8 PLAT LEVEL UP 18 AWG GXL X652A (4)
2 WHT 4-8 PLAT LEVEL UP 18 AWG GXL CO01-J7 (15)
2 WHT 4-8 PLAT LEVEL UP 18 AWG GXL X103B (5)
3121728 7-23
RL737
RL736
X738
CO01-J8
AH712+
CO01-J7 AH712-
X729
S783
S782
IP740
S664
CO01-J1 X303A
CO01-J2
1001196222-F
MAE20760
7-24 3121728
X729 ANALYZER CO01-J1 NATURAL

CONN WIRE WIRE
WIRE LABEL GAUGE JACKET TO CONN POS WIRE LABEL GAUGE JACKET TO
POS COLOR COLOR
1 WHT 1-66 POWER 18 AWG GXL CO01-J2 (26) 1
2 WHT 1-81 RECEIVE 18 AWG GXL CO01-J2 (28) 2
3 WHT 1-82 TRANSMIT 18 AWG GXL CO01-J2 (29) 3
4 BLK 000-10-12 GND 18 AWG GXL CO01-J2 (27) 4
5 WHT 1-3 TELE IN 18 AWG GXL SW707 (3)
6 WHT 1-5 TELE OUT 18 AWG GXL SW707 (1)
IP740 18 OHM 7 WHT 1-6 PLTF ROTATE RIGHT 18 AWG GXL SW708 (3)
WIRE 8 WHT 1-7 PLTF ROTATE LEFT 18 AWG GXL SW708 (1)
CONN POS WIRE LABEL GAUGE JACKET TO 9 WHT 1-8 LEVEL UP 18 AWG GXL SW709 (3)
COLOR
1 WHT P10 18 AWG GXL X738 (1) 10 WHT LEVEL DOWN 18 AWG GXL SW709 (1)
2 WHT P2 18 AWG GXL S663 (1) 11 WHT 1-13 JIB UP 18 AWG GXL SW718 (3)
12 WHT 1-14 JIB DOWN 18 AWG GXL SW718 (1)
13 WHT 1-103 SPD PMP POT GND 18 AWG GXL SW731 (5)
14 WHT 1-9 START SWITCH 18 AWG GXL SW710 (3)
X738 SG SNSR 15 WHT 1-10 AUX POWER 18 AWG GXL SW710 (1)
WIRE 16 WHT 1-110 CRAB STEER 18 AWG GXL SW751 (3)
CONN POS WIRE LABEL GAUGE JACKET TO
COLOR 17 WHT 1-111 COORD STEER 18 AWG GXL SW751 (1)
1 WHT P10 18 AWG GXL IP740 (1) 18 WHT 1-70 SWITCHES PWR 18 AWG GXL SW724 (2)
2 BLK 1-86 SG GND 18 AWG GXL CO01-J7 (21) 19
3 WHT P4 18 AWG GXL RL736 (86) 20 WHT 1-91 ST SWITCH 18 AWG GXL X305A (12)
4 WHT P5 18 AWG GXL RL736 (85) 21 WHT 1-50 DUAL CAPACITY 18 AWG GXL SW733 (3)
22
23 WHT 1-88 ST/SG INPUT 2 18 AWG GXL RL736 (87)
S664 24
WIRE 25 WHT 4-88 PLAT ANGLE SEN 1 18 AWG GXL X652A (8)
CONN POS WIRE LABEL GAUGE JACKET TO 26 WHT 4-89 PLAT ANGLE SEN 2 18 AWG GXL X652A (9)
COLOR
1 BLK 000-10-34 OPTION GND 18 AWG GXL X652A (1) 27 WHT 1-12 MAX SPEED 18 AWG GXL SW724 (3)
28 WHT 1-11 MIN SPEED 18 AWG GXL SW724 (1)
1 BLK 000-10-34 OPTION GND 18 AWG GXL CO01-J7 (29)
29 WHT 1-4 SOFT TOUCH 18 AWG GXL SW719-1 (1)
2 BLK 000-10-34 OPTION GND 18 AWG GXL X303A (6)
30 WHT 1-15 HEAD LIGHTS 18 AWG GXL SW726-1 (1)
31 WHT 1-2 HORN 18 AWG GXL SW711-1 (1)
32 WHT 1-101 CREEP SW 18 AWG GXL SW731 (2)
RL736 SG RELAY #2 33 WHT 1-68 FUEL SELECT 18 AWG GXL SW727 (3)
WIRE 34 WHT 1-105 SPD PMP POT PWR 18 AWG GXL SW731 (4)
COLOR 35 WHT 1-104 SPD PMP POT SGL 18 AWG GXL SW731 (6)
30 WHT P9-1 18 AWG GXL RL737 (30)
85 WHT P5 18 AWG GXL X738 (4)
85 WHT P5-1 18 AWG GXL RL737 (85) AH712+ ALARM
86 WHT P4 18 AWG GXL X738 (3)
CONN WIRE
86 WHT P4-1 18 AWG GXL RL737 (86) WIRE LABEL GAUGE JACKET TO
87 WHT 1-88 ST/SG INPUT 2 18 AWG GXL CO01-J1 (23) POS COLOR
87a 1 WHT 1-34 PLAT ALRM 18 AWG GXL CO01-J7 (19)
RL737 SG RELAY #1 X303A

WIRE WIRE
CONN POS WIRE LABEL GAUGE JACKET TO COLOR
COLOR
1
30 WHT P9 18 AWG GXL S663 (2)
30 WHT P9-1 18 AWG GXL RL736 (30) 2
85 WHT P5-1 18 AWG GXL RL736 (85) 3
4
86 WHT P4-1 18 AWG GXL RL736 (86)
5 BLK 000-10-11 VALVES GND 18 AWG GXL CO01-J7 (23)
87 WHT P1 18 AWG GXL CO01-J7 (18)
6 BLK 000-10-34 OPTION GND 18 AWG GXL S664 (2)
87a
7 WHT 1-89 OPTION POWER 18 AWG GXL CO01-J2 (33)
8 YEL CAN 20 AWG J1939 CABLE MS16 (3)
9 GRN CAN 20 AWG J1939 CABLE MS16 (6)
10
11 BLK 000-10-30-2 LSS GND 18 AWG GXL S783 (2)
12 WHT 1-33-2 LSS PWR 18 AWG GXL S782 (2)
CO01-J8
WIRE
COLOR
1 BLK 000-10-14 GND 12 AWG GXL X103B (16)
2 WHT 1-1 12 AWG GXL X103B (12)
3121728 7-25
AH712- ALARM CO01-J7 BLACK

WIRE WIRE
CONN POS WIRE LABEL GAUGE JACKET TO CONN POS WIRE LABEL GAUGE JACKET TO
COLOR COLOR
1 WHT 000-10-16 PLAT ALARM GND 18 AWG GXL CO01-J7 (20) 1 WHT 1-37 GROUND MODE 18 AWG GXL X103B (11)
2 WHT 1-45 PLATF EMS 18 AWG GXL SW715-2B (2B)
3 WHT 1-44 EMS 18 AWG GXL X103B (4)
4 WHT 1-40 FOOT SW 18 AWG GXL X305A (5)
S783
5 WHT 1-41 PLAT ROTATE LEFT 18 AWG GXL X652A (13)
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 6 WHT 1-42 PLAT ROTATE RIGHT 18 AWG GXL X652A (14)
COLOR 7 WHT 1-90 SG POWER 18 AWG GXL S663 (1)
1 BLK 000-10-30 LSS GND 18 AWG GXL CO01-J7 (22) 8 WHT 1-39 FOOT SW DISENGAGED 18 AWG GXL X305A (4)
2 BLK 000-10-30-2 LSS GND 18 AWG GXL X303A (11) 9 WHT 1-35 GENERATOR SWITCH 18 AWG GXL X305A (1)
2 BLU LSS GND 20 AWG CABLE X687 (3) 10
11 WHT 4-125 PLAT ANGLE SEN 5V 18 AWG GXL X652A (10)
12
S782 13
WIRE 14 BLK 000-40-90 PLAT SEN GND 18 AWG GXL X652A (21)
CONN POS WIRE LABEL GAUGE JACKET TO 15 WHT 4-8 PLAT LEVEL UP 18 AWG GXL S653 (2)
COLOR
1 WHT 1-33 LSS PWR 18 AWG GXL CO01-J2 (32) 16 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL S654 (2)
2 WHT 1-33-2 LSS PWR 18 AWG GXL X303A (12) 17
2 WHT LSS PWR 20 AWG CABLE X687 (2) 18 WHT P1 18 AWG GXL RL737 (87)
19 WHT 1-34 PLAT ALRM 18 AWG GXL AH712+ (1)
20 WHT 000-10-16 PLAT ALARM GND 18 AWG GXL AH712- (1)
21 BLK 1-86 SG GND 18 AWG GXL X738 (2)
CO01-J2 BLUE 22 BLK 000-10-30 LSS GND 18 AWG GXL S783 (1)
WIRE 23 BLK 000-10-11 VALVES GND 18 AWG GXL X303A (5)
COLOR 24
1 25 WHT 1-36 JIB UP 18 AWG GXL X652A (15)
2 26 WHT 1-43 JIB DOWN 18 AWG GXL X652A (16)
3 27
4 WHT 1-67 PLTF ORIENT OVERRIDE 18 AWG GXL SW728 (1) 28
5 29 BLK 000-10-34 OPTION GND 18 AWG GXL S664 (1)
6 WHT 1-20 TILT 18 AWG GXL GD725-J4 (5) 30 GRN CAN 20 AWG J1939 CABLE MS16 (4)
7 WHT 1-32 FOOTSWICH ENABLE 18 AWG GXL GD725-J2 (2) 31 YEL CAN 20 AWG J1939 CABLE MS16 (1)
8 WHT 1-25 SYSTEM DISTRESS 18 AWG GXL GD725-J3 (6) 32
9 WHT 1-24 CREEP 18 AWG GXL GD725-J2 (1) 33
10 WHT 1-99 SERVICE CABLE 18 AWG GXL GD725-J3 (5) 34
11 WHT 1-22 PLATFORM OVERLOAD 18 AWG GXL GD725-J4 (3) 35
12 WHT 1-21 500#/600# MODE 18 AWG GXL GD725-J4 (4)
13 WHT 1-27 1000# MODE 18 AWG GXL GD725-J3 (4)
14 WHT 1-28 DRIVE ORIENT SW 18 AWG GXL GD725-J3 (3)
15 WHT 1-23 GENERATOR ON 18 AWG GXL GD725-J4 (2)
16 WHT 1-31 SOFT TCH/SKY GUARD 18 AWG GXL LB543+ (1)
17 WHT 1-29 GLOW PLUG 18 AWG GXL GD725-J4 (6)
18 BLK 000-10-27 GND 18 AWG GXL GD725-J2 (6)
19 WHT 1-120 PLT LVL 18 AWG GXL GD725-J4 (1)
20 WHT 1-121 DRV DISABLE 18 AWG GXL GD725-J3 (1)
21 WHT 1-30 LOW FUEL 18 AWG GXL GD725-J2 (3)
22 WHT 1-498 1/4 FUEL 18 AWG GXL GD725-J1 (1)
25 BLK 1-497 FUEL GND 18 AWG GXL GD725-J1 (4)
26 WHT 1-66 POWER 18 AWG GXL X729 (1)
27 BLK 000-10-12 GND 18 AWG GXL X729 (4)
28 WHT 1-81 RECEIVE 18 AWG GXL X729 (2)
29 WHT 1-82 TRANSMIT 18 AWG GXL X729 (3)
30
31
32 WHT 1-33 LSS PWR 18 AWG GXL S782 (1)
33 WHT 1-89 OPTION POWER 18 AWG GXL X303A (7)
34 WHT 1-85 ST POWER 18 AWG GXL X305A (9)
35 WHT 1-501 FUEL FULL 18 AWG GXL GD725-J1 (6)
7-26 3121728
3121728 7-27
7-28
SW724
SW711-1
SW711-2
SW727
SW708
SW751
SW709
SW731
GD725-J3
GD725-J4 1001196222-F
MAE20780
3121728
SW751 STEER SELECT GD725-J4

WIRE WIRE
COLOR COLOR
1 WHT 1-111 COORD STEER 18 AWG GXL CO01-J1 (17) 1
2 WHT 1-69 SWITCHES PWR 18 AWG GXL SW724 (2) 2 WHT 1-23 GENERATOR ON 18 AWG GXL CO01-J2 (15)
2 WHT 1-80 SWITCHES PWR 18 AWG GXL SW727 (2) 3 WHT 1-22 PLATFORM OVERLOAD 18 AWG GXL CO01-J2 (11)
3 WHT 1-110 CRAB STEER 18 AWG GXL CO01-J1 (16) 4 WHT 1-21 500#/600# MODE 18 AWG GXL CO01-J2 (12)
4 5 WHT 1-20 TILT 18 AWG GXL CO01-J2 (6)
5 6 WHT 1-29 GLOW PLUG 18 AWG GXL CO01-J2 (17)
6
SW708 PLATFORM ROTATE

SW711-2 HORN WIRE
WIRE CONN POS WIRE LABEL GAUGE JACKET TO
COLOR 1 WHT 1-7 PLTF ROTATE LEFT 18 AWG GXL CO01-J1 (8)
1 WHT 1-102 SW PWR 18 AWG GXL SW731 (3) 2 WHT 1-72 SWITCHES PWR 18 AWG GXL SW733 (2)
1 WHT 1-87 SW PWR 18 AWG GXL SW719-2 (1) 2 WHT 1-73 SWITCHES PWR 18 AWG GXL SW709 (2)
3 WHT 1-6 PLTF ROTATE RIGHT 18 AWG GXL CO01-J1 (7)
4
5
SW711-1 HORN
6
WIRE
COLOR
1 WHT 1-2 HORN 18 AWG GXL CO01-J1 (31)
SW709 LEVEL
WIRE
COLOR
SW731 PUMP POT
1 WHT LEVEL DOWN 18 AWG GXL CO01-J1 (10)
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 2 WHT 1-73 SWITCHES PWR 18 AWG GXL SW708 (2)
COLOR 2 WHT 1-74 SWITCHES PWR 18 AWG GXL SW710 (2)
1 3 WHT 1-8 LEVEL UP 18 AWG GXL CO01-J1 (9)
2 WHT 1-101 CREEP SW 18 AWG GXL CO01-J1 (32) 4
3 WHT 1-102 SW PWR 18 AWG GXL SW711-2 (1) 5
3 WHT 1-71 SW PWR 18 AWG GXL SW707 (2) 6
4 WHT 1-105 SPD PMP POT PWR 18 AWG GXL CO01-J1 (34)
5 WHT 1-103 SPD PMP POT GND 18 AWG GXL CO01-J1 (13)
6 WHT 1-104 SPD PMP POT SGL 18 AWG GXL CO01-J1 (35)
SW724 ENGINE SPEED
WIRE
COLOR
GD725-J3
1 WHT 1-11 MIN SPEED 18 AWG GXL CO01-J1 (28)
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 2 WHT 1-69 SWITCHES PWR 18 AWG GXL SW751 (2)
COLOR 2 WHT 1-70 SWITCHES PWR 18 AWG GXL
1 3 WHT 1-12 MAX SPEED 18 AWG GXL
2 4
3 WHT 1-28 DRIVE ORIENT SW 18 AWG GXL CO01-J2 (14) 5
4 WHT 1-27 1000# MODE 18 AWG GXL CO01-J2 (13) 6
5 WHT 1-99 SERVICE CABLE 18 AWG GXL CO01-J2 (10)
6 WHT 1-25 SYSTEM DISTRESS 18 AWG GXL CO01-J2 (8)
SW727 FUEL SELECT

WIRE
COLOR
1
2 WHT 1-78 SWITCHES PWR 18 AWG GXL SW726-2 (1)
2 WHT 1-80 SWITCHES PWR 18 AWG GXL SW751 (2)
3 WHT 1-68 FUEL SELECT 18 AWG GXL CO01-J1 (33)
4
5
6
3121728 7-29
7-30
SW719-2
SW726-1
SW726-2
SW728
SW719-1 SW718
SW707
SW733
GD725-J2
LB543+ SW710
LB543-
GD725-J1
SW715-1B
1001196222-F
MAE20790
SW715-2B
3121728
SW715-1BE STOP LB543+ SKYGUARD WARNING

WIRE WIRE
COLOR COLOR
1B WHT 1-62 EMS B+ 18 AWG GXL X103B (9) 1 WHT 1-31 SOFT TCH/SKY GUARD 18 AWG GXL CO01-J2 (16)
SW715-2B E STOP LB543- SKYGUARD WARNING

WIRE WIRE
COLOR COLOR
2B WHT 1-45 PLATF EMS 18 AWG GXL CO01-J7 (2) 1 BLK 000-10-501 GND 18 AWG GXL GD725-J2 (6)
SW726-2 HEAD AND TAIL LIGHTS

GD725-J2 WIRE
COLOR 1 WHT 1-77 SWITCHES PWR 18 AWG GXL SW718 (2)
1 WHT 1-24 CREEP 18 AWG GXL CO01-J2 (9) 1 WHT 1-78 SWITVCHES PWR 18 AWG GXL SW727 (2)
2 WHT 1-32 FOOTSWICH ENABLE 18 AWG GXL CO01-J2 (7)
3 WHT 1-30 LOW FUEL 18 AWG GXL CO01-J2 (21)
4
5 SW726-1 HEAD AND TAIL LIGHTS
6 BLK 000-10-27 GND 18 AWG GXL CO01-J2 (18) WIRE
6 BLK 000-10-501 GND 18 AWG GXL LB543- (1) COLOR
1 WHT 1-15 HEAD LIGHTS 18 AWG GXL CO01-J1 (30)
SW710 START AUX

WIRE SW719-1 SOFT TOUCH/SKYGUARD
CONN POS WIRE LABEL GAUGE JACKET TO WIRE
COLOR CONN POS WIRE LABEL GAUGE JACKET TO
1 WHT 1-10 AUX POWER 18 AWG GXL CO01-J1 (15) COLOR
2 WHT 1-74 SWITCHES PWR 18 AWG GXL SW709 (2) 1 WHT 1-4 SOFT TOUCH 18 AWG GXL CO01-J1 (29)
3 WHT 1-9 START SWITCH 18 AWG GXL CO01-J1 (14)
4 SW719-2 SOFT TOUCH/SKYGUARD
5 WIRE
6 CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
1 WHT 1-87 SW PWR 18 AWG GXL SW711-2 (1)
SW707 MAIN TELE

WIRE GD725-J1
1 WHT 1-5 TELE OUT 18 AWG GXL CO01-J1 (6) COLOR
2 WHT 1-71 SW PWR 18 AWG GXL SW731 (3) 1 WHT 1-498 1/4 FUEL 18 AWG GXL CO01-J2 (22)
2 WHT 1-81 SW PWR 18 AWG GXL SW733 (2) 2 WHT 1-500 1/2 FUEL 18 AWG GXL CO01-J2 (24)
3 WHT 1-3 TELE IN 18 AWG GXL CO01-J1 (5) 3 WHT 1-499 3/4 FUEL 18 AWG GXL CO01-J2 (23)
4 4 BLK 1-497 FUEL GND 18 AWG GXL CO01-J2 (25)
5 5
6 6 WHT 1-501 FUEL FULL 18 AWG GXL CO01-J2 (35)
SW718J IB LIFT SW728 DRIVE ORIENTATION OVERRIDE

WIRE WIRE
COLOR COLOR
1 WHT 1-14 JIB DOWN 18 AWG GXL CO01-J1 (12) 1 WHT 1-67 PLTF ORIENT OVERRIDE 18 AWG GXL CO01-J2 (4)
2 WHT 1-76 SWITCHES PWR 18 AWG GXL SW728 (2) 2 WHT 1-75 SWITCHES PWR 18 AWG GXL SW710 (2)
2 WHT 1-77 SWITCHES PWR 18 AWG GXL SW726-2 (1) 2 WHT 1-76 SWITCHES PWR 18 AWG GXL SW718 (2)
3 WHT 1-13 JIB UP 18 AWG GXL CO01-J1 (11) 3
4 4
5 5
6 6
SW733 DUAL CAPACITY

WIRE
COLOR
1
2 WHT 1-81 SW PWR 18 AWG GXL SW707 (2)
3 WHT 1-50 DUAL CAPACITY 18 AWG GXL CO01-J1 (21)
4
5
6
3121728 7-31
7-32
SW719-2
SW719-1 LB543-
SW708 LB543+
SW718
SW731 SW707
SW724 SW727
SW709
SW751
GD725-J2 SW715-1B
GD725-J3
SW733 SW726-2
GD725-J4
SW711-2
GD725-J1
SW711-1
SW726-1
SW715-2B
SW710 SW728
RL736
RL737 CO01-J7
S654
X652A
CO01-J8 MS16
S782
S783
S653
IP740
S664 S663
X303A AH712+
AH712- X738
X305A
CO01-J2 X687
X103B
CO01-J1
X729
1001196222-F
MAE20800
3121728
3121728
BACK VIEW OF CONNECTOR
SAME FOR BOTH ENDS
19 8
9
18 7 2 10
17 6 1 3 11
16 5 4 12
15 13
14
6 CONTACTS SIZE #12

13 CONTACTS SIZE #16
1 HOLE PLUG 1 HOLE PLUG

2 GREEN/J1939 2 GREEN/J1939
3 YELLOW/J1939 3 YELLOW/J1939
4 ORANGE 4 ORANGE
5 BLUE 5 BLUE
6 YELLOW 6 YELLOW
7 BROWN 7 BROWN
9 RED/BLK 9 RED/BLK
10 ORANGE 12GA 10 ORANGE 12GA
11 BLU/BLK 11 BLU/BLK
12 RED 12GA 12 RED 12GA
13 ORN/BLK 13 ORN/BLK
15 YEL/BLK 15 YEL/BLK
16 BLACK 12GA 16 BLACK 12GA
18 BLK/WHT 12GA 18 BLK/WHT 12GA
1001188533-C
MAE20520
Figure 7-33. Main Boom Harness (Without Jib)
7-33
7-34
SAME FOR BOTH ENDS
19 8 9
18 7 2 10
17 6 1 3 11
16 5 4 12
15 13
14
6 CONTACTS SIZE #12


4 ORANGE 4 ORANGE
5 BLUE 5 BLUE
6 YELLOW 6 YELLOW
7 BROWN 7 BROWN
9 RED/BLK 9 RED/BLK
1001188534-C
MAE20530
Figure 7-34. Main Boom Harness (With Jib)
3121728
3121728
19 8
9
18 7 2 10
17 6 1 3 11
16 5 4 12
15 13
14
6 CONTACTS SIZE #12


4 ORANGE 4 ORANGE
5 BLUE 5 BLUE
6 YELLOW 6 YELLOW
7 BROWN 7 BROWN
9 RED/BLK 9 RED/BLK
1001206082-C
MAE20540
Figure 7-35. Main Boom Harness (TT)
7-35
7-36
SN465
TELE PROX LEFT
X616B
TELE RETRACTED PROX SNSR
SN625
TELE PROX RIGHT
1001189003-D
MAE20550
Figure 7-36. Proximity Switch Harness (Telescope In)
3121728
SN465 TELE PROX LEFT

WIRE
COLOR
1 ORN/BLK CABLE CABLE 18 AWG TFFN X616B (1)
2 BLU/RED CABLE CABLE 18 AWG TFFN X616B (3)
3 BLK/RED CABLE CABLE 18 AWG TFFN X616B (2)
X616B TELE RETRACTED PROX SNSR

1 ORN/BLK CABLE CABLE 18 AWG TFFN SN465 (1)
2 BLK/RED CABLE CABLE 18 AWG TFFN SN465 (3)
3 BLU/RED CABLE CABLE 18 AWG TFFN SN465 (2)
4 YEL/BLK CABLE CABLE 18 AWG TFFN SN625 (1)
5 BRN/BLK CABLE CABLE 18 AWG TFFN SN625 (3)
6 BLU/BLK CABLE CABLE 18 AWG TFFN SN625 (2)
SN625 TELE PROX RIGHT

1 YEL/BLK CABLE CABLE 18 AWG TFFN X616B (4)
2 BLU/BLK CABLE CABLE 18 AWG TFFN X616B (6)
3 BRN/BLK CABLE CABLE 18 AWG TFFN X616B (5)
3121728 7-37
7-38
SN467
CAPACITY LENGTH RIGHT
X615B
DUAL CAP LENGTH PROX SENSOR
SN627
CAPACITY LENGTH LEFT
1001189004-D
MAE20590
Figure 7-37. Proximity Switch Harness (Capacity)
3121728
SN467 CAPACITY LENGTH RIGHT

1 ORN/BLK CABLE CABLE 18 AWG TFFN X615B (4)
2 BLU/RED CABLE CABLE 18 AWG TFFN X615B (6)
3 BLK/RED CABLE CABLE 18 AWG TFFN X615B (5)
X615B DUAL CAP LENGTH PROX SENSOR

WIRE
COLOR
1 YEL/BLK CABLE CABLE 18 AWG TFFN SN627 (1)
2 BRN/BLK CABLE CABLE 18 AWG TFFN SN627 (3)
3 BLU/BLK CABLE CABLE 18 AWG TFFN SN627 (2)
4 ORN/BLK CABLE CABLE 18 AWG TFFN SN467 (1)
5 BLK/RED CABLE CABLE 18 AWG TFFN SN467 (3)
6 BLU/RED CABLE CABLE 18 AWG TFFN SN467 (2)
SN627 CAPACITY LENGTH LEFT

WIRE
COLOR
1 YEL/BLK CABLE CABLE 18 AWG TFFN X615B (1)

2 BLU/BLK CABLE CABLE 18 AWG TFFN X615B (3)
3 BRN/BLK CABLE CABLE 18 AWG TFFN X615B (2)
3121728 7-39
7-40
SW118-2B
SHEET 3 SHEET 4
FC631 E-STOP
FUSE BLOCK
MS650
CO69-J12 IGN FUNCTION LB280
SW118-1B STROBE LIGHT
MS647 E-STOP
X102A
NEGATIVE BUS
MS325
CAN 2 GD414
MDI/
X429 S509 MS131 HOUR
CAN 1 METER
SW531-1
SW104-1 MSSO
SHEET 7 KEY SW HV95
CO69-J8 S123 SW531-2
SW104-3 MSSO DRIVE FORWARD
X513B KEY SW X181A
CO69-J7 S469 SW104-B
VALVE KEY SW X479
S121 HARNESS S468
S621
X701A
X126 S171
S758
S757 ANALYZER HV94 X183A
S300 DRIVE
X755 REVERSE
TELEMATICS CO69-J1 S98 IP136
30A
X616A
TELESCOPE RETRACTEDR
PROXIMIT SENSOR
X530
X615A GENERATOR
CONNECTOR X281 SHEET 8
DUAL CAPACITY LENGTH GND
PROXIMITY SENSOR
HV96
X743A X450
2 SPEED AUX PUMP RELAY ENABLE
MAIN BOOM HV292
ANGLE SENSOR SN476 OSC AXLE #1
HV97 X282
SHEET 5 TILT SENSOR BRAKE HV293 AUX PUMP RELAY B+
OSC AXLE #2
SHEET 6
1001188642-G
MAE20610
Figure 7-38. Turntable Harness - Sheet 1 of 8
3121728
LB280 STROBE LIGHT

WIRE
COLOR
1 YEL 4-54 STRB LIGHT 18 AWG GXL MS650 (3)
2 BLK 000-40-14 STRB GND 18 AWG GXL MS647 (3)
3121728 7-41
7-42
X102A
CO69-J12
X429
DIAGNOSTIC
CONNECTOR
CO69-J7
CO69-J8
1001188642-G
MAE20620
3121728
CO69-J12 CO69-J7
WIRE WIRE
COLOR COLOR
1 1 WHT 4-42 PLTF EMS 18 AWG GXL S121 (1)
2 2 WHT 4-132 PLAT MODE 18 AWG GXL S121 (1)
3 YEL CAN2 HI 20 AWG J1939 CABLE MS325 (3) 3 RED 4-201 18 AWG GXL S766 (1)
4 GRN CAN2 LO 20 AWG J1939 CABLE MS325 (4) 4 BLU/BLK 4-86 BM ANGLE SEN 1 18 AWG TFFN X743A (3)
5 5
6 WHT 4-96 CAN2 TERM 18 AWG GXL CO69-J12 (7) 6 WHT 4-133 CAN1 TERM 18 AWG GXL CO69-J7 (17)
7 WHT 4-96 CAN2 TERM 18 AWG GXL CO69-J12 (6) 7 BLU/RED 4-87 BM ANGLE SEN 2 18 AWG TFFN X743A (4)
8 WHT 4-163 MSSO 18 AWG GXL SW531-1 (1) 8
9 BLK 000-40-76 GND 18 AWG GXL X743A (1)
10 WHT 4-123 GND 18 AWG GXL SN476 (2)
11
X429
12
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 13 YEL CAN 1 HI 20 AWG J1939 CABLE MS131 (12)
COLOR 14 WHT 4-53 GROUND MODE 18 AWG GXL X102A (11)
A BLK 000-40-11 NEGATIVE 18 AWG GXL MS647 (4) 15 WHT 4-52 FOOT SW 18 AWG GXL X102A (6)
B WHT 4-65 18 AWG GXL S757 (1) 16 WHT 4-118 PWR 5V 18 AWG GXL X743A (2)
C YEL CAN2 HI 20 AWG J1939 CABLE MS325 (2) 17 WHT 4-133 CAN1 TERM 18 AWG GXL CO69-J7 (6)
D GRN CAN2 LO 20 AWG J1939 CABLE MS325 (7) 18
E 19 BLK 000-40-13 GND 18 AWG GXL FC631 (1)
F 20
G 21 WHT 4-110 PROX 1 18 AWG GXL X616A (3)
H WHT 4-66 IGN 18 AWG GXL FC631 (40) 22
J 23 WHT 4-115 CAPACITY 18 AWG GXL X615A (6)
24 GRN CAN 1 LO 20 AWG J1939 CABLE MS131 (4)
25 BLK 000-40-51 GND 18 AWG GXL GD414 (1)
X102A 26
WIRE 27
CONN POS WIRE LABEL GAUGE JACKET TO 28 BLK 000-40-75 GND 18 AWG GXL S469 (1)
COLOR
1 29 RED 4-97 PWR 18 AWG GXL S758 (2)
2 GRN CAN 1 LO 18 AWG J1939 CABLE MS131 (4) 30
3 YEL CAN 1 HI 18 AWG J1939 CABLE MS131 (1) 31 WHT 4-203 BROKEN CBL POW 18 AWG GXL X513B (4)
4 WHT 4-43 PLTF EMS 18 AWG GXL S121 (2) 32 WHT 4-116 POWER 12V 18 AWG GXL X479 (1)
5 WHT 4-8 PLAT LEVEL UP 18 AWG GXL X701A (3) 33 WHT 4-119 PWR 12V 18 AWG GXL S468 (1)
6 WHT 4-52 FOOT SW 18 AWG GXL CO69-J7 (15) 34 WHT 4-108 VCC 18 AWG GXL SN476 (1)
7 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL X701A (4) 35 WHT 4-92 DOS SW 18 AWG GXL X479 (2)
8
9 RED 4-47 PLTF EMS 18 AWG GXL SW104-1 (1)
10 CO69-J8
11 WHT 4-53 GROUND MODE 18 AWG GXL CO69-J7 (14) WIRE
12 RED 4-71 12 AWG GXL FC631 (37) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
13 WHT 4-15 HIGH PRES DUMP 18 AWG GXL X701A (1)
14 1 BLK 000-40-8 MODL GND 10 AWG GXL X281 (1)
15 WHT 4-16 LOW PRES DUMP 18 AWG GXL X701A (2) 2 RED 4-35 IGN 12 AWG GXL FC631 (32)
16 BLK 000-40-12 PLATF GND 12 AWG GXL CO69-J8 (3) 3 BLK 000-40-12 PLATF GND 12 AWG GXL X102A (16)
17 3 BLK 000-40-64 BATT GND 16 AWG GXL MS647 (1)
18 4 YEL 4-36 MODL PWR 14 AWG GXL MS650 (1)
19
3121728 7-43
7-44
FC631
FUSE BLOCK
S766
S509
S121
S621
MS131
CAN 1
MS325
CAN2
MS650
MS647
IGN FUNCTION
NEGATIVE BUS
1001188642-G
MAE20630
3121728
MS325 AN 2
S121
WIRE
COLOR 1 YEL CAN2 HI 20 AWG J1939 CABLE GD414 (3)
1 WHT 4-132 PLAT MODE 18 AWG GXL CO69-J7 (2) 2 YEL CAN2 HI 20 AWG J1939 CABLE X429 (C)
1 WHT 4-42 PLTF EMS 18 AWG GXL CO69-J7 (1) 3 YEL CAN2 HI 20 AWG J1939 CABLE CO69-J12 (3)
2 WHT 4-41 18 AWG GXL FC631 (30) 4 GRN CAN2 LO 20 AWG J1939 CABLE CO69-J12 (4)
2 WHT 4-43 PLTF EMS 18 AWG GXL X102A (4) 5 GRN CAN2 LO 20 AWG J1939 CABLE GD414 (4)
6 GRN CAN2 LO 20 AWG J1939 CABLE X183A (4)
7 GRN CAN2 LO 20 AWG J1939 CABLE X429 (D)
S621 8
WIRE 9
CONN POS WIRE LABEL GAUGE JACKET TO 10 YEL CAN2 HI 20 AWG J1939 CABLE X183A (3)
COLOR
1 RED 4-350 12 AWG GXL FC631 (28) 11
1 RED 4-550 12 AWG GXL FC631 (33) 12
2 RED 4-166 12 AWG GXL FC631 (2)
2 RED 4-563 LIGHT OPT 18 AWG GXL FC631 (47)
MS131 CAN 1
WIRE
S509 COLOR
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 1 YEL CAN 1 HI 18 AWG J1939 CABLE X102A (3)
COLOR
1 WHT 4-38 18 AWG GXL FC631 (26) 2 YEL CAN 1 HI 20 AWG J1939 CABLE CO69-J7 (13)
1 RED 4-39 18 AWG GXL FC631 (25) 3 YEL CAN 1 HI 20 AWG J1939 CABLE SN476 (3)
2 WHT 4-170 18 AWG GXL FC631 (10) 4 GRN CAN 1 LO 18 AWG J1939 CABLE X102A (2)
5 GRN CAN 1 LO 20 AWG J1939 CABLE CO69-J7 (24)
6 GRN CAN 1 LO 20 AWG J1939 CABLE SN476 (4)
7
S766 8
WIRE 9
COLOR 10
11
1 RED 4-201 18 AWG GXL CO69-J7 (3)
12
2 RED 4-202 18 AWG GXL FC631 (29)
2 RED 4-40 18 AWG GXL SW104-1
MS650 IGN FUNCTION

WIRE
COLOR
1 YEL 4-36 MODL PWR 14 AWG GXL CO69-J8 (4)
2 YEL 4-72 IGN 18 AWG GXL FC631 (36)
3 YEL 4-54 STRB LIGHT 18 AWG GXL LB280 (1)
4 YEL 4-84 IGN 18 AWG GXL X183A (1)
5 YEL 4-81 GEN IGN 18 AWG GXL FC631 (45)
6
7
8
9
10
11
12
MS647 NEGATIVE BUS

WIRE
COLOR
1 BLK 000-40-64 BATT GND 16 AWG GXL CO69-J8 (3)
2 BLK 000-40-47 OSC VL Vs GND 18 AWG GXL S300 (1)
3 BLK 000-40-14 STRB GND 18 AWG GXL LB280 (2)
4 BLK 000-40-11 NEGATIVE 18 AWG GXL X429 (A)
5 BLK 000-40-161 GEN GND 18 AWG GXL X530 (3)
6 BLK 000-40-557 GND 18 AWG GXL X181A (2)
7 BLK 000-40-558 GND 18 AWG GXL X755 (2)
8
9
10
11
12
3121728 7-45
FC631
WIRE
COLOR
1 BLK 000-40-13 GND 18 AWG GXL CO69-J7 (19)
2 RED 4-166 12 AWG GXL S621 (2)
3
4
5
6
7
8
9 RED 4-37 12AWG 12 AWG GXL S123 (1)
10 WHT 4-170 18 AWG GXL S509 (2)
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25 RED 4-39 18 AWG GXL S509 (1)
26 WHT 4-38 18 AWG GXL S509 (1)
27
28 RED 4-350 12 AWG GXL S621 (1)
29 RED 4-202 18 AWG GXL S766 (2)
30 WHT 4-41 18 AWG GXL S121 (2)
31
32 RED 4-35 IGN 12 AWG GXL CO69-J8 (2)
33 RED 4-550 12 AWG GXL S621 (1)
34 RED 4-552 18 AWG GXL SW118-2B (2B)
35 WHT 4-50 18 AWG GXL S123 (1)
36 YEL 4-72 IGN 18 AWG GXL MS650 (2)
37 RED 4-71 12 AWG GXL X102A (12)
38 RED 4-51 12 AWG GXL S123 (2)
39 WHT 4-65 - 18 AWG GXL S757 (2)
40 WHT 4-66 IGN 18 AWG GXL X429 (H)
41 YEL 4-82 GEN IGN 18 AWG GXL X530 (1)
42
43
44
45 YEL 4-81 GEN IGN 18 AWG GXL MS650 (5)
46
47 RED 4-563 LIGHT OPT 18 AWG GXL S621 (2)
48
7-46 3121728
3121728 7-47
7-48
S123
X701A
X513B
VALVE HARNESS
S758
S469 S468
S757
X755
TELEMATICS X126
ANALYZER
X616A
TELESCOPE RETRACTED PROXIMIT SENSOR
X615A
DUAL CAPACITY LENGTH PROXIMITY SENSOR
X743A
MAIN BOOM ANGLE SENSOR
CO69-J1
SN476
TILT SENSOR
1001188642-G
MAE20650
3121728
S469
X743A
WIRE
COLOR 1 BLK 000-40-75 GND 18 AWG GXL CO69-J7 (28)
1 BLK 000-40-76 GND 18 AWG GXL CO69-J7 (9) 1 BLK 000-40-98 GND 18 AWG GXL X615A (5)
2 WHT 4-118 PWR 5V 18 AWG GXL CO69-J7 (16) 2 BLK 000-40-167 GND 18 AWG GXL X615A (2)
3 BLU/BLK 4-86 BM ANGLE SEN1 18 AWG TFFN CO69-J7 (4) 2 BLK 000-40-77 GND 18 AWG GXL X616A (2)
4 BLU/RED 4-87 BM ANGLE SEN2 18 AWG TFFN CO69-J7 (7) 2 BLK 000-40-80 GND 18 AWG GXL X616A (5)
X513B VALVE HARNESS S468

WIRE WIRE
COLOR COLOR
1 BLK 000-40-43 CF 16 AWG GXL S171 (1) 1 WHT 4-114 PWR 12V 18 AWG GXL X615A (4)
2 1 WHT 4-119 PWR 12V 18 AWG GXL CO69-J7 (33)
3 2 WHT 4-11 PWR 12V 18 AWG GXL X616A (1)
4 WHT 4-203 BROKEN CBL POW 18 AWG GXL CO69-J7 (31) 2 WHT 4-113 PWR 12V 18 AWG GXL X616A (4)
5 2 WHT 4-168 PWR 12V 18 AWG GXL X615A (1)
6
X755 TELEMATICS
S758 WIRE
COLOR 1 WHT 4-65-2 - 18 AWG GXL S757 (2)
1 RED 4-97-1 PWR 18 AWG GXL GD414 (2) 2 BLK 000-40-558 GND 18 AWG GXL MS647 (8)
2 RED 4-97 PWR 18 AWG GXL CO69-J7 (29) 3 RED 4-97-2 PWR 18 AWG GXL S758 (2)
2 RED 4-97-2 PWR 18 AWG GXL X755 (3) 4 WHT 4-51-1 PLTFM EN 18 AWG GXL SW104-3 (1)
X701A X126 ANALYZER

WIRE WIRE
COLOR COLOR
1 WHT 4-15 HIGH PRES DUMP 18 AWG GXL X102A (13) 1 WHT 4-5 POWER 18 AWG GXL CO69-J1 (28)
2 WHT 4-16 LOW PRES DUMP 18 AWG GXL X102A (15) 2 WHT 4-6 RECEIVE 18 AWG GXL CO69-J1 (29)
3 WHT 4-8 PLAT LEVEL UP 18 AWG GXL X102A (5) 3 WHT 4-7 TRANSMIT 18 AWG GXL CO69-J1 (30)
4 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL X102A (7) 4 BLK 000-40-4 GND 18 AWG GXL CO69-J1 (31)
S757
WIRE
COLOR
1 WHT 4-65-1 18 AWG GXL X429 (B)
2 WHT 4-65 18 AWG GXL FC631 (39)
2 WHT 4-65-2 18 AWG GXL X755 (1)
SN476 TILT SENSOR

WIRE
COLOR
1 WHT 4-108 VCC 18 AWG GXL CO69-J7 (34)

2 WHT 4-123 GND 18 AWG GXL CO69-J7 (10)
3 YEL CAN 1 HI 20 AWG J1939 CABLE MS131 (3)
4 GRN CAN 1 LO 20 AWG J1939 CABLE MS131 (6)
S123
WIRE
COLOR
1 WHT 4-50 18 AWG GXL FC628 (35)
1 RED 4-37 12AWG 12 AWG GXL FC628 (9)
2 RED 4-79 12 AWG GXL IP136 (1)
2 RED 4-51 12 AWG GXL FC628 (38)
3121728 7-49
X616A TELESCOPE RETRACTED PROXIMIT SENSOR

WIRE
COLOR
1 WHT 4-111 PWR 12V 18 AWG GXL S468 (2)
2 BLK 000-40-77 GND 18 AWG GXL S469 (2)
3 WHT 4-110 PROX 1 18 AWG GXL CO69-J7 (21)
4 WHT 4-113 PWR 12V 18 AWG GXL S468 (2)
5 BLK 000-40-80 GND 18 AWG GXL S469 (2)
6 WHT 4-117 PROX 2 18 AWG GXL CO69-J1 (34)
CO69-J1
WIRE
COLOR
1
2 WHT 4-120 OSC AXL V 2 18 AWG GXL HV293 (1)
3 WHT 4-3 DRIVE FORWARD 16 AWG GXL HV95 (1)
4
5
6 WHT 4-4 DRIVE REVERSE 16 AWG GXL HV94 (1)
7 WHT 4-121 OSC AXL V 1 18 AWG GXL HV292 (1)
8
9 BLK 000-40-162 GND 18 AWG GXL SW531-2 (1)
10 WHT 4-94 EMR4 IGNITION 18 AWG GXL X181A (1)
11 WHT 4-67 START 16 AWG GXL X183A (2)
12 WHT 4-80 GLOW PLUG 16 AWG GXL X181A (4)
13 WHT 4-78 AUX PUMP 16 AWG GXL X450 (1)
14
15
16
17
18
19
20 WHT 4-2 TWO SPEED 18 AWG GXL HV96 (1)
21
22 WHT 4-74 GEN ON 18 AWG GXL X530 (2)
23 WHT 4-1 BRAKE 18 AWG GXL HV97 (1)
24
25
26
27 BLK 000-40-3 GND 18 AWG GXL S98 (2)
28 WHT 4-5 POWER 18 AWG GXL X126 (1)
29 WHT 4-6 RECEIVE 18 AWG GXL X126 (2)
30 WHT 4-7 TRANSMIT 18 AWG GXL X126 (3)
31 BLK 000-40-4 GND 18 AWG GXL X126 (4)
32 RED 4-76 ALT EXCITE 16 AWG GXL X183A (5)
33
34 WHT 4-117 PROX 2 18 AWG GXL X616A (6)
35 WHT 4-167 CAP PROX 2 18 AWG GXL X615A (3)
X615ADUAL CAPACITY LENGTH PROXIMITY SENSOR

WIRE
COLOR
1 WHT 4-168 PWR 12V 18 AWG GXL S468 (2)
2 BLK 000-40-167 GND 18 AWG GXL S469 (2)
3 WHT 4-167 CAP PROX 2 18 AWG GXL CO69-J1 (35)
4 WHT 4-114 PWR 12V 18 AWG GXL S468 (1)
5 BLK 000-40-98 GND 18 AWG GXL S469 (1)
6 WHT 4-115 CAPACITY 18 AWG GXL CO69-J7 (23)
7-50 3121728
3121728 7-51
7-52
X479
IP136
S300 S98 30A
X450
AUX PUMP
RELAY ENABLE
X281 X282
GND AUX PUMP RELAY B+
HV292
OSC AXLE #1
HV96
2 SPEED
X530
GENERATOR
CONNECTOR
HV293 1001188642-G
OSC AXLE #2 MAE20660
HV97
BRAKE
3121728
X479 X281 GND

WIRE WIRE
COLOR COLOR
1 WHT 4-116 POWER 12V 18 AWG GXL CO69-J7 (32) 1 BLK 000-40-8 MODL GND 10 AWG GXL CO69-J8 (1)
2 WHT 4-92 DOS SW 18 AWG GXL CO69-J7 (35)
X282 AUX PUMP RELAY B+

S300 WIRE
WIRE COLOR
COLOR 1 RED 4-49 B+ AUX PMP 10 AWG GXL IP136 (2)
1 BLK 000-40-47 OSC VL Vs GND 18 AWG GXL MS647 (2)
2 BLK 000-40-72 18 AWG GXL HV293 (2)
2 BLK 000-40-73 18 AWG GXL HV292 (2)
X530 GENERATOR CONNECTOR
WIRE
COLOR
S98
WIRE 1 YEL 4-82 GEN IGN 18 AWG GXL FC631 (41)
COLOR
1 BLK 000-40-1 GND 18 AWG GXL HV97 (2) 2 WHT 4-74 GEN ON 18 AWG GXL CO69-J1 (22)
1 BLK 000-40-2 GND 18 AWG GXL HV96 (2)
2 BLK 000-40-3 GND 18 AWG GXL CO69-J1 (27) 3 BLK 000-40-161 GEN GND 18 AWG GXL MS647 (5)
IP136 30A
WIRE
COLOR
1 RED 4-79 10 AWG GXL S123 (2)
2 RED 4-49 B+ AUX PMP 10 AWG GXL X282 (1)
HV292 OSC AXLE #1

WIRE
COLOR
1 WHT 4-121 OSC AXL V 1 18 AWG GXL CO69-J1 (7)
2 BLK 000-40-73 18 AWG GXL S300 (2)
HV293 OSC AXLE #2

WIRE
COLOR
1 WHT 4-120 OSC AXL V 2 18 AWG GXL CO69-J1 (2)
2 BLK 000-40-72 18 AWG GXL S300 (2)
HV97 BRAKE
WIRE
COLOR
1 WHT 4-1 BRAKE 18 AWG GXL CO69-J1 (23)
2 BLK 000-40-1 GND 18 AWG GXL S98 (1)
HV96 2 SPEED
WIRE
COLOR
1 WHT 4-2 TWO SPEED 18 AWG GXL CO69-J1 (20)
2 BLK 000-40-2 GND 18 AWG GXL S98 (1)
X450 AUX PUMP RELAY ENABLE

WIRE
COLOR
1 WHT 4-78 AUX PUMP 16 AWG GXL CO69-J1 (13)
3121728 7-53
7-54
SW118-2B
E-STOP SW118-1B
E-STOP
GD414
MDI/HOURMETER
SW531-1
MSSO
SW531-2
MSSO
SW104-1
KEY SW
SW104-3
KEY SW SW104-B 1001188642-G
KEY SW MAE20670
3121728
SW118-2B E-STOP
WIRE
COLOR
2B RED 4-552 18 AWG GXL FC631 (34)
SW118-1B E-STOP
WIRE
COLOR
1B RED 4-46 18 AWG GXL SW104-B (1)
GD414 MDI/HOURMETER
WIRE
COLOR
2 RED 4-97-1 PWR 18 AWG GXL S758 (1)
3 YEL CAN2 HI 20 AWG J1939 CABLE MS325 (1)
4 GRN CAN2 LO 20 AWG J1939 CABLE MS325 (5)
5
6
SW531-1 MSSO
WIRE
COLOR
1 WHT 4-163 MSSO 18 AWG GXL CO69-J12 (8)
SW531-2 MSSO
WIRE
COLOR
SW104-3 KEY SW
WIRE
COLOR
1 RED 4-40 18 AWG GXL S766 (2)
SW104-B KEY SW
WIRE
COLOR
1 RED 4-46 18 AWG GXL SW118-1B (1B)
SW104-1 KEY SW
WIRE
COLOR
1 RED 4-47 PLTF EMS 18 AWG GXL X102A (9)
1 WHT 4-51-1 PLTFM EN 18 AWG GXL X755 (4)
3121728 7-55
7-56
HV95
S171 DRIVE FORWARD
X181A
HV94
DRIVE REVERSE
X183A
1001188642-G
MAE20680
3121728
S171
1 BLK 000-40-43 CF 16 AWG GXL X513B (1)
2 BLK 000-40-40 CF 16 AWG GXL HV95 (2)
2 BLK 000-40-41 CF 16 AWG GXL HV94 (2)
HV94 DRIVE REVERSE

WIRE
COLOR
1 WHT 4-4 DRIVE REVERSE 16 AWG GXL CO69-J1 (6)
2 BLK 000-40-41 CF 16 AWG GXL S171 (2)
HV95 DRIVE FORWARD

WIRE
COLOR
1 WHT 4-3 DRIVE FORWARD 16 AWG GXL CO69-J1 (3)
2 BLK 000-40-40 CF 16 AWG GXL S171 (2)
X183A
WIRE
COLOR
1 YEL 4-84 IGN 18 AWG GXL MS650 (4)
2 WHT 4-67 START 16 AWG GXL CO69-J1 (11)
3 YEL CAN2 HI 20 AWG J1939 CABLE MS325 (10)
4 GRN CAN2 LO 20 AWG J1939 CABLE MS325 (6)
5 RED 4-76 ALT EXCITE 16 AWG GXL CO69-J1 (32)
6
X181A
WIRE
COLOR
1 WHT 4-94 EMR4 IGNITION 18 AWG GXL CO69-J1 (10)
2 BLK 000-40-557 GND 18 AWG GXL MS647 (7)
3
4 WHT 4-80 GLOW PLUG 16 AWG GXL CO69-J1 (12)
5
6
7
8
3121728 7-57
FUSE BOX LAYOUT

POPULATE FUSE BOX AS PER CHART.
USE DIODE KEYS AS REQUIRED.
DESIGNATION POSITION RATING

FUSES F1 28,32 15A
F2 33,37 15A
F3 34,38 3A
F4 35,39 5A
F5 36,40 5A
F6 41,45 5A
F7 42,46
F8 43,47
F9 44,48
DIODES D1 29 ANODE
25 CATHODE
D2 30 ANODE
26 CATHODE
D3 31 ANODE
27 CATHODE
RELAYS R1 10 (relay post 85) 35A
1 (relay post 86)
2 (relay post 87)
9 (relay post 30)
6 (relay post 87a)
R2 12 (relay post 85)
3 (relay post 86)
4 (relay post 87)
11 (relay post 30)
8 (relay post 87a)
13 (relay post 86)
14 (relay post 87)
21 (relay post 30)
18 (relay post 87a)
15 (relay post 86)
16 (relay post 87)
23 (relay post 30)
20 (relay post 87a)
7-58 3121728
LB280
3121728
X102A X429
FC 631 X530
HC293
HV96
HV94 C069-J7 XV292

X450
HV95 X282
X701A
GD414
X513B XV97 X281
IP136
X183A C069-J8 X755 X126
X181A
CO69-J1
SN476 X616A 1001188642-G

MAE20700
X615A
7-59
LENGTH FROM TO
WIRE NO COLOR WIRE GAUGE JACKET PIN PIN
(mm) REFERENCE REFERENCE
000-40-11 BLK 18 GXL 755 MS647 4 X429 A
000-40-12 BLK 12 GXL 370 CO69-J8 3 X102A 16
000-40-13 BLK 18 GXL 414 FC631 1 CO69-J7 19
000-40-14 BLK 18 GXL 6232 LB280 2 MS647 3
000-40-161 BLK 18 GXL 3612 MS647 5 X530 3
000-40-162 BLK 18 GXL 3207 SW531-2 1 CO69-J1 9
000-40-167 BLK 18 GXL 271 X615A 2 S469 2
000-40-1 BLK 18 GXL 497 HV97 2 S98 1
000-40-2 BLK 18 GXL 545 HV96 2 S98 1
000-40-3 BLK 18 GXL 3036 CO69-J1 27 S98 2
000-40-40 BLK 16 GXL 1009 HV95 2 S171 2
000-40-41 BLK 16 GXL 965 HV94 2 S171 2
000-40-43 BLK 16 GXL 2844 S171 1 X513B 1
000-40-47 BLK 18 GXL 3179 MS647 2 S300 1
000-40-4 BLK 18 GXL 305 X126 4 CO69-J1 31
000-40-51 BLK 18 GXL 3022 CO69-J7 25 GD414 1
000-40-557 BLK 18 GXL 5769 X181A 2 MS647 6
000-40-558 BLK 18 GXL 878 MS647 7 X755 2
000-40-64 BLK 16 GXL 674 CO69-J8 3 MS647 1
000-40-72 BLK 18 GXL 629 S300 2 HV293 2
000-40-73 BLK 18 GXL 653 S300 2 HV292 2
000-40-75 BLK 18 GXL 1305 CO69-J7 28 S469 1
000-40-76 BLK 18 GXL 1587 CO69-J7 9 X743A 1
000-40-77 BLK 18 GXL 268 S469 2 X616A 2
000-40-80 BLK 18 GXL 254 S469 2 X616A 5
000-40-8 BLK 10 GXL 3923 CO69-J8 1 X281 1
000-40-98 BLK 18 GXL 278 S469 1 X615A 5
4-108 WHT 18 GXL 2269 SN476 1 CO69-J7 34
4-110 WHT 18 GXL 1584 CO69-J7 21 X616A 3
4-111 WHT 18 GXL 166 S468 2 X616A 1
4-113 WHT 18 GXL 150 S468 2 X616A 4
4-114 WHT 18 GXL 171 S468 1 X615A 4
4-115 WHT 18 GXL 1597 CO69-J7 23 X615A 6
4-116 WHT 18 GXL 3214 CO69-J7 32 X479 1
4-117 WHT 18 GXL 1123 X616A 6 CO69-J1 34
4-118 WHT 18 GXL 1571 CO69-J7 16 X743A 2
4-119 WHT 18 GXL 1468 CO69-J7 33 S468 1
4-11 WHT 18 GXL 740 X102A 7 X701A 4
4-120 WHT 18 GXL 3519 CO69-J1 2 HV293 1
4-121 WHT 18 GXL 3552 CO69-J1 7 HV292 1
4-123 WHT 18 GXL 2223 SN476 2 CO69-J7 10
4-132 WHT 18 GXL 239 S121 1 CO69-J7 2
4-133 WHT 18 GXL 67 CO69-J7 17 CO69-J7 6
4-15 WHT 18 GXL 708 X102A 13 X701A 1
4-163 WHT 18 GXL 2854 SW531-1 1 CO69-J12 8
4-166 RED 12 GXL 105 FC631 2 S621 2
4-167 WHT 18 GXL 1132 CO69-J1 35 X615A 3
4-168 WHT 18 GXL 163 X615A 1 S468 2
7-60 3121728
LENGTH FROM TO
4-169-1 RED 18 GXL 435 CO69-J7 3 FC631 46
4-16 WHT 18 GXL 760 X102A 15 X701A 2
4-170 WHT 18 GXL 144 FC631 10 S509 2
4-1 WHT 18 GXL 3497 HV97 1 CO69-J1 23
4-201 RED 18 GXL 760 S766 1 CO69-J7 3
4-202 RED 18 GXL 489 FC631 29 S766 2
4-203 WHT 18 GXL 1175 CO69-J7 31 X513B 1
4-2 WHT 18 GXL 3604 HV96 1 CO69-J1 20
4-350 RED 12 GXL 102 S621 1 FC631 28
4-35 RED 12 GXL 490 CO69-J8 2 FC631 32
4-36 YEL 14 GXL 599 CO69-J8 4 MS650 1
4-37 RED 12 GXL 287 FC631 9 S123 1
4-38 WHT 18 GXL 147 FC631 26 S509 1
4-39 RED 18 GXL 126 FC631 25 S509 1
4-3 WHT 16 GXL 4351 HV95 1 CO69-J1 3
4-40 RED 18 GXL 2314 SW104-3 1 S766 2
4-41 WHT 18 GXL 163 S121 2 FC631 30
4-42 WHT 18 GXL 251 CO69-J7 1 S121 1
4-43 WHT 18 GXL 351 X102A 4 S121 2
4-46 RED 18 GXL 425 SW104-B 1 SW118-1B 1B
4-47 RED 18 GXL 3107 SW104-1 1 X102A 9
4-49 RED 10 GXL 329 IP136 2 X282 1
4-4 WHT 16 GXL 4306 HV94 1 CO69-J1 6
4-50 WHT 18 GXL 282 S123 1 FC631 35
4-51-1 WHT 18 GXL 3271 SW104-1 1 X755 4
4-51-2 WHT 18 GXL 0
4-51 RED 12 GXL 300 S123 2 FC631 38
4-52 WHT 18 GXL 299 X102A 6 CO69-J7 15
4-53 WHT 18 GXL 299 CO69-J7 14 X102A 11
4-54 YEL 18 GXL 6144 LB280 1 MS650 3
4-550 RED 12 GXL 109 S621 1 FC631 33
4-552 RED 18 GXL 2511 SW118-2B 2B FC631 34
4-563 RED 18 GXL 123 FC631 47 S621 2
4-5 WHT 18 GXL 309 X126 1 CO69-J1 28
4-65-1 WHT 18 GXL 908 X429 B S757 1
4-65-2 WHT 18 GXL 282 S757 2 X755 1
4-65 WHT 18 GXL 463 FC631 39 S757 2
4-66 WHT 18 GXL 585 X429 H FC631 40
4-67 WHT 16 GXL 5428 X183A 2 CO69-J1 11
4-6 WHT 18 GXL 297 X126 2 CO69-J1 29
4-71 RED 12 GXL 500 FC631 37 X102A 12
4-72 YEL 18 GXL 256 MS650 2 FC631 36
4-74 WHT 18 GXL 3275 CO69-J1 22 X530 2
4-76 RED 16 GXL 5445 X183A 5 CO69-J1 32
4-78 WHT 16 GXL 3701 CO69-J1 13 X450 1
4-79 RED 10 GXL 3111 S123 2 IP136 1
4-7 WHT 18 GXL 305 X126 3 CO69-J1 30
3121728 7-61
LENGTH FROM TO
4-80 WHT 16 GXL 5439 CO69-J1 12 X181A 4
4-81 YEL 18 GXL 267 MS650 5 FC631 45
4-82 YEL 18 GXL 3459 X530 1 FC631 41
4-84 YEL 18 GXL 5687 MS650 4 X183A 1
4-86 BLU/BLK 18 TFFN 1585 X743A 3 CO69-J7 4
4-87 BLU/RED 18 TFFN 1559 X743A 4 CO69-J7 7
4-8 WHT 18 GXL 738 X102A 5 X701A 3
4-92 WHT 18 GXL 3130 CO69-J7 35 X479 2
4-94 WHT 18 GXL 5456 CO69-J1 10 X181A 1
4-96 WHT 18 GXL 85 CO69-J12 6 CO69-J12 7
4-97-1 RED 18 GXL 3000 GD414 2 S758 1
4-97-2 RED 18 GXL 323 S758 2 X755 3
4-97 RED 18 GXL 755 CO69-J7 29 S758 2
CAN 1 HI YEL 20 J1939 CABLE 703 CO69-J7 13 MS131 2
CAN 1 HI YEL 18 J1939 CABLE 793 MS131 1 X102A 3
CAN 1 HI YEL 20 J1939 CABLE 2215 SN476 3 MS131 3
CAN 1 LO GRN 20 J1939 CABLE 727 CO69-J7 24 MS131 5
CAN 1 LO GRN 18 J1939 CABLE 825 MS131 4 X102A 2
CAN 1 LO GRN 20 J1939 CABLE 2183 SN476 4 MS131 6
CAN2 HI YEL 20 J1939 CABLE 855 MS325 2 X429 C
CAN2 HI YEL 20 J1939 CABLE 586 CO69-J12 3 MS325 3
CAN2 HI YEL 20 J1939 CABLE 5827 X183A 3 MS325 10
CAN2 HI YEL 20 J1939 CABLE 2463 GD414 3 MS325 1
CAN2 LO GRN 20 J1939 CABLE 842 MS325 7 X429 D
CAN2 LO GRN 20 J1939 CABLE 637 CO69-J12 4 MS325 4
CAN2 LO GRN 20 J1939 CABLE 5893 X183A 4 MS325 6
CAN2 LO GRN 20 J1939 CABLE 2487 GD414 4 MS325 5
7-62 3121728
3121728 7-63
7-64
SN471 X743B
MAIN BOOM
ANGLE SENSOR
S294
S295
1001189005-B
MAE20810
Figure 7-46. Boom Angle Sensor Harness
3121728
S295
WIRE
COLOR
1 BLK 000-40-76 GND 18 AWG GXL X743B (1)
2 BLK/RED 000-40-78 GND 18 AWG TFFN SN471 (A)
2 BRN/BLK 000-40-79 GND 18 AWG TFFN SN471 (E)
S294
WIRE
COLOR
1 WHT 4-108 PWR 5V 18 AWG GXL X743B (2)
2 ORN/BLK 4-106 PWR 5V 18 AWG TFFN SN471 (B)
2 YEL/BLK 4-112 PWR 5V 18 AWG TFFN SN471 (F)
X743B
WIRE
COLOR
1 BLK 000-40-76 GND 18 AWG GXL S295 (1)
2 WHT 4-108 PWR 5V 18 AWG GXL S294 (1)
3 BLU/BLK 4-86 BM ANGLE SEN 1 18 AWG TFFN SN471 (C)
4 BLU/RED 4-87 BM ANGLE SEN 2 18 AWG TFFN SN471 (D)
SN471 MAIN BOOM ANGLE SENSOR

WIRE
COLOR
A BLK/RED 000-40-78 GND 18 AWG TFFN S295 (2)
B ORN/BLK 4-106 PWR 5V 18 AWG TFFN S294 (2)
C BLU/BLK 4-86 BM ANGLE SEN 1 18 AWG TFFN X743B (3)
D BLU/RED 4-87 BM ANGLE SEN 2 18 AWG TFFN X743B (4)
E BRN/BLK 000-40-79 GND 18 AWG TFFN S295 (2)
F YEL/BLK 4-112 PWR 5V 18 AWG TFFN S294 (2)
3121728 7-65
7-66
X474
FUEL LEVEL GND
AH387
ALARM
X473 SHEET 2
R001 FUEL LEVEL
HV687 HV378
R002 TELE DUMP SWING RIGHT
HV684
STEER DUMP
HV685
REAR STEER LEFT
X701B
HV373
STEER
RIGHT
S688 S415 HV379
CO69-J2 S389 S386
SWING HV374
LEFT STEER LEFT
HV686
REAR STEER RIGHT
X767 HV371
CABLE SERVICE MAIN TELE IN
SENSOR HV804 HV372
HV376
BYPASS DUMP MAIN TELE OUT
CO69-J3 MAIN LIFT UP
HV366
MAIN DUMP
X745A
S705
X513A
SHEET 3
1001188643-G
MAE20820
Figure 7-47. Main valve Harness (4WS) - Sheet 1 of 4
3121728
X473 FUEL LEVEL

WIRE
COLOR
1 WHT 4-75 FUEL SNSR 18 AWG GXL CO69-J2 (25)
X474 FUEL LEVEL GND

WIRE
COLOR
1 BLK 000-40-45 18 AWG GXL CO69-J2 (6)
X745A
WIRE
COLOR
1 WHT 4-25 LIFT DN 18 AWG GXL CO69-J2 (22)
2 WHT 4-28 AUX DN 18 AWG GXL CO69-J2 (21)
3 BLK 000-40-36 CF 18 AWG GXL S705 (1)
4 BLK 000-40-120 CF 18 AWG GXL CO69-J3 (2)
3121728 7-67
7-68
HV687
TELE DUMP
HV684
HV378
STEER DUMP
SWING RIGHT
HV685
REAR STEER LEFT
HV373
STEER RIGHT
HV374
STEER LEFT
HV379
SWING LEFT
HV686
HV376 REAR STEER RIGHT
MAIN LIFT UP
HV371
HV804 MAIN TELE IN
BYPASS DUMP HV372
MAIN TELE OUT
HV366
MAIN DUMP 1001188643-G
MAE20830
3121728
HV379 SWING LEFT

WIRE HV686 REAR STEER RIGHT
1 WHT 4-27 SWG LEFT 18 AWG GXL CO69-J2 (34) COLOR
2 BLK 000-40-39 CF 18 AWG GXL S389 (1) 1 WHT 4-104 REAR STR RHT 18 AWG GXL CO69-J2 (32)
2 BLK 000-40-63 REAR STR RT GND 18 AWG GXL S415 (1)
HV366 MAIN DUMP HV371 MAIN TELE IN

WIRE WIRE
COLOR COLOR
1 WHT 4-14 MAIN DUMP 18 AWG GXL CO69-J2 (13) 1 WHT 4-19 TELE IN 18 AWG GXL CO69-J2 (9)
2 BLK 000-40-25 GND 18 AWG GXL S688 (1) 2 BLK 000-40-31 18 AWG GXL S386 (1)
HV687 TELE DUMP HV372 MAIN TELE OUT

WIRE WIRE
COLOR COLOR
1 WHT 4-150 TELE DUMP 18 AWG GXL CO69-J2 (31) 1 WHT 4-20 TELE OUT 18 AWG GXL CO69-J2 (20)
000-40-150 2 BLK 000-40-21 18 AWG GXL S386 (1)
2 BLK 18 AWG GXL S688 (1)
TELE DUMP GROUND
HV804 BYPASS DUMP

HV378 SWING RIGHT WIRE
WIRE COLOR
CONN POS WIRE LABEL GAUGE JACKET TO 1 WHT 4-85 BYPASS DUMP 18 AWG GXL CO69-J2 (4)
COLOR
1 WHT 4-26 SWG RHT 18 AWG GXL CO69-J2 (35) 2 BLK 000-4-85 BP DUMP GND 18 AWG GXL S688 (2)
2 BLK 000-40-37 CF 18 AWG GXL S389 (1)
HV376 MAIN LIFT UP

HV684 STEER DUMP WIRE
WIRE COLOR
CONN POS WIRE LABEL GAUGE JACKET TO 1 WHT 4-24 LIFT UP 18 AWG GXL CO69-J2 (11)
COLOR
1 WHT 4-23 STR DUMP 18 AWG GXL CO69-J2 (1) 2 BLK 000-40-35 CF 18 AWG GXL S705 (1)
2 BLK 000-40-33 STR DUMP GND 18 AWG GXL CO69-J2 (18)
HV685 REAR STEER LEFT

WIRE
COLOR
1 WHT 4-103 REAR STR LEFT 18 AWG GXL CO69-J2 (33)
000-40-49
2 BLK 18 AWG GXL S415 (2)
REAR STR LEFT GND
HV373 STEER RIGHT

WIRE
COLOR
1 WHT 4-21 STR RIGHT 18 AWG GXL CO69-J2 (8)
2 BLK 000-40-32 GND 18 AWG GXL S415 (1)
HV374 STEER LEFT

WIRE
COLOR
1 WHT 4-22 STR LEFT 18 AWG GXL CO69-J2 (19)
2 BLK 000-40-34 GND 18 AWG GXL S415 (1)
3121728 7-69
AH387
7-70
ALARM
R001
R002
X701B
CO69-J2
S389 S386 S688 S415
X767
CABLE SERVICE SENSOR
S705
CO69-J3
X513A 1001188643-G
MAE20840
3121728
CO69-J2 AH387 ALARM

WIRE WIRE
COLOR COLOR
1 WHT 4-23 STR DUMP 18 AWG GXL HV684 (1) A WHT 4-30 ALRM 18 AWG GXL CO69-J3 (7)
2 B WHT 4-29 ALRM 18 AWG GXL CO69-J2 (27)
3 WHT 4-15 HIGH PRES DUMP 18 AWG GXL X701B (1) C BLK 000-40-10 ALRM GND 18 AWG GXL CO69-J2 (29)
4 WHT 4-85 BP DUMP 18 AWG GXL HV767 (1)
5 WHT 4-8 PLAT LEVEL UP 18 AWG GXL R001 (1)
6 BLK 000-40-45 18 AWG GXL X474 (1)
X513A
7 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL R002 (2)
WIRE
8 WHT 4-21 STR RIGHT 18 AWG GXL HV373 (1) CONN POS WIRE LABEL GAUGE JACKET TO
9 WHT 4-19 TELE IN 18 AWG GXL HV371 (1) COLOR
10 1 BLK 000-40-44 CF 18 AWG GXL CO69-J3 (1)
11 WHT 4-24 LIFT UP 18 AWG GXL HV376 (1) 2 WHT 4-102 HEAD & TAIL LIGHTS 18 AWG GXL CO69-J2 (26)
12 3 WHT 4-105 CRIBBING 18 AWG GXL CO69-J3 (9)
13 WHT 4-14 MAIN DUMP 18 AWG GXL HV366 (1) 4 WHT 4-206 BRKN CBL PWR 18 AWG GXL X767 (1)
14 5
15 6
16
17
18 BLK 000-40-33 STR DUMP GND 18 AWG GXL HV684 (2) S386
19 WHT 4-22 STR LEFT 18 AWG GXL HV374 (1) WIRE
20 WHT 4-20 TELE OUT 18 AWG GXL HV372 (1) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
21 WHT 4-28 AUX DN 18 AWG GXL X745A (2)
22 WHT 4-25 LIFT DN 18 AWG GXL X745A (1) 1 BLK 000-40-21 18 AWG GXL HV372 (2)
23 WHT 4-16 LOW PRES DUMP 18 AWG GXL X701B (2) 1 BLK 000-40-31 18 AWG GXL HV371 (2)
24 2 BLK 000-40-7 CF 18 AWG GXL CO69-J3 (6)
25 WHT 4-75 FUEL SNSR 18 AWG GXL X473 (1)
26 WHT 4-102 HEAD & TAIL LIGHTS 18 AWG GXL X513A (2)
27 WHT 4-29 ALRM 18 AWG GXL AH387 (B)
28 BLK 000-40-53 GND 18 AWG GXL S415 (2) S688
29 BLK 000-40-10 ALRM GND 18 AWG GXL AH387 (C) WIRE
30 BLK 000-40-151 GND 18 AWG GXL S688 (2) COLOR
31 WHT 4-150 TELE DUMP 18 AWG GXL HV687 (1) 000-40-150
1 BLK 18 AWG GXL HV687 (2)
32 WHT 4-104 REAR STR RHT 18 AWG GXL HV686 (1) TELE DUMP GROUND
33 WHT 4-103 REAR STR LEFT 18 AWG GXL HV685 (1) 1 BLK 000-40-25 GND 18 AWG GXL HV366 (2)
34 WHT 4-27 SWG LEFT 18 AWG GXL HV379 (1) 2 BLK 000-4-85 BP DUMP GND 18 AWG GXL HV804 (2)
35 WHT 4-26 SWG RHT 18 AWG GXL HV378 (1) 2 BLK 000-40-151 GND 18 AWG GXL CO69-J2 (30)
CO69-J3
WIRE
COLOR
1 BLK 000-40-44 CF 18 AWG GXL X513A (1)
2 BLK 000-40-120 CF 18 AWG GXL X745A (4)
3 WHT 4-204 BRKN CBL GND 18 AWG GXL X767 (3)
4 BLK 000-40-38 CF 18 AWG GXL S389 (2)
5
6 BLK 000-40-7 CF 18 AWG GXL S386 (2)
7 WHT 4-30 ALRM 18 AWG GXL AH387 (A)
8 WHT 4-205 BRKN CBL SIGNAL 18 AWG GXL X767 (2)
9 WHT 4-105 CRIBBING 18 AWG GXL X513A (3)
10
11
12
13
14 BLK 000-40-50 CF 18 AWG GXL S705 (2)
R002
WIRE
COLOR
1 WHT 4-11-2 PLT LVL DN 18 AWG GXL X701B (4)
2 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL CO69-J2 (7)
3121728 7-71
S415
WIRE
COLOR
1 BLK 000-40-32 GND 18 AWG GXL HV373 (2)
1 BLK 000-40-34 GND 18 AWG GXL HV374 (2)
1 BLK 000-40-63 REAR STR RT GND 18 AWG GXL HV686 (2)
2 BLK 000-40-49 REAR STR LEFT GND 18 AWG GXL HV685 (2)
R001
WIRE
COLOR
2 WHT 4-8-2 PLT LVL UP 18 AWG GXL X701B (3)
S705
WIRE
COLOR
1 BLK 000-40-35 CF 18 AWG GXL HV376 (2)
1 BLK 000-40-36 CF 18 AWG GXL X745A (3)
2 BLK 000-40-50 CF 18 AWG GXL CO69-J3 (14)
S389
CONN POS WIRE WIRE LABEL GAUGE JACKET TO
COLOR
1 BLK 000-40-37 CF 18 AWG GXL HV378 (2)
1 BLK 000-40-39 CF 18 AWG GXL HV379 (2)
2 BLK 000-40-38 CF 18 AWG GXL CO69-J3 (4)
X701B
WIRE
COLOR
1 WHT 4-15 HIGH PRES DUMP 18 AWG GXL CO69-J2 (3)
2 WHT 4-16 LOW PRES DUMP 18 AWG GXL CO69-J2 (23)
3 WHT 4-8-2002 PLT LVL UP 18 AWG GXL R001 (2)
4 WHT 4-11-2002 PLT LVL DN 18 AWG GXL R002 (1)
X767 CABLE SERVICE SENSOR

WIRE
COLOR
1 WHT 4-206 BRKN CBL PWR 18 AWG GXL X513A (4)
2 WHT 4-205 BRKN CBL SIGNAL 18 AWG GXL CO69-J3 (8)
3 WHT 4-204 BRKN CBL GND 18 AWG GXL CO69-J3 (3)
7-72 3121728
R002
3121728
R001
AH387
ALARM
X701B
CO69-J3
X767
S170
S100
HV687
X474 S688 S415 TELE DUMP
FUEL LEVEL GND
CO69-J2 HV366
X513A MAIN DUMP
HV804
BYPASS DUMP
HV686 S705
REAR STEER RIGHT
X473 HV372
FUEL LEVEL MAIN TELE OUT
HV373
STEER RIGHT
HV378
SWING RIGHT
HV376
MAIN LIFT UP
HV374 HV379
STEER LEFT SWING LEFT
HV371
HV685 X745A MAIN TELE IN
REAR STEER LEFT
HV684
STEER DUMP
1001188643-G
MAE20860
7-73
7-74
X473
AH387 FUEL LEVEL
ALARM
X474 SHEET 2
R001 HV372
FUEL LEVEL GND
R002 HV378 MAIN TELE OUT
X767 SWING RIGHT
CABLE SERVICE HV373
SENSOR S386 STEER RIGHT
CO69-J2 X701B S688
S415
S389
HV687
TELE DUMP
HV374
HV371 STEER LEFT
HV376 HV379 MAIN TELE IN
CO69-J3 X745A MAIN LIFT UP SWING LEFT
S705
HV804
BYPASS DUMP VALVE
X513A HV366
SHEET 3 MAIN DUMP
1001192909-G
MAE20870
3121728
X473 FUEL LEVEL

WIRE
COLOR
1 WHT 4-75 FUEL SNSR 18 AWG GXL CO69-J2 (25)
X474 FUEL LEVEL GND

WIRE
COLOR
1 BLK 000-40-45 18 AWG GXL CO69-J2 (6)
X745A
WIRE
COLOR
1 WHT 4-25 LIFT DN 18 AWG GXL CO69-J2 (22)
2 WHT 4-28 AUX DN 18 AWG GXL CO69-J2 (21)
3 BLK 000-40-36 CF 18 AWG GXL S705 (1)
4 BLK 000-40-120 CF 18 AWG GXL CO69-J3 (2)
3121728 7-75
7-76
HV378
SWING RIGHT HV372
MAIN TELE OUT
HV373
STEER RIGHT
HV687
TELE DUMP
HV804
BYPASS DUMP
VALVE
HV374
HV376
MAIN LIFT UP STEER LEFT
HV379 HV371
HV366 SWING LEFT MAIN TELE IN
MAIN DUMP 1001192909-G
MAE20880
3121728
HV687 TELE DUMP HV371 MAIN TELE IN

WIRE WIRE
COLOR COLOR
1 WHT 4-150 TELE DUMP 18 AWG GXL CO69-J2 (31) 1 WHT 4-19 TELE IN 18 AWG GXL CO69-J2 (9)
2 BLK 000-40-31 CF 18 AWG GXL S386 (1)

2 BLK 000-40-150 TELE DUMP GROUND 18 AWG GXL S688 (1)
HV804 BYPASS DUMP VALVE

WIRE
HV378 SWING RIGHT CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 1 WHT 4-85 BYPASS DUMP 18 AWG GXL CO69-J2 (4)
COLOR
2 BLK 000-4-85 BP DUMP GND 18 AWG GXL S688 (2)
1 WHT 4-26 SWG RHT 18 AWG GXL CO69-J2 (35)
2 BLK 000-40-37 CF 18 AWG GXL S389 (1)

HV376 MAIN LIFT UP
WIRE
COLOR
HV379 SWING LEFT
WIRE 1 WHT 4-24 LIFT UP 18 AWG GXL CO69-J2 (11)
COLOR
2 BLK 000-40-35 CF 18 AWG GXL S705 (1)
1 WHT 4-27 SWG LEFT 18 AWG GXL CO69-J2 (34)
2 BLK 000-40-39 CF 18 AWG GXL S389 (1)

HV366 MAIN DUMP
WIRE
COLOR
HV373 STEER RIGHT
1 WHT 4-14 MAIN DUMP 18 AWG GXL CO69-J2 (13)
WIRE
COLOR 2 BLK 000-40-25 GND 18 AWG GXL S688 (1)
1 WHT 4-21 STR RIGHT 18 AWG GXL CO69-J2 (8)
2 BLK 000-40-32 GND 18 AWG GXL S415 (1)
HV374 STEER LEFT

WIRE
COLOR
1 WHT 4-22 STR LEFT 18 AWG GXL CO69-J2 (19)
2 BLK 000-40-34 GND 18 AWG GXL S415 (1)
HV372 MAIN TELE OUT

COLOR
1 WHT 4-20 TELE OUT 18 AWG GXL CO69-J2 (20)
2 BLK 000-40-21 18 AWG GXL S386 (1)
3121728 7-77
7-78
AH387
ALARM
R001
R002
X767
X701B
S688
S389 S386 S415
CO69-J2
CO69-J3
S705
1001192909-G
MAE20890
X513A
3121728
CO69-J2 R001
WIRE WIRE
COLOR COLOR
1
2
3 WHT 4-15 HIGH PRES DUMP 18 AWG GXL X701B (1) 2 WHT 4-8-2002 PLT LVL UP 18 AWG GXL X701B (3)
4 WHT 4-85 BP DUMP 18 AWG GXL HV804 (1)
5 WHT 4-8 PLAT LEVEL UP 18 AWG GXL R001 (1)
6 BLK 000-40-45 18 AWG GXL X474 (1)
7 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL R002 (2) X767 CABLE SERVICE SENSOR
8 WHT 4-21 STR RIGHT 18 AWG GXL HV373 (1) WIRE
9 WHT 4-19 TELE IN 18 AWG GXL HV371 (1) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
10 1 WHT 4-206 BRKN CBL PWR 18 AWG GXL X513A (4)
11 WHT 4-24 LIFT UP 18 AWG GXL HV376 (1) 2 WHT 4-205 BRKN CBL SIGNAL 18 AWG GXL CO69-J3 (8)
12 3 WHT 4-204 BRKN CBL GND 18 AWG GXL CO69-J3 (3)
13 WHT 4-14 MAIN DUMP 18 AWG GXL HV366 (1)
14
15
16 AH387 ALARM
17 WIRE
18 COLOR
19 WHT 4-22 STR LEFT 18 AWG GXL HV374 (1) A WHT 4-30 ALRM 18 AWG GXL CO69-J3 (7)
20 WHT 4-20 TELE OUT 18 AWG GXL HV372 (1) B WHT 4-29 ALRM 18 AWG GXL CO69-J2 (27)
21 WHT 4-28 AUX DN 18 AWG GXL X745A (2) C BLK 000-40-10 ALRM GND 18 AWG GXL CO69-J2 (29)
22 WHT 4-25 LIFT DN 18 AWG GXL X745A (1)
23 WHT 4-16 LOW PRES DUMP 18 AWG GXL X701B (2)
24 X513A
25 WHT 4-75 FUEL SNSR 18 AWG GXL X473 (1) WIRE
26 WHT 4-102 HEAD & TAIL LIGHTS 18 AWG GXL X513A (2) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
27 WHT 4-29 ALRM 18 AWG GXL AH387 (B) 1 BLK 000-40-44 CF 18 AWG GXL CO69-J3 (1)
28 BLK 000-40-53 GND 18 AWG GXL S415 (2) 2 WHT 4-102 HEAD & TAIL LIGHTS 18 AWG GXL CO69-J2 (26)
29 BLK 000-40-10 ALRM GND 18 AWG GXL AH387 (C) 3 WHT 4-105 CRIBBING 18 AWG GXL CO69-J3 (9)
30 BLK 000-40-151 GND 18 AWG GXL S688 (2) 4 WHT 4-206 BRKN CBL PWR 18 AWG GXL X767 (1)
31 WHT 4-150 TELE DUMP 18 AWG GXL HV687 (1) 5
32 6
33
34 WHT 4-27 SWG LEFT 18 AWG GXL HV379 (1)
35 WHT 4-26 SWG RHT 18 AWG GXL HV378 (1)
S705
WIRE
COLOR
CO69-J3
1 BLK 000-40-3 CK 18 AWG GXL HV376 (2)
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 1 BLK 000-40-36 CK 18 AWG GXL X745A (3)
COLOR 2 BLK 000-40-50 CK 18 AWG GXL CO69-J3 (14)
1 BLK 000-40-44 CF 18 AWG GXL X513A (1)

2 BLK 000-40-120 CF 18 AWG GXL X745A (4)
3 WHT 4-204 BRKN CBL GND 18 AWG GXL X767 (3) S415
4 BLK 000-40-38 CF 18 AWG GXL S389 (2) WIRE
5 COLOR
6 BLK 000-40-7 CF 18 AWG GXL S386 (2) 1 BLK 000-40-32 GND 18 AWG GXL HV373 (2)
7 WHT 4-30 ALRM 18 AWG GXL AH387 (A) 1 BLK 000-40-34 GND 18 AWG GXL HV374 (2)
8 WHT 4-205 BRKN CBL SIGNAL 18 AWG GXL X767 (2) 2 BLK 000-40-53 GND 18 AWG GXL CO69-J2 (28)
9 WHT 4-105 CRIBBING 18 AWG GXL X513A (3)
10
11
12 S688
13 WIRE
14 BLK 000-40-50 CF 18 AWG GXL S705 (2) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
000-40-150
1 BLK 18 AWG GXL HV687 (2)
TELE DUMP GROUND
X701B 1 BLK 000-40-25 GND 18 AWG GXL HV366 (2)
WIRE
COLOR 2 BLK 000-4-85 BP DUMP GND 18 AWG GXL HV804 (2)
1 WHT 4-15 HIGH PRES DUMP 18 AWG GXL CO69-J2 (3)
2 WHT 4-16 LOW PRES DUMP 18 AWG GXL CO69-J2 (23) 2 BLK 000-40-151 GND 18 AWG GXL CO69-J2 (30)
3 WHT 4-8-2002 PLT L LVL UP 18 AWG GXL R001 (2)
4 WHT 4-11-2002 PLT L LVL UP 18 AWG GXL R002 (1)
3121728 7-79
S386
WIRE
COLOR
1 BLK 000-40-21 18 AWG GXL HV372 (2)
1 BLK 000-40-31 18 AWG GXL HV371 (2)
2 BLK 000-40-7 CF 18 AWG GXL CO69-J3 (6)
S389
WIRE
COLOR
1 BLK 000-40-37 CF 18 AWG GXL HV378 (2)
1 BLK 000-40-39 CF 18 AWG GXL HV379 (2)
2 BLK 000-40-38 CF 18 AWG GXL CO69-J3 (4)
R002
WIRE
COLOR
1 WHT 4-11-2 PLT LVL DN 18 AWG GXL X701B (4)
2 WHT 4-11 PLAT LEVEL DOWN 18 AWG GXL CO69-J2 (7)
7-80 3121728
3121728
R001
AH387
ALARM
R002
X701B
CO69-J3
X767
S389
S386 S688
S415
CO69-J2
X474
X513A
S705 HV366
HV372 MAIN DUMP
MAIN TELE OUT
HV804
X473 HV687 BYPASS DUMP
TELE DUMP HV379
SWING LEFT
HV378
SWING RIGHT
HV374
STEER LEFT
HV373
STEER RIGHT
X745A HV376
MAIN LIFT UP
HV371
MAIN TELE IN
1001192909-G
MAE20910
7-81
7-82
XCO69-J4
SHEET 2
SW141
SW142
SW144 SW140
SW145 SW143
XC069-J4
SW146 GD529-J3 1001188644-E
MAE21040
GD529-J2
GD529-J4
GD529-J1
Figure 7-55. Ground Control Harness - Sheet 1 of 2
3121728
XCO69-J4
WIRE
COLOR
1 WHT 5-23 CRIBBING ENABLED 18 AWG GXL GD529-J3 (1)
2 WHT 5-35 SYSTEM FAULT 18 AWG GXL GD529-J4 (5)
3 WHT 5-24 GLOW PLUG 18 AWG GXL GD529-J2 (3)
4 WHT 5-9 IGNITION START 18 AWG GXL SW143 (1)
5 WHT 5-6 LEVEL DOWN 18 AWG GXL SW142 (3)
6 WHT 5-4 ROTATE LEFT 18 AWG GXL SW140 (3)
7 WHT 5-1 TELE IN 18 AWG GXL SW141 (3)
8 WHT 5-11 JIB DOWN 18 AWG GXL SW144 (3)
9
10
11
12
13 WHT 5-36 LO LVL FUEL 18 AWG GXL GD529-J1 (5)
14 WHT 5-25 PLATFORM OVERLOAD 18 AWG GXL GD529-J3 (6)
15
16 WHT 5-8 AUX POWER 18 AWG GXL SW143 (3)
17 WHT 5-5 LEVEL UP 18 AWG GXL SW142 (1)
18 WHT 5-3 ROTATE RIGHT 18 AWG GXL SW140 (1)
19 WHT 5-10 JIB UP 18 AWG GXL SW144 (1)
20
21
22
23 WHT 5-12 MAIN LIFT UP 18 AWG GXL SW145 (1)
24
25 WHT 5-26 SWITCH POWER 18 AWG GXL SW141 (2)
26 WHT 5-22 NO CHARGE 18 AWG GXL GD529-J4 (1)
27
28 WHT 5-21 ENGINE HIGH TEMP 18 AWG GXL GD529-J4 (3)
29 WHT 5-20 ENGINE LOW OIL PRES 18 AWG GXL GD529-J4 (2)
30 WHT 5-2 TELE OUT 18 AWG GXL SW141 (1)
33 WHT 5-13 MAIN LIFT DOWN 18 AWG GXL SW145 (3)
34 WHT 5-15 SWING LEFT 18 AWG GXL SW146 (3)
35 WHT 5-14 SWING RIGHT 18 AWG GXL SW146 (1)
3121728 7-83
GD529-J2
SW146
SWING
SW141
MAIN TELE
SW143
IGNITION START AUX POWER
SW142
LEVEL
PLATFORM GD529-J3
GD529-J4
SW140
ROTATE
PLATFORM
SW144
JIB
SW145
MAIN LIFT
1001188644-E
GD529-J1 MAE21050
Figure 7-56. Ground Control Harness - Sheet 2 of 2
7-84 3121728
GD529-J1 SW140 PLATFORM ROTATE

CONN POS WIRE WIRE LABEL GAUGE JACKET TO WIRE
COLOR COLOR
1 1 WHT 5-3 ROTATE RIGHT 18 AWG GXL XCO69-J4 (18)
2 2 WHT 5-27 18 AWG GXL SW141 (2)
3 2 WHT 5-28 18 AWG GXL SW142 (2)
4 BLK 000-50-2 GND 18 AWG GXL XCO69-J4 (32) 3 WHT 5-4 ROTATE LEFT 18 AWG GXL XCO69-J4 (6)
5 WHT 5-36 LO LVL FUEL 18 AWG GXL XCO69-J4 (13) 4
6 5
6
GD529-J3
WIRE SW141 MAIN TELE
COLOR CONN POS WIRE LABEL GAUGE JACKET To
1 WHT 5-23 CRIBBING ENABLED 18 AWG GXL XCO69-J4 (1) COLOR
2 1 WHT 5-2 TELE OUT 18 AWG GXL XCO69-J4 (30)
3 2 WHT 5-26 SWITCH POWER 18 AWG GXL XCO69-J4 (25)
4 2 WHT 5-27 18 AWG GXL SW140 (2)
5 3 WHT 5-1 TELE IN 18 AWG GXL XCO69-J4 (7)
6 WHT 5-25 PLATFORM OVERLOAD 18 AWG GXL XCO69-J4 (14) 4
5
6
SW144 JIB
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO SW146 SWING
COLOR WIRE
1 WHT 5-10 JIB UP 18 AWG GXL XCO69-J4 (19) CONN POS WIRE LABEL GAUGE JACKET To
COLOR
2 WHT 5-30 18 AWG GXL SW143 (2)
1 WHT 5-14 SWING RIGHT 18 AWG GXL XCO69-J4 (35)
2 WHT 5-31 18 AWG GXL SW145 (2)
2 WHT 5-32 18 AWG GXL SW145 (2)
3 WHT 5-11 JIB DOWN 18 AWG GXL XCO69-J4 (8)
3 WHT 5-15 SWING LEFT 18 AWG GXL XCO69-J4 (34)
4
4
5
5
6
6
GD529-J2 SW143 IGNITION START AUX POWER

WIRE WIRE
COLOR COLOR
1 1 WHT 5-9 IGNITION START 18 AWG GXL XCO69-J4 (4)
2 2 WHT 5-29 18 AWG GXL SW142 (2)
3 WHT 5-24 GLOW PLUG 18 AWG GXL XCO69-J4 (3) 2 WHT 5-30 18 AWG GXL SW144 (2)
4 3 WHT 5-8 AUX POWER 18 AWG GXL XCO69-J4 (16)
5 4
6 BLK 000-50-1 GND 18 AWG GXL XCO69-J4 (31) 5
6
GD529-J4
WIRE SW145 MAIN LIFT
1 WHT 5-22 NO CHARGE 18 AWG GXL XCO69-J4 (26) COLOR
2 WHT 5-20 ENGINE LOW OIL PRES 18 AWG GXL XCO69-J4 (29) 1 WHT 5-12 MAIN LIFT UP 18 AWG GXL XCO69-J4 (23)
3 WHT 5-21 ENGINE HIGH TEMP 18 AWG GXL XCO69-J4 (28) 2 WHT 5-31 18 AWG GXL SW144 (2)
4 2 WHT 5-32 18 AWG GXL SW146 (2)
5 WHT 5-35 SYSTEM FAULT 18 AWG GXL XCO69-J4 (2) 3 WHT 5-13 MAIN LIFT DOWN 18 AWG GXL XCO69-J4 (33)
6 4
5
6
SW142 PLATFORM LEVEL

WIRE
COLOR
1 WHT 5-5 LEVEL UP 18 AWG GXL XCO69-J4 (17)
2 WHT 5-28 18 AWG GXL SW140 (2)
2 WHT 5-29 18 AWG GXL SW143 (2)
3 WHT 5-6 LEVEL DOWN 18 AWG GXL XCO69-J4 (5)
4
5
6
3121728 7-85
7-86
HV704
MAIN AUX DOWN
HV703
MAIN LIFT
DOWN
X745B
1001205923-A
MAE21070
Figure 7-57. Lift Cylinder Harness
3121728
HV703 MAIN LIFT DOWN

WIRE
COLOR
1 WHT 4-25 LIFT DN 18 AWG GXL X745B (1)
2 BLK 000-40-36 CF 18 AWG GXL X745B (3)
HV704 MAIN AUX DOWN

WIRE
COLOR
1 WHT 4-28 AUX DN 18 AWG GXL X745B (2)
2 BLK 000-40-120 CF 18 AWG GXL X745B (4)
X745B
WIRE
COLOR
1 WHT 4-25 LIFT DN 18 AWG GXL HV703 (1)
2 WHT 4-28 AUX DN 18 AWG GXL HV704 (1)
3 BLK 000-40-36 CF 18 AWG GXL HV703 (2)
4 BLK 000-40-120 CF 18 AWG GXL HV704 (2)
3121728 7-87
7-88
SHEET 2
X481 S802
RL799
S240 X206
S483
S484
X800
B+ AT AUX PUMP RELAY
IP803
5A X181B X183B
SHEET 3
X801
B- AT AUX
PUMP RELAY RL563-86
RL563-30
S480
RL564-86
EC566-D+
ALTERNATOR EXCITE
RL564-87
EC566-B+
ALTERNATOR B+
EC562
ENGINE STARTER
X239
1001188236-F
MAE21110
Figure 7-58. Deutz D2011L04 Engine Harness - Sheet 1 of 3
3121728
EC566-D+ ALTERNATOR EXCITE

WIRE
COLOR
1 RED 6-51 ALT EXCITE 16 AWG GXL X183B (5)
EC566-B+ ALTERNATOR B+
WIRE
COLOR
1 - FUSE LINK 12 AWG FUSIBLE LINK S480 (2)
EC562 ENGINE STARTER

WIRE
COLOR
1 RED 12AWG 12 AWG GXL RL563-30 (1)
S480
WIRE
COLOR
1 RED 8 AWG 8 AWG GXL RL564-87 (1)
2 - FUSE LINK 12 AWG FUSIBLE LINK EC566-B+ (1)
X239
WIRE
COLOR
A WHT 6-17 DIAGNOSTIC 18 AWG GXL S240 (2)
B BLK 000-6-3 18 AWG GXL X206 (2)
K WHT 24-6 18 AWG GXL X206 (11)
L WHT 23-6 18 AWG GXL X206 (10)
X800 B+ AT AUX PUMP RELAY

WIRE
COLOR
1 RED FUSE LEAD 12 AWG GXL IP803 (2)
IP803 5A
WIRE
COLOR
1 RED 6-15-2 16 AWG GXL RL799 (1)
2 RED FUSE LEAD 12 AWG GXL X800 (1)
X801 B- AT AUX PUMP RELAY

WIRE
COLOR
1 BLK 000-6-1-3 10 AWG GXL S802 (2)
3121728 7-89
7-90
X481 RL799
X206
S802
S484 S240
S483
1001188236-F
MAE21120
3121728
X481 X206
WIRE WIRE
COLOR COLOR
A YEL CABLE CAN HI 18 AWG CABLE S484 (1) 1 BLK 000-6-1 GROUND 16 AWG TFFN S802 (1)
B GRN CABLE CAN LO 18 AWG CABLE S483 (2) 2 BLK 000-6-3 18 AWG GXL X239 (B)
C 3
4
5
6
S484
7
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 8
COLOR 9
1 YEL CABLE CAN HI 18 AWG CABLE X183B (3) 10 WHT 6-23 18 AWG GXL X239 (L)
1 YEL CABLE CAN HI 18 AWG CABLE X481 (A) 11 WHT 6-24 18 AWG GXL X239 (K)
2 YEL CABLE CAN HI 18 AWG CABLE X206 (12) 12 YEL CABLE CAN HI 18 AWG CABLE S484 (2)
13 GRN CABLE CAN LO 18 AWG CABLE S483 (2)
14 WHT 6-15-3 18 AWG GXL RL799 (4)
RL799 15
CONN POS WIRE WIRE LABEL GAUGE JACKET TO 16
COLOR 17
1 RED 6-15-2 16 AWG GXL IP803 (1) 18
2 WHT 6-15 DIAGNOSTIC 18 AWG GXL S240 (2) 19
3 20
4 WHT 6-15-3 18 AWG GXL X206 (14) 21
5 BLK 000-6-1-2 18 AWG GXL S802 (1) 22
23
24
25
S483
WIRE
COLOR
1 GRN CABLE CAN LO 18 AWG CABLE X183B (4)
2 GRN CABLE CAN LO 18 AWG CABLE X481 (B)
2 GRN CABLE CAN LO 18 AWG CABLE X206 (13)
S240
WIRE
COLOR
1 WHT 6-16 18 AWG GXL X183B (1)
2 WHT 6-15 DIAGNOSTIC 18 AWG GXL RL799 (2)
2 WHT 6-17 DIAGNOSTIC 18 AWG GXL X239 (A)
S802
WIRE
COLOR
1 BLK 000-6-1 GROUND 16 AWG TFFN X206 (1)
1 BLK 000-6-1-2 18 AWG GXL RL799 (5)
2 BLK 000-6-1-3 10 AWG GXL X801 (1)
3121728 7-91
X181B
7-92
X183B
RL563-86
RL563-30
RL564-86
RL564-87
1001188236-F
MAE21130
3121728
X183B
WIRE
COLOR
1 WHT 6-16 18 AWG GXL S240 (1)
2 WHT 6-25 ENGINE START 14 AWG GXL RL563-86 (1)
3 YEL CABLE CAN HI 18 AWG CABLE S484 (1)
4 GRN CABLE CAN LO 18 AWG CABLE S483 (1)
5 RED 6-51 ALT EXCITE 16 AWG GXL EC566-D+ (1)
6
X181B
WIRE
COLOR
1
2
3
4 WHT 6-18 GLOW 18 AWG GXL RL564-86 (1)
5
6
7
8
RL564-86
WIRE
COLOR
1 WHT 6-18 GLOW 18 AWG GXL X181B (4)
RL564-87
WIRE
COLOR
1 RED 8 AWG 8 AWG GXL S480 (1)
RL563-86
WIRE
COLOR
1 WHT 6-25 ENGINE START 14 AWG GXL X183B (2)
RL563-30
WIRE
COLOR
1 RED 12AWG 12 AWG GXL EC562 (1)
3121728 7-93
7-94
SHEET 3
T920
ENGINE SHEET 4
GROUND
SHEET 2
S951 S952
1001188237-F
MAE21140
Figure 7-61. Deutz T4F Engine Harness - Sheet 1 of 5
3121728
T920 ENGINE GROUND

WIRE
COLOR
1 BLK 000-148-246 ECM GND 8 AWG GXL S945 (1)
1 BLK 000-48-1 ENG GND 14 AWG GXL X941 (4)
1 BLK 000-48-2 ENG GND 18 AWG GXL X950 (B)
1 BLK 000-48-3 GND 18 AWG GXL X999 (2)
S952
WIRE
COLOR
1 GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE S954 (2)
2 GRN CAN 1 LO CUSTOMER CAN LO 20 AWG J1939 CABLE X901 (4)
2 GRN CAN 1 LO CUSTOMER CAN LO 20 AWG J1939 CABLE X950 (F)
S951
WIRE
COLOR
1 YEL CAN 1 HI CUSTOMER CAN HIGH 20 AWG J1939 CABLE S953 (2)
2 YEL CAN 1 HI CUSTOMER CAN HIGH 20 AWG J1939 CABLE X901 (3)
2 YEL CAN 1 HI CUSTOMER CAN HIGH 20 AWG J1939 CABLE X950 (M)
3121728 7-95
7-96
X955
ECM-J2
X965
S945
S954 S969
S944
S953 S968
ECM-J1
1001188237-F
MAE21150
3121728
ECM-J2
X955
WIRE
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
A YEL CAN 1 HI CUSTOMER CAN HIGH 20 AWG J1939 CABLE S953 (2)
1
B GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE S954 (2)
2 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW EIC (61)
C
4 BLK 248-4 MPROP ACTUATOR 1.5 mm² FLRYW EIC (19)
5 BLK 248-5 MPROP ACTUATOR 1.5 mm² FLRYW EIC (20)
X965 6
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 7 BLK 248-7 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (32)
A YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S969 (2) 8
B GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE S968 (2) 9
C 10
11
12
13
S953
14
15
CAN 1 HI CUSTOMER
1 YEL 20 AWG J1939 CABLE ECM-J1 (54) 16 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW EIC (35)
CAN HIGH 17
CAN 1 HI CUSTOMER 18 BLK 248-18 INJECTOR 4 1.5 mm² FLRYW EIC (37)
2 YEL 20 AWG J1939 CABLE S951 (1)
CAN HIGH 248-19 EHXAUST GAS
CAN 1 HI CUSTOMER 19 BLK 1.5 mm² FLRYW EIC (47)
2 YEL 20 AWG J1939 CABLE X955 (A) RECIRCULATION
CAN HIGH 248-20 EHXAUST GAS
20 BLK 1.5 mm² FLRYW EIC (48)
RECIRCULATION
21
S954 22
CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO 23 BLK 248-23 GLOW SENSE 0.75 mm² FLRYW MS932 (E)
1 GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE ECM-J1 (76) 248-24
2 GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE S952 (1) BOOST PRESSURE / TEMP
2 GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE X955 (B) 25 BLK 248-25 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (31)
26 BLK 248-26 RAIL PRESSURE FUEL 0.75 mm² FLRYW EIC (25)
248-27
S968 BOOST PRESSURE / TEMP
WIRE 28 BLK 248-28 COOLING TEMPERATURE 0.75 mm² FLRYW EIC (24)
CONN POS WIRE LABEL GAUGE JACKET TO 29 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW EIC (27)
COLOR
30
1 GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE ECM-J1 (53)
31
2 GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE S963 (1)
2 GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE X965 (B) 32 BLK 248-32 INJECTOR 3 1.5 mm² FLRYW EIC (38)
34
35 BLK 248-35 GLOW RELAY CONTROL GND 0.75 mm² FLRYW RL553-85 (1)
S969 36
WIRE 37 BLK 248-37 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (14)
COLOR 38 SHLD 248-38 ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (1)
1 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE ECM-J1 (75) 39 BLK 248-39 ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (15)
2 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S964 (1) 40 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW EIC (28)
2 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE X965 (A) 41
42
43 BLK 248-43 OIL PRESSURE 0.75 mm² FLRYW EIC (23)
44 BLK 248-44 OIL PRESSURE 0.75 mm² FLRYW EIC (26)
S945
45
WIRE
CONN POS WIRE LABEL GAUGE JACKET TO 46 BLK 248-46 INJECTOR 2 1.5 mm² FLRYW EIC (40)
COLOR 47
1 BLK 000-148-246 ECM GND 8 AWG GXL T920 (1) 48 BLK 248-48 INJECTOR 4 1.5 mm² FLRYW EIC (42)
2 BLK 148-2 ECM GND 2.5 mm² FLRYW ECM-J1 (2) 49
52 WHT 248-52 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (13)
53 SHLD 248-53 ENGINE SPEED CAMSHAFT 18 AWG CABLE EIC (9)
S944 54 WHT 248-54 ENGINE SPEED CRANKSHAFT 18 AWG CABLE EIC (21)
WIRE 55
COLOR
1 RED 1-148-135 ECM PWR 8 AWG GXL RL930-2 (1) 57
2 RED 148-1 ECM PWR 2.5 mm² FLRYW ECM-J1 (1) 58
3121728 7-97
ECM-J1
ECM-J1
CONN WIRE
CONN WIRE WIRE LABEL GAUGE JACKET TO
WIRE LABEL GAUGE JACKET TO POS COLOR
POS COLOR
72 BLK 148-72 THROTTLE FLAP 3 0.75 mm² FLRYW EIC (49)
1 RED 148-1 ECM PWR 2.5 mm² FLRYW S944 (2)
73 BLK 148-73 START SIGNAL 0.75 mm² FLRYW EIC (3)
2 BLK 148-2 ECM GND 2.5 mm² FLRYW S945 (2)
74
75 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S969 (1)
76 GRN CAN 1 LO CUSTOMER CAN LOW 20 AWG J1939 CABLE S954 (1)
77
78
7
79
8
80
9
81
10
82 BLK 148-82 EHXAUST GAS RECIRCULATION 0.75 mm² FLRYW EIC (51)
11
83
12
84
13 BLK 148-13 COOLANT LEVEL SIG 0.75 mm² FLRYW SN939 (3)
14
86
15 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (68)
87 BLK 148-87 COOLANT LEVEL GND 0.75 mm² FLRYW SN939 (2)
16
88 BLK 148-88 IGNITION 0.75 mm² FLRYW S946 (2)
17
89
18
90
19
91
20
92
21
93
22
94
23
NC SHLD CAN 1 SHLD CUSTOMER CAN SHIELD 18 AWG J1939 CABLE X901 (6)
24
25
148-26
26 BLK 0.75 mm² FLRYW RL930 (2)
FUEL PUMP RELAY CTRL GND
27
28 BLK 148-28 START RTN 0.75 mm² FLRYW EIC (2)
29 BLK 148-29 COOLANT LEVEL PWR 0.75 mm² FLRYW SN939 (1)
30
31
32
33
34
35 BLK 148-35-2 START 0.75 mm² FLRYW S1001 (1)
36
37
38 BLK 148-38 THROTTLE FLAP 4 0.75 mm² FLRYW EIC (52)
39
40
41
42
43
45
46
47
48
49
50
51
52
53 GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE S968 (1)
55
56 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW EIC (34)
57 BLK 148-57 WATER IN FUEL SW RTN 0.75 mm² FLRYW X941 (2)
58
59
60
61 BLK 148-61 FUEL LOW PRESSURE 0.75 mm² FLRYW EIC (17)
62
63
64 BLK 148-64 WATER IN FUEL SW 0.75 mm² FLRYW X941 (1)
65
66
67
68 BLK 148-15-68 CLUTCH SWITCH 0.75 mm² FLRYW ECM-J1 (15)
69
70
71
7-98 3121728
3121728 7-99
RL553-30-2
RL553-30
RL553-86
RL553-85
RL553-30-1
RL930-1
RL930-2
PWR MODULE
RL930
X960
S946
X999
X941 S1001
X902
X901 1001188237-F
MAE21160
7-100 3121728
RL930-1 RL930
WIRE WIRE
COLOR COLOR
1 WHT 48-96 FUEL PUMP 14 AWG GXL X941 (3) 1 YEL 2-48-4 IGNITION 18 AWG GXL S946 (2)
148-26
2 BLK 0.75 mm² FLRYW ECM-J1 (26)
FUEL PUMP RELAY CTRL GND
RL930-2
S963
COLOR
WIRE
1 RED 1-148-135 ECM PWR 8 AWG GXL S944 (1) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
CAN 2
1 GRN 20 AWG J1939 CABLE S968 (2)
LO DIAG CAN LOW
RL553-30-1 CAN 2
2 GRN 20 AWG J1939 CABLE X950 (G)
WIRE LO DIAG CAN LOW
COLOR CAN 2
2 GRN 20 AWG J1939 CABLE X960 (B)
1 RED 48-13 GLOW 8 AWG GXL EC18 (2) LO DIAG CAN LOW
X901
RL553-30-2
WIRE
COLOR
1
1 ORG 248-23-1 GLOW SENSE 18 AWG GXL MS932 (F)
2 BLK 148-35-1 START 18 AWG GXL S1001 (2)
4 GRN CAN 1 LO CUSTOMER CAN LO 20 AWG J1939 CABLE S952 (2)
RL553-30 5 RED 47-8 ALT EXCITE 16 AWG GXL EC555-D+ (1)
WIRE CAN 1
CONN POS WIRE LABEL GAUGE JACKET TO 6 SHLD 20 AWG J1939 CABLE ECM-J1 (NC)
COLOR SHLD CUSTOMER CAN SHIELD
1 RED 48-14 8 AWG GXL EC18 (1)
X902
WIRE
RL553-86 CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
WIRE 1 YEL 2-1-99 IGNITION 18 AWG GXL MS932 (G)
COLOR 2
1 YEL 2-48-3 18 AWG GXL S946(2) 3
4
5
6
RL553-85 7
WIRE 8
COLOR
1 BLK 248-35 GLOW RLY CONTROL 0.75 mm² FLRYW ECM-J2(35)
X941
WIRE
S964 COLOR
WIRE 148-64
CONN POS WIRE LABEL GAUGE JACKET TO 1 BLK 0.75 mm² FLRYW ECM-J1 (64)
COLOR WATER IN FUEL SW
1 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S969 (2) 148-57
2 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE X950 (H) WATER IN FUEL SW RTN
2 YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE X960 (A) 3 WHT 48-96 FUEL PUMP 14 AWG GXL RL930-1 (1)
4 BLK 000-48-1 ENG GND 14 AWG GXL T920 (1)
S1001
X960
WIRE
COLOR
1 BLK 148-35-2 START 0.75 mm² FLRYW ECM-J1 (35)
A YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S964 (2)
1 BLK 148-35-3 18 AWG GXL X999 (1)
B GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE S963 (2)
2 BLK 148-35-1 START 18 AWG GXL X901 (2)
C
S946 X999
WIRE WIRE
COLOR COLOR
1 YEL 2-48-1 IGNITION 16 AWG GXL MS932 (H) 1 BLK 148-35-3 18 AWG GXL S1001 (1)
1 YEL 2-48-2 IGNITION 18 AWG GXL X950 (A) 2 BLK 000-48-3 GND 18 AWG GXL T920 (1)
2 YEL 2-48-3 IGNITION 18 AWG GXL RL553-86 (1)
2 YEL 2-48-4 IGNITION 18 AWG GXL RL930 (1)
2 BLK 148-88 IGNITION 0.75 mm² FLRYW ECM-J1 (88)
3121728 7-101
7-102
EC18
SN939
MS932 X950
DEUTZ DIAGNOSTIC
EIC
LOOM TO ELBOW
EC555-D+
1001188237-F
MAE21180
3121728
EC18 248-37
14 BLK 18 AWG CABLE ECM-J2 (37)
WIRE ENGINE SPEED CAMSHAFT
COLOR 248-39
15 BLK 18 AWG CABLE ECM-J2 (39)
1 RED 48-14 8 AWG GXL RL553-30 (1) ENGINE SPEED CRANKSHAFT
2 RED 48-13 GLOW 8 AWG GXL RL553-30-1 (1) 16
148-61
SN939 17 BLK 0.75 mm² FLRYW ECM-J1 (61)
FUEL LOW PRESSURE
WIRE
CONN POS WIRE LABEL GAUGE TO 18
COLOR 19 BLK 248-4 MPROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (4)
COOLANT LEVEL 20 BLK 248-5 MPROP ACTUATOR 1.5 mm² FLRYW ECM-J2 (5)
1 BLK 148-29 0.75 mm² ECM-J1 (29)
PWR 21 WHT 248-54 ENGINE SPEED CRANKSHAFT 18 AWG CABLE ECM-J2 (54)
COOLANT LEVEL 22 BLK 248-24 BOOST PRESSURE / TEMP 0.75 mm² FLRYW ECM-J2 (24)
2 BLK 148-87 0.75 mm² ECM-J1 (87)
GND 23 BLK 248-43 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (43)
COOLANT LEVEL 24 BLK 248-28 COOLING TEMPERATURE 0.75 mm² FLRYW ECM-J2 (28)
3 BLK 148-13 0.75 mm² ECM-J1 (13)
SIG 248-26
4 RAIL PRESSURE FUEL
26 BLK 248-44 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (44)
27 BLK 248-29 OIL PRESSURE 0.75 mm² FLRYW ECM-J2 (29)
EC555-D+ 28 BLK 248-40 AIR INLET TEMP 0.75 mm² FLRYW ECM-J2 (40)
WIRE 29 BLK 248-27 BOOST PRESSURE / TEMP 0.75 mm² FLRYW ECM-J2 (27)
COLOR
31 BLK 248-25 RAIL PRESSURE FUEL 0.75 mm² FLRYW ECM-J2 (25)
1 RED 47-8 ALT EXCITE 16 AWG GXL X901 (5)
32 BLK 248-7 RAIL PRESSURE FUEL 0.75 mm² FLRYW ECM-J2 (7)
33
34 BLK 148-56 AIR INLET TEMP 0.75 mm² FLRYW ECM-J1 (56)
MS932 35 BLK 248-16 INJECTOR 1 1.5 mm² FLRYW ECM-J2 (16)
WIRE 36
CONN POS WIRE LABEL GAUGE JACKET TO 37 BLK 248-18 INJECTOR 4 1.5 mm² FLRYW ECM-J2 (18)
COLOR
A 38 BLK 248-32 INJECTOR 3 1.5 mm² FLRYW ECM-J2 (32)
B 39
C 40 BLK 248-46 INJECTOR 2 1.5 mm² FLRYW ECM-J2 (46)
D 41 BLK 248-3 INJECTOR 2 1.5 mm² FLRYW ECM-J2 (3)
E BLK 248-23 GLOW SENSE 0.75 mm² FLRYW ECM-J2 (23) 42 BLK 248-48 INJECTOR 4 1.5 mm² FLRYW ECM-J2 (48)
F ORG 248-23-1 GLOW SENSE 18 AWG GXL RL553-30-2 (1) 43
G YEL 2-1-99 IGNITION 18 AWG GXL X902 (1) 44
H YEL 2-48-1 IGNITION 16 AWG GXL S946 (1) 45
148-85 EHXAUST GAS
RECIRCULATION
248-19 EHXAUST GAS
X950 47 BLK 1.5 mm² FLRYW ECM-J2 (19)
RECIRCULATION
WIRE 248-20 EHXAUST GAS
CONN POS WIRE LABEL GAUGE JACKET TO 48 BLK 1.5 mm² FLRYW ECM-J2 (20)
COLOR RECIRCULATION
A YEL 2-48-2 IGNITION 18 AWG GXL S946 (1) 49 BLK 148-72 THROTTLE FLAP 3 0.75 mm² FLRYW ECM-J1 (72)
B BLK 000-48-2 ENG GND 18 AWG GXL T920 (1) 148-44 EHXAUST GAS
C 50 BLK 0.75 mm² FLRYW ECM-J1 (44)
RECIRCULATION
D
148-82 EHXAUST GAS
E 51 BLK 0.75 mm² FLRYW ECM-J1 (82)
F GRN CAN 1 LO CUSTOMER CAN LO 20 AWG J1939 CABLE S952 (2) RECIRCULATION
G GRN CAN 2 LO DIAG CAN LOW 20 AWG J1939 CABLE S963 (2) 52 BLK 148-38 THROTTLE FLAP 4 0.75 mm² FLRYW ECM-J1 (38)
H YEL CAN 2 HI DIAG CAN HIGH 20 AWG J1939 CABLE S964 (2) 53
J 54
K 55
L 56
CAN 1 HI CUSTOMER 57
M YEL 20 AWG J1939 CABLE S951 (2) 58
CAN HIGH
59
60
61 BLK 248-2 INJECTOR 3 1.5 mm² FLRYW ECM-J2 (2)
EIC
62 BLK 248-33 INJECTOR 1 1.5 mm² FLRYW ECM-J2 (33)
CONN WIRE
POS COLOR
248-38
1 SHLD 18 AWG CABLE ECM-J2 (38)
ENGINE SPEED CRANKSHAFT
2 BLK 148-28 START RTN 0.75 mm² FLRYW ECM-J1 (28)
3 BLK 148-73 START SIGNAL 0.75 mm² FLRYW ECM-J1 (73)
4
5
6
7
8
248-53
9 SHLD 18 AWG CABLE ECM-J2 (53)
ENGINE SPEED CAMSHAFT
10
11
12
248-52
13 WHT 18 AWG CABLE ECM-J2 (52)
ENGINE SPEED CAMSHAFT
3121728 7-103
7-104
EIC SN939
EC18
EC555 - D+
RL930
ECM-J2
X901
ECM-
X950
X901 X960
X965
X902
X941
X955
Figure 7-65. Deutz T4F Engine Harness - Sheet 5 of 5 1001188237-F

MAE21330
3121728
3121728 7-105
7-106
X183B
TO TT HARNESS X183A
X206
FUEL PUMP NEG
X207
FUEL PUMP POS
X205
TO FORD HARNESS
1001215218-C
MAE21340
Figure 7-66. Ford Engine Harness
3121728
X207 FUEL PUMP POS

WIRE
COLOR
1 WHT 6-54 FUEL PUMP POS 16 AWG GXL X205 (5)
X206 FUEL PUMP NEG

WIRE
COLOR
000-60-11
1 BLK 16 AWG GXL X205 (18)
FUEL PUMP NEG
X183B TO TT HARNESS X183A

WIRE
COLOR
1 WHT 6-14 IGNITION 16 AWG GXL X205 (1)
6-12
2 WHT 18 AWG GXL X205 (15)
ENGINE START
3 YEL CAN HI 20 AWG J1939 CABLE X205 (28)
4 GRN CAN LO 20 AWG J1939 CABLE X205 (29)
5
6
X205 TO FORD HARNESS

WIRE
COLOR
1 WHT 6-14 IGNITION 16 AWG GXL X181B (1)
2
3
4
5 WHT 6-54 FUEL PUMP POS 16 AWG GXL X208 (1)
6
7
8
9
10
11
12
13
14
15 WHT 6-12 ENGINE START 18 AWG GXL X181 (2)
16
17
18 BLK 000-60-11 16 AWG GXL X207 (1)
FUEL PUMP NEG
19
20
21
22
23
24
25
26
27
28 YEL CAN HI 20 AWG J1939 CABLE X181 (3)
29 GRN CAN LO 20 AWG J1939 CABLE X181 (4)
30
31
32
33
34
35
36
37
38
39
40
41
42
3121728 7-107
7-108
X668
REAR RIGHT
SHEET 2
X666
REAR LEFT
X675
X676 X674
X505
S671
IP629 S672
10A
LB670
FRONT
RIGHT
RL673
HEAD AND TAIL LIGHTS
LB495
FRONT LEFT
1001193592-C
MAE21350
Figure 7-67. Chassis Head and Tail Lights Harness - Sheet 1 of 2
3121728
X505
WIRE
COLOR
1 WHT 4-145 18 AWG GXL RL673 (5)
LB670 FRONT RIGHT

WIRE
COLOR
1 WHT 6-29 12V+ 16 AWG GXL S671 (1)
2 BLK 000-60-29 GND 16 AWG GXL S672 (1)
LB495 FRONT LEFT

WIRE
COLOR
1 WHT 6-11 12V+ 16 AWG GXL S671 (1)
2 BLK 000-60-11 GND 16 AWG GXL S672 (1)
X666 REAR LEFT

WIRE
COLOR
1
2 BLK 000-60-12 GND 16 AWG GXL S672 (2)
3 WHT 6-13 12V+ 16 AWG GXL S671 (2)
4
3121728 7-109
7-110
X668
REAR RIGHT
X675
X676
X674
IP629
10A
RL673
HEAD AND
TAIL LIGHTS
S672
S671
1001193592-C
MAE21380
Figure 7-68. Chassis Head and Tail Lights Harness - Sheet 2 of 2
3121728
IP629 10A
WIRE
COLOR
1 WHT 4-146 14 AWG GXL X675 (1)
2 WHT 4-146 14 AWG GXL RL673 (1)
RL673 HEAD AND TAIL LIGHTS

WIRE
COLOR
1 WHT 4-146 14 AWG GXL IP629 (2)
2 BLK 000-40-109 GND 16 AWG GXL X676 (1)
3
4 WHT 6-8 12V+ 14 AWG GXL S671 (2)
5 WHT 4-145 18 AWG GXL X505 (1)
X676
WIRE
COLOR
1 BLK 000-40-109 GND 16 AWG GXL RL673 (2)
X675
WIRE
COLOR
1 WHT 4-146 14 AWG GXL IP629 (1)
X668 REAR RIGHT

WIRE
COLOR
1
2 BLK 000-60-30 GND 16 AWG GXL S672 (2)
3 WHT 6-30 12V+ 16 AWG GXL S671 (2)
4
X674
WIRE
COLOR
1 BLK 4-122 14 AWG GXL S672 (2)
S671
WIRE
COLOR
1 WHT 6-11 12V+ 16 AWG GXL LB495 (1)
2 WHT 6-29 12V+ 16 AWG GXL LB670 (1)
1 WHT 6-13 12V+ 16 AWG GXL X666 (2)
2 WHT 6-30 12V+ 16 AWG GXL X668 (2)
2 WHT 6-8 12V+ 14 AWG GXL RL673 (4)
S672
WIRE
COLOR
1 BLK 000-60-11 GND 16 AWG GXL LB495 (2)
2 BLK 000-60-29 GND 16 AWG GXL LB670 (2)
1 BLK 000-60-12 GND 16 AWG GXL X666 (3)
2 BLK 000-60-30 GND 16 AWG GXL X668 (3)
2 BLK 4-122 14 AWG GXL X674 (1)
3121728 7-111
7-112
SHEET 2
LB641
REAR RIGHT
LB639
REAR LEFT
X678
X680
X679 X677
S642
IP630 S643
20A
LB640
FRONT RIGHT
LB638
RL168 FRONT LEFT
1001193593-B
MAE21360
Figure 7-69. Chassis Work Lights Harness - Sheet 1 of 2
3121728
LB638 FRONT LEFT

WIRE
COLOR
1 WHT 6-4 12V+ 16 AWG GXL S642 (1)
2 BLK 000-60-3 GND 16 AWG GXL S643 (1)
X680
WIRE
COLOR
1 WHT 4-28 16 AWG GXL RL168 (5)
LB640 FRONT RIGHT

WIRE
COLOR
1 WHT 6-6 12V+ 16 AWG GXL S642 (1)
2 BLK 000-60-5 GND 16 AWG GXL S643 (1)
LB639 REAR LEFT

WIRE
COLOR
1 WHT 6-5 12V+ 16 AWG GXL S642 (2)
2 BLK 000-60-4 GND 16 AWG GXL S643 (2)
3121728 7-113
7-114
LB641
REAR RIGHT
X678
X679
X677
IP630
10A
RL168
HEAD AND
TAIL LIGHTS
S642 S643
1001193593-B
MAE21370
Figure 7-70. Chassis Work Lights Harness - Sheet 2 of 2
3121728
X678
WIRE
COLOR
1 WHT 4-70 14 AWG GXL IP630 (1)
X679
COLOR
1 BLK 000-40-9 GND 16 AWG GXL RL168 (2)
RL168 HEAD AND TAIL LIGHTS

WIRE
COLOR
1 WHT 4-70 14 AWG GXL IP630 (2)
2 BLK 000-40-9 GND 16 AWG GXL X679 (1)
3
4 WHT 6-8 12V+ 14 AWG GXL S642 (2)
5 WHT 4-28 16 AWG GXL X680 (1)
IP630 20A
WIRE
COLOR
1 WHT 4-70 14 AWG GXL X678 (1)
2 WHT 4-70 14 AWG GXL RL168 (1)
X677
WIRE
COLOR
1 BLK 000-40-17 14 AWG GXL S643 (2)
S642
WIRE
COLOR
1 WHT 6-412V+ 16 AWG GXL LB638 (1)
1 WHT 6-6 12V+ 16 AWG GXL LB640 (1)
2 WHT 6-5 12V+ 16 AWG GXL LB639 (1)
2 WHT 6-7 12V+ 16 AWG GXL LB641 (1)
2 WHT 6-8 12V+ 14 AWG GXL RL168 (4)
LB641 REAR RIGHT

WIRE
COLOR
1 WHT 6-7 12V+ 16 AWG GXL S642 (2)
2 BLK 000-60-6 GND 16 AWG GXL S643 (2)
S643
WIRE
COLOR
1 BLK 000-60-3 GND 16 AWG GXL LB638 (2)
1 BLK 000-60-5 GND 16 AWG GXL LB640 (2)
2 BLK 000-40-17 14 AWG GXL X677 (1)
2 BLK 000-60-4 GND 16 AWG GXL LB639 (2)
2 BLK 000-60-6 GND 16 AWG GXL LB641 (2)
3121728 7-115
7-116
TCU
S407
S410
DIAG_CONN
S408 S409 S406
DIAG_CONN_1
1001120612-A
MAE21400
Figure 7-71. ClearSky Harness
3121728
S406 TCU
WIRE WIRE
COLOR COLOR
1 BLK 0-100-1 GND 16 AWG GXL TCU (16) 1
1 BLK 0-100-2 GND 16 AWG GXL DIAG_CONN (A) 2
2 BLK 0-100-3 GND 16 AWG GXL DIAG_CONN_1 (A) 3
4
5
6
S407 7 YEL 4-100-1CAN HI 18 AWG GXL S408 (1)
WIRE 8
COLOR 9
1 RED 1-100-2 B+ 16 AWG GXL DIAG_CONN (B) 10
1 RED 1-100-3 B+ 16 AWG GXL DIAG_CONN_1 (B) 11
2 RED 1-100-1 B+ 16 AWG GXL TCU (23) 12
13
14
S408 15 YEL/RED 2-100-1 IGN 18 AWG GXL S410 (2)
WIRE 16 BLK 0-100-1 GND 16 AWG GXL S406 (1)
COLOR
18
1 YEL 4-100-1 CAN HI 18 AWG GXL TCU (7)
19
1 YEL 4-100-3 CAN HI 18 AWG GXL DIAG_CONN_1 (C)
20
2 YEL 4-100-2 CAN HI 18 AWG GXL DIAG_CONN (C)
21
22 GRN 3-100-1 CAN LO 18 AWG GXL S409 (1)
23 RED 1-100-1 B+ 16 AWG GXL S407 (2)
S409
WIRE
COLOR DIAG_CONN_1
1 GRN 3-100-1 CAN LO 18 AWG GXL TCU (22) WIRE
1 GRN 3-100-3 CAN LO 18 AWG GXL DIAG_CONN_1 (D) CONN POS WIRE LABEL GAUGE JACKET TO
COLOR
2 GRN 3-100-2 CAN LO 18 AWG GXL DIAG_CONN (D)
A BLK 0-100-3 GND 16 AWG GXL S406 (2)
B RED 1-100-3 B+ 16 AWG GXL S407 (1)
C YEL 4-100-3 CAN HI 18 AWG GXL S408 (1)
S410 D GRN 3-100-3 CAN LO 18 AWG GXL S409 (1)
WIRE E BLK 5-100-1 SHLD 18 AWG GXL DIAG_CONN (E)
COLOR F
1 YEL/RED 2-100-2 IGN 18 AWG GXL DIAG_CONN (H) G
2 YEL/RED 2-100-1 IGN 18 AWG GXL TCU (15) H YEL/RED 2-100-3 IGN 18 AWG GXL S410 (2)
2 YEL/RED 2-100-3 IGN 18 AWG GXL DIAG_CONN_1 (H) J
DIAG_CONN
WIRE
COLOR
A BLK 0-100-2 GND 16 AWG GXL S406 (1)
B RED 1-100-2 B+ 16 AWG GXL S407 (1)
C YEL 4-100-2 CAN HI 18 AWG GXL S408 (2)
D GRN 3-100-2 CAN LO 18 AWG GXL S409 (2)
E BLK 5-100-1 SHLD 18 AWG GXL DIAG_CONN_1 (E)
F
G
H YEL/RED 2-100-2 IGN 18 AWG GXL S410 (1)
J
3121728 7-117
7-118
SHEET 2
MS700 X652B
GROUND BUSS
MS699
PLATFORM BUSS
1001191328-D
SN698 MAE21410
PLAT ANGLE
SENSOR
Figure 7-72. Platform Valve Harness - Sheet 1 of 2
3121728
MS699 PLATFORM BUSS X652B

WIRE WIRE
COLOR COLOR
1 1 BLK 000-10-34 OPTION GND 18 AWG GXL MS682 (1)
2 2
3 3 WHT 4-15 HIGH PRESSURE DUMP 18 AWG GXL HV660 (3)
4 4 WHT 4-8 PLAT LEVEL UP 18 AWG GXL HV381 (4)
5 5 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL HV380 (5)
6 BLK 000-40-91 GND 18 AWG GXL SN698 (A) 6
7 BLK 000-40-92 GND 18 AWG GXL SN698 (E) 7
8 BLK 000-40-90 - 18 AWG GXL X652B (21) 8 WHT 4-88 PLAT ANGLE SEN 1 18 AWG GXL SN698 (D)
9 9 WHT 4-89 PLAT ANGLE SEN 2 18 AWG GXL SN698 (C)
10 WHT 4-127 PWR 5V 18 AWG GXL SN698 (B) 10 WHT 4-125 PLAT ANGLE SEN 5V 18 AWG GXL MS699 (8)
11 WHT 4-126 PWR 5V 18 AWG GXL SN698 (F) 11
12 WHT 4-125 PLAT ANGLE SEN 5V 18 AWG GXL X652B (10) 12 WHT 4-16 LOW PRESSURE DUMP 18 AWG GXL HV661 (12)
13 WHT 4-9 ROTATE LEFT 18 AWG GXL HV383 (13)
14 WHT 4-10 ROTATE RIGHT 18 AWG GXL HV382 (14)
15
SN698 PLAT ANGLE SENSOR
16
WIRE 17
COLOR 18
A BLK 000-40-91 GND 18 AWG GXL MS699 (4) 19
B WHT 4-127 PWR 5V 18 AWG GXL MS699 (2) 20
C WHT 4-89 PLAT ANGLE SEN 2 18 AWG GXL X652B (9) 21 BLK 000-40-90 18 AWG GXL MS699 (6)
D WHT 4-88 PLAT ANGLE SEN 1 18 AWG GXL X652B (8)
E BLK 000-40-92 GND 18 AWG GXL MS699 (5)
F WHT 4-126 PWR 5V 18 AWG GXL MS699 (7)
MS700 GROUND BUSS

WIRE
COLOR
1
2 BLK 000-10-34 OPTION GND 18 AWG GXL X652B (1)
3 BLK 000-40-27 - 18 AWG GXL HV661 (2)
4 BLK 000-40-26 18 AWG GXL HV660 (2)
5
6
7 BLK 000-40-20 18 AWG GXL HV382 (2)
8 BLK 000-40-19 18 AWG GXL HV383 (2)
9 BLK 000-40-30 18 AWG GXL HV380 (2)
10 BLK 000-40-22 18 AWG GXL HV381 (2)
11
12
3121728 7-119
7-120
HV381
PLTF LVL UP
HV380
HV382 PLTF LVL DOWN
PLTF ROT R
HV383
PLTF ROT L
HV660
HI PRS DUMP
HV661
LO PRS DUMP
1001191328-D
MAE21420
Figure 7-73. Platform Valve Harness Sheet 2 of 2
3121728
HV381 PLTF LVL UP

WIRE
COLOR
1 WHT 4-8 PLAT LEVEL UP 18 AWG GXL X652B (1)
2 BLK 000-40-22 18 AWG GXL MS700 (10)
HV380 PLTF LVL DOWN

WIRE
COLOR
1 WHT 4-7 PLAT LEVEL DOWN 18 AWG GXL X652B (1)
2 BLK 000-40-30 18 AWG GXL MS682 (9)
HV383 PLTF ROT L

WIRE
COLOR
1 WHT 4-9 ROTATE LEFT 18 AWG GXL X652B (1)
2 BLK 000-40-19 18 AWG GXL MS700 (8)
HV382 PLTF ROT R

WIRE
COLOR
1 WHT 4-10 ROTATE RIGHT 18 AWG GXL X652B (1)
2 BLK 000-40-20 18 AWG GXL MS700 (7)
HV660HI PRS DUMP

WIRE
COLOR
1 WHT 4-15 HIGH PRESSURE DUMP 18 AWG GXL X652B (1)
2 BLK 000-40-26 18 AWG GXL MS700 (4)
HV661LO PRS DUMP

WIRE
COLOR
1 WHT 4-16 LOW PRESSURE DUMP 18 AWG GXL X652B (1)
2 BLK 000-40-27 18 AWG GXL MS700 (3)
3121728 7-121
7-122
RL-502
X305B-8
X305B-7
X305B-10 IP608
18 OHM RL-503
X305B-11
X500
1001196298-A
MAE21430
Figure 7-74. Skyguard Harness
3121728
IP608 18 OHM
WIRE
COLOR
1 WHT P2 18 AWG GXL X305B-7 (1)
2 WHT P10 18 AWG GXL X500 (1)
X305B-8
WIRE
COLOR
1 BLK P6 18 AWG GXL X500 (2)
X305B-7
WIRE
COLOR
1 WHT P2 18 AWG GXL IP608 (1)
1 WHT P9 18 AWG GXL RL-503 (1)
X500
WIRE
COLOR
1 WHT P10 18 AWG GXL IP608 (2)
2 BLK P6 18 AWG GXL X305B-8 (1)
X305B-10
WIRE
COLOR
X305B-11
WIRE
COLOR
RL-503
WIRE
COLOR
1 WHT P9 18 AWG GXL X305B-7 (1)
1 WHT P9-1 18 AWG GXL RL-502 (1)
2 WHT P5-1 18 AWG GXL RL-502 (2)
3
4 WHT P1 18 AWG GXL X305B-10 (1)
5 WHT P4-1 18 AWG GXL RL-502 (5)
RL-502
WIRE
COLOR
1 WHT P9-1 18 AWG GXL RL-503 (1)
2 WHT P5 18 AWG GXL X500 (4)
2 WHT P5-1 18 AWG GXL RL-503 (2)
3
4 WHT P3 18 AWG GXL X305B-11 (1)
5 WHT P4 18 AWG GXL X500 (3)
5 WHT P4-1 18 AWG GXL RL-503 (5)
3121728 7-123
7-124 3121728
7.9 ELECTRICAL SCHEMATICS
SHEET 2: PLATFORM
PLATFORM BOX HARNESS SG READY
SHEET 3: PLATFORM AND BOOM COMPONENTS LSS HARNESS
BOOM CONTROL CABLE - NO JIB ,WITH JIB , TT
TELE IN PROX SWITCHES 600/1000# CAPACITY PROX SWITCHES CABLE
SHEET 4: CHASSIS, TURNTABLE TURNTABLE HARNESS
BOOM ANGLE SENSOR CABLE
SHEET 5: GROUND USER INTERFACE
4WS MAIN VALVE HARNESS, 2WS MAIN VALVE HARNESS
GROUND CONTROL PANEL HARNESS
LIFT CYLINDER HARNESS
SHEET 6: ENGINE SCHEMATIC DEUTZ - T4i
DEUTZ T4i ENGINE HARNESS , T4i ENG POS , T4i ENG NEG
POS BATTERY , AUX TO AUX
SHEET 7: ENGINE SCHEMATIC DEUTZ T4F

DEUTZ T4F ENGINE HARNESS
T4F ENG POS , T4F ENG NEG
SHEET 8: ENGINE SCHEMATIC FORD

FORD ENGINE HARNESS
FORD ENG POS , FORD ENGINE NEG
SHEET 9: PLATFORM CHASSIS HEAD AND TAIL PLATF WORKLIGHTS,

CLEARSKY CHASSIS HEAD AND TAIL LIGHTS
CHASSIS WORK LIGHTS CLEAR SKY
SHEET 10: PLATFORM VALVE HARNESS WITH OUT JIB
SHEET 11: SKYGUARD

1001186701-K
MAE20920
Figure 7-75. Electrical Schematic - Sheet 1 of 19
3121728 7-125
1 2 3 4 5
PLTFM SNSR PLTFM SNSR
RELAY #1 RELAY #2 IP740
PUMP POT 18 OHM
WHT P10 WHT P2
87a
87a
87
30
85
86
86
85
30
87
87a
87a
87
30
85
86
86
85
30
87
X738
RL737
RL736
SOFT TCH/SKY GUARD
2
3
1
H HORN OVERRIDE
WHT P5-1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P1
WHT P5
WHT P4-1
WHT P4
WHT P9
WHT P10
BLK 1-86 SG GND
WHT P4
WHT P5
4
2
6
3
5
1
SW731
1
1
SW719-1
SW719-2
SW711-1
SW711-2
BLK 000-10-14 GND 12 AWG

WHT 1-1 (12)
WHT 1-2 HORN
WHT 1-103 SPD PMP POT GND
WHT 1-4 SOFT TOUCH

WHT 1-101 CREEP SW
WHT 1-71 SW PWR

WHT 1-105 SPD PMP POT PWR
WHT 1-87 SW PWR

WHT 1-102 SW PWR
WHT 1-104 SPD PMP POT SGL
WHT 1-87 SW PWR

WHT 1-102 SW PWR
CO01-J8
SW707
2
1
6
5 CO01-J1
WHT 1-91 ST SWITCH
4 20 SOFT TOUCH SWITCH SKYGUARD INPUT #1 SWITCH 18
MAIN TELE
G 3
WHT 1-3 RETRACT WHT 1-88 ST/SG INPUT 2
23 SKYGUARD INPUT #2 SWITCH SKYGUARD GROUND 21
BLK 1-86 SG GND
WHT 1-4 SOFT TOUCH
GROUND EMS
WHT 1-71 SW PWR
GROUND
WHT 1-34 PLAT ALRM
2 29 SOFT TOUCH/SKYGUARD OVERRIDE BUTTON PLATFORM ALARM 19
WHT 1-5 EXTEND WHT 1-2 HORN WHT 000-10-16 PLAT ALARM GND
1 31 HORN BUTTON PLATFORM ALARM GROUND 20
WHT 1-81 SW PWR WHT 1-41 PLAT ROTATE LEFT
3 PLATFORM ROTATE LEFT 5
WHT 1-103 SPD PMP POT GND WHT 1-35 GENERATOR SWITCH
13 SPEED PUMP POTENTIOMETER GROUND GENERATOR SWITCH 9
WHT 1-104 SPD PMP POT SGL WHT 1-39 FOOT SW DISENGAGED
SW733 35 SPEED PUMP POTENTIOMETER SIGNAL FOOTSWITCH DISENGAGE 8
WHT 4-89 PLAT ANGLE SEN 2 WHT 1-40 FOOT SW
6 26 PLATFORM ANGLE #2 FOOTSWITCH POWER 4
WHT 1-105 SPD PMP POT PWR WHT 1-90 SG POWER
5 34 SPEED PUMP POTENTIOMETER POWER SKYGUARD POWER 7
WHT 1-101 CREEP SW BLK 000-10-34 OPTION GND
DUAL CAPACITY
4 32 CREEP SWITCH VALVES GROUND 29

WHT 1-50 DUAL CAPACITY
3 16 CRAB STEER SELECT 33
WHT 1-81 SW PWR WHT 1-111 COORD STEER
2 17 COORDINATED STEER SELECT 34
1 WHT 1-72 SWITCHES PWR 19 28
WHT 1-3 TELE IN
5 MAIN TELESCOPE IN SWITCH 32
WHT 1-5 TELE OUT
6 MAIN TELESCOPE OUT SWITCH 27
WHT 4-88 PLAT ANGLE SEN 1
25 PLATFORM ANGLE #1 35
BLK 000-10-11 VALVES GND
SW708 22 VALVES GROUND 23
BLK 000-10-30 LSS GND
6 4 LSS GROUND 22
5 24 17
WHT 1-50 DUAL CAPACITY YEL CAN
PLATFORM ROTATE
4 21 DUAL CAPACITY SWITCH CAN HIGH 31

WHT 1-6 PLTF ROTATE RIGHT WHT 1-6 PLTF ROTATE RIGHT WHT 4-7 PLAT LEVEL DOWN
3 7 PLATFORM ROTATE RIGHT SWITCH PLATFORM LEVEL DOWN 16
WHT 1-72 SWITCHES PWR WHT 1-7 PLTF ROTATE LEFT GRN CAN
PLATFORM ROTATE LEFT SWITCH CAN LOW
F 2
WHT 1-7 PLTF ROTATE LEFT WHT 1-8 LEVEL UP
8 30
WHT 4-8 PLAT LEVEL UP
1 9 PLATFORM LEVEL UP SWITCH PLATFORM LEVEL UP 15
WHT 1-73 SWITCHES PWR WHT LEVEL DOWN WHT 1-43 JIB DOWN
10 PLATFORM LEVEL DOWN SWITCH JIB DOWN VALVE 26
WHT 1-9 START SWITCH WHT 1-36 JIB UP
14 ENGINE START SWITCH JIB UP VALVE 25
WHT 1-10 AUX POWER WHT 1-42 PLAT ROTATE RIGHT
15 AUXILIARY POWER SWITCH PLATFORM ROTATE RIGHT 6
SW709
WHT 1-13 JIB UP WHT 1-44 EMS
6 11 JIB UP SWITCH PLATFORM EMS TO GROUND BOARD 3
WHT 1-14 JIB DOWN WHT 1-37 GROUND MODE
5 12 JIB DOWN SWITCH GROUND MODE 1
WHT 1-15 HEAD LIGHTS
4 30 HEAD/TAIL LIGHT SWITCH 12
LEVEL
WHT 1-8 LEVEL UP

3 1 13
WHT 1-73 SWITCHES PWR 2 10
2
WHT LEVEL DOWN WHT 1-68 FUEL SELECT
1 33 FUEL SELECT SWITCH 24
WHT 1-74 SWITCHES PWR WHT 1-11 MIN SPEED WHT 1-45 PLATF EMS
28 MAX ENGINE TORQUE SWITCH PLATFORM EMS 2
WHT 1-70 SWITCHES PWR WHT 4-125 PLAT ANGLE SEN 5V
18 SWITCHES POWER +5 VOLTS 11
WHT 1-12 MAX SPEED BLK 000-40-90 PLAT SEN GND
SW710 27 MAX ENGINE SPEED SWITCH ANALOG GROUND (PLATFORM ANGLE) 14
CO01-J7
6
5
WHT 1-46 STEER R SW
6
4
PLATFORM MODULE
START/AUX
WHT 1-9 START SWITCH WHT 1-47 STEER L SW

3 5
WHT 1-74 SWITCHES PWR 8
2
WHT 1-10 AUX POWER 4
1
WHT 1-75 SWITCHES PWR BLK 000-10-17 D/S JS GND
7
WHT 1-48 D SGL
E 3
WHT 1-49 D/S JS PWR
SW728 1
WHT 1-52 D CTR TAP S723
6 2
5 CO01-J6
DRIVE ORIENTATION
4
OVERRIDE SW
DRIVE ORIENTATION OVERRIDE SWITCH
WHT 1-75 SWITCHES PWR

VEHICLE SYSTEM DISTRESS INDICATOR
SOFT-TOUCH / SKYGUARD INDICATOR

3
PLATFORM OVERLOAD INDICATOR
GLOW PLUG ENGAGED INDICATOR
2 8
750/1000# CAPACITY INDICATOR
WHT 1-53 SWNG CTR TAP

WHT 1-67 PLTF ORIENT OVERRIDE

FUNCTION ENABLE INDICATOR
1 6
PLATFORM LEVEL INDICATOR
S721
DRIVE DISABLED INDICATOR
GENERATOR ON INDICATOR
FUEL 1/2 FULL INDICATOR

CHASSIS TILT INDICATOR
CREEP SPEED INDICATOR
WHT 1-54 PWR

1
FUEL FULL INDICATOR
LOW FUEL INDICATOR
ANALYZER TRANSMIT
INDICATOR GROUND
INDICATOR GROUND
SOFT TOUCH POWER
WHT 1-57 SWING SGL
ANALYZER GROUND
ANALYZER RECEIVE
4
ANALYZER POWER
SW718
BLK 000-10-18 GND
DOS INDICATOR
OPTION POWER
6 7
WHT 1-58 ML SGL
3
LSS POWER
5
4 2
JIB LIFT
WHT 1-13 JIB UP S722

3 CO01-J5
2
WHT 1-14 JIB DOWN WHT 1-59 ML CTR TAP
1
20
21
25
23
24
22
26
28
29
27
30
33
34
35
32
31
12
11
15
17
10
13
14
19
18
16
4
2
6
3
5
8
9
7
1
CO01-J2
D WHT 1-77 SWITCHES PWR

1
HEAD AND TAIL

LIGHTS
SW726-2
WHT 1-23 GENERATOR ON
WHT 1-29 GLOW PLUG

WHT 1-22 PLATFORM OVERLOAD
WHT 1-99 SERVICE CABLE
BLK 000-10-27 GND
BLK 000-10-12 GND

WHT 1-21 500#/600# MODE
WHT 1-31 SOFT TCH/SKY GUARD

WHT 1-67 PLTF ORIENT OVERRIDE
WHT 1-25 SYSTEM DISTRESS
WHT 1-89 OPTION POWER
WHT 1-32 FOOTSWICH ENABLE
WHT 1-24 CREEP
BLK 1-497 FUEL GND

WHT 1-499 3/4 FUEL
WHT 1-66 POWER

WHT 1-27 1000# MODE
WHT 1-85 ST POWER
WHT 1-500 1/2 FUEL
WHT 1-81 RECEIVE

WHT 1-30 LOW FUEL
WHT 1-82 TRANSMIT

WHT 1-501 FUEL FULL
WHT 1-498 1/4 FUEL

WHT 1-20 TILT
WHT 1-15 HEAD LIGHTS

1
WHT 1 - 28 DRIVE ORIENT SW
SW726-1
WHT 1-33 LSS PWR
SW727
6
5
4
FUEL SELECT
WHT 1-68 FUEL SELECT

3
2
1
SW751
6
5
[7,G]
4
STEER SELECT
WHT 1-110 CRAB STEER

3
C 2
WHT 1-111 COORD STEER
1
WHT 1-81 RECEIVE
WHT 1-66 POWER
SW724
6 BLK 000-10-501 GND
5
4
ENGINE SPEED
WHT 1-12 MAX SPEED

LB543+
LB543-
3
GD725-J4
GD725-J3
GD725-J2
GD725-J1

2
1
1
4
4
2
2
6
5
6
5
6
5
6
5
3
1
WHT 1-11 MIN SPEED

1
2
1
ENGINE HIGH TEMPERATURE
PLATFORM OVERLOAD
GLOW PLUG
CREEP
SPARE
DRIVE ORIENTATION
CRIBBING ENABLE
SOFT TOUCH
1000# MODE
GROUND
NO CHARGE
500# MODE
ENABLE
BROKEN CABLE
TILT
AXLE SET
FOOT SWITCH ENABLE

ENGINE PREHEAT
N/C
GENERATOR
LOW FUEL
N/C
SYSTEM FAULT
SKYGAURD
WARNING
B
FAULT CABLE ORIENTATION OIL PRESSURE
TEMPERATURE
LOW FUEL CRIBBING ENABLE SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW
ENGINE HIGH
Y G Y R G Y G R
Y
PREHEAT OVERLOAD
NO CHARGE GLOW PLUG CREEP ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH
G G Y R Y R G R
G
LED LIGHTS
SHEET 2
1 2 3 4 5
7-126 3121728
4 5 6 7 8
IP740
WHT P10 18 OHM WHT P2
X738
AH712+
4
2
3
WHT 1-34 PLAT ALRM

1
H
ALARM
AH712-
WHT 000-10-16 PLAT ALARM GND
1
WHT P10
BLK 1-86 SG GND
WHT P4
WHT P5
BLK 000-10-14 GND 12 AWG

WHT 1-1 (12)
X305A
WHT 1-35 GENERATOR SWITCH
1
WHT 1-38 GEN IGN SWITCH
2
3
WHT 1-39 FOOT SW DISENGAGED
4
WHT 1-40 FOOT SW
5
6
CO01-J8
7 TO SHEET 3
2
1
S663 8
WHT 1-85 ST POWER X305B
9
SKYGUARD INPUT #1 SWITCH 18 10
SKYGUARD GROUND 21
BLK 1-86 SG GND
11
G
WHT 1-91 ST SWITCH
GROUND
WHT 1-34 PLAT ALRM

PLATFORM ALARM 19 12
GROUND EMS
WHT 000-10-16 PLAT ALARM GND

PLATFORM ALARM GROUND 20 13
WHT 1-41 PLAT ROTATE LEFT WHT 1-551
PLATFORM ROTATE LEFT 5 14
WHT 1-35 GENERATOR SWITCH WHT 1-551
GENERATOR SWITCH 9 15
WHT 1-39 FOOT SW DISENGAGED
FOOTSWITCH DISENGAGE 8
WHT 1-40 FOOT SW
FOOTSWITCH POWER 4
WHT 1-90 SG POWER
SKYGUARD POWER 7
BLK 000-10-34 OPTION GND
VALVES GROUND 29 X303A
33 [4,C] 7
S664 BLK 000-10-34 OPTION GND
34 6
28 1
32 2
27 3
TO SHEET 3
35 4
BLK 000-10-11 VALVES GND BLK 000-10-11 VALVES GND
VALVES GROUND 23 5 X303B
BLK 000-10-30 LSS GND BLK 000-10-30 LSS GND BLK 000-10-30-2 LSS GND
LSS GROUND 22 11
WHT 1-33 LSS PWR S783 WHT 1-33-2 LSS PWR
17 12
YEL CAN YEL CAN
CAN HIGH 31 S782 8
WHT 4-7 PLAT LEVEL DOWN GRN CAN
PLATFORM LEVEL DOWN 16 9
CAN LOW GRN CAN
30
10
F
PLATFORM LEVEL UP 15
WHT 1-43 JIB DOWN
JIB DOWN VALVE 26 X687
WHT 1-36 JIB UP BLU LSS GND
JIB UP VALVE 25 3
WHT 1-42 PLAT ROTATE RIGHT WHT LSS PWR
PLATFORM ROTATE RIGHT 6 2
WHT 1-44 EMS
PLATFORM EMS TO GROUND BOARD 3 1
WHT 1-37 GROUND MODE GENERIC GRY CAN1 LO
GROUND MODE 1 5
GENERIC BLK CAN1 HI
12 4
13
10
24
WHT 1-45 PLATF EMS
10
11
12
4
2
6
3
8
9
7
1
PLATFORM EMS 2
MS16
WHT 4-125 PLAT ANGLE SEN 5V
+5 VOLTS 11
BLK 000-40-90 PLAT SEN GND
ANALOG GROUND (PLATFORM ANGLE) 14
CO01-J7
GRY CAN1 LO
BLK CAN1 HI
BLK 000-10-14 GND
YEL CAN
YEL CAN
YEL CAN
GRN CAN
GRN CAN
GRN CAN
WHT 1-46 STEER R SW WHT 1-1 12 AWG
6
PLATFORM MODULE 5
WHT 1-47 STEER L SW RIGHT
STEER
WHT 1-51 PWR LEFT

8
4 X103B
ELECTRONIC JOYSTICK
BLK 000-10-17 D/S JS GND

DRIVE / STEER
7 12
WHT 1-48 D SGL
E
DRIVE
3 16
WHT 1-49 D/S JS PWR WHT 1-50 PWR
1 1
WHT 1-52 D CTR TAP S723 GRN CAN
2 2
YEL CAN
CO01-J6 3
WHT 1-44 EMS
4
VEHICLE SYSTEM DISTRESS INDICATOR
SOFT-TOUCH / SKYGUARD INDICATOR
5
S653 _2 GRN 2-5 FOOT SW
GLOW PLUG ENGAGED INDICATOR
8 SHEET 3 [G,3] 6
WHT 1-53 SWNG CTR TAP

FUNCTION ENABLE INDICATOR
6 10 TO SHEET 3
S721 WHT 1-55 PWR WHT 1-37 GROUND MODE
DRIVE DISABLED INDICATOR
5 11
CREEP SPEED INDICATOR
WHT 1-54 PWR X103A BOOM CABLE

SWING
1 18
FUEL FULL INDICATOR
LOW FUEL INDICATOR
ANALYZER TRANSMIT
INDICATOR GROUND
INDICATOR GROUND
SOFT TOUCH POWER
WHT 1-57 SWING SGL BLK 000-10+19 GND

ANALYZER GROUND
ANALYZER RECEIVE
4 19
ANALYZER POWER
BLK 000-10-18 GND WHT 4-16 PLAT DUMP 2

ELECTRONIC JOYSTICK
DOS INDICATOR
LIFT AND SWING

OPTION POWER
7 15
WHT 1-58 ML SGL WHT 4-7 PLAT LEVEL DOWN
3 7
LSS POWER
BLK 000-10-20 GND S654 WHT 4-15 PLAT DUMP 1

2 13
S722
CO01-J5 8
LIFT
WHT 1-56 PWR

14
WHT 1-59 ML CTR TAP
17
WHT 1-62 EMS B+
9
20
21
25
23
24
22
26
28
29
27
30
33
34
35
32
31
17
10
13
14
19
18
16
2
3
5
8
9
7
1
SW715-1B
SW715-1A
D
WHT 1-62 EMS B+
1B
WHT 1-99 SERVICE CABLE
BLK 000-10-27 GND
BLK 000-10-12 GND

WHT 1-31 SOFT TCH/SKY GUARD
WHT 1-25 SYSTEM DISTRESS
WHT 1-32 FOOTSWICH ENABLE
WHT 1-24 CREEP
BLK 1-497 FUEL GND

WHT 1-499 3/4 FUEL
WHT 1-66 POWER

WHT 1-27 1000# MODE
WHT 1-85 ST POWER
WHT 1-500 1/2 FUEL
WHT 1-81 RECEIVE

WHT 1-30 LOW FUEL
WHT 1-82 TRANSMIT

WHT 1-501 FUEL FULL
WHT 1-498 1/4 FUEL
1A
E STOP
WHT 1 - 28 DRIVE ORIENT SW
PLATFORM
2A
WHT 1-33 LSS PWR WHT 1-45 PLATF EMS
2B
SW715-2A
SW715-2B
X652A
WHT 4-15 PLAT DUMP 1
3
WHT 4-7 PLAT LEVEL DOWN
5
WHT 4-16 PLAT DUMP 2
12
4
1
WHT 1-43 JIB DOWN
16
[7,G]
WHT 1-36 JIB UP

15
WHT 1-42 PLAT ROTATE RIGHT
14
11 C
2
WHT 4-125 PLAT ANGLE SEN 5V TO SHEET 5
WHT 1-82 TRANSMIT
BLK 000-10-12 GND
10
WHT 1-81 RECEIVE
WHT 1-66 POWER
7
PLATFORM ANGLE SENSOR
6
17
BLK 000-10-501 GND
18
19
20
LB543+
LB543-
BLK 000-40-90 PLAT SEN GND

GD725-J3
GD725-J2
GD725-J1
21
1

X729
4
4
2
2
6
5
6
5
6
5
8
1

4
2
3
1
9
WHT 1-41 PLAT ROTATE LEFT
13
GLOW PLUG
SPARE
DRIVE ORIENTATION
CRIBBING ENABLE
SOFT TOUCH
1000# MODE
GROUND
NO CHARGE
ENABLE
BROKEN CABLE
AXLE SET
FOOT SWITCH ENABLE

N/C
LOW FUEL
N/C
SYSTEM FAULT
ANALYZER PORT
SKYGAURD
WARNING
B
SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW
Y R G Y G R
PREHEAT OVERLOAD
ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH
Y R Y R G R
LED LIGHTS
SHEET 2 1001186701-K
4 5 6 7 8
MAE20930
3121728 7-127
1 2 3 4 5
OPTION OPTION OPTION OPTION

FOOT SWITCH
SOFT SOFT
GENERATOR SWITCH SKY GUARD
TOUCH TOUCH
INPUT 2
INPUT 1
GND
PWR
2
3
1
SW35
X537
4
2
2
3
3
1
1
4
2
3
SN540
SN541
1
4
2
3
5
6
1
X537
SW34
WHT
BLK
WHT
BLK
BLK 2-3 FOOT SW DISENGAGED 16AWG
WHT 2-4 FOOT SW 16AWG
GRN 2-5 FOOT SW 16AWG
WHT INPUT 1
WHT INPUT 2
BLK GND
WHT PWR
WHT 2-1 GEN ON
1
WHT 2-2 GEN SW PWR
2
3 *
BLK 2-3 FOOT SW DISENGAGED 16AWG
4
WHT 2-4 FOOT SW 16AWG
TO SHEET 2 5
G 6
X305A WHT PWR
7
BLK GND
8
WHT
9
WHT INPUT 1
10
WHT INPUT 2
11
BLK
12
13
14
WHT
15
X305B
X510
BLK 000-3-14 GND 22AWG BLK 000-3-14 GND 22AWG
3 3
RED 3-13 PWR 22AWG RED 3-13 PWR 22AWG LSS MODULE
2 2
TO SHEET 2, F8 YEL 3-21 CAN HI YEL 3-21 CAN HI SINGLE CELL
4 4
GRN 3-22 CAN LO GRN 3-22 CAN LO
X687 5 5
OPTION
SHIELD SHIELD
1 1
X691
X104B
1 1 1
GRN GRN GRN
2 2 2
YEL YEL YEL
3 3 3
ORN ORN ORN
4 4 4
BLU BLU BLU
5 5 5
YEL YEL YEL
6 6 6
BRN BRN BRN
7 7 7
8 8 8
RED/BLK RED/BLK RED/BLK
TO SHEET 2 9 9 9
ORN 12 AWG ORN 12 AWG ORN 12 AWG
10 10 10
X103B BOOM CABLE BLU/BLK BLU/BLK BLU/BLK
11 11 11
RED 12 AWG RED 12 AWG RED 12 AWG
12 12 12
ORN/BLK ORN/BLK ORN/BLK
13 13 13
14 14 14
YEL/BLK YEL/BLK YEL/BLK
15 15 15
BLK 12 AWG BLK 12 AWG BLK 12 AWG
16 16 16
C 17
BLK/WHT 12 AWG BLK/WHT 12 AWG
17 17
BLK/WHT 12 AWG
18 18 18
19 19 19
X103A X104A
CAPACITY LENGTH CAPACITY LENGTH EXTEND/RETRACT
RIGHT PROX 1 LEFT PROX 2 LEFT PROX 1
+ - + - + -
2
2
3
3
2
3
1
1
1
SN467
SN465
SN627
ORN/BLK
ORN/BLK
BLU/BLK
BLU/RED
BLU/RED
YEL/BLK
BRN/BLK
BLK/RED
BLK/RED
B
ORN/BLK
ORN/BLK
BLU/BLK
BLU/RED
BLU/RED
YEL/BLK
BRN/BLK
BLK/RED
BLK/RED
X615B
4
2
6
5
3
1
A
DUAL CAPACITY LENGTH
PROXIMITY SENSOR
SHEET #4
ZONE D8
X615A
NOTE: ALL WIRES ARE 18AWG UNLESS OTHERWISE SPECIFIED SHEET 3

1 2 3 4 5
7-128 3121728
4 5 6 7 8
OPTION
LOW TEMP
CUTOUT SENSOR
CAN LO
CAN HI
GND
PWR
X521
4
2
3
1
X521
WHT 3-26
YEL 80-5
WHT 1-43
GRN 81-5
G
SHEET 2, F8
1
MS16 PIN 12 T536
SHEET 2, F8
1
MS16 PIN 10 T537
T534
7 1
T535
6 1
1
2
3
TO SHEET 2 11
12
X303A
4
8
5
9
10
X303B
F
CO44-J2
1
2
3
YEL CAN1 HI
4
5
YEL CAN1 HI
1 6
TO F5 X303B PIN 8 T391
OPTION
7
8
GRN CAN1 LO GRN CAN1 LO
1 9
TO F5 X303B PIN 9 T392 10
11
4 CELL LSS
12
SHIELD LSS GND SHIELD LSS GND
1 NC
TO F5 X303B PIN 10 T393
CO44-J1 E
WHT LSS PWR WHT LSS PWR
1 1
TO F5 X303B PIN 12 T395
WHT LSS GND
2
3
4
WHT LSS GND
1 5
TO F5 X303B PIN 11 T394 6
7
8
9
10
11
12
X104B X102B
1 1 1
GRN GRN GRN
2 2 2
YEL YEL YEL
3 3 3
ORN ORN ORN
4 4 4
BLU BLU BLU
5 5 5
YEL YEL YEL
6 6 6
BRN BRN BRN
7 7 7
8 8 8
RED/BLK RED/BLK RED/BLK
9 9 9 TO SHEET 4
ORN 12 AWG ORN 12 AWG ORN 12 AWG
10 10 10
BLU/BLK BLU/BLK BLU/BLK X102 BOOM CABLE
11 11 11
RED 12 AWG RED 12 AWG RED 12 AWG
12 12 12
ORN/BLK ORN/BLK ORN/BLK
13 13 13
14 14 14
YEL/BLK YEL/BLK YEL/BLK
15 15 15
BLK 12 AWG BLK 12 AWG BLK 12 AWG
16 16 16
BLK/WHT 12 AWG
17 17
BLK/WHT 12 AWG BLK/WHT 12 AWG
17 C
18 18 18
19 19 19
X104A
CAPACITY LENGTH CAPACITY LENGTH EXTEND/RETRACT EXTEND/RETRACT
RIGHT PROX 1 LEFT PROX 2 LEFT PROX 1 RIGHT PROX 2
+ - + - + - + -
2
2
3
2
2
3
3
1
1
1
SN467
SN465
SN627
SN625
ORN/BLK
ORN/BLK
BLU/BLK
BLU/BLK
BLU/RED
BLU/RED
YEL/BLK
YEL/BLK
BRN/BLK
BRN/BLK
BLK/RED
BLK/RED
B
ORN/BLK
ORN/BLK
BLU/BLK
BLU/BLK
BLU/RED
BLU/RED
YEL/BLK
BRN/BLK
YEL/BLK
BRN/BLK
BLK/RED
BLK/RED
X615B
X616B
4
4
2
2
6
5
6
3
5
1
A
DUAL CAPACITY LENGTH TELESCOPE RETRACTED
PROXIMITY SENSOR PROXIMITY SENSOR
SHEET #4 SHEET #4
ZONE D8 ZONE E8
X615A X616A
SHEET 3 1001186701-K
4 5 6 7 8
MAE20940
3121728 7-129
1 2 3 4 5
F1 F2 F3 F4 F5 F6
5A
3A
5A
15A
5A
15A
ENGINE PIVOT POINT
WHT 4-1 BRAKE

1
40
45
41
28
37
33
38
34
39
35
36
32
BLK 000-40-1 GND S98
BRAKE
[4,B]
2
[5,B]
1
HV97
X281
WHT 4-65
RED 4-552
WHT 4-50 DIAG

WHT 4-66 IGN
YEL 4-72 IGN
RED 4-51 12AWG
RED 4-71 12AWG
RED 4-350 12AWG
RED 4-550 12AWG
YEL 4-81 GEN IGN

RED 4-35 IGN 12AWG
YEL 4-82 GEN IGN

H HV96
BLK 000-40-2 GND
2 SPEED
2
WHT 4-2 TWO SPEED
1
BLK 000-40-8 MODL GND 10AWG
YEL 4-36 MODL PWR 14AWG

BLK 000-40-64 BATT GND 16AWG
DRIVE FORWARD
BLK 000-40-40 CF 16AWG

1
WHT 4-3 DRIVE FORWARD 16AWG
2
HV95
S171 X513B
BLK 000-40-43 CF 16 AWG CONNECTS TO X513A
1
2
ON SHEET 5
HV94 3
BLK 000-40-41 CF 16AWG WHT 4-203 BROKEN CBL POW
2 [6,G] 4
DRIVE REVERSE
WHT 4-4 DRIVE REVERSE 16AWG

1 5 BLK 000-40-12 PLATF GND 12AWG
6
[5 , B ]
[5 , B ]
[5 , B ]
[2,F ]
CO69-J8
4
2
3
1
WHT 4-120 OSC AXL V 2
OSC AXLE #2
1
CO69-J1
VALVE 2
2 BLK 000-40-3 GND

27
HV293
5
S300 WHT 4-1 BRAKE
23 BRAKE VALVE
MODULE GROUND
MODULE POWER
WHT 4-2 TWO SPEED
20 2 SPEED VALVE
GROUND TO PLATFORM MODULE

POWER TO PLATFORM MODULE
G HV292 WHT 4-3 DRIVE FORWARD 16AWG
3 DRIVE FORWARD VALVE
OSC AXLE #1
VALVE 1
2 WHT 4-4 DRIVE REVERSE 16AWG

6 DRIVE REVERSE VALVE
1 1
2 OSCILLLATING AXLE VALVE #2
4
7 OSCILLLATING AXLE VALVE #1
BLK 000-40-162 GND
1 8
BLK 000-40-162 GND
MSSO
SW531-2 9 MSSO GROUND

WHT 4-163 MSSO
1 [6,E] 16
WHT 4-78 AUX PUMP 16AWG
SW531-1 AUX PUMP RELAY 1 13 APU ENABLE RELAY
X450 14
X181A 15
WHT 4-94 EMR4 IGNITION WHT 4-94 EMR4 IGNITION
1 10 ECU POWER
BLK 000-40-557 GND WHT 4-80 GLOW PLUG 16AWG
2 12 ENGINE GLOW PLUG RELAY
TO ENGINE HARNESS 3
WHT 4-80 GLOW PLUG 16AWG
17
4 18
5 21
WHT 4-5 POWER
6 1 28 ANALYZER POWER
WHT 4-6 RECEIVE
7 2 29 ANALYZER RS-232 RX
ANALYZER
WHT 4-7 TRANSMIT

8 3 30 ANALYZER RS-232 TX
BLK 000-40-4 GND
F 4 31 ANALYZER GROUND
X126 24
3
BLK 000-40-161 GEN GND
25
UNIVERSAL GROUND MODULE
GENERATOR WHT 4-74 GEN ON WHT 4-74 GEN ON
2 22 GENERATOR ENABLE RELAY
CONNECTOR YEL 4-82 GEN IGN
1 [5,G] 26
X530 19 BRAKE/2 SPEED VALVE GROUND
WHT 4-67 START 16AWG
11 ENGINE START RELAY
RED 4-76 ALT EXCITE 16AWG
32 ALTERNATOR EXCITATION
33
WHT 4-117 PROX 2
[7,E] 34 TELSCOPE RETRACTED SWITCH #2
WHT 4-167 CAP PROX 2
[7,D] 35 CAPACITY LENGTH SWITCH #2
CO69-J2
10
21
14
28
30
5
7
12
E 23
13
20
9
3
15
4
16
8
TO SHEET 5 27
31
CO69-J2 11
22
35
34
1
2
17
33
24
18
D 26
32
25
6
29
19
20
21
22
23
24
25
26
27
28
29
30
31
32
10
14
11
12
13
10
11
12
13
14
15
16
17
18
19
4
4
2
2
6
6
5
3
9
8
9
7
7
1
1
CO69-J3
CO69-J4
TO SHEET 5 TO SHEET 5
CO69-J3 CO69-J4
C
WHT 4-65
[5 , H ]
S757
TO ENGINE
[5 , G ]
SHEET 5-[4,C]
PIVOT GND STUD

[5 , G ]
[5 , G ]
[5,H]
B
BLK 000-40-14 STRB GND
BLK 000-40-64 BATT GND 16 AWG
YEL 4-54 STRB LIGHT


BLK 000-40-11 NEGATIVE
WHT 4-67 START 16AWG

BLK 000-40-558 GND
BLK 000-40-557 GND

GRN CAN2 LO
YEL 4-84 IGN
YEL 4-54 STRB LIGHT

YEL CAN2 HI
GRN CAN2 LO
WHT 4-66 IGN

YEL CAN2 HI
YEL 4-81 GEN IGN
WHT 4-65-1
YEL 4-72 IGN
YEL 4-84 IGN
WHT 4-31
LB280
2
1
X183A
MS647
4
2
6
3
5
1
X429
4
2
3
5
6
8
9
7
1
12
11
10
MS650
A
J
H
F
B
C
G
E
4
2
3
5
6
8
9
7
DIAGNOSTIC
1
10
11
12
ENGINE CONNECTORS
CONNECTOR
NEGATIVE BUS
4460933 STROBE
LIGHT IGN POWER
A 4460933
NOTE: ALL WIRES ARE 18AWG UNLESS OTHERWISE SPECIFIED

SHEET 4
1 2 3 4 5
7-130 3121728
4 5 6 7 8
FUSE BOX
TO B+ AUX
MTB SELECT SWITCH
R4 R3 R2
F1 F2 F3 F4 F5 F6 F7 F8 F9 D1 D2 D3 R1 PUMP RELAY
MTB EMS
1
5A
3A
5A
15A
5A
15A
X282
ENGINE PIVOT POINT
85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a 85 86 87 30 87a
40
45
41
46
42
47
43
48
44
28
29
25
26
27
24
23
20
22
21
37
33
38
34
39
35
36
30
31
32
19
15
16
17
13
14
18
12
11
10
4
2
3
8
5
9
6
7
1
[4,B]
RED 4-49 B+ AUX PMP

[5,B]
1
X281
1
SW104-B1
SW104-1
SW104-3
SW104-2
SW104-4
SW104-B
WHT 4-41
WHT 4-66 IGN
YEL 4-72 IGN
YEL 4-81 GEN IGN
RED 4-350 12AWG
RED 4-202
RED 4-39
WHT 4-38
RED 4-166 12AWG

RED 4-51 12AWG
WHT 4-65
WHT 4-170
YEL 4-82 GEN IGN
RED 4-35 IGN 12AWG
RED 4-71 12AWG
RED 4-552
RED 4-550 12AWG
WHT 4-50 DIAG
BLK 000-40-13 GND
RED 4-37 EMS 12AWG

RED 4-563 LIGHT OPT
2A
2B
1A
1B
H
SW118-2B
SW118-1A
SW118-2A
SW118-1B
BLK 000-40-8 MODL GND 10AWG
BLK 000-40-64 BATT GND 16AWG
30A
S509
RED 4-46 18AWG
RED 4-40 18AWG

WHT 4-51-1 PLTFM EN
RED 4-47 PLTF EMS
RED 4-552
RED 4-46 18AWG
IP136
CONNECTS TO X513A
S621
ON SHEET 5
RED 4-79
RED 4-563 LIGHT OPT
BLK 000-40-12 PLATF GND 12AWG
[5 , B ]
[5 , B ]
[5 , B ]
[2,F ]
CO69-J8 RED 4-37 EMS 12AWG S123
4
2
3
1
WHT 4-50 DIAG

RED 4-51 12AWG
X102A
BLK 000-40-12 PLATF GND 12AWG
26 16
RED 4-71 12AWG
12 12
WHT 4-203 BROKEN CBL POW
BRAKE VALVE BROKEN CABLE POWER 31 [3,G] 8
RED 4-47 PLTF EMS
2 SPEED VALVE 30 9
MODULE POWER
MODULE GROUND
GROUND TO PLATFORM MODULE

POWER TO PLATFORM MODULE
DRIVE FORWARD VALVE 27

RED 4-202 WHT 4-11 PLAT LEVEL DOWN
7
G
RED 4-201 RED 4-40 18AWG WHT 4-8 PLAT LEVEL UP
DRIVE REVERSE VALVE GROUND MODE 3 5
BLK 000-40-13 GND S766 WHT 4-15 HIGH PRES DUMP
IGNITION RELAY GROUND 19 13
OSCILLLATING AXLE VALVE #2 22 10
X43 BOOM CABLE

8 14
OSCILLLATING AXLE VALVE #1 WHT 4-42 PLTF EMS
PLATFORM EMS 1 17
TO SHEET 3
WHT 4-52 FOOT SW S121
FOOTSWITCH 15 18
WHT 4-53 GROUND MODE WHT 4-43 PLTF EMS
MSSO GROUND GROUND MODE POWER TO PLATFORM 14 4
WHT 4-52 FOOT SW
20 6
WHT 4-53 GROUND MODE
APU ENABLE RELAY 18 11
5 19
WHT 4-16 LOW PRES DUMP
11 15
WHT 4-133 CAN1 TERM GRN CAN 1 LO
ECU POWER CAN1 TERMINATOR 17 2
YEL CAN 1 HI
ENGINE GLOW PLUG RELAY CAN1 TERMINATOR 6 3
WHT 4-132 PLAT MODE
PLATFORM MODE 2 1
YEL CAN 1 HI
CAN1 HIGH 13 CONNECTS TO X701B
X701A
GRN CAN 1 LO
CAN1 LOW 24 MS131
IN MAIN VALVE HARNESS
2
3
1
WHT 4-108 VCC YEL CAN 1 HI
ANALYZER POWER TILT SENSOR POWER 34 1
WHT 4-123 GND YEL CAN 1 HI
ANALYZER RS-232 RX TILT SENSOR GROUND 10 2
WHT 4-110 PROX 1 YEL CAN 1 HI 20AWG
ANALYZER RS-232 TX TELESCOPE RETRACTED SWITCH #1 21 3
BLK 000-40-76 GND
BOOM ANGLE SENSOR GROUND
ANALYZER GROUND 9
WHT 4-118 PWR 5V
10
F
BOOM ANGLE SENSOR POWER 16 11
UNIVERSAL GROUND MODULE BLU/BLK 4-86 BM ANGLE SEN 1
2 X 6 Buss Bar
BOOM ANGLE SENSOR #1 4 12
CAN 1
BLU/RED 4-87 BM ANGLE SEN 2 GRN CAN 1 LO
GENERATOR ENABLE RELAY BOOM ANGLE SENSOR #2 7 4
WHT 4-119 PWR 12V GRN CAN 1 LO
TELESCOPE RETRACTED SWITCH POWER 33 5
BLK 000-40-75 GND GRN CAN 1 LO 20AWG
BRAKE/2 SPEED VALVE GROUND TELESCOPE RETRACTED SWITCH GROUND 28 6
WHT 4-115 CAPACITY
ENGINE START RELAY CAPACITY LENGTH SWITCH #1 23 7
WHT 4-116 POWER 12V
ALTERNATOR EXCITATION TRANSPORT SWITCHES POWER 32 8
WHT 4-92 DOS SW
DOS SWITCH 35 9
BLK 000-40-51 GND
TELSCOPE RETRACTED SWITCH #2 GROUND DISPLAY GROUND 25
RED 4-97 PWR
CAPACITY LENGTH SWITCH #2 GROUND DISPLAY POWER 29
SN476
CO69-J7
WHT 4-108 VCC
BLU/RED 4-87 BM ANGLE SEN 2

BLU/BLK 4-86 BM ANGLE SEN 1
WHT 4-163 MSSO 1
WHT 4-123 GND GND
[2,G]
TILT SENSOR
MSSO SWITCH 8 2
CAN BASED
WHT 4-96 CAN2 TERM YEL CAN 1 HI 20AWG B+
CAN2 TERMINATOR 7 3
GRN CAN 1 LO 20AWG CAN-L
CAN2 TERMINATOR 6 4
CAN-H
CAN2 SHIELD 5
GRN CAN2 LO
CAN2 LOW 3
YEL CAN2 HI
CAN2 HIGH 4
2
1 X616A
WHT 4-111 PWR 12V
CO69-J12 1
TELESCOPE RETRACTED
E
BLK 000-40-77 GND
X743A
2 PROXIMITY SENSOR
WHT 4-110 PROX 1
4
2
3
3 SHEET #3
WHT 4-113 PWR 12V
4 ZONE C5/6
BLK 000-40-80 GND X616B
S469 5
S468 WHT 4-117 PROX 2
[3,F] 6
4
2
3
1
X743B
SN471
BLK 000-40-76 GND S295
BLK/RED 000-40-78 GND
A
WHT 4-108 PWR 5V S294 ORN/BLK 4-106 PWR 5V
B
ANGLE SENSOR
BLU/BLK 4-86 BM ANGLE SEN 1
MAIN BOOM
C
BRN/BLK 000-40-79 GND
E
YEL/BLK 4-112 PWR 5V
F
BLU/RED 4-87 BM ANGLE SEN 2
D
D
X615A
WHT 4-168 PWR 12V
1 DUAL CAPACITY LENGTH
BLK 000-40-167 GND
2 PROXIMITY SENSOR
WHT 4-167 CAP PROX 2
[3,F] 3 SHEET #3
WHT 4-114 PWR 12V ZONE C5
4
BLK 000-40-98 GND X615B
5
WHT 4-115 CAPACITY
6
CABLE
X479 1
WHT 4-116 POWER 12V
1 2 2
OSC AXLE #2
DOS
WHT 4-92 DOS SW
2 1 3
X478 4
CABLE
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
10
14
11
12
13
10
11
12
13
14
15
16
17
18
19
4
4
2
2
6
6
5
3
9
8
9
7
7
1
SN289
CO69-J3
CO69-J4
TO SHEET 5 TO SHEET 5
X755
WHT 4-65-2
CO69-J3 CO69-J4 1
BLK 000-40-558 GND
RED 4-97-2 PWR
2 C
3
4
S758
TELEMATICS CONNECTOR
WHT 4-65
BLK 000-40-51 GND

RED 4-97-1 PWR
YEL CAN2 HI
[5 , H ]
GRN CAN2 LO
S757
GD414
4
2
6
5
1
NC
TO ENGINE
[5 , G ]
SHEET 5-[4,C]
PIVOT GND STUD

[5 , G ]
[5 , G ]
[5,H]
B
BLK 000-40-64 BATT GND 16 AWG
YEL 4-54 STRB LIGHT


BLK 000-40-558 GND
BLK 000-40-557 GND
MDI/HOURMETER
GRN CAN2 LO
GRN CAN2 LO
GRN CAN2 LO
GRN CAN2 LO
YEL CAN2 HI
YEL CAN2 HI
YEL CAN2 HI
YEL CAN2 HI
YEL 4-54 STRB LIGHT
GRN CAN2 LO
WHT 4-66 IGN

YEL CAN2 HI
WHT 4-65-1
YEL 4-81 GEN IGN
YEL 4-72 IGN
YEL 4-84 IGN

LB280
WHT 4-31
2
1
MS647
MS325
X429
4
2
6
3
8
9
7
1
12
11
10
2
9
8
6
5
3
7
1
MS650
12
11
10
A
J
H
F
B
C
G
E
4
2
3
5
6
8
9
7
DIAGNOSTIC
1
10
11
12
CONNECTOR
NEGATIVE BUS 2 x6 Buss Bar

4460933 STROBE
IGN POWER CAN 2
LIGHT
4460933 A
SHEET 4 1001186701-K
4 5 6 7 8
MAE20950
3121728 7-131
1 2 3 4 5
CONNECTS TO X701A
MAIN VALVE IN TURNTABLE HARNESS
HARNESS
4
2
3
1
X701B
H
R001
WHT 4-11-2 PLT LVL DN

HV804
WHT 4-8-2 PLT LVL UP

BLK 000-4-85 BP DUMP GND
BYPASS DUMP
R002
2 TO SHEET 4
WHT 4-85 BYPASS DUMP
1
CO69-J2
HV687 CO69-J2
TELESCOPE DUMP
BLK 000-40-150 TELE DUMP GROUND

2 10
WHT 4-150 TELE DUMP WHT 4-150 TELE DUMP
1 31 TELESCOPE DUMP VALVE
17
12
WHT 4-16 LOW PRES DUMP
HV366 S688 23 PLATFORM DUMP VALVE #2
BLK 000-40-25 GND BLK 000-40-151 GND
MAIN DUMP
2 30 MAIN DUMP VALVE GROUND

WHT 4-14 MAIN DUMP WHT 4-14 MAIN DUMP
1 13 MAIN DUMP VALVE
16
HV371 2
MAIN TELE IN
BLK 000-40-31
2 24
1
WHT 4-19 RETRACT WHT 4-19 TELE IN
9 MAIN TELESCOPE IN VALVE TO SHEET 4
14 MAIN TELESCOPE GROUND
S386 WHT 4-20 TELE OUT
20 MAIN TELESCOPE OUT VALVE
CO69-J4
G WHT 4-8 PLAT LEVEL UP
5
HV372 PLATFORM LEVEL UP VALVE
MAIN TELE OUT
BLK 000-40-21
2 7
BLK 000-40-53 GND PLATFORM LEVEL DOWN VALVE
WHT 4-20 EXTEND MAIN TELESCOPE OUT SWITCH 30
1 28 STEER VALVES GROUND
WHT 4-15 HIGH PRES DUMP SWITCHES POWER 25
3 PLATFORM DUMP VALVE #1
MAIN TELESCOPE IN SWITCH 7
15
WHT 4-21 STR RIGHT PLATFORM ROTATE RIGHT SWITCH 18
8 FRONT STEER RIGHT VALVE
HV685 PLATFORM ROTATE LEFT SWITCH
BLK 000-40-49 REAR STR LEFT GND WHT 4-22 STR LEFT 6
REAR STR LFT
2 19 FRONT STEER LEFT VALVE

WHT 4-103 REAR STR LEFT WHT 4-28 AUX DN PLATFORM LEVEL UP SWITCH 17
1 21 AUX POWER MAIN LIFT DOWN VALVE
WHT 4-24 LIFT UP PLATFORM LEVEL DOWN SWITCH 5
11 MAIN LIFT UP VALVE
WHT 4-25 LIFT DN 4
22 MAIN LIFT DOWN VALVE ENGINE START SWITCH
WHT 4-26 SWG RHT AUXILIARY POWER/FUNCTION ENABLE SWITCH 16
HV684 35 SWING RIGHT VALVE
BLK 000-40-33 STR DUMP GND WHT 4-27 SWG LEFT 19
STR DUMP
2 34 SWING LEFT VALVE JIB UP SWITCH

WHT 4-23 STR DUMP WHT 4-23 STR DUMP 8
1 1 STEER DUMP VALVE JIB DOWN SWITCH
WHT 4-85 BYPASS DUMP 23
4 MAIN LIFT UP SWITCH
WHT 4-103 REAR STR LEFT 33
33 REAR STEER LEFT VALVE MAIN LIFT DOWN SWITCH
BLK 000-40-33 STR DUMP GND 35
HV686 18 STEER DUMP GROUND VALVE SWING RIGHT SWITCH
BLK 000-40-63 REAR STR RT GND
REAR STR RHT
WHT 4-104 REAR STR RHT SWING LEFT SWITCH 34

2 32 REAR STEER RIGHT VALVE
WHT 4-104 REAR STR RHT WHT 4-75 FUEL SNSR
1 10
25 FUEL SENSOR SIGNAL
BLK 000-40-45 21
6 FUEL SENSOR GROUND
MAIN VALVE BANK
11
29 GROUND ALARM GROUND
HV373 22
F BLK 000-40-32 GND S415 27 GROUND ALARM
STR RHT
2 12
WHT 4-21 STR RIGHT 26 HEAD/TAIL LIGHT ENABLE RELAY
1 INDICATORS GROUND 32
LOW FUEL INDICATOR 13
HV374
BLK 000-40-34 GND GLOWPLUG INDICATOR 3
2
STR LFT
WHT 4-22 STR LEFT INDICATORS GROUND 31

1
CRIBBING ENABLED INDICATOR 1
PLATFORM OVERLOADED INDICATOR 14
HV378 BATTERY LOW/NOT CHARGING INDICATOR 26

BLK 000-40-37 CF
ENGINE LOW OIL PRESSURE INDICATOR 29
SWG RHT
2
WHT 4-26 SWG RHT ENGINE HIGH COOLANT TEMPERATURE INDICATOR 28
1
SYSTEM DISTRESS INDICATOR 2
S389 27
HV379 9
BLK 000-40-39 CF TO SHEET 4
SWG LFT
2 20
WHT 4-27 SWG LEFT
1 15
C069-J3
CO69-J3 24
BLK 000-40-120 CF XCO69-J4
2 AUXILIARY DOWN VALVES CURRENT FEEDBACK
5
BLK 000-40-7 CF
MAIN LIFT UP
HV376 S705 6 TELESCOPE FLOW CONTROL VALVE CURRENT FEEDBACK

BLK 000-40-35 CF BLK 000-40-50 CF
2 14 MAIN LIFT VALVES CURRENT FEEDBACK
WHT 4-24 LIFT UP BLK 000-40-38 CF
E 1 4 SWING VALVES CURRENT FEEDBACK
WHT 4-204 SERV CBL GND
3 CABLE SERVICE SWITCH GROUND
WHT 4-30 ALRM
7 GROUND ALARM POWER
1 DRIVE VALVES CURRENT FEEDBACK
WHT 4-205 SERV CBL SIGNAL
8 CABLE BREAK SWITCH
BLK 000-40-36 CF
9 CRIBBING ENABLE SWITCH

WHT 4-25 LIFT DN
WHT 4-28 AUX DN
10
HV703
MAIN LIFT DOWN
BLK 000-40-36 CF 11
BLK 000-40-10 ALRM GND
2
WHT 4-25 LIFT DN 12
1
X745B 13
WHT 4-29 ALRM
WHT 4-30 ALRM
1 1
WHT 4-102 HEAD & TAIL LIGHTS
2 2
+
3
WHT 4-206 SERV CBL PWR
3 X768 SN683
BLK 000-40-120 CF WHT 4-205 SERV CBL SIGNAL BLK SIGNAL (22)
BROKEN CABLE PROX SENSOR

4 4 22 2
X473
WHT 4-105 CRIBBING

X474
HV704 WHT 4-206 SERV CBL PWR BRN POWER
4360527
MAIN AUX DN
X745A
LIFT CYLINDER
BLK 000-40-120 CF 11 1
BLK 000-40-44 CF
2 WHT 4-204 SERV CBL GND BLU GROUND (22)

1
1
WHT 4-28 AUX DN 33 3

SN472
1
X767
AH387
2
1
-
A
C
B
D
X513A
4
2
6
3
5
1
ALARM
CONNECTS TO X513B
FUEL
SENSOR
ON SHEET 4
HV381
BLK 000-40-22
PLTF LVL UP
2
1 1
WHT 4-31
SHEET 4-[5,B] 2
WHT 4-32
3
4
HV380 5
WHT 4-32
PLTF LVL DOWN
BLK 000-40-30 1 6
2
WHT 4-7 PLAT LEVEL DOWN X398 SW396
1
CONNECTS TO PIN 3
C HV383
BLK 000-40-19
IN CONNECTOR X513B ON SHEET 4
PLTF ROT LFT
2
WHT 4-9 ROTATE LEFT
1
HV382
BLK 000-40-20
PLTF ROT RHT
2
WHT 4-10 ROTATE RIGHT
PLATFORM VALVE BANK
X652B
BLK 000-40-90
HV364 21
BLK 000-40-23
JIB UP
2 20
WHT 4-12 JIB UP
1 19
18
17
HV365 WHT 4-13 JIB DOWN
BLK 000-40-24 16
JIB DOWN
2 WHT 4-12 JIB UP

WHT 4-13 JIB DOWN 15
1 WHT 4-10 ROTATE RIGHT
14
WHT 4-9 ROTATE LEFT
13
WHT 4-16 LOW PRESSURE DUMP TO SHEET 2
HV660 12
HIGH PRES DUMP
BLK 000-40-26
2 11 X652A PLATFORM ANGLE SENSOR
WHT 4-15 HIGH PRESSURE DUMP WHT 4-125 PLAT ANGLE SEN 5V
B 1 10
9
8
HV661 7
LOW PRES DUMP
BLK 000-40-27
2 6
WHT 4-16 LOW PRESSURE DUMP WHT 4-7 PLAT LEVEL DOWN
1 5
4
WHT 4-15 HIGH PRESSURE DUMP
3
2
1
B L K 0 0 0 - 4 0 -9 2 G N D
W H T 4 - 1 2 6 P W R5 V
BLK 000-40-92 GND
BLK 000-40-91 GND

WHT 4-127 PWR 5V
WHT 4-127 PWR 5V
BLK 000-40-91 GND
B L K 0 0 0 -4 0 -2 7
B LK 0 0 0 - 4 0 - 2 2
BLK 000-40-90
BLK 000-40-26
BLK 000-40-23
BLK 000-40-20
BLK 000-40-24
BLK 000-40-19
BLK 000-40-30
PLATFORM VALVE HARNESS WITH JIB

A
SN662
A
D
F
C
B
MS681
E
MS682
2
9
8
6
5
3
7
4
2
9
8
6
5
3
7
1
1
12
11
10
12
11
10
GROUND BUSS GENERIC

GENERIC GENERIC PLTF ANGLE SENSOR
SHEET 5
1 2 3 4 5
7-132 3121728
4 5 6 7 8
H
GROUND CONTROL
TO SHEET 4
PANEL HARNESS
CO69-J2
MAIN EXTEND/ RETRACT ROTATE LEVEL IGNITION START JIB MAIN LIFT SWING
CO69-J2
AUX POWER
10
31 TELESCOPE DUMP VALVE
17
12
23 PLATFORM DUMP VALVE #2
30 MAIN DUMP VALVE GROUND
13 MAIN DUMP VALVE
4
2
2
6
6
3
5
1
1
16
SW141
SW140
SW142
SW143
SW144
SW145
SW146
2
24
9 MAIN TELESCOPE IN VALVE
TO SHEET 4
WHT 5-31
WHT 5-31
WHT 5-27
WHT 5-28
WHT 5-27
WHT 5-28
WHT 5-30
WHT 5-29
WHT 5-29
WHT 5-32
WHT 5-30
WHT 5-32
14 MAIN TELESCOPE GROUND
20 MAIN TELESCOPE OUT VALVE
CO69-J4
5 PLATFORM LEVEL UP VALVE
G
7 PLATFORM LEVEL DOWN VALVE
WHT 5-2 TELE OUT
MAIN TELESCOPE OUT SWITCH 30
28 STEER VALVES GROUND WHT 5-26 SWITCH POWER
SWITCHES POWER 25
3 PLATFORM DUMP VALVE #1 WHT 5-1 TELE IN
MAIN TELESCOPE IN SWITCH 7
15
8 PLATFORM ROTATE RIGHT SWITCH 18
FRONT STEER RIGHT VALVE WHT 5-4 ROTATE LEFT
PLATFORM ROTATE LEFT SWITCH 6
19 FRONT STEER LEFT VALVE
WHT 5-5 LEVEL UP
PLATFORM LEVEL UP SWITCH 17
21 AUX POWER MAIN LIFT DOWN VALVE WHT 5-6 LEVEL DOWN
11 PLATFORM LEVEL DOWN SWITCH 5
MAIN LIFT UP VALVE WHT 5-9 IGNITION START
ENGINE START SWITCH 4
22 MAIN LIFT DOWN VALVE WHT 5-8 AUX POWER
AUXILIARY POWER/FUNCTION ENABLE SWITCH 16
35 SWING RIGHT VALVE WHT 5-10 JIB UP
JIB UP SWITCH 19
34 SWING LEFT VALVE
WHT 5-11 JIB DOWN
STEER DUMP VALVE JIB DOWN SWITCH 8
1
WHT 5-12 MAIN LIFT UP
MAIN LIFT UP SWITCH 23
4
WHT 5-13 MAIN LIFT DOWN
REAR STEER LEFT VALVE MAIN LIFT DOWN SWITCH 33
33
WHT 5-14 SWING RIGHT
SWING RIGHT SWITCH 35
18 STEER DUMP GROUND VALVE WHT 5-15 SWING LEFT
32 REAR STEER RIGHT VALVE SWING LEFT SWITCH 34
10
25 FUEL SENSOR SIGNAL
FUEL SENSOR GROUND 21
6
11
29 GROUND ALARM GROUND
22
27 GROUND ALARM
12
F
26 HEAD/TAIL LIGHT ENABLE RELAY BLK 000-50-2 GND
INDICATORS GROUND 32
WHT 5-36 LO LVL FUEL
LOW FUEL INDICATOR 13
WHT 5-24 GLOW PLUG
GLOWPLUG INDICATOR 3
BLK 000-50-1 GND
INDICATORS GROUND 31
WHT 5-23 CRIBBING ENABLED
CRIBBING ENABLED INDICATOR 1
WHT 5-25 PLATFORM OVERLOAD
PLATFORM OVERLOADED INDICATOR 14
WHT 5-22 NO CHARGE
BATTERY LOW/NOT CHARGING INDICATOR 26
WHT 5-20 ENGINE LOW OIL PRES
ENGINE LOW OIL PRESSURE INDICATOR 29
WHT 5-21 ENGINE HIGH TEMP
ENGINE HIGH COOLANT TEMPERATURE INDICATOR 28
WHT 5-35 SYSTEM FAULT
SYSTEM DISTRESS INDICATOR 2
27
9
TO SHEET 4
20
15
C069-J3
CO69-J3 24
BLK 000-40-120 CF XCO69-J4
2 AUXILIARY DOWN VALVES CURRENT FEEDBACK
5
BLK 000-40-7 CF
6 TELESCOPE FLOW CONTROL VALVE CURRENT FEEDBACK
GD529-J4
GD529-J3
GD529-J2
GD529-J1
BLK 000-40-50 CF
14 MAIN LIFT VALVES CURRENT FEEDBACK
4
2
2
6
5
6
3
6
3
3
1
1
BLK 000-40-38 CF
4 SWING VALVES CURRENT FEEDBACK E
WHT 4-204 SERV CBL GND
3 CABLE SERVICE SWITCH GROUND
WHT 4-30 ALRM
7 GROUND ALARM POWER
SOFT TOUCH
DRIVE VALVES CURRENT FEEDBACK
NO CHARGE
FOOT SWITCH ENABLE

DRIVE ORIENTATION
BROKEN CABLE
GLOW PLUGS
PLATFORM OVERLOAD
GND
500# MODE
SYSTEM FAULT
CRIBBING ENABLE

CRIBBING ENABLED
N/C
ENABLE
NO CHARGE
AXLE SET
GROUND
SYSTEM FAULT
ENGINE PREHEAT
N/C
LOW FUEL LEVEL

1
WHT 4-205 SERV CBL SIGNAL
8 CABLE BREAK SWITCH
9 CRIBBING ENABLE SWITCH
10
11
12
13
WHT 4-102 HEAD & TAIL LIGHTS

WHT 4-206 SERV CBL PWR
X768 SN683
WHT 4-205 SERV CBL SIGNAL BLK SIGNAL (22) TEMPERATURE
LOW FUEL CRIBBING ENABLE SYSTEM BROKEN 1000# MODE DRIVE AXLE SET ENGINE LOW
BROKEN CABLE PROX SENSOR
22 2
WHT 4-105 CRIBBING
WHT 4-206 SERV CBL PWR BRN POWER ENGINE HIGH

4360527
11 1
BLK 000-40-44 CF
WHT 4-204 SERV CBL GND BLU GROUND (22)

33 3
Y G Y R G Y G R
X767 Y
-
PREHEAT OVERLOAD
NO CHARGE GLOW PLUG CREEP ENGINE TILT 500# MODE PLATFORM GENERATOR FOOT SWITCH
G
G G Y R Y R G R D
X513A
4
2
3
5
6
1
GROUND
CONNECTS TO X513B PANEL DISPLAY
ON SHEET 4
1
WHT 4-31
SHEET 4-[5,B] 2
WHT 4-32
CRIBBING SWITCH
3
OPTION
4
5
WHT 4-32
1 6
X398 SW396
CONNECTS TO PIN 3
IN CONNECTOR X513B ON SHEET 4 C
X652B
BLK 000-40-90
21
20
19
18
17
WHT 4-13 JIB DOWN
16
WHT 4-12 JIB UP
15
14
WHT 4-9 ROTATE LEFT
13
WHT 4-16 LOW PRESSURE DUMP TO SHEET 2
12
11 X652A PLATFORM ANGLE SENSOR
WHT 4-125 PLAT ANGLE SEN 5V
10 B
9
8
7
6
5
4
3
2
1
WH T 4 - 12 6 P W R 5V
BLK 000-40-91 GND

BLK 000-40-92 GND
WHT 4-127 PWR 5V

WHT 4-127 PWR 5V
A
SN662
A
D
F
C
B
MS681
E
2
3
1
12
11
10
SHEET 5 PLTF ANGLE SENSOR
1001186701-K
4 5 6 7 8
MAE20960
3121728 7-133
7-134
F
B
C
H
D
G
1
1
2
2
HARNESS
TO TURNTABLE
BLK 2/0 2/0 AWG GROUND STUD LOCATED
1
ON THE ENGINE BLOCK
X559
1
3
5
6
1
2
4
7
3
5
6
8
2
4
X183B
X181B
BLK 2/0 2/0 AWG
BLK 2/0 2/0 AWG GROUND STUD LOCATED ON THE
1
PIVOT POINT OF AN ENGINE TRAY
X558
WHT 6-16 18 AWG

WHT 6-18 GLOW 18 AWG
YEL CABLE CAN HI 18 AWG

GRN CABLE CAN LO 18 AWG
RED 6-51 ALT EXCITE 16 AWG
3
3
BLK 2/0 2/0 AWG
WHT 6-25 ENGINE START 14 AWG

BLK 2/0 2/0 AWG
1
MS561- M
AUX PUMP
RED 2/0 2/0 AWG

1
MS561+
BLK 2/0 2/0 AWG

1
BLK 16AWG 16 AWG
BT557-
BATTERY
RED 2/0 2/0 AWG

1
BT557+
RL560-87
RED 2/0 2/0 AWG 87
1
RED 2/0 2/0 AWG
RL560-30
RED 2/0 2/0 AWG 30
1
RELAY
RL560-86
AUX PUMP
86
1
RL560-85
BLK 16AWG 16 AWG 85
1
4
4
RL563-87
RED 2/0 2/0 AWG 87
1

RED 2/0 2/0 AWG
RL563-30
RED 12AWG 12 AWG 30
1
RELAY
START
RL563-86
W H T 6 -2 5 E N G IN E S T AR T
86
1
RL563-85
85
1
S240
DEUTZ T4I ENGINE HARNESS SCHEMATIC
RL564-87
RED 2/0 2/0 AWG 87
1
RED 8 AWG
RL564-30
RED 6AWG 30
1
RELAY
WHT 6-18 GLOW 18 AWG RL564-86

GLOW PLUGS
86
1
RL564-85
85
1
S483
3 C RED 6AWG
GRN CABLE CAN LO 18 AWG 1
GLOW PLUGS
2 B
YEL CABLE CAN HI 18 AWG EC565
1 A
CAN TERMINATOR
X485 X481
RED 8 AWG 8 AWG
5
5
EC566-B+
S484
- FUSE LINK 12 AWG

X239 1 B+
WHT 6-17 DIAGNOSTIC 18 AWG S480
A RED 6-51 ALT EXCITE 16 AWG EC566-D+
BLK 000-6-3 18 AWG
B 1 D+
ALTERNATOR
W H T 6 -2 4 18 AW G
DIAGNOSTIC
CONNECTOR
K EC566-W
ALTERNATOR
W H T 6 -2 3 18 AW G
L 1 W
G
H
E
D
1
EC562-B-
RED 12AWG
1
ENGINE STARTER
SHEET 6
3121728
4 5 6 7 8
G
DEUTZ T4I ENGINE HARNESS SCHEMATIC
AUX PUMP START GLOW PLUGS GLOW PLUGS ALTERNATOR ENGINE STARTER
RELAY RELAY RELAY
ALTERNATOR
D+
M
B+
W
BT557+
1
EC566-D+
EC566-B+
EC566-W
87
30
86
85
87
30
86
85
87
30
86
85
1
EC565
RL563-85
RL560-85
RL563-87
RL563-30
RL563-86
RL560-30
RL560-87
RL560-86
RL564-85
RL564-87
RL564-30
RL564-86
1
EC562-B+
EC562
EC562-B-
1
1
RED 6AWG
- FUSE LINK 12 AWG

BLK 16AWG 16 AWG
RED 2/0 2/0 AWG

RED 2/0 2/0 AWG
RED 12AWG 12 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 6AWG
RED 8 AWG
RED 12AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG
F
S480
RED 8 AWG 8 AWG

TO AUX RELAY B+ TO AUX RELAY CASE GND
V_ECM RELAY
1
1
X800
X801
W H T 6 -2 5 E N G IN E S T AR T
RED 6-51 ALT EXCITE 16 AWG
87a
87
30
85
86
WHT 6-18 GLOW 18 AWG
RED FUSE LEAD
BLK 000-6-1-3
4
2
3
5
1
RL799
WHT 6-15-3
RED 6-15-2
BLK 000-6-1-2
E
DEUTZ TIER 4I
S802
5A
ENGINE CONNECTOR
IP803
4
3 GRD (TEMPA11) 2
8 COOLANT
17 ADC7 (TEMP3) 1 TEMPERATURE
9
BLK 000-6-1 GROUND 16 AWG
25
S240 24
WHT 6-15 18 AWG
SPEED 13 2 ENGINE
23
GRD (SPEED) 12 SPEED CAMSHAFT
22 1
21
GRD (ACD2) 23 1
20
ADC5 (TEMP1) 4 2 CHARGE AIR
16
PRESSURE
+5V REF (ADC2) 25 3
15
ADC2 24 4
ERM2 ENGINE CONTROL TO ENGINE
14 14
NTB TO ERM2 ENGINE CONTROL
19
18
D
+5V REF (ADC4) 22
1 1 1 ENGINE OIL
S483 GRN CABLE CAN LO 18 AWG ADC4 21
13 13 2 PRESSURE
YEL CABLE CAN HI 18 AWG GND (ADC4) 20
12 12 3
S484 9
8
ACTOR OUR 14 1
7
ACTOR OUT 15 2
6 END
RACK MEAS CAN 17 3
ACTUATOR
5
RACK MEAS SIGNAL 19 4
2 2
RACK MEAS REF 18 5
11 11
10 10
X206
C
WHT 6-17 DIAGNOSTIC 18 AWG
18 AW G
18 AW G
BLK 000-6-3 18 AWG
W H T 6 -2 4
W H T 6 -2 3
X481
X239
A
C
B
D
H
B
K
E
X485
CONNECTOR
2
3
DIAGNOSTIC
CAN TERMINATOR
SHEET 6 1001186701-K
4 5 6 7 8
MAE20970
3121728 7-135
1 2 3 4 5
FUEL PUMP 20A (SW), ECM 30A (CONT)

ECM-J2 EIC BUSSMANN DIODE PACK
BLK 248-33 INJECTOR 1 1.5mm² YELLOW CONNECTOR
33 62 (BLUE)
BLK 248-16 INJECTOR 1 1.5mm² GENERIC
16 35 RELAY, POWER MODULE
BLK 248-48 INJECTOR 4 1.5mm²
48 42
18 37
32 38
BLK 248-2 INJECTOR 3 1.5mm² 5A 10A
2 61
46 40
H 3
BLK 148-28 START RTN 0.75mm²
41
6 2
BLK 248-5 MPROP ACTUATOR 1.5mm²
2
5 20
1
RL930-B+
RL930-1
RL930-2
BLK 248-4 MPROP ACTUATOR 1.5mm²
RL930
A
G
D
H
C
B
E
F
MS932
4 19
1
BLK 248-37 ENGINE SPEED CAMSHAFT
RL553-30-2
37 14
WHT 248-52 ENGINE SPEED CAMSHAFT
BUSBAR
52 13
SHLD 248-53 ENGINE SPEED CAMSHAFT
53 9
BLK 248-39 ENGINE SPEED CRANKSHAFT
39 15
WHT 248-54 ENGINE SPEED CRANKSHAFT
54 21
YEL 2-48-4 IGNITION
ORG 248-23-1 GLOW SENSE

YEL 2-48-1 IGNITION 16AWG
BLK 148-26 FUEL PUMP RELAY CTRL GND 0.75mm²

RED 1-148-135 ECM PWR

YEL 2-1-99 IGNITION
WHT 48-96 FUEL PUMP 14AWG

BLK 248-23 GLOW SENSE 0.75mm²
SHLD 248-38 ENGINE SPEED CRANKSHAFT
38 1
BLK 248-7 RAIL PRESSURE FUEL 0.75mm²
7 32
8 57
BLK 148-73 START SIGNAL 0.75mm²
9 3
10 4
11 5
12 6
13 7
14 8
A [J2]
15 10
17 11
ECM CONNECTOR 19
BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²
47
G 20
48
21 12
22 59
23 16
S946
BLK 248-24 BOOST PRESSURE / TEMP 0.75mm² EIC (ENGINE INTERFACE CONNECTION)
24 22
25 31
26 25
BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²
27 29
BLK 248-28 COOLING TEMPERATURE 0.75mm²
28 24
BLK 248-29 OIL PRESSURE 0.75mm²
29 27
30 33
31 60
BLK 148-61 FUEL LOW PRESSURE 0.75mm²
34 17
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
35 18
36 58
1 30
BLK 248-40 AIR INLET TEMP 0.75mm² BLK 248-40 AIR INLET TEMP 0.75mm²
40 28
BLK 148-56 AIR INLET TEMP 0.75mm²
41 34
42 36
43 23
F 44 26
45 39
47 43
49 44
50 45
51 46
BLK 148-72 THROTTLE FLAP 3 0.75mm²
55 49
56 50
57 52
58 51
59 53
60 54
55
56
ECM-J1
7
8
9
10
E 11
12
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
13
S951
14
BLK 148-15-68 CLUTCH SWITCH 0.75mm²
15
16
17
18
S952
19
20
21
22
23
24
25
26
27
BLK 148-28 START RTN 0.75mm²
28
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
29
30
31
D 32
33
34
BLK 148-35-2 START 0.75mm²
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
C 52
GRN CAN 2 LO DIAG CAN LOW 20AWG S968
53
YEL CAN 1 HI CUSTOMER CAN HIGH 20AWG
54
S953
55
BLK 148-56 AIR INLET TEMP 0.75mm²
56
BLK 148-57 WATER IN FUEL SW RTN 0.75mm²
57
K [J1]
58 X966
59 C C
ECM CONNECTOR 60
GRN CAN 2 LO DIAG CAN LOW
B B
BLK 148-61 FUEL LOW PRESSURE 0.75mm² YEL CAN 2 HI DIAG CAN HIGH
61 A A
120 OHM
62 X965
63
BLK 148-64 WATER IN FUEL SW 0.75mm²
64
65
66
67 X955
BLK 148-15-68 CLUTCH SWITCH 0.75mm² YEL CAN 1 HI CUSTOMER CAN HIGH 120 OHM
68 A A
GRN CAN 1 LO CUSTOMER CAN LOW
69 B B
70 C C
71 X956
72
B 73
BLK 148-73 START SIGNAL 0.75mm²
74
YEL CAN 2 HI DIAG CAN HIGH S969
75
76
S954
77
78
79
80
81
82
83
84
85
86
BLK 148-87 COOLANT LEVEL GND 0.75mm²
87
BLK 148-88 IGNITION 0.75mm²
88
89
90
91
92
93
A
94
RED 148-5 ECM PWR 2.5mm²
5 S944
3
1
BLK 148-2 ECM GND 2.5mm²
2
BLK 148-4 ECM GND 2.5mm² S945
4
BLK 148-6 ECM GND 2.5mm²
6
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
NC

1 2 3 4 5
7-136 3121728
4 5 6 7 8
FUEL PUMP 20A (SW), ECM 30A (CONT)

DEUTZ T4F ENGINE HARNESS SCHEMATIC
BUSSMANN DIODE PACK
YELLOW CONNECTOR
(BLUE)
GENERIC
RELAY, POWER MODULE

GROUND STUD LOCATED ON THE
AUX PUMP BATTERY AUX PUMP START GLOW PLUGS
5A ENGINE STARTER ALTERNATOR
10A
RELAY RELAY RELAY
GROUND STUD LOCATED

GLOWPLUGS
ON THE ENGINE BLOCK

ALTERNATOR
D+
B+
M
W
M
1
RL553-30
2
1
1
BT545+
1
1
BT545-
RL930-B+
RL930-1
RL930-2
EC555-D+
EC555-B+
EC555-W
RL930
A
G
D
H
C
B
E
F
87
30
86
85
87
30
86
85
MS932
87
30
86
85
1
1
1
1
1
MS550+
MS550-
RL553-30-2
X548
X547
BUSBAR
RL549-85
RL549-87
RL549-30
RL549-86
RL553-87
RL552-85
RL552-87
RL552-30
RL552-86
RL553-30-1
1
RL553-85
2
RL553-86
1
1
EC551-B+
EC551-B-
EC551
1
EC18
BLK 2/0 2/0 AWG
YEL 2-48-4 IGNITION
RED 48-13 GLOW 8AWG

BLK 2/0 2/0 AWG
YEL 2-48-3 IGNITION
RED 48-14 GLOW 8AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG

YEL 2-48-1 IGNITION 16AWG
BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG
R E D 2 /0
BLK 16AWG 16 AWG
RED 4AWG
BLK 16AWG 16 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG

RED 14AWG
BLK 2/0 2/0 AWG
RED 4AWG
RED 48-13 GLOW 8AWG

BLK 2/0 2/0 AWG
RED 1-148-135 ECM PWR

YEL 2-1-99 IGNITION
RED 2/0 2/0 AWG

RED 14AWG
150A
IP556
G
S946
BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²
X901
S1001 1 VSW
BLK 148-35-1 START
2 START
YEL CAN 1 HI CUSTOMER CAN HIGH
3 CAN + (HI)
GRN CAN 1 LO CUSTOMER CAN LO
4 CAN - (LOW)
VEHICLE INTERFACE 1
SHLD CAN 1 SHLD CUSTOMER CAN SHIELD
5 ALT EXCITE
F
6 CAN SHIELD
X902
YEL 2-1-99 IGNITION
1 EMR4 IGNITION
2 GROUND
3 GENERATOR ENABLE
4 GLOW
5 GENERATOR POWER VEHICLE INTERFACE 2

X999 X1000 6 GENERATOR GROUND
BLK 148-35-3 1.5 k
1 1 7 PLUGGED
BLK 000-48-3 GND
2 2 8 PLUGGED
E
S951
S952
X950
YEL 2-48-2 IGNITION
A
BLK 000-48-2 ENG GND
B
C
D
E
GRN CAN 1 LO CUSTOMER CAN LO
F
D
S963 S964 YEL CAN 2 HI DIAG CAN HIGH
G DEUTZ DIAGNOSTIC
H
J
K
L
YEL CAN 1 HI CUSTOMER CAN HIGH
M
X960
YEL CAN 2 HI DIAG CAN HIGH 120 OHM
A A
B B
C C
X961
SN939 PWR
BLK 148-29 COOLANT LEVEL PWR 0.75mm²
1
BLK 148-13 COOLANT LEVEL SIG 0.75mm²
3
NORMALLY CLOSED
COOLANT LEVEL
SIG
BLK 148-87 COOLANT LEVEL GND 0.75mm²
2
4
GND
X941 X942
BLK 148-64 WATER IN FUEL SW 0.75mm² BLK 148-64 WATER IN FUEL SW 16AWG
1 1 1
WIF SWITCH
BLK 148-57 WATER IN FUEL SW RTN 0.75mm² BLK 148-57 WATER IN FUEL SW RTN 16AWG
2 2
2 WATER IN FUEL
3 3 SN959
BLK 000-48-1 ENG GND 14AWG BLK 000-48-1 ENG GND 14AWG
X955 4 4
YEL CAN 1 HI CUSTOMER CAN HIGH 120 OHM
A A
FUEL PUMP

B B 1
M
C C 2 FUEL PUMP
X956 EC958
X958A EC958+
1
WHT 48-96 FUEL PUMP
1 B
FUEL PUMP
2 EC958- M
1
BLK 000-48-3 GND
BLK 000-48-1 ENG GND 14AWG T920 2 x 5mm 14 AWG RING
BLK 000-148-246 ECM GND 8AWG
1 GND
3/8" 6 AWG RING
SHEET 7 1001186701-K
4 5 6 7 8
MAE20980
3121728 7-137
1 2 3 4 5
CAMSHAFT POSITION SENSOR

DK BLUE/ORANGE 18
GRAY/RED 18
BROWN/WHITE 18
2L1T-14A464-CA CONN
ALL TERMINALS MUST

3 2 1 BE GOLD PLATED
YELLOW/BLACK 18
DK GREEN/PURPLE 18
YELLOW/RED 18
WHITE/PINK 18
RED 16 RED 16 RED 16 RED 16
HDGCP90 HO2S #1 HO2S #2
FCI SHD SHD
H 211 PC 90 2S 0009 CONNECTOR
211 A 90 0007 LOCKING CAM
GRAY/RED 18
GRAY/LT BLUE 18
A
B
PED_12160825 CONNECTOR
PED_12177150 TERM (GOLD)
GRAY/RED 18
GRAY/YELLOW 18 A
B
211 A 90 0008 COVER RED 18 PED_12089678 WIRE SEAL RED 18 PED_12089678 WIRE SEAL
F6VB-14A464-EA CONN F6VB-14A464-EA CONN F6VB-14A464-EA CONN F6VB-14A464-EA CONN C C
211 CC 2S 1460 TERMINAL (GOLD) BLACK/LT GREEN 18 PED_12176368 LOCK BLACK/LT BLUE 18 PED_12160826 LOCK
FOCB-14474-AA TERM FOCB-14474-AA TERM FOCB-14474-AA TERM FOCB-14474-AA TERM D D
1 YELLOW/BLACK 18
SPK_COIL1A
2 WHITE/PINK 18 F4SB-14603-EA SEAL F4SB-14603-EA SEAL F4SB-14603-EA SEAL F4SB-14603-EA SEAL
SPK_COIL1B
3 YELLOW/RED 18 FOCB-14A468-AA LOCK 2 1 FOCB-14A468-AA LOCK FOCB-14A468-AA LOCK FOCB-14A468-AA LOCK
SPARK_COIL2A 2 1 2 1 2 1
4 BLACK/WHITE 16
SPK_GND IGNITION COIL CYL #4 IGNITION COIL CYL #3 IGNITION COIL CYL #2 IGNITION COIL CYL #1
5 DK GREEN/PURPLE 18
SPK_COIL2B
6
SPK_COIL3A
7
SPK_COIL3B
8
UEGOS 9 GRAY/RED 18 TWR
UEGOC 10 LT GREEN/WHITE 18 A
UEGOP B
UEGPR
11 BROWN/WHITE 18
C
GASOLINE SENSOR INTERFACE
12 DK GREEN/ORANGE 18 WHITE/LT GREEN 18
AUX ANA PD1 13 D
WHITE/LT GREEN 18
(FRP) AUX ANA PD2
14 DK GREEN/PURPLE 18 PED_12160482 CONNECTOR
CAN1 +
15 ORANGE/LT GREEN 18 PED_12048074 TERMINAL
CAN1 - TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
16 PED_12160480 LOCK
CAN2-
17
CAN2 +
18
AUX ANA PD3
19 BROWN/WHITE 18 LT GREEN/RED 18
5V EXT 1
20 GRAY/RED 18 GRAY/RED 18
5V RTN 21 GRAY/LT BLUE 18
EGO1
EGO2
22 GRAY/YELLOW 18
BOSCH KOMPAKT 1 928 403 736 CONN CHT GROUND
23 LT GREEN/BLACK 18
MAP 24
1 928 498 060 TERMINAL AMP
AUX ANA PUD3 1 928 300 599 SEAL 184002-1 CONNECTOR 10MM BLACK/WHITE 12
25 GRAY 18 TERMINALS MUST
CRANK + 171662-1 TERMINAL
26 DK BLUE 18 LT GREEN/BLACK 18 BE GOLD PLATED
CRANK - 4 1 2 184024-1 SPACER
27 GRAY/RED 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH BROWN/WHITE 18 184140-1 WIRE SEAL RING
CAM + 3
CAM -
28 DK BLUE/ORANGE 18 GRAY 18
2
TMAP SENSOR
29 DK GREEN/BLACK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH GRAY/RED 18
SPEED + 30 LT BLUE/RED 18 1
SPEED - 31 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
5V EXT 2
32 LT BLUE/RED 18
5V RTN 2
33 DK GREEN/BLACK 18
PULSE IN
34 TAN/LT BLUE 18 TAN/LT BLUE 18
GOV 1 DK GREEN/WHITE 18
35 BLACK/WHITE 16
OIL PRESS
36 GRAY 18
G IAT
ECT
37 LT GREEN/RED 18
BLACK/WHITE 16
BLACK/WHITE 16
BLACK/WHITE 12
38 LT GREEN/WHITE 18
(FRT) AUX ANA PU1
39 LT BLUE/BLACK 18
(LPTEMP) AUX ANA PU2
40 BLACK/ORANGE 18
(IVS) AUX ANA PU3
41 WHITE/LT BLUE 18
F2 RED/LT GREEN 18 RED/LT GREEN 18
RED/LT GREEN 18
(BRAKE) AUX DIG 3
42 BLACK/YELLOW 18
(GOV2) AUX DIG 4 TAN/YELLOW 18
TACH
43 5A
44 RED/LT GREEN 18
VSW
AUX ANA PUD2
45 DK BLUE/WHITE 18 VSW
AUX ANA PUD1
46 PURPLE/LT BLUE 18 F3
47 GRAY/WHITE 18 RED/TAN 14 RED 14 RED 12
TPS 1
48 YELLOW/WHITE 18
TPS 2
49 YELLOW/DK BLUE 18
(FUELSELECT)AUX DIG1
50
10A
AUX DIG 2
KNOCK +
51 YELLOW/RED 18
DK GREEN/PURPLE 18
ECM
52 RED 14
KNOCK -
53 LT BLUE/BLACK 18 TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH GRAY 18 BLACK/YELLOW 18
FPP1
54 LT BLUE/YELLOW 18 DK BLUE 18
(FPP2) FPP2-IVS
55 DK GREEN 18 DK GREEN/ORANGE 18
PC TX 56 ORANGE 18
PC RX 57 DK BLUE/WHITE 18
KNOCK 2+ 58 1 2 F7RB-14A464-AA CONN LT BLUE/YELLOW 18
KNOCK 2- 59 1L2T-14474-RA TERM
VBAT PROT 60 RED/TAN 16
VBAT
EGOH 2
61 BLACK/LT BLUE 18 CRANK SENSOR GRAY/RED 18 GRAY/RED 18
62 BLACK/LT GREEN 18 BROWN/WHITE 18 BROWN/WHITE 18
EGOH 1 63 RED/TAN 14
INJ HS TAN 16
64 RED 12
INJ1 LS
65 BROWN/YELLOW 16 BOSCH THROTTLE BATT+
INJ2 LS
66 BROWN/LT BLUE 16 8MM
INJ3 LS RING RED 16
67 WHITE 16 GRAY/WHITE 18 RED 16 ALTERNATOR
INJ4 LS 68 YELLOW/WHITE 18 6 3
INJ5 LS 5 WHITE 18 WHITE 18 F4SB-14A464-SA CONN
69 BLACK/WHITE 16 LT BLUE/DK GREEN 18
GROUND 4 2 E7DB-14A468-DA LOCK
70 BROWN/WHITE 18 XL3T-14471-HA TERM (16 GA)
INJ6 LS GRAY/RED 18 3 RED/TAN 18
71 XL3T-14471-EA (18 GA)
AUX PWM8 LT GREEN/PURPLE 18 GRAY/ORANGE 18 2 1
72
STARTER 73 RED/YELLOW 18 1
RELAY 74 PINK/LT GREEN 18 AMP_1-967616-1 CONNECTOR
MIL BLACK/RED 16
75 AMP_965906-5 TERMINAL
F UEGO H
AUX PWM7
76
77 WHITE/BLACK 18
AMP_967067-1 SEAL E0BB-14489-CA CONN
LOCKOFF E7EB-14474-CA TERM
78 LT BLUE/ORANGE 18 DK GREEN/WHITE 18
(FUEL PUMP) AUX PWM6
79 RED/TAN 16
VBAT ALTERNATOR S TERMINAL
80 LT BLUE/DK GREEN 18 F56B-14474-HA TERM
DBW + BLACK/WHITE 16
81 F65B-14A464-CA CONN
GROUND 82 GRAY/ORANGE 18 F75B-14603-CA SEAL
DBW - 83
AUX PWM5 REC 84 RED/BLACK 18
AUX PWM5 85 ORANGE/LT GREEN 18 OIL PRESSURE
AUX PWM1 86 RED/WHITE 18 BLACK/ORANGE 18
AUX PWM4 87 TAN/GREEN 18 DK GREEN/WHITE 18
AUX PWM2 88 TAN/YELLOW 18
RED 18
AUX PWM4 REC 89 PINK/BLACK 16 PINK/LT GREEN 18
FP REC AUX PWM3 REC
90 BLACK/RED 16
FUEL PUMP AUX PWM3
ORANGE/LT GREEN 18
YELLOW/DK BLUE 18
PURPLE/LT BLUE 18
TAN/GREEN 18
WHITE/LT BLUE 18
RED/BLACK 18
ORANGE/LT GREEN 18
DK GREEN/PURPLE 18
DIAGNOSTIC CONNECTOR DK GREEN 18

ORANGE 18
BROWN/WHITE 18 2 3 DK GREEN 18
GRAY/RED 18 1 4 ORANGE 18
LT BLUE/PINK 18
5 8 ORANGE/LT GREEN 18
PED_12052641 CONNECTOR 6 7 DK GREEN/PURPLE 18 PINK/BLACK 16
PED_12048074 TERMINAL BLACK/RED 16
PED_12052634 LOCK EPC_1F1T-14A624-AA-004 CONN
PED_12048086 SEAL TWR MOLEX_33093-0009 TERM (18-20)
MOLEX_33094-0001 TERM (14-16)
WHITE/BLACK 18 EPC_E6DB-14A468-DA LOCK RING
E RED/LT GREEN 18 A
B
DEUTSCH_0413-204-2005 CAV. PLUG
EPC_F5AB-14A666-AA CAP LT BLUE/PINK 16 30
87A
6MM 87 RED/TAN 16
LPG LOCKOFF
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH STARTER SOLENOID LT BLUE/PINK 18 86
LT GREEN/PURPLE 18 85
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH
STARTER RELAY
PINK/BLACK 16
YELLOW/RED 18
BROWN/LT BLUE 16 DK GREEN/PURPLE 18
F4
RED 16 RED 16 PINK/BLACK 16 PINK/BLACK 16
RED 16
TAN 16
TERMINALS MUST
BROWN/YELLOW 16
WHITE 16 BE GOLD PLATED 15A
98AG-14A624-ABB CONN FUEL PUMP 20A
RED/TAN 16
7114-4103-08 (AU) TERM
KNOCK SENSOR M1
RED 16 LT BLUE/ORANGE 18 2
RED 16 3 STARTER
98AG-14A464-SBA CONN 98AG-14A464-SBA CONN 98AG-14A464-SBA CONN 98AG-14A464-SBA CONN PINK/BLACK 16 5 10A
97BG-14474-AEA TERM 97BG-14474-AEA TERM 97BG-14474-AEA TERM 97BG-14474-AEA TERM RED/LT GREEN 18 1 RED 18 RED/TAN 18
XW43-14603-AA SEAL XW43-14603-AA SEAL XW43-14603-AA SEAL XW43-14603-AA SEAL UNUSED 4
2 1 2 1 2 1 2 1 F6
U25 FUEL PUMP RELAY
INJ CYL #4 INJ CYL #3 INJ CYL #2 INJ CYL #1 Value ALTERNATOR
1-1924067-9 CONNECTOR
1418850-2 TERMINAL
964972-1 SEAL
RED/WHITE 18 - 2 F1
RED 18 RED 16 RED/LT BLUE 16
1
+
10A
D EPR
RED/YELLOW 18 2
RED 16 3 F5
RED 14 5 RED 16 RED 16
RED/TAN 18 1
4
UNUSED 15A
POWER RELAY RELAYED POWER
FORD ENGINE HARNESS SCHEMATIC

C POWER
ENGINE STARTER FUEL PUMP

START
GROUND STUD LOCATED ON THE
AUX PUMP
AUX PUMP BATTERY

RELAY RELAY
1
1
GROUND STUD LOCATED
X207
X206
ON THE ENGINE BLOCK
M
M
1
BT256+
BT256-
87
30
86
85
85
86
30
87
MS275-
1
1
MS275+
1
1
X273
X272
RL544-85
RL544-87
RL544-30
RL544-86
RL274-85
RL274-86
RL274-30
RL274-87
1
1
EC276-B+
EC276-B-
EC276
RED 2/0 2/0 AWG
B L K 2 /0 2 /0 A W G
BLK 16AWG 16 AWG
BLK 16AWG 16 AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
BLK 000-60-11 FUEL PUMP NEG 16 AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 14AWG 14 AWG

BLK 2/0 2/0 AWG
RED 2/0 2/0 AWG
RED 2/0 2/0 AWG
WHT 6-54 FUEL PUMP POS 16 AWG

RED 2/0 2/0 AWG
RED 14AWG
BLK 2/0 2/0 AWG
FORD ENGINE HARNESS

B
X181B 5
5 18
WHT 6-14 IGNITION WHT 6-14 IGNITION TO 42 PIN FORD ENGINE
TO TURN TABLE 1 1
BLK CAN LO BLK CAN LO
4 29 CONNECTOR
RED CAN HI RED CAN HI
HARNESS 3 28
2
WHT 6-12 ENGINE START WHT 6-12 ENGINE START
15
BLANK TERMINALS OMMITTED
6
X205
X247
4 4
GRN 6-22 GRN 6-22 HARNESS SUPPLED BY FORD
3 3
A FUEL REGULATOR RED 6-21 RED 6-21 FUEL REGULATOR
2 2
WHT 6-20 WHT 6-20 TO FORD HARNESS
1 1
BLK 6-19 BLK 6-19
X248
SHEET 8
1 2 3 4 5
7-138 3121728
4 5 6 7 8
DK BLUE/ORANGE 18
GRAY/RED 18
BROWN/WHITE 18
ALL TERMINALS MUST

BE GOLD PLATED
HO2S #1 HO2S #2
GRAY/RED 18 SHD SHD
GRAY/LT BLUE 18
A
B
GRAY/RED 18
GRAY/YELLOW 18 A
B
PED_12177150 TERM (GOLD) H
RED 18 PED_12089678 WIRE SEAL RED 18 PED_12089678 WIRE SEAL
C C PED_12160826 LOCK
BLACK/LT GREEN 18 PED_12176368 LOCK BLACK/LT BLUE 18
D D
GRAY/RED 18 TWR
LT GREEN/WHITE 18 A
B
BROWN/WHITE 18
C
GASOLINE SENSOR INTERFACE
WHITE/LT GREEN 18
D
PED_12048074 TERMINAL
PED_12160480 LOCK
LT GREEN/RED 18
GRAY/RED 18
CHT GROUND
AMP
184002-1 CONNECTOR 10MM BLACK/WHITE 12
TERMINALS MUST
171662-1 TERMINAL VEHICLE INTERFACE CONNECTOR
BE GOLD PLATED
4 1 2 184024-1 SPACER
184140-1 WIRE SEAL RING
3
2
TMAP SENSOR
1
FORD 42 PIN CONNECTOR
LT BLUE/RED 18 F2VB-14A464-LA CONN
36 ROADSPEED - F6DB-14487-AA TERM (FOR 1,9,34,&42)
DK GREEN/BLACK 18
35 ROADSPEED + E7EB-14487-AA TERM (ALL OTHER 18-20 AWG)
TAN/LT BLUE 18
24 GOV SELECT 1 F2UB-14487-AA TERM (ALL OTHER 14-16 AWG)
BLACK/WHITE 16
F1VB-14A468-BA SPACER (2 REQD)
BLACK/WHITE 16
BLACK/WHITE 16
BLACK/WHITE 12
F1VB-14A468-AA SPACER (1 REQD)
F6HT-14A666-HA PLUG (SMALL CAVITY)
G
F6HT-14A666-GA PLUG (LARGE CAVITY)
LT BLUE/BLACK 18
14 FPP1
F2 RED/LT GREEN 18 RED/LT GREEN 18
RED/LT GREEN 18
1 VSW
5A
VSW
F3
RED/TAN 14 RED 14 RED 12
10A
ECM
RED 14
BLACK/YELLOW 18
23 GOV SELECT 2
DK GREEN/ORANGE 18
32 ANA AUX PD1
DK BLUE/WHITE 18
37 AUX ANA PU2B
LT BLUE/YELLOW 18
12 FPP2
GRAY/RED 18
33 ANA RTN
BROWN/WHITE 18
31 VREF
RED 12
BOSCH THROTTLE BATT+
8MM
GRAY/WHITE 18 RING RED 16 RED 16 ALTERNATOR
YELLOW/WHITE 18 6 3
5 WHITE 18 WHITE 18 F4SB-14A464-SA CONN
LT BLUE/DK GREEN 18
4 2 E7DB-14A468-DA LOCK
BROWN/WHITE 18 XL3T-14471-HA TERM (16 GA)
GRAY/RED 18 3 RED/TAN 18
XL3T-14471-EA (18 GA)
GRAY/ORANGE 18 2 1
1
AMP_1-967616-1 CONNECTOR
AMP_965906-5 TERMINAL
AMP_967067-1 SEAL E0BB-14489-CA CONN F
E7EB-14474-CA TERM
DK GREEN/WHITE 18
ALTERNATOR S TERMINAL
F56B-14474-HA TERM
F65B-14A464-CA CONN
F75B-14603-CA SEAL
OIL PRESSURE
BLACK/ORANGE 18
25 IVS
DK GREEN/WHITE 18
26 OIL PRES
TAN/YELLOW 18
2 TACH
PINK/LT GREEN 18
6 MIL
ORANGE/LT GREEN 18
39 AUX OUT1
YELLOW/DK BLUE 18
PURPLE/LT BLUE 18
7 FUEL SELECT
10 AUX ANA PD1B
TAN/GREEN 18
27 AUX OUT 2
WHITE/LT BLUE 18
4 BRAKE
RED/BLACK 18
16 AUX PWM 5
ORANGE/LT GREEN 18
29 CAN -
DK GREEN/PURPLE 18
28 CAN +
DK GREEN 18
11 RS 232+
ORANGE 18
3 RS 232-
3 DK GREEN 18
4 ORANGE 18
LT BLUE/PINK 18 15 START COMMAND
8 ORANGE/LT GREEN 18
7 DK GREEN/PURPLE 18 PINK/BLACK 16 5 FUEL PUMP + CAN TERMINATION CONNECTOR
BLACK/RED 16
18 FUEL PUMP -
12010996 CONN 12015791 CONN
12089305 TRM MALE 14/16 12124580 TRM FEMALE 14/16
12089040 TRM MALE 18/20 12089188 TRM FEMALE 18/20
RING SHD TWR
LT BLUE/PINK 16 30
87A WHITE 18 WHITE 18
E
6MM 87 RED/TAN 16
STARTER SOLENOID LT BLUE/PINK 18 86
85
LT GREEN/PURPLE 18
TWIST WIRES 10 TURNS(360 DEG)/FOOT FULL LENGTH DEPR
STARTER RELAY RED/LT BLUE 16 V-RELAY
PINK/BLACK 16 DK GREEN/PURPLE 18 CAN +
WHITE 18 CAN TERM
1 2 3 AMP 174262-2 CONN
BLACK/WHITE 18 GROUND
F4 ORANGE/LT GREEN 18 CAN - AMP 174263-7 LOCK
PINK/BLACK 16 PINK/BLACK 16 RED/TAN 18 VBAT
4 5 6 AMP 171662-1 TERM
AMP 172888-2 SEAL
15A
FUEL PUMP 20A
RED/TAN 16 RED 16
KNOCK SENSOR M1
RED 16 LT BLUE/ORANGE 18 2
RED 16 3 STARTER
PINK/BLACK 16 5 10A
RED/LT GREEN 18 1 RED 18 RED/TAN 18
UNUSED 4
FUEL PUMP RELAY F6

ALTERNATOR
F1
RED 16 RED/LT BLUE 16
10A
EPR
D
RED/YELLOW 18 2
RED 16 3 F5
RED 14 5 RED 16
RED 16
RED/TAN 18 1
4
UNUSED 15A
POWER RELAY RELAYED POWER
SHEET 8 1001186701-K
4 5 6 7 8
MAE20990
3121728 7-139
1 2 3 4 5
PLATFORM WORK LIGHTS (OPTION) CHASSIS HEAD AND TAIL LIGHTS (OPTION)
H
LED PLATFORM WORK LIGHT
LB495
LED PALTFORM WORK LIGHT WHT 6-11 12V+ 16AWG
2
FRONT LEFT
FRONT RIGHT
1 1
WHT 6-29 12V+ 16AWG
2
LB670
2
1
LB637
2
1
LB157
S671
S672
BLK 000-60-1 GND 16AWG
WHT 6-1 12V+ 16AWG
WHT 6-2 12V+ 16AWG

X668
1
G
REAR RIGHT
WHT 6-30 12V+ 16AWG
4 3
2 2
REAR LEFT
WHT 6-13 12V+ 16AWG
3 4
1
X666

WHT 6-1 12V+ 16AWG
WHT 6-2 12V+ 16AWG

WHT 6-8 12V+ 14AWG 87
WHT 4-146 14AWG

4
WHT 4-146 14AWG 30
1
87a
R E LE
3
BLK 000-40-109 GND 16AWG 85
2
WHT 4-145 86
5
RL673
X532
4
2
3
10A
4
2
3
1
X664
IP629
WHT 12V+ 16AWG
WHT 12V+ 16AWG

BLK GND 16AWG
BLK GND 16AWG
BLK 000-40-109 GND 16AWG

WHT 4-146 14AWG
BLK 4-122 14AWG
WHT 4-145
IP648
IP649
3A
3A
BLK GND 16AWG BLK GND 16AWG

J8_1 J8
CJ01-8
X674
X675
X676
X505
BLK GND 12AWG BLK GND 12AWG
1 1
1
YEL/RED 12V+ 12AWG YEL/RED 12V+ 12AWG
2 2
TO SHEET 2 WHT 12V+ 16AWG WHT 12V+ 16AWG
PLUG HARNESS BETWEEN PLATFORM BOARD AND EXISTING HARNESS
MOUNT ON AUX PUMP RELAY B+
PAGE 5 X513B PIN 2

MOUNT ON AUX PUMP RELAY BOLT
RED 201-1 12V+ 16AWG

23
GRN 203-1 CAN LOW
22
21
20
19
18
17
BLK 200-1 GND 16AWG
16
YEL/RED 202-1 IGN
15
14
13
12
11
10
9
8
YEL 204-1 CAN HI
C 7
6
5
4
3
2
1
TCU
J J
YEL/RED 202-2 IGN YEL/RED 202-3 IGN
H H
S570
G G
F F
E E
GRN 203-2 CAN LOW GRN 203-3 CAN LOW
D D
YEL 204-2 CAN HI S569 YEL 204-3 CAN HI
C C
RED 201-2 12V+ 16AWG S486 RED 201-3 12V+ 16AWG
B B
B A
BLK 200-2 GND 16AWG S568 BLK 200-3 GND 16AWG
A
S567
X111-2 X111-1
CLEAR SKY (OPTION)

1 2 3 4 5
7-140 3121728
4 5 6 7 8
CHASSIS WORK LIGHTS (OPTION)

CHASSIS HEAD AND TAIL LIGHTS (OPTION)
H
LB495 LB638
WHT 6-11 12V+ 16AWG BLK 000-60-3 GND 16AWG
2 2
FRONT LEFT
FRONT LEFT
BLK 000-60-11 GND 16AWG BLK 000-60-29 GND 16AWG WHT 6-4 12V+ 16AWG WHT 6-6 12V+ 16AWG
1 1 1 1
FRONT RIGHT
FRONT RIGHT
WHT 6-29 12V+ 16AWG BLK 000-60-5 GND 16AWG
2 2
LB670 LB640
S671
S642
S672
S643
X668
WHT 6-7 12V+ 16AWG
1 LB639 1
REAR RIGHT
4
WHT 6-30 12V+ 16AWG
3 2
2
G
REAR RIGHT
REAR LEFT
BLK 000-60-12 GND 16AWG BLK 000-60-30 GND 16AWG WHT 6-5 12V+ 16AWG
2 2 1 LB641
REAR LEFT
WHT 6-13 12V+ 16AWG

3 4
1
X666
H E AD AN D T AIL L IG H T S
H E AD AN D T AIL L IG H T S
WHT 4-70 14AWG
WHT 6-8 12V+ 14AWG 87 WHT 6-8 12V+ 14AWG 87
WHT 4-146 14AWG
4 4
WHT 4-146 14AWG 30 WHT 4-70 14AWG 30
1 1
R E LE
R E LE
87a 87a
3 3
BLK 000-40-109 GND 16AWG 85 BLK 000-40-9 GND 16AWG 85
2 2
WHT 4-145 86 WHT 4-28 16AWG 86
5 5
RL673 RL168
IP630FUSE 6
10A
10A
IP629

BLK 000-40-109 GND 16AWG
BLK 000-40-17 14AWG
WHT 4-70 14AWG
WHT 4-28 16AWG

WHT 4-146 14AWG
BLK 4-122 14AWG
WHT 4-145
X677
X678
X679
X680
X674
X675
X676
X505
1
1
PAGE 5 X513B PIN 2

PAGE 5 X513B PIN 2


2500W GENERATOR HARNESS C
RED 4-557 GEN PWR 12AWG

1
X633
RED 4-555 GEN PWR 12AWG
1 87
4
TO SHEET 4 X632 30A RED 4-556 GEN PWR 30
1
87a
GEN RELAY
1 IP634 3
WHT 4-554 GEN ON 85
TO X530 2
BLK 000-40-553 GND
2
86
3 5
X631 RL630
SHEET 9 1001186701-K
4 5 6 7 8
MAE21000
3121728 7-141
1 2 3 4 5
PLATFORM VALVE HARNESS WITHOUT JIB
E
PLAT LVL UP
HV381
BLK 000-40-22
2
1
PLAT LVL DN
HV380
BLK 000-40-30
2
1
HV383
ROT LFT
BLK 000-40-19
2
WHT 4-9 ROTATE LEFT
1
HV382
ROT RHT
BLK 000-40-20
2
D 1
X652B
HV364 BLK 000-40-90
21
BLK 000-40-23
JIB UP
2 20
WHT 4-12 JIB UP
1 19
18
17
HV365 WHT 4-13 JIB DOWN
JIB DOWN
BLK 000-40-24 16
2 WHT 4-12 JIB UP
WHT 4-13 JIB DOWN 15
1 WHT 4-10 ROTATE RIGHT
14
WHT 4-9 ROTATE LEFT
13 TO SHEET 2
WHT 4-16 LOW PRESSURE DUMP
HI PRS DUMP
HV660 12
BLK 000-40-26
2 11 X652A PLATFORM ANGLE SENSOR
WHT 4-15 HIGH PRESSURE DUMP WHT 4-125 PLAT ANGLE SEN 5V
1 10
9
8
LO PRS DUMP
HV661 7
BLK 000-40-27
2 6
WHT 4-16 LOW PRESSURE DUMP WHT 4-7 PLAT LEVEL DOWN
1 5
4
C 3
2
1
BLK 000-40-92 GND
BLK 000-40-91 GND

WHT 4-127 PWR 5V
WHT 4-126 PWR 5V
BLK 000-40-92 GND
BLK 000-40-91 GND
WHT 4-127 PWR 5V

BLK 000-40-22
BLK 000-40-27
BLK 000-40-90
BLK 000-40-20
BLK 000-40-30
BLK 000-40-19
BLK 000-40-26
BLK 000-40-23
BLK 000-40-24
SN698
A
D
F
C
B
E
MS700
MS699
11
12
2
6
9
8
3
7
10
12
11
4
2
9
8
6
5
3
7
10
B GROUND BUSS
GENERIC
GENERIC PLTF ANGLE SENSOR
NOTE: ALL WIRES ARE 18AWG UNLESS OTHERWISE SPECIFIED GENERIC
SHEET 10 1001186701K
1 2 3 4 5
MAE21010
7-142 3121728
3121728 7-143
1 2 3 4
PLTFM SNSR PLTFM SNSR

RELAY #1 RELAY #2
D D
87a
87a
87
30
85
86
86
85
30
87
RL-502
RL-503
WHT P4-1
WHT P9-1
WHT P5-1
WHT P4-1
WHT P5-1
WHT P9-1
WHT P3
WHT P1
WHT P5
WHT P9
WHT P4
SKYGUARD INPUT #2
TO SHEET 3-G1
SKYGUARD INPUT #1 X305A (11)
TO SHEET 3-G1
WHT P3
X305A (10)
X305B-11
C C
WHT P1
1
X305B-10
X305B-8
BLK P6
WHT P9
13
WHT P2 18 OHM
X305B-7 SKYGUARD GND
IP608
POWER TO SHEET 3-G1
TO SHEET 3-G1 X305A (8)
X305A (7)
WHT P10
WHT P5
WHT P4
BLK P6
X500
4
2
3
1
4
2
3
1
B B
SKYGUARD (OPTION)
PLTFM SNSR
A A
SHEET 11 1001186701-K
1 2 3 4
MAE21020
7-144 3121728
3121728
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417
Visit our website for JLG Worldwide Locations

www.jlg.com

JLG 600s-600sj Ingles Manual de Servicio

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JLG 600s-600sj Ingles Manual de Servicio

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Service and Maintenance Manual

May 30, 2018 - Rev C

0300224266 0300224756 0300233720 B300002216

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

Original Issue A - August 04, 2017

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Maximum Travel Grade (Gradeability) Turning Radius (Outside)

Gross Machine Weight (Approximate) Horizontal Reach from center of rotation -

Horizontal Reach over side - 600S

Horizontal Reach from center of rotation -

Horizontal Reach over end - 660SJ

Horizontal Reach over side - 660SJ

Tail Swing 4 ft. (1.22 m)

1.3 CAPACITIES Table 1-6. Ford MSG425 Specifications

Table 1-5. Deutz D2011L04 Specifications

1.5 TIRES 1.6 CRITICAL STABILITY WEIGHTS

1.7 HYDRAULIC OIL

Density 0.92 @ 15°C (59°F)

Table 1-10. Mobil DTE 10 Excel 32 Type Synthetic Biodegradable

1.8 TORQUE REQUIREMENTS

Specific Gravity 32.1 Table 1-15. Torque Requirements

Engine Mounting Bolt

Figure 1-1. Maintenance and Lubrication Diagram - Deutz D2011L04

Figure 1-2. Maintenance and Lubrication Diagram - Deutz TD2.9

Figure 1-3. Maintenance and Lubrication Diagram - Ford MSG425

1.9 MAINTENANCE AND LUBRICATION 2. Swing Drive Hub

NOTE: The following numbers correspond to those in Figure 1-1.,

Table 1-16. Lubrication Specifications. FILL PORT

Lube Point(s) - Level/Fill Plug

Lube Point(s) - 1 Grease Fittings

4. Hydraulic Charge Filter 7. Hydraulic Tank

Interval - Change after first 50 hrs. and every 6 months

Lube Point(s) - Fill Cap/Spin-on Element 

Interval - Change after first 50 hrs. and every 6 months

9. Fuel Filter - Deutz 2011 12. Fuel Pre-Filter - Deutz D2.9

Lube Point(s) - Replaceable Element 

10. Oil Change w/Filter - Deutz 2.9

Lube Point(s) - Replaceable Element

11. Fuel Filter - Deutz 2.9

Lube Point(s) - Replaceable Element

B. Air Filter - Deutz 2011

Lube Point(s) - Fill Cap/Spin-on Element

15. Fuel Filter - Ford MSG425 Lube Point(s) - Replaceable Element

Lube Point(s) - Replaceable Element

16. Engine Coolant - Ford MSG425

Lube Point(s) - Fill Cap

Lube Point - Replaceable Element

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