1200 SJP Part 2

SECTION 4 - BOOM & PLATFORM
Support Installation 5. Position the platform on the platform support and

install the bolts securing the platform to the platform
1. Using a suitable device, support the platform support support.
and position it on the rotator.
NOTE: The platform support weighs approximately 81.6 lb

(57 kg).
2. Install the rotator center bolt and locknut.
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MAF27870
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MAF27880
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6. Connect the electrical cables to the platform control

3. Apply Medium Strength Threadlocker Compound to the console.
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eight bolts securing the support to the rotator and

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install the bolts.

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MAF27860
4. Torque the nut on the rotator center bolt to 586 ft. lbs.
(795 Nm). Torque the retaining bolts to 35 ft. lbs.
(50 Nm).
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A, B, D
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C, D
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1001167596-M
MAF27890M
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A Torque to 35 ft. lbs. (50 Nm)

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B Medium Strength Threadlocking Compound

C Torque to 586 ft. lbs. (795 Nm)
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D Check torque every 150 hours of operation

E Torque to 65 ft. lbs (88 Nm)
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Figure 4-1. Platform Support Torque Values

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4.3 BOOM REMOVAL, DISASSEMBLY/ASSEMBLY, & 6. Tag and disconnect the telescope, tank, and pressure
hoses as indicated below from the main valve and cap
CABLE REPLACEMENT ends.
Removal
1. Place machine on firm, level ground.
2. Slightly elevate the boom and support the fly boom
with a crane or an adequate lifting device capable of
handling 6 - 7 tons.
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3. Place blocking under lift cylinder to hold it in place.

4. Remove lift cylinder pin securing the lift cylinder rod to
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the boom.
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1. Pivot Pin
2. Bolt
3. Keeper Pin
5. Remove the boom end cover.
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4 5 6
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A B 2
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A B
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1001139517-F
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MAE35330F
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1. Boom Base 5. Jib Rotator
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2. Boom Inner Mid 6. Jib Assembly
3. Boom Outer Mid 7. Platform Rotator
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4. Boom Fly
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Figure 4-2. Boom Assembly - Sheet 1 of 7
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4-12
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SECTION A-A
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1001139517-F
MAE35340F
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1. Outer Mid Extend Block 4. Retract Rope Retainer Plate 7. Retract Rope Retainer Plate
2. Outer Mid Retract Sheave 5. Rope Retainer Block 8. Lock Plate
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3. Rope Retainer Block 6. Fly Retract Sheave 9. Tele Cylinder Wear Pad
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1001139517-F
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MAE35350F
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1. Upper Rear Wear Pad 6. Shim
2. Shim 7. Tele Cylinder Pulley Assembly
3. Telescope Cylinder 8. Bottom Rear Wear Pad
4. Trunnion Keeper Block 9. Shim
5. Lower Rear Wear Pad
4-13
4-14
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1001139517-F
MAE35360F
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1. Sheave Deflector 6. Rope Retainer Block
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2. Sheave Deflector 7. Level Cylinder
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3. Rope Retainer Block 8. Front Lower Wear Pad
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4. Fly Extension Sheave 9. Lock Plate
5. Rope Retainer Block
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1001139517-F
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MAE35370F
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1. Front Upper Wear Pad 7. Jib Rotator
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2. Shim 8. Jib Rotator Cam
3. Pivot Assembly 9. Front Side Wear Pad
4. Platform Rotator 10. Shim
5. Jib Cylinder 11. Shim
6. Lower Jib Link 12. Lock Plate
4-15
4-16
8.0 ± 0.5”
203 ± 13 mm 9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
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1001139517-F
MAE35380F
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1. Outer Mid Extend Rope 4. Outer Mid Retract Rope
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2. Fly Extend Rope 5. Proximity Switch Spring ts
3. Fly Retract Rope 6. Switch Adjustment Block
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1.375 .062
1.375 .062
1.125 .062
1.125 .062
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1.438 .062
1.438 .062 rts

VIEW A-A SECTION D-D
1001139517-F
MAE35390F
4-17
7. Tag and disconnect the three electrical wires that run to 13. Using the lifting device, remove boom from chassis.
the power track and the wire that goes to the proximity
switch.
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14. Place boom on saw horses or other adequate supports.
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Disassembly
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It is not necessary to completely remove the entire boom
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assembly from the machine to replace the cables. In the fol-
lowing procedure, the base boom section will remain on the
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8. Unbolt the power track.
machine.
9. Remove the bolt securing the keeper pin and remove
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the keeper pin from boom pivot pin.
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10. Using the lifting device, support the rear of the boom to NEVER HANDLE WIRE ROPE WITH BARE HANDS.
remove the load from the pivot pin.
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1. Position the boom so that it is horizontal. If the boom is

below horizontal, ensure that the boom is not on the
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boom rest.
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2. Use an adequate lifting device to support the weight of

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the jib and platform assembly.

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3. Tag and disconnect the hoses and electrical harnesses

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that run to the platform. Cap or plug all openings.

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4. Pull the hoses and harnesses through the jib and lay
them off to the side of the boom.
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5. Remove the bolt and keeper pin securing the platform

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level pivot pin and remove the pin.

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11. Remove the boom pivot pin.

12. Move all of the hydraulic hoses and electrical wires so
they are free from chassis.
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6. Remove the bolt and keeper pin securing the jib pivot 9. Pull the disconnected tube back to allow room to dis-
pin and remove the pin. connect the lower tube.
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7. Remove the jib and platform assembly from the boom.
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8. Attach a lifting device to the powertrack for support and

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unbolt the upper powertrack tube from the fly boom.

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10. Unbolt the lower powertrack tube from the outer mid 12. Remove the bolts securing the side wear pads to the
boom section and the mounting bracket from the inner front of the base boom and remove the pads and shims.
mid boom section.
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13. Remove the boom length plate.
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11. Attach a strap or other similar device around the pow-

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ertrack and boom to keep the powertrack secure

throughout the cable replacement procedure.
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14. Remove the cover over the boom length limit switch at 16. Tag and disconnect the wiring harness running to the
the front of the boom base section. Remove the switch. boom length sensor. Remove all the bolts and washers
securing the sensor, including those that secure the
measuring cable to the telescope cylinder, and remove
the length sensor.
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17. Tag and disconnect the hydraulic hoses from the tele-
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scope cylinder. Cap or plug all openings.
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15. Remove the rear boom cover.

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18. Remove the front side, top, and lower wear pads from
the boom base section.
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19. Remove the keepers for the outer mid retract cable 22. Remove the adjustment nuts for the for the outer mid
adjustment nuts at the front of the boom base section. extend cables along with the Broken Cable proximity
switch, spring, and adjustment plate.
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23. Remove the cable mounting plate.
20. Loosen and remove the outer mid retract cable adjust-
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ment nuts.
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21. Remove the adjustment bolt keepers for the outer mid
extend cable adjustment nuts at the rear of the boom.
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24. Remove the cover plate from the bottom of the boom 26. Remove the outer mid retract cables from the attach-
and remove the sheave blocks. ment fixtures at the front of the boom base section.
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27. Attach an auxiliary hydraulic power source to the tele-
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scope cylinder and extend the cylinder rod enough to
turn the trunnion in a vertical position.
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25. Remove the trunnion blocks that secure the telescope

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cylinder rod to the boom base section.

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28. Pull the inner mid, outer mid, and fly boom sections out 29. Remove the trunnion blocks that secure the telescope
of the base boom section. Use additional lifting devices cylinder barrel to the inner mid boom section.
and reposition any lifting straps as necessary as the sec-
tions are withdrawn. It will be helpful during this step to
pull the outer mid retract cable out from the front of the
base section as the other sections are being pulled out.
This will prevent the cables from tangling as the sections
are withdrawn.
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30. Attach a lifting device to the telescope cylinder and pull
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the cylinder, along with the outer mid extend cables out
of the inner mid boom section. Reposition the lifting
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device as necessary to balance the cylinder.
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31. Remove the hardware attaching the outer mid extend 33. Remove the rear bottom wear pad.
block and remove the block and outer mid extend
cables.
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34. Remove the lock plates from the fly boom retract cable
adjustment nuts and remove the adjustment nuts from
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the fly boom retract cables and from the fly boom
extend cables at the front of the inner mid boom sec-
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tion.
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32. Remove the cable retainer plate, cable retainer block,
bushing, and sheave.
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35. Pull the fly boom extend cables from their mounting of the inner mid boom section so it doesn’t move as the
receptacles. other sections are withdrawn.
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36. Remove the top, side, and bottom wear pads from the
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front of the inner mid boom sections.

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38. Pull the sections out enough to allow easy removal of

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the cable retainer blocks and sheave blocks for the fly
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boom retract cables at the front of the inner mid boom

section.
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37. Attach a strap to pull the outer mid and fly boom sec-
tions out of the inner mid boom section. Secure the rear
NOTE: When pulling the outer mid and fly boom sections out of
the inner mid boom section, make sure the outer mid
retract cables do not catch at the rear of the boom section.
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39. Pull the sections the rest of the way out of the inner mid 41. Remove the cable retract retainer plates, cable retainer
boom section, pulling the fly boom retract cables out at blocks, sheaves, and bushings from the rear of the outer
the same time. mid boom section.
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40. Remove the outer mid retract cables from the rear of the
inner mid boom section.
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42. Remove the front wear pads from the outer mid boom
section.
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43. Remove the upper rear wear pads from the fly boom ing bolt, keeper pin, pin, bushings, and sheave from the
section. front of the outer mid boom section.
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44. Remove the cable retainer blocks and shims.
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45. Pull the fly boom extend cables out enough to have
clearance to remove the sheave, and remove the retain-
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NOTE: When pulling the fly boom section out of the outer mid 48. Remove the fly boom extend cables from the bottom of
boom section, make sure the fly boom retract cables do not the fly boom section.
catch at the rear of the boom section.
46. Attach a lifting device to the fly boom section and pull
the section and fly boom extend cables from the outer
mid boom section. Secure the rear of the outer mid
boom section so it doesn’t move when the fly boom sec-
tion is withdrawn.
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49. Thoroughly clean the boom sections.
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Assembly
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47. Remove the tape from the fly boom section and remove to NEVER HANDLE WIRE ROPE WITH BARE HANDS.
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the fly boom retract cables. NOTE: Moderately apply Super Lube JLG Part No. 3020042 to all
four inner surfaces of both ends of each boom section to a
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minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom

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section only needs Super Lube applied to the insertion end.

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Super Lube is also to be moderately applied to all outer sur-

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faces of interior wear pads after they are installed to the

insertion end of boom sections. Care should be taken to
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avoid application on exposed painted surfaces of the fully

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extended boom. Refer to Section 1 - Remove the Platform

Support. Refer to Section 4.2, Platform, Platform.
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WIRE ROPE NUTS ARE CLOSE IN SIZE AND CAN BE SWITCHED. REFER TO THE
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JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF

BASE BOOM, WILL BE BLACK IN COLOR.
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31215055 4-29
wire rope and place them into the fly boom, tape the
slots to keep the rope from jumping out.
TAKE EXTRA CARE NOT TO CROSS ANY WIRE ROPES DURING THE ASSEMBLY
PROCEDURE.
1. Install the fly extend wire rope button ends into the slots
on the bottom of the fly boom section. Place tape over
the wire ends to keep them in place during assembly.
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2. Fabricate a special fixture as shown below to keep four

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extend wire ropes from crossing over each other.

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3. Install the fly retract wire rope button ends into the slots
in the side of the fly boom, coil the remaining lengths of
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Ft-Lbs. Nm
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A 190 260
B 190 260
C 35 48
D 40 55
Figure 4-9. Boom Assembly Torque Values - Sheet 1 of 2
31215055 4-31
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NOTE: If any rotator bolts are replaced, all bolts

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on the rotator should be retorqued. Check

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torque on the bolts every 150 hours of

operation.
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Ft-Lbs. Nm
E 340 460
F 480 651
G 190 260
Figure 4-10. Boom Assembly Torque Values - Sheet 2 of 2
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4. Install the fly boom section partially into the outer mid 7. Install the sheave, bushings, pin, keeper pin, and retain-
boom section. ing bolt to the front of the outer mid boom section.
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DO NOT ALLOW THE FLY BOOM TO REST ON THE FOUR EXTEND WIRE ROPES
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8. Install the cable retainer blocks and shims.
WHILE INSERTING IT INTO THE OUTER MID BOOM.
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5. Apply Medium Strength Threadlocking Compound to
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the bolts and install the front lower wear pads and shims
to the outer mid boom as marked during disassembly.
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Torque the bolts to 50 ft.lbs. (68 Nm).
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the bolts and install the front upper, and side wear pads
on the outer mid boom section as marked during disas-
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sembly. Torque the bolts to 50 ft.lbs. (68 Nm).

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6. Install the fly boom section most of the way into the
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outer mid boom section, leaving enough of the fly out

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so there is adequate slack in the fly boom extend cables

to allow for installation of the front sheave.
31215055 4-33
10. Apply Medium Strength Threadlocking Compound to 12. Apply a thin coat of moly paste lubricant to the inside
the bolts and install the rear upper and side wear pads diameter of the sheave composite bearings. Install the
on the outer mid boom section as marked during disas- fly retract sheaves and bushings while guiding the wire
sembly. Torque the bolts to 50 ft.lbs. (68 Nm). ropes into the sheave grooves. Apply moly paste lubri-
cant on the inside diameter of the sheave bushing cup.
Ensure the sheaves move freely. Apply High Strength
Threadlocking Compound to the sheave retaining bolts
and torque to 165 ft.lbs. (224 Nm). Install the cable
retract retainer plates and cable retainer blocks.
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11. Uncoil the fly retract wire ropes from the fly boom.
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Route the threaded ends of the wire ropes through the
holes in the outer mid boom plates at the retract sheave
locations.
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the bolts and install the lower rear wear pad onto the
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outer mid boom section. Torque the bolts to 50 ft.lbs.

(68 Nm).
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the bolts and install the side and upper wear pads on
the rear of the inner mid boom section. Torque the bolts
to 50 ft.lbs. (68 Nm).
15. Lubricate the wear surfaces on the inside of the inner
mid boom section with Super Lube.
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16. Feed the fly boom retract cable into the inner mid boom 18. Attach the fly boom retract cables in the inner mid
section from the front. boom section to the receptacles at the rear of the outer
mid boom section.
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19. Put tape over the holes to keep the cable ends from
jumping out.
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17. Using an adequate lifting device, align the outer mid

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boom section with the inner mid boom section.

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20. Push the outer mid assembly part way into the inner
mid boom section. Apply Medium Strength Threadlock-
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ing Compound to the bolts and install the front bottom

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wear pad into the inner mid boom section. Torque the
bolts to 50 ft.lbs. (68 Nm).
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31215055 4-35
21. Push the outer mid assembly into the inner mid while 23. Push the outer mid assembly almost completely into the
pulling the boom cables out the back fo the inner mid inner mid boom section.
section at the same time. Leave 3 to 4 feet of the outer
mid section sticking out of the inner mid section.
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24. Install the cable retainer blocks over the fly boom retract
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cables and insert the fly boom extend cable into the
22. Push the retract cable ends into the mounting recepta- mounting receptacles.
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cles and install the cable sheaves and adjustment nuts.
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25. Apply Medium Strength Threadlocking Compound the

bolts and install the side and top wear pads into the
4-36 31215055
inner mid boom section. Torque the bolts to 50 ft.lbs. and torque to 165 ft.lbs. (224 Nm). Install the cable
(68 Nm). retainer blocks and cable retainer plates.
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26. Put moly paste on the sheave mounts at the rear of the
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inner mid boom section and install the sheaves.
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27. Apply a thin coat of moly paste lubricant to the inside

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diameter of the sheave composite bearings. Install the

retract sheaves and bushings while guiding the wire
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ropes into the sheave grooves. Apply moly paste lubri-

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cant on the inside diameter of the sheave bushing cup.

Ensure the sheaves move freely. Apply High Strength
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Threadlocking Compound to the sheave retaining bolts

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31215055 4-37
28. Apply Medium Strength Threadlocking Compound to 31. Install the other end of the outer mid extend cables into
the bolts and install the rear bottom wear pad on the the cable guide block.
rear of the inner mid boom section. Torque the bolts to
50 ft.lbs. (68 Nm).
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32. Route the cables around the sheave on the cylinder and
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install the cable retainer block.
29. Install a new sheave on the telescope cylinder.
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30. Install the outer mid extend cables into the cable pulley
at the rod end of the telescope cylinder.
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4-38 31215055
33. Using an adequate lifting device, insert the cylinder and

cables part way into the inner mid boom.
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34. Apply Medium Strength Threadlocking Compound to 37. Using Super Lube®, lubricate all wear surfaces on the
the bolts and attach the cable guide to the inner mid inside of the boom base section and the outside of the
boom section with the mounting hardware. Torque the inner mid boom section.
bolts to 165 ft.lbs. (224 Nm).
38. Insert the inner mid boom section part way into the
boom base section enough to be able to pull the outer
mid retract cables out through the hole at the bottom
front of the boom base section.
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35. Push the cylinder the rest of the way into the inner mid
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boom assembly.
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36. Install the cylinder trunnion blocks and shims. 39. Apply Medium Strength Threadlocking Compound to
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the bolts and install the front lower wear pads into the
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boom base section. Torque the bolts to 50 ft.lbs. (68

Nm).
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4-40 31215055
40. Push the inner mid boom assembly the rest of the way 46. Install the outer mid retract cable adjustment nuts at the
into the boom base section, adjusting the lifting device front of the boom base section.
as necessary to keep the weight balanced.
the bolts and install the side and upper wear pads into
the boom base section. Torque the bolts to 50 ft.lbs.
(68 Nm).
42. Install the boom transport length sensor on the side of
the boom base section.
43. Attach the powertrack tubes.
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44. If necessary, attach a source of auxiliary hydraulic power
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and retract the boom enough to allow installation of the
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cable adjustment plate at the rear of the base boom sec-
tion and install the plate.
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47. Install the boom length sensors and angle sensors as
tagged during removal.
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45. Install the broken cable sensor and the outer mid extend
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cable adjustment nuts.

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48. Connect the hydraulic hoses to the telescope cylinder as

49. Adjust the boom cables. Refer to Section 4.13 - Wire
Rope Tensioning Adjustment.
50. Perform a boom calibration as described in Section 6
under Calibrating the Boom Sensors.
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**
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SECTION A-A
* Apply Medium Strength Threadlocking Compound
** Apply High Strength Threadlocking Compound 1001139517-F
MAE36190F
Figure 4-11. Locations for Threadlocker Application - Sheet 1 of 4
4-42 31215055
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*
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*
* Apply Medium Strength Threadlocking Compound 1001139517-F
MAE36200F
31215055 4-43
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*
*
*
1001139517-F
MAE36210F
4-44 31215055
#0100011
*
#0100011
* #0100011
*
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#0100011
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#0100011
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#0100019
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#0100011
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#0100011
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#0100011
*

** Apply High Strength Threadlocking Compound 1001139517-F1001139517-F
MAE36220F MAE36220F
31215055 4-45
4.4 ROTATOR Installation

1. Supporting the rotator and jib lift cylinder, align rotator
Removal with jib lift cylinder and jib. Using a soft head mallet,
install pin (1) to the jib assembly. Install hardware secur-
1. Remove the Platform Support. Refer to Section 4.2, Plat-
ing pin (1).
form, Platform.
2. Tag and disconnect hydraulic lines to rotator. Use suit- NOTE: The rotator approximately weighs 50 lb (23 kg).
able container to retain any residual hydraulic fluid. Cap
or plug all openings of hydraulic lines and ports. 2. Using a soft head mallet install pin (2) to jib assembly
and install the rotator. Install hardware securing pin (2).
NOTE: The rotator approximately weighs 50 lb (23 kg).
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3. Install the platform and platform support. Refer Section
4.2, Platform.
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3. Supporting the rotator and jib lift cylinder, remove hard-
ware from pin (1). Using a suitable brass drift and ham-
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4. Remove cap or plugs from openings of hydraulic lines
mer remove pin (1). and ports and connect hydraulic lines to the rotator as
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4. Remove the hardware from pin (2). Using a suitable
brass drift and hammer, remove pin (2) and remove the
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rotator.
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JIB LIFT CYLINDER

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MAE37620
Figure 4-15. Platform Rotator Removal and Installation
4-46 31215055
4.5 BOOM LUBRICATION APPLICATION 4.6 BOOM SHIMMING PROCEDURE

This procedure applies to booms after assembly or during 1. Measure and record the dimension and direction of any
annual application using Super Lube® lubricant (JLG sweep found in the fly boom section. Measure and
PN 3020042). record the inside width and inside height of the outer
1. Position the boom on the boom rest using the 500 lb mid boom opening.
capacity setting.
2. Telescope main boom section as far as it will extend at
this position, approximately 3 ft. (0.9 m).
3. From the front of the machine (boom pivot end), moder-
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ately apply lubricant to the interior surfaces of the base
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boom, inner mid boom, and outer mid boom. To pre-
vent misdiagnosis of hydraulic leaks, take care to pre-
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vent excessive application of lubrication.
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4. At the rear of the machine, apply lubricant to the side,
top and bottom surfaces of the fly boom, outer mid, and
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inner mid specifically to wear pad contact paths. To pre- SWEEP
vent misdiagnosis of hydraulic leaks, take care to pre- MEASUREMENT
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vent excessive application of lubrication.
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5. After application of the lubricant is complete, cycle the
boom through its full range of travel 2 times.
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TOP VIEW OF BOOM SECTION

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Figure 4-16. Measuring Boom Section Sweep

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NOTE: Wear Pad bolt lengths should be flush to one thread below
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the surface of the insert. When installing wear pads in the

following steps, the wear pad bolt lengths may need to be
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adjusted as shim thicknesses are adjusted.
2. Install the side wear pads on the fly boom sides. Shim as
necessary to match the outer mid boom dimension
recorded in step 1 ± 1/32” (± 0.8 mm). Shims should be
divided as evenly as possible between the side pads
unless corrections are needed to compensate for sweep
recorded in step 1. If the sweep is to the left the internal
side pads on the left should have more shims than the
right side pads and vise versa.
3. Install the bottom wear pad(s) and shims if applicable
on the fly boom.
31215055 4-47
4. Install the top wear pad(s) on the fly boom and shim as 4.7 JIB ROTATOR ORIENTATION
necessary to obtain 0 - 1/16” (0 - 1.6 mm) less than the
corresponding dimension recorded in step 2. In order for the Jib Rotator to rotate properly, it must be
installed with the timing marks running parallel to the flat
5. Slide the fly into the outer mid boom leaving 2 - 6 feet rotator mounting plate as shown below.
(0.6-1.8 m) exposed.
6. Install the bottom wear pad(s) and shims if necessary
into the end of the outer mid boom.
7. Temporarily insert the side pads on one side and slide
the fly boom to that side. Insert the other side pads and
using shims, measure how many will be required to fill
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the remaining space. Install the total amount of shims
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as evenly as possible between the two sides unless cor-
rections are needed to compensate for out-of-square
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booms or for corrections due to sweep recorded in step
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1. Care should be taken to keep the bottom pads evenly
loaded while shimming the side pads.
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NOTE: Do not install more shims than will fit because this may
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result in a boom being shimmed too tight. The use of pry
bars or wedges should only be used to finish installing a
or
shim that can be installed by hand more than ½ of its
length.
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Figure 4-17. Jib Rotator Orientation
8. Install the top wear pads and shims into the end of the
om
outer mid boom leaving a gap of 0” to 1/16” between
the top of the fly boom and inside of the outer mid 4.8 JIB LIFT END OF STROKE DAMPENING
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boom.
The jib lift cylinder is constructed in a way that causes the jib
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9. Repeat steps 1-7 to install the fly/outer mid assembly lift cylinder oil flow to be restricted by an orifice while raising
into the inner mid boom. the jib within 5 degrees of maximum elevation. This restriction
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slows the jib lift speed while raising the jib. The oil flow is not
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10. Repeat steps 1-7 to assemble the fly/out mid/inner mid

restricted while lowering the jib and therefore the speed is not
assembly into the base boom.
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altered.
11. Complete the boom assembly. The boom should be
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functionally tested and evaluated for boom sweep.

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Boom sweep should be limited to no more than 5/16" (8

mm). If necessary, the boom may be re-shimmed by
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moving shims from one side to the other to further cor-

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rect any remaining boom sweep. There may be some

instances where no shims are used under a given side
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pad to pass the criteria for boom sweep at final inspec-

tion of machine.
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4-48 31215055
4.9 LOAD SENSING PIN REMOVAL AND 6. Use the Load Pin Removal Tool (JLG PN 4846765) to pre-
vent the pin from being damaged, and use a hammer to
INSTALLATION remove the pin. To make the tool refer to Figure 4-18.,
Load Pin Removal Tool, JLG PN 4846765. If the Load Pin
1. Place the machine on a firm, level surface.
Removal Tool is not available, use an arbor of the proper
NOTE: Replacing the load sensing pin requires the boom sensors size (as shown below). If excessive force is necessary to
be re-calibrated. Make sure the machine is in an area move the pin, it may be necessary to carefully activate
where this can be accomplished after installation of the lift using the auxiliary power switch to relieve lift cylin-
new pin. der weight from the load sensing pin.
2. Swing the engine tray out to gain access to the sensing

pin and retaining pin.
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NOTE: The lift cylinder weighs 787 lb (357 kg.)
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3. Run a nylon strap capable of supporting the weight of
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the lift cylinder around the bottom of the cylinder. Lift
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up on the strap to relieve the weight of the lift cylinder
on the load sensing pin.
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7. When installing a new pin, make sure all of the holes in
the turntable and lift cylinder are aligned. If the new
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load sensing pin does not push 1/2 to 3/4 of the way in
by hand, remove the pin and align the holes better. Also
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make sure the pin is installed with the strain relief con-
nector opposing the pin orientation bar as shown. Refer
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to Figure 4-28., Pivot Pin Installation.

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4. Loosen and remove the bolt that secures the retaining

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pin and remove the retaining pin.

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8. Using an oak block, carefully tap the pin until it is fully

installed. Secure the pin in place with the retaining pin
and retaining pin bolt.
5. Disconnect the wiring harness from the strain relief con-

nector at the opposite side of the load sensing pin. DO NOT TAP ON THE CENTER OF THE PIVOT PIN.
9. Connect the wiring harness to the strain relief connector

and re-calibrate the boom sensors.
31215055 4-49
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Figure 4-18. Load Pin Removal Tool, JLG PN 4846765
4-50 31215055
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Figure 4-19. Boom/Jib Sensors and Switches Installation - Sheet 1 of 4
31215055 4-51
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4-52 31215055
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31215055 4-53
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4-54 31215055
SEE DETAIL A
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SEE DETAIL C
BOOM LENGTH
SENSOR
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DETAIL C
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ANGLE SENSOR INSTALLATION

TYPICAL ON LEFT & RIGHT SIDES
OF BOOM
0273696-H
MAE36150H
31215055 4-55
SEE DETAIL D
SEE DETAIL E
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DETAIL D
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SENSOR #1 SENSOR #1
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PIN # DESC SENSOR HARNESS PIN # DESC SENSOR HARNESS

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PIN #1 POWER RED RED PIN #1 POWER RED RED

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PIN #2 OUTPUT WHITE BLUE PIN #2 PWM OUT WHITE BLUE
PIN #3 GROUND BLACK BLACK

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PIN #3 GROUND BLACK BLACK
SENSOR #2 SENSOR #2
PIN # DESC SENSOR HARNESS PIN # DESC SENSOR HARNESS
PIN #1 POWER RED ORANGE PIN #1 POWER RED ORANGE
PIN #2 OUTPUT WHITE YELLOW PIN #2 PWM OUT WHITE YELLOW
PIN #3 GROUND BLACK BLACK PIN #3 GROUND BLACK BLACK
0273696-H
MAE36160H
4-56 31215055
JIB STOW SWITCH TO

ACTIVATE WHEN JIB ROTATES
90˚ CCW FROM CENTER
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POSITION SWITCH MOUNT
TO ACHIEVE 0.000" - 0.030"
CLEARANCE BETWEEN SWITCH
ROTATOR
CAM to ROLLERS AND ROTATOR CAM
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SWITCH TO ACTIVATE WHEN

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DUAL CAPACITY - JIB POSITION

JIB IS ROTATED 5˚ ± 1˚ BOTH
DIRECTIONS FROM CENTER
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DETAIL E
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NOTE:
PUSH NUT
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ASSEMBLE COMPONENTS AS SHOWN TO

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FORM A SUBASSEMBLY WHICH WILL MOUNT

TO JIB PIVOT
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SENSOR MOUNT
ENSURE THE PUSHNUTS HOLD SENSOR SENSOR COVER
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MOUNT FIRMLY TO SENSOR COVER SO

ALL WIRES ARE CONTAINED IN THE
SUBASSEMBLY PRIOR TO INSTALL ON
THE JIB PIVOT.
MOUNTING BOLT
0273696-H
MAE36170H
31215055 4-57
SEE DETAIL F BOOM LENGTH LIMIT SWITCH TO ACTIVATE WHEN

FLY BOOM IS EXTENDED 12" ± 1.5" (1350SJP)
or 24" ± 1.5" (1200SJP)
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[30.5 cm ± 3.8 cm (1350SJP)
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or 60.96 cm ± 3.8 cm (1200SJP)]
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DETAIL F
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DETAIL B
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PROXIMITY SWITCH
TO AVOID DAMAGING PROXIMITY , INSTALL AND ADJUST AFTER ASSEMBLING

SWITCH BLOCK, COMPRESSION SPRING AND TORQING WIRE ROPES.
TO ADJUST PROXIMITY SWITCH:

1. THREAD SWITCH IN UNTIL IT CONTACTS ADJUSTER BLOCK.
2. THREAD SWITCH OUT 1/8 TO 1/2 TURN TO ACHIEVE PROPER SENSING RANGE.
3. TIGHTEN JAM NUT
0273696-H
MAE36180H
4-58 31215055
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0271875 D
1. Bar
2. Blade
3. Mount
A Adjust top blades 0.000 to 0.063" (0 to 1.6 mm) from top boom plate
B Adjust side blades 0.000 to 0.063" (0 to 1.6 mm) from side boom plate
C Apply Threadlocker PN 0100019 & torque to 50 ft.lbs. (70 Nm)
Figure 4-27. Boom Wiper Installation
31215055 4-59
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1 Pivot Pin
2 Bolt
3 Keeper Rod
4 Load Sensing Pin
5 Pin Orientation Bar
* Position the Load Sensing Pin with the strain relief connector opposite the pin
orientation bar as shown
CAUTION: Pounding on the Load Sensing Pin for removal can destroy the internal
strain gauge. Use care when removing the pin.
Figure 4-28. Pivot Pin Installation
4-60 31215055
4.10 POWERTRACK MAINTENANCE 3. Remove the screws from the flat bar on the other side of
the powertrack.
One Piece Bracket Maintenance

1. Place the powertrack on a workbench.
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pa
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4. Pull up on the loose side of the round bar to allow the
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poly roller to slide off.
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2. Remove the screws from the bars on one side of the
powertrack on the first link.
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31215055 4-61
5. Slide the poly roller off of the round bar. 7. Slide the flat bar out.
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6. Hold the round bar to remove the other screw. 8. Remove the snap ring from one side of the bracket.
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9. Remove the snap ring from the other side of the bracket.
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4-62 31215055
10. Push down with slight pressure on the link and slide the Two Piece Bracket Maintenance
bracket side up and over the extrusion on the link.
1. Loosen the screw.
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11. Repeat the previous step on the other side.
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2. Slide the roller off the bar.
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12. Slide the bracket off of the powertrack.

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3. Hold the bar tightly and remove the other screw.

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31215055 4-63
4. Hold the flat bar and remove the screws. 7. Slide the link out.
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5. Remove the snap rings and pins. Snap Rings and Screws
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WHEN PERFORMING MAINTENANCE ON THE POWERTRACK, MAKE SURE TO
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DISCARD AND REPLACE ALL OLD SCREWS.
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Make sure screws are tight and installed properly.
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6. Remove the screws from the bar. Remove the snap ring
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and pin. LOOSE SCREW TIGHT SCREW

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4-64 31215055
Make sure that all snap rings are closed and seated. A seated and closed snap ring is shown below.
CLOSED
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OPEN
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10-24 x 0.812 button torx socket head with blue locking patch:
An open snap ring is shown below. • Tighten to 45-50 in.lbs. (5-5.6 Nm).
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• Use T-25 torx bit.
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• Do not reuse this screw. After removing replace with a new
one.
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A snap ring that is not seated is shown below.

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31215055 4-65
4-66
TIE ELECTRIC CABLES TOGETHER
EVERY 8" (20cm) WITHIN T/T TO BOOM POWERTRACK
CONTINUE TYING ELECTRIC CABLES
UNTIL THEY PASS THRU HOSE CLAMP
(CUT OFF EXCESS STRAP AT EACH TIE POINT)
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SEE DETAIL C
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B B
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2
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SEE DETAIL F
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A or A
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0271570-R
0271800-Q
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MAE35400
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Figure 4-29. Powertrack Installation - Sheet 1 of 6
31215055
31215055
APPLY RUBBER PAD AFTER BUTTON HEAD SCREWS
HAVE BEEN ASSEMBLED AND TIGHTENED
APPLY CLEAR ADHESIVE GEL TO SURFACE OF
RUBBER PAD AND ASSEMBLE TO APPLY RUBBER PAD AFTER BUTTON HEAD SCREWS
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CORRESPONDING PART AS SHOWN HAVE BEEN ASSEMBLED AND TIGHTENE
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RUBBER PAD AND ASSEMBLE TO
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DETAIL D
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RUBBER PAD AND ASSEMBLE TO
CORRESPONDING PART AS SHOWN
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USE WASHER AS A SHIM
MAX OF (4) ON EACH MTG BOLT
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TYPICAL, LEFT OR RIGHT SIDE
OF MOUNTING FLANGE
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DETAIL C
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APPLY CLEAR ADHESIVE GEL UNDERNEATH THE HEAD
OF BUTTON HEAD SCREW PRIOR TO ASSEMBLING
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T/T TO BOOM POWERTRACK TO THE POWERTRACK/HOOD BRACKET
0271570-R
0271800-Q
MAE35410
4-67
4-68
APPLY CLEAR ADHESIVE GEL TO SURFACE
OF RUBBER PAD AND ASSEMBLE TO
CORRESPONDING PARTAS SHOWN
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Di DETAIL E
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ROUTE HOSES/CABLES THROUGH LOOP
ON ROTATOR SUPPORT AS SHOWN
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TRIM EXCESS
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AS REQUIRED
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RUBBER CLAMP PAD AND ASSEMB
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AS SHOWN
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ASSEMBLE STAUFF CLAMPS TO
TWO TAPPED BLOCKS ON THE
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BOTTOM SIDE OF THE UPPER
JIB LINK
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0271570-
0271800-
MAE35420
31215055
31215055
ADJUST POWERTRACK POSITION SO THAT
THERE IS A 1/4" ±1/8" CLEARANCE BETWEEN THE PUSH
TUBES AND POWERTRACK ROLLERS AT THESE
TWO LOCATIONS. ADJUST IN THE RETRACTED POSITION
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RUBBER PAD AND ASSEMBLE AS SHOWN
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VIEW A-A
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VIEW B-B
ROUTE TIE STRAPPED HARNESSES BETWEEN
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TELESCOPE CYLINDER HOSES AS SHOWN BELOW
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TELESCOPE RETRACT HOSE
TELESCOPE EXTEND HOSE (OUTSIDE OF BEND RADIUS)
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(INSIDE OF BEND RADIUS)
HARNESS BUNDLE
0271570-R
0271800-Q
MAE35430
4-69
4-70
Table 4-2. Hose/Cable Pull Chart
LETTER DESCRIPTION DIM "X"
IN. CM
P LEVEL UP HOSE (PORT L1) 64 162.5
Q LEVEL DOWN HOSE (PORT L2) 64 162.5
R SWING RIGHT HOSE (PORT S1) 64 162.5
S SWING LEFT HOSE (PORT S2) 64 162.5
T JIB LIFT UP HOSE (PORT J1) 64 162.5
U JIB LIFT DOWN HOSE (PORT J2) 64 162.5
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to NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm)
DIM "Z"
MAINTAIN 63" OF HOSE/CABLE BETWEEN END STRETCH HOSE OUT AND
OF UPPER PUSH TUBE AND JIB CLAMP MEASURE IN A STRAIGHT LINE
P
SEE DETAIL H
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A
B
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Table 4-1. Hose/Cable Pull Chart
C
LETTER DESCRIPTION DIM "X"
D
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FT. (IN.) CM
E
A HARNESS, TRANSPORT LIMIT SWITCH (18/3 CABLE) 6 (72) 182.8
F
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B HARNESS, BOOM ANGLE SENSOR (LEFT) (18/3 CABLE) 1.5 (18) 45.8
G
C HARNESS, BOOM ANGLE SENSOR (RIGHT) (18/3 CABLE) 1.5 (18) 45.8
H
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D HARNESS, BOOM LENGTH SENSOR (18/3 CABLE) 1.5 (18) 45.8
I
E BROKEN CABLE PROXIMITY SENSOR (YELLOW CABLE) 5 (60) 152.4
J
F AC CABLE (10/3) 13 (156) 396.2
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K G CONTROL CABLE (18/8) 6 (72) 182.8
L H TELESCOPE EXTEND HOSE (5/8 10M3K) 7 (84) 213.3
M I TELESCOPE RETRACT HOSE (1/2 8M3K) 7 (84) 213.3
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N J PRESSURE HOSE TO PLATFORM VALVE (3/8 6M4K) 6 (72) 182.8
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DIM "X" K RETURN HOSE TO PLATFORM VALVE (1/2 8M3K) 6 (72) 182.8
STRETCH HOSE/CABLE OUT AND
MEASURE IN A STRIGHT LINE L AIR LINE (1/2 8LOLA) OPTIONAL 10 (120) 304.8
M WELD LEAD (3/0 CABLE) OPTIONAL 10 (120) 304.8
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N 7500W GENERATOR (8/5 CABLE) OPTIONAL 10 (120) 304.8
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NOTE: ALL CABLE/HOSE LENGTHS TO BE ± 1" (2.5 cm) rp
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0271570-R
0271800-Q
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MAE35440
31215055
31215055
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7" (17.8 CM)
MAINTAIN HOSE/CABLE LOOP
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ROUTE HOSES TO INBOARD SIDE AT THIS DIMENSION
OF CENTER POWERTRACK DIVIDER
m 7" (17.8 CM)
MAINTAIN HOSE/CABLE LOOP
AT THIS DIMENSION
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DETAIL H
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RETURN HOSE TO PLATFORM VALVE
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ROUTE CABLES AND OPTIONAL AIRLINE/WELD LEAD/ PRESSURE HOSE TO PLATFORM VALVE
7500W GEN. CABLE TO OUTBOARD SIDE OF CENTER AC CABLE
POWERTRACK DIVIDER
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CONTROL CABLE
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VIEW SHOWING POWERTRACK LOADING 0271570-R
(PUSH TUBES NOT SHOWN FOR CLARITY) 0271800-Q
MAE35450
4-71
4.11 HOSE ROUTING PROCEDURE 4. Inspect sheaves for condition of bearings/pins. (See
Dimension Of Sheaves for proper dimension.)
For proper hose routing and cable wrap placement and
clamping, refer to Figure 4-29., Figure 4-30., Figure 4-31., Fig- 5. Inspect sheaves for condition of flanges. (See Dimension
ure 4-32., Figure 4-33., and Figure 4-34. It is important to peri- Of Sheaves for proper dimension.)
odically inspect hoses, wraps and clamps for proper slack 6. Inspect sheaves with a groove wearout gauge for exces-
adjustments and clamping integrity (pull check). Any sive wear.
changes as a result of inspection should be verified by per-
forming full strokes of boom functions especially lift, tele-
scope, jib, and platform rotate.
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4.12 WIRE ROPE
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IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER
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PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE
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ROPES INSPECTED/SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR
MISADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH.
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Observe the groove so that it may be clearly seen
Each day before using the machine: whether the contour of the gauge matches the
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contour of the bottom of the groove.
1. Raise the main boom to approximately horizontal.
2. Extend and retract the boom sections.
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7. Ropes passing inspection should be lubricated with wire
rope lubricant before reassembly.
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3. Check for delayed movement of the fly section, which
indicates loose wire ropes. Three Month Inspection
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Inspection 1. Remove boom covers and visually (with flashlight)

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inspect the ropes for rust, broken wires, frays, abuse, or

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NOTE: The pictures in this paragraph are just samples to show the any signs of abnormalities.
replacement criteria of the rope.
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2. Check rope tension by deflecting the ropes by hand

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properly tensioned ropes should have little or no move-

1. Inspect ropes for broken wires, particularly valley wire
ment.
breaks and breaks at end terminations.
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Additional Inspection Required If:

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1. Machine is exposed to hostile environment or condi-

tions.
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2. Erratic boom operation or unusual noise exists.

Flexing a wire rope can often expose broken wires hid-
3. Machine is idle for an extended period.
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den in valleys between strands.

4. Boom is overloaded or sustained a shock load.
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2. Inspect ropes for corrosion. 5. Boom exposed to electrical arc. Wires may be fused
internally.
3. Inspect ropes for kinks or abuse.
12 Year or 7000 Hour Replacement
1. Mandatory wire rope and sheave replacement.
A kink is caused by pulling down a loop

in a slack line during improper handling,
installation, or operation.
4-72 31215055
Additional Replacement Criteria

1. Sheaves and wire rope must be replaced as sets. PROPER BOOM POSITIONS DO NOT MEAN THAT THE WIRE ROPE TENSIONS
ARE CORRECT.
2. Rusted or corroded wire ropes.
3. Kinked, “bird caged”, or crushed ropes. If the measurements do not fall within the tolerances in Figure
4-36., Wire Rope Tensioning, adjust the booms using the re-
4. Ropes at end of adjustment range. positioning procedures that follow.
5. Sheaves failing wearout gage inspection.
INNER MID BOOM SECTION REPOSITIONING
6. Ropes with 6 total broken wires in one rope lay, 3 in one The inner mid section of the boom is positioned by the
strand in one rope lay, 1 valley break, or 1 break at any hydraulic cylinder. No adjustments can be made to this sec-
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end termination. tion. The wire ropes within the assembly only control the
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movement of the Outer Mid Boom and Fly Boom sections.
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4.13 WIRE ROPE TENSIONING ADJUSTMENT OUTER MID BOOM SECTION REPOSITIONING
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If the Outer Mid Boom falls within the dimension and toler-
ance of Figure 4-36., Wire Rope Tensioning, proceed to the Fly
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Boom Section Positioning procedure in this section. If the
ANY TIME THE WIRE ROPE TENSIONING HAS BEEN ADJUSTED, BOOM CALI-
Outer Mid Boom section is outside of the tolerance as shown,
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BRATION SHOULD BE PERFORMED IMMEDIATELY AFTERWARD.
perform the following procedure.
or
Before adjusting wire rope tension, the boom sections must 1. Extend the boom assembly so the platform moves
be in the proper position as shown in Figure 4-36., Wire Rope 5 to 6 feet (1.5 to 1.8 m) from the fully retracted position.
Tensioning. This is so the wire ropes are equalized on both
sides of the sheaves and are seated properly in the sheave to 2. Remove any covers necessary to access the wire rope
om
adjustment nuts.
grooves. This is necessary for proper tensioning of the wire
ropes.
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This section covers the two major operations in tensioning the

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wire ropes which are as follows:

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• Positioning the boom sections (so that proper tensioning

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can be achieved).
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• Tensioning the wire rope.

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Boom Section Re-Positioning

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NOTE: Because the Outer Mid Boom is used to control the move-
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ment of the Fly Boom, any repositioning of the Outer Mid

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Boom section will also affect the position of the Fly Boom
section. Correctly position the Outer Mid Boom before
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repositioning the Fly Boom.

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NOTE: Use the Telescope function of the machine to position the

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boom sections. Do not use the wire rope adjustment nuts

to position the booms. This may cause damage to the wire
rope adjustment threads.
1. Ensure the machine is placed on firm, level ground.

2. Before making any adjustments, position the boom
assembly in the fully retracted position.
3. Take preliminary measurements of the position of each
boom section and compare them to Figure 4-36., Wire
Rope Tensioning. If the measurements fall within the tol-
erances in the figure, proceed to Wire Rope Tensioning
in this section.
31215055 4-73
3. Remove the lock plates and nylon collar locknuts from a. If the Outer Mid Boom still does not fall within the
the wire rope adjustment nuts. dimension and tolerance of Figure 4-36., repeat the
Outer Mid Boom positioning procedure.
b. If the Outer Mid Boom falls within the dimension
and tolerance of Figure 4-36., proceed to the Fly
Boom Section Positioning procedure in this section.
NOTE: Because the Outer Mid Boom is used to control the move-
ment of the Fly Boom, any repositioning of the Outer Mid
Boom Section will also affect the position of the Fly Boom
section. After repositioning the Outer Mid Boom, always
check the Fly Boom position per Figure 4-36.
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FLY BOOM SECTION REPOSITIONING
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If the Fly Boom section location and the Outer Mid Boom sec-
tion location are both within the dimensions and tolerances in
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Figure 4-36., proceed to the Wire Rope Tensioning Procedure
Outer Mid Retract Adjusting in this section.
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Nuts and Lock Plates
If the Fly Boom section is outside of the tolerance as shown in
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Figure 4-36. while the boom assembly is fully retracted, per-
form the following procedure:
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1. Extend the boom assembly such that the platform
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moves 5 to 6 feet (1.5-1.8 m) from the fully retracted
position.
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2. Remove the lock plates and nylon collar locknuts from
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the wire rope adjustment nuts.

3. If the Fly Boom needs to be retracted farther in:
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a. Loosen the Fly Boom Extend Adjustment Nuts by an

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Outer Mid Extend Adjusting amount equal to twice the distance the boom needs
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Nuts and Lock Plates to move to be in tolerance.

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4. If the Outer Mid Boom needs to be retracted:

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a. Loosen the Outer Mid Boom Extend Adjustment

Nuts by an amount equal to twice the distance the
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boom needs to move to be in tolerance.

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b. Fully retract the boom.

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c. To remove the slack caused by the previous step,

tighten the Outer Mid Boom Extend Adjustment
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Nuts until they just contact the plate.

5. If the Outer Mid Boom needs to be extended out:
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a. Loosen the Outer Mid Boom Retract Adjustment Fly Boom Extend Adjusting
Nuts by an amount equal to twice the distance the
boom needs to move to be in tolerance
b. Fully retract the boom.
b. Extend the boom 3-4 feet (1-1.5m).
c. To remove the slack caused by the previous step, tighten the Fly Boom Extend Adjustment Nuts until
tighten the Outer Mid Boom Retract Adjustment they just contact the plate.
Nuts until they just contact the plate.
6. Fully retract the boom sections.
7. Verify that the exposed boom section dimensions meet
the dimensions and tolerances of Figure 4-36., Wire
Rope Tensioning.
4-74 31215055
4. If the Fly Boom needs extended: 1. Remove any covers necessary to access the wire rope
adjustment nuts.
a. Loosen the Fly Boom Retract Adjustment Nuts by an
amount equal to twice the distance the boom needs
to move to be in tolerance.
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Fly Boom Retract Adjusting
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b. Extend the boom 3-4 feet (1-1.5m).
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tighten the Fly Boom Retract Adjustment Nuts until
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they just contact the plate.
d. Fully retract the boom sections.
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5. Verify that the exposed boom section dimensions meet
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the dimensions and tolerances of Figure 4-36., Wire

Rope Tensioning.
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a. If the Fly Boom still does not fall within the dimen-
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sion and tolerance of Figure 4-36., repeat the Fly 2. If not already done, remove the lock plates and nylon
Boom Section Repositioning procedure.
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collar locknuts from the wire rope adjustment nuts.

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b. If the Fly Boom falls within the dimension and toler- 3. Position the boom so that it is horizontal within ±5°. If
ance of Figure 4-36., proceed to the Wire Rope Ten- the boom is below horizontal, ensure that the boom is
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sioning Procedure. not on the boom rest.

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Wire Rope Tensioning Procedure 4. Extend the boom so the platform moves 5 to 6 feet (1.5-
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1.8 m) from the fully retracted position. This is done to

NOTE: Verification of the rope tension should be determined by position the boom so the ropes to be tensioned are not
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proper function of the boom assembly and by the dimen- under load.
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sions and tolerances of Figure 4-36., Wire Rope Tensioning. 5. When extending the boom in the previous step, if the
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boom reaches the end of travel and then automatically

retracts a small amount, the ropes may still be under
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load. If so, perform the following steps:

REPEAT WIRE ROPE TENSIONING PROCEDURE ONLY AS NECESSARY TO
ACHIEVE PROPER TENSION. a. Note where the boom hits the end of stroke.
b. Retract 3-4 feet (1-1.3 m).
c. Extend the boom and stop just before the boom
IF THE BOOMS HAVE BEEN PROPERLY POSITIONED AND THERE IS NOT hits the end of stroke.
ENOUGH ADJUSTMENT REMAINING ON THE WIRE ROPES TO ACHIEVE TORQUE,
THE SERVICE LIFE OF THE WIRE ROPES HAS BEEN CONSUMED. DO NOT PRO-
CEED WITH THE REMAINDER OF THIS PROCEDURE. REPLACE THE WIRE ROPES
AND SHEAVES.
31215055 4-75
6. Using tool JLG PN 4120043, torque the Outer Mid Boom 9. Using tool JLG PN 4120043, torque the Outer Mid Boom
Retract Adjustment Nuts to 80 ft-lb (108 Nm), alternat- Extend Adjustment Nuts to 80 ft-lb (108 Newton
ing between the two ropes until both maintain the meters), alternating between the two ropes until both
required torque. maintain the required torque.
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Outer Mid Extend Adjusting
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Outer Mid Retract Adjusting
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Nuts and Lock Plates 10. Using tool JLG PN 4120040, torque the Fly Extend
Adjustment Nuts to 10 ft-lb (13.5 Nm), starting with the
or
inside ropes and doing the outside ropes last. Refer to
7. Using tool JLG PN 4120043, torque the Fly Boom Retract
Figure 4-35., Torque Sequence for Fly Extend Rope.
Adjuster Nuts to 80 ft-lb (108 Nm), alternating between
the two ropes until both maintain the required torque.
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Alternate between the four ropes until all maintain the
required torque.
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Fly Boom Retract Adjusting Fly Boom Extend Adjusting

Nuts and Lock Plates Nuts and Lock Plates
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8. Retract the boom 2-3 feet (0.6-1.0 m). Do not fully retract
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or bottom out the booms.

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3 1 2 4
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Figure 4-35. Torque Sequence for Fly Extend Rope
4-76 31215055
11. Repeat the following boom movement steps three 18. Install all covers.
times. This is to ensure that the wire rope tension has
equalized on both sides of the sheaves and the ropes are
seated properly in the sheave grooves.
a. Fully retract the boom.
b. Extend the boom such that the platform moves 5 to
6 feet (1.5-1.8 m) from fully retracted position.
12. Verify the Fly Boom and Outer Mid Boom Retract wire
rope torques.
a. If the torque values are not correct, repeat the Wire
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Rope Tensioning procedure.
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b. If the torque values are correct, proceed to the next
step.
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13. Retract the boom 2-3 feet (0.5-1 m). Do not fully retract
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or bottom out the boom.
14. Verify the Fly Boom and Outer Mid Boom Extend wire
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rope torques.
or
a. If the torque values are not correct, repeat the Wire
Rope Tensioning procedure.
b. If the torque values are correct, proceed to the next
step. to
om
15. Check for proper function of the boom assembly. When
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properly torqued and positioned, all three moving

boom sections will move simultaneously.
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16. Install new nylon collar locknuts to the Fly Boom Extend
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wire rope fittings. Do not re-use the old nylon collar lock
nuts. Torque the locknuts to 10 ft-lb (13.5 Nm)
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17. Reinstall the lock plates to the remaining adjuster nuts.

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31215055 4-77
9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
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OUTER MID BOOM
FLY BOOM
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BASE BOOM
INNER MID BOOM
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NOTE: Boom shown in fully retracted position.

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Figure 4-36. Wire Rope Tensioning

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4-78 31215055
31215055
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Figure 4-37. Outer Mid Boom Extend/Retract Cables
4-79
4-80
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Figure 4-38. Fly Boom Extend/Retract Cables
31215055
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1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
Figure 4-39. Wire Rope Adjustment Tools (Optional)
31215055 4-81
4.14 BROKEN BOOM CABLE PROXIMITY SWITCH To avoid damaging the proximity switch, install and adjust
after assembling the switch block, compression spring, and
This system uses a proximity switch to detect excessive move- torquing the wire ropes.
ment of the cable block. If movement is detected the Cable
Break indicator will illuminate in the platform control panel.
No restrictions are made to the functionality of the control sys-
Adjusting the Proximity Switch
tem. It is the responsibility of the operator to take immediate 1. Thread the switch in until it contacts the adjuster block.
action.
2. Thread the switch out 1/8 to 1/2 turn to achieve proper
sensing range.
3. Tighten the jam nut.
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Figure 4-40. Broken Boom Cable Proximity Switch Location

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4.15 ELECTRONIC PLATFORM LEVELING PRIMARY AND SECONDARY TILT SENSOR INTERACTION
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The secondary tilt sensor is used as a backup to the primary tilt

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NOTE: For more detailed information concerning system adjust-

sensor. Any time a tilt set point is reset, a value from each sen-
ment and operation, refer to Section 6 - JLG Control Sys-
sor shall be set.
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tem.
If a fault occurs with the primary sensor, control will revert to
Description the secondary sensor. (This is discussed in more detail in the
error response section.)
Electronic platform leveling replaces the conventional hydrau-
lic method of platform leveling. Because of the mounting orientation of the tilt sensors, the
primary tilt sensor will output ascending voltage values with
To control electronic platform leveling the platform is
increases in positive platform tilt angle. The backup or second-
equipped with a pair of tilt sensors, one primary and one sec-
ary tilt sensor will output descending voltage values with
ondary, mounted to the non-rotating portion of the platform
increases in positive platform angle.
rotator. The tilt sensors are monitored regularly and the plat-
form level up and down valves are automatically controlled to
maintain set point as the machine is operated.
4-82 31215055
PLATFORM VALVES In order to obtain acceptable performance while performing

all hydraulic functions, five sets of parameters are used. These
The platform specific valves are located in a manifold at the
“zones” allow compensation for differences in how the basket
platform.
level changes when doing different functions. These zones are
There are individual proportional control valves that control as follows:
each of the four platform functions; Platform Level, Platform
1. Lift up
Rotate, Jib Lift, and Jib Swing.
2. Lift down
There is also a Platform Dump Valve, located in the platform
valve manifold, which is used to hydraulically isolate the con- 3. Other boom functions
trol valves and to improve hydraulic response.
4. Drive
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The Ground Module controls this valve to provide manual
5. Auxiliary
platform leveling in the event that the Platform Module is
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inoperable. The other boom functions zone includes Swing, Telescope, Jib
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swing (It is not necessary to level with jib lift, since the
In ground mode, the platform dump valve is turned on when-
mechanical linkage keeps the basket level).
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ever any platform or jib valve output is turned on. Whenever
all platform and jib valves are turned off, the platform dump These zones are prioritized when multiple functions are active.
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valve is turned off. The priorities are as follows.
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In platform mode, the platform dump valve is turned on 1. Auxiliary power and any other function, zone = auxiliary
whenever the footswitch is depressed. power
or
2. Drive and any other function, zone = Drive
Normal Operation
AUTOMATIC LEVELING to
3. Lift up and any other function, zone = Lift up
om
Two tilt sensors, mounted on either side of the platform sup- 4. Lift down and any other function, zone = Lift down
port, are used to measure the incline of the platform with 5. Other boom functions, zone = Other boom functions
t.c
respect to gravity and control the automatic leveling function,

one is used as the primary sensor and one as a secondary back During the power-up procedure, function enable, in both Plat-
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up sensor. form and Ground Mode, is delayed during the 1.5 second
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startup lamp test. During this 1.5 second startup period, the
The level system shall assume a new fixed set point (fixed basket level up valve will be energized at 100% duty cycle for
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incline of the platform with respect to gravity) each time the 0.5 second, and then the basket level down valve energized at
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control system is powered up (cycling of the EMS). 100% duty cycle for 0.5 second. This will help to keep the
valves from sticking.
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Automatic platform leveling only functions while operating

drive, telescope, lift or swing. It does not operate while operat-
nt
PLATFORM LEVEL MANUAL OVERRIDE

ing any other function (e.g. rotate, jib, or steer).
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In addition to automatic leveling the operator is able to manu-

The proportional control for these valves varies. This is depen- ally adjust the platform level position by means of the level
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dant on the tilt variance from target as well as on the impact override switches located at the platform and ground control
coil temperature is having on the current to the valves.
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positions (similar to a Master/Slave hydraulic system).

If a command from the Platform Level Up and Down toggle The level system assumes a new set point after a level over-
to
switch on either the platform or the ground is received, auto- ride switch is operated. In other words the operator can chose
matic platform leveling will cease and the appropriate output a platform level incline other than level with gravity and the
Go
will be commanded to turn on. system will maintain this set point during automatic leveling.
When the toggle switch is released, after ¼ second, the current
filtered value of tilt angle will be taken as the new set point.
31215055 4-83
4.16 ROTARY ACTUATOR Required Tools

Upon assembly and disassembly of the actuator there are
Theory of Operation basic tools required. The tools and their intended functions are
The L20 Series rotary actuator is a simple mechanism that uses as follows:
the sliding spline operating concept to convert linear piston
motion into powerful shaft rotation. Each actuator is com-
posed of a housing with integrated gear teeth (01) and only
two moving parts: the central shaft with integrated bearing
tube and mounting flange (02), and the annular piston sleeve
(03). Helical spline teeth machined on the shaft engage
matching splines on the inside diameter of the piston. The
rts
outside diameter of the piston carries a second set of splines,
of opposite hand, which engage with matching splines in the
pa
housing. As hydraulic pressure is applied, the piston is dis-
placed axially within the housing - similar to the operation of a
ur
hydraulic cylinder - while the splines cause the shaft to rotate.
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When the control valve is closed, oil is trapped inside the actu-
ator, preventing piston movement and locking the shaft in
r
position.
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1. Flashlight - helps examine timing marks, component
failure and overall condition.
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2. Felt Marker - match mark the timing marks and outline
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troubled areas.
3. Allen wrench - removal of port plugs and set screws.
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4. Box knife - removal of seals.

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5. Seal tool - assembly and disassembly of seals and wear

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guides.
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6. Pry bar - removal of end cap and manual rotation of

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shaft.
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7. Rubber mallet- removal and installation of shaft and pis-

ton sleeve assembly.
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8. Nylon drift - installation of piston sleeve

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9. End cap dowel pins - removal and installation of end cap

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(sold with Helac seal kit).

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Bars indicate starting positions As fluid pressure is applied, the

to
of piston and shaft. Arrows indi- piston is displaced axially while

cate direction they will rotate. the helical gearing causes the
Go
The housing with integral ring piston and shaft to rotate simul-
gear remains stationary. taneously. The double helix
design compounds rotation:
shaft rotation is about twice that
of the piston.
The shaft is supported radially by the large upper radial bear-

ing and the lower radial bearing. Axially, the shaft is separated
from the housing by the upper and lower thrust washers. The
end cap is adjusted for axial clearance and locked in position
by set screws or pins.
4-84 31215055
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PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
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2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-41. Rotary Actuator - Exploded View
31215055 4-85
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PARTS HARDWARE SEALS BEARINGS ACCESSORIES

1. Housing 103.1. Screw 200. T-Seal 302. Wear Guide 400. Stop Tube
2. Shaft 103.2 . Washer 202. T-Seal 304. Thrust Washer 420.1 Bushing
3. Piston Sleeve 106.1. Port Plug 204. O-ring 420.2 Bushing
4. End Cap 106.2. Port Plug 205. Cup Seal 421.1 Bushing
109 . Lock Pin 207. Backup Ring
113. Capscrew 304.1. Wiper Seal
Figure 4-42. Rotary Actuator - Assembly Drawing
4-86 31215055
Disassembly 3. Remove the lock pins using an ”Easy Out” (a size #2 is

shown).
1. Remove the cap screws (113) over end cap lock pins
(109).
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If the pin will not come out with the ”Easy Out”, use 5/1
6” drill bit to a depth of 1/2” (12.7mm) to drill out the
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entire pin.
2. Using a 1/8” (3.18mm) drill bit, drill a hole in the center
or
of each lock pin to a depth of approximately 3/16” 4. Install the end cap (4) removal tools provided with the
(4.76mm). Helac seal kit.
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5. Using a metal bar, or something similar, unscrew the end

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cap (4) by turning it counter clockwise.

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31215055 4-87
6. Remove the end cap (4) and set aside for later inspec- 8. Every actuator has timing marks for proper engage-
tion. ment.
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7. Remove the stop tube if included. The stop tube is an
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available option to limit the rotation of the actuator.
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9. Prior to removing the shaft, (2), use a felt marker to

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clearly indicate the timing marks between shaft and pis-

ton. This will greatly simplify timing during assembly.
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4-88 31215055
10. Remove the shaft (2). It may be necessary to strike the 13. At the point when the piston gear teeth come out of
threaded end of the shaft with a rubber mallet. engagement with the housing gear teeth, mark the pis-
ton and housing with a marker as shown.
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11. Before removing the piston (3), mark the housing (1)
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ring gear in relation to the piston O.D. gear. There should 14. Remove the o-ring (204) and backup ring (207) from end
or
now be timing marks on the housing (1) ring gear, the cap (4) and set aside for inspection.
piston (3) and the shaft (2).
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15. Remove the wear guides (302) from the end cap (4) and
12. To remove the piston (3) use a rubber mallet and a plas- shaft (2).
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tic mandrel so the piston is not damaged.

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31215055 4-89
16. To remove the main pressure seals (205), it is easiest to 19. Remove the piston O.D. seal (202).
cut them using a sharp razor blade being careful not to
damage the seal groove.
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20. Remove the piston I.D. seal (200). You may now proceed
to the inspection process.
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17. Remove the thrust washers (304), from the end cap (4)
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and shaft (2).
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18. Remove the wiper seal (304.1) from its groove in the end
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cap (4) and shaft (2).

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4-90 31215055
Inspection 3. Inspect the wear guide condition and measure thick-

ness (not less than 0.123” or 3.12 mm).
1. Clean all parts in a solvent tank and dry with com-
pressed air prior to inspecting. Carefully inspect all criti-
cal areas for any surface finish abnormalities: Seal
grooves, bearing grooves, thrust surfaces, rod surface,
housing bore and gear teeth.
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Assembly
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1. Gather all the components and tools into one location
prior to re-assembly. Use the cut away drawing to refer-
2. Inspect the thrust washers (304) for rough or worn
edges and surfaces. Measure it’s thickness to make sure to ence the seal orientations.
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it is within specifications (Not less than 0.092” or 2.34
mm).
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31215055 4-91
2. Install the thrust washer (304) onto shaft (2) and end cap 4. Using a seal tool install the main pressure seal (205) onto
(4). shaft (2) and end cap (4). Use the seal tool in a circular
motion.
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3. Install the wiper seal (304.1/green 0-ring) into it’s groove 5. Install the wear guide (302) on the end cap (4) and shaft
on the shaft (2) and end cap (4) around the outside edge
or
(2).
of the thrust washer (304).
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6. Install the inner T-seal (200) into the piston (3) using a
circular motion.
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Install the outer T-seal (202) by stretching it around the

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groove in a circular motion.

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4-92 31215055
Each T-seal has 2 Backup rings (see drawing for orienta- 7. Insert the piston (3) into the housing (1) as shown, until
tion). the outer piston seal (202) is touching inside the hous-
ing bore.
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Beginning with the inner seal (200) insert one end of b/u
ring in the lower groove and feed the rest in using a cir- 8. Looking from the angle shown, rotate the piston (3) until
or
cular motion. Make sure the wedged ends overlap cor- the marks you put on the piston and the housing (1)
rectly. during disassembly line up as shown. Using a rubber
Repeat this step for the outer seal (202). to mallet, tap the piston into the housing up to the point
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where the gear teeth meet.
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31215055 4-93
9. Looking from the opposite end of the housing (1) you 11. Looking from the view shown, use the existing timing
can see if your timing marks are lining up. When they do, marks to line up the gear teeth on the shaft (2) with the
tap the piston (3) in until the gear teeth mesh together. gear teeth on the inside of the piston (3). Now tap the
Tap the piston into the housing the rest of the way until flange end of the shaft with a rubber mallet until the
it bottoms out. gear teeth engage.
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10. Install the shaft (2) into the piston (3). Be careful not to 12. Install 2 bolts in the threaded holes in the flange. Using a
damage the seals. Do not engage the piston gear teeth
yet.
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bar, rotate the shaft in a clockwise direction until the
wear guides are seated inside the housing bore.
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13. Install the stop tube onto the shaft end. Stop tube is an
available option to limit the rotation of an actuator.
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4-94 31215055
14. Coat the threads on the end of the shaft with anti-seize 17. Tighten the end cap (4). In most cases the original holes
grease to prevent galling. for the lock pins will line up.
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18. Place the lock pins (109) provided in the Helac seal kit in
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15. Install the 0-ring (204) and Backup ring (207) into the
the holes with the dimple side up. Then, using a punch,
inner seal groove on the end cap (4).
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tap the lock pins to the bottom of the hole.
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16. Thread the end cap (4) onto the shaft (2) end. Make sure
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the wear guide stays in place on the end cap as it is 19. Insert the set screws (113) over the lock pins. Tighten
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threaded into the housing (1). them to 25 in. lbs. (2.825 Nm).
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31215055 4-95
Installing Counterbalance Valve Bleeding After Installation

Refer to Figure 4-43., Rotator Counterbalance Valve. NOTE: Bleeding will be necessary if excessive backlash is displayed
1. Make sure the surface of the actuator is clean, free of any after the actuator is installed. To do this, bleeder valves
contamination and foreign debris including old Loctite. must be installed in the actuator at the locations shown
below. The following steps are recommended when a mini-
2. Make sure the new valve has the O-rings in the counter- mum of two gallons (8 liters) is purged.
bores of the valve to seal it to the actuator housing.
3. The bolts that come with the valve are grade 8 bolts.
New bolts should be installed with a new valve. Medium
Strength Threadlocking Compound should be applied
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to the shank of the three bolts at the time of installation.
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4. Torque the 1/4-inch bolts 110 to 120 inch pounds (12.4
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to 13.5 Nm). Do not torque over 125 inch pounds (14.1
Nm). Torque the 5/16-inch bolts 140 inch pounds (15.8
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Nm). Do not torque over 145 inch pounds (16.3 Nm).
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Testing the Actuator
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If the equipment is available, the actuator should be tested on
a hydraulic test bench. The breakaway pressure — the pres-
or
sure at which the shaft begins to rotate — should be approxi-
to
mately 400 psi (28 bar). Cycle the actuator at least 25 times at
3000 psi (210 bar) pressure. After the 25 rotations, increase the
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pressure to 4500 psi (315 bar) to check for leaks and cracks. 1. Connect a 5 foot (1.5 m) long 3/16" inside diameter, 5/
Perform the test again at the end of the rotation in the oppo- 16" outside diameter clear vinyl drain tube to each of
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site direction. the two bleeder valves. Secure the tubes in place with
hose clamps.
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TESTING THE ACTUATOR FOR INTERNAL LEAKAGE

2. Place the end of the tubes in a clean 5 gallon (19 L) con-
If the actuator is equipped with with a counterbalance valve,
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tainer to collect the purged oil. The oil can be returned

plug the valve ports. Connect the hydraulic lines to the hous-
to the reservoir when the procedure is complete.
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ing ports. Bleed all air from the actuator (see Installation and
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Bleeding) Rotate the shaft to the end of rotation at 3000 psi 3. Open both bleeder valves 1/4 turn. Using the hydraulic
(210 bar) and maintain pressure. Remove the hydraulic line system, rotate the platform to the end of rotation and
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from the non-pressurized side. maintain hydraulic pressure. Oil with small air bubbles
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should be seen flowing through the tubes. Allow 1/2

Continuous oil flow from the open housing port indicates
gallon (2 L) of oil to be purged from the actuator.
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internal leakage across the piston. Replace the line and rotate
the shaft to the end of rotation in the opposite direction. 4. Keep the bleeder valves open and rotate the platform in
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Repeat the test procedure outlined above for the other port. If the opposite direction to the end of rotation. Maintain
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there is an internal leak, disassemble, inspect and repair. hydraulic pressure until an additional 1/2 gallon (2 L) of
oil is pumped out.
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5. Repeat steps 3 and 4. After the last 1/2 gallon (2 L) of oil

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is purged, close both bleed nipples before rotating away

from the end of rotation.
4-96 31215055
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Figure 4-43. Rotator Counterbalance Valve

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31215055 4-97
4.17 BOLT-ON EXTERNAL FALL ARREST • Cable: Inspect cable for proper tension, broken strands,
kinks, or any signs of corrosion.
The bolt-on external fall arrest system is designed to provide a
lanyard attach point while allowing the operator to access GAP
GAPSHOWING:
SHOWING:
areas outside the platform. Exit/Enter the platform through INCORRECT
INCORRECT
the gate area only. The system is designed for use by one per-
son.
Personnel must use fall protection at all times. A full body har-
ness is required with lanyard not to exceed 6 ft. (1.8 M) in
length, that limits the maximum arrest force to 900 lbs. (408
kg). NO GAP:
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NO GAP: CORRECT
CORRECT
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Bolt-On External Fall Arrest System capacity is 310 lb (140 kg) -
one (1) person maximum.
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Do not move the platform during use of the bolt-on external
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fall arrest system.
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DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM.
Figure 4-44. Bolt-On External Fall Arrest Cable Tension
or
BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.
• Fittings & Brackets: Ensure all fittings are tight and there are
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no signs of fractures. Inspect brackets for any damage.
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IF THE BOLT-ON EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL • Attachment Ring: No cracks or signs of wear are accept-
OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND able. Any signs of corrosion requires replacement.
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THE PLATFORM FULLY INSPECTED BEFORE RETURNING TO SERVICE. REFER TO

• Attaching Hardware: Inspect all attaching hardware to
THE SERVICE MANUAL FOR REMOVAL AND INSTALLATION PROCEDURES.
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ensure there are no missing components and hardware is

THE BOLT-ON EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPEC- properly tightened.
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TION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION

• Platform Rails: No visible damage is acceptable.
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MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER.

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Installation
Inspection Before Use
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1. Install the retaining hardware (bolts, nuts, and washers)

The bolt-on external fall arrest system must be inspected
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and secure the brackets to the platform rail. Tighten the

before each use of the mobile elevating work platform. nuts but do not torque them yet.
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Replace components if there are any signs of wear or damage.

BOLT
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Before each use, perform a visual inspection of the following

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components:
WASHER
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WASHER
NUT
4-98 31215055
2. Attach the fall arrest cable to the right hand bracket 5. Use the two jam nuts to prevent the cable from rotating
Using the attaching bolt and nut. Orient the bolt as while the nut is tightened. Tighten the nut until the bel-
shown below. Do not tighten the nut so cable can still leville washers are fully compressed and no gap is pres-
rotate. ent at the outside diameter of the washers. Ensure the
cable has not rotated during tightening.
BOLT
NUT
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6. Tighten the first jam nut against the retaining nut to
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keep the nut from loosening. Tighten the remaining jam
3. Install the Attachment Ring onto the cable. nut against the first jam nut.
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4. Without twisting the fall arrest cable, pull it thru the left 7. Torque the nuts and bolts securing the brackets to
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hand bracket and mark the top of the swaged cable end. 15 ft.lbs. (20 Nm).
Install the fall arrest cable through the left hand bracket
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and secure it using the belleville washers, washer, retain-
ing nut, and jam nuts. Orient the hardware as shown
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below and with the belleville washers so the gap is pres-

ent at the outside diameter of the washers. install the
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nuts onto the cable finger tight so the mark on the cable
does not move.
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WASHER
BELLEVILLE
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NUT WASHER
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JAM NUT
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31215055 4-99
7
1,2,3,4
9 1. Belleville Washer
2. Washer
5 3. Hex Nut
4. Jam Nut
5. LH Bracket
6 6. Attachment Ring
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7. Cable
8. RH Bracket
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9. Decal
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Figure 4-45. Bolt-On External Fall Arrest System
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4-100 31215055
4.18 SKYGUARD Function Test

Operation SKYGUARD ONLY
Perform this function test if SkyGuard only is selected in
SkyGuard provides enhanced control panel protection. machine setup (refer to Table 6-2).
When the SkyGuard sensor is activated, functions in use at
the time of actuation will reverse or cutout. The SkyGuard From the Platform Control Console in an area free from obstruc-
Function Table provides more details on these functions. tions:
Consult the following illustrations to determine which type 1. Operate the telescope out function, then activate Sky-
of SkyGuard the machine is equipped with. Regardless of Guard sensor.
the type, SkyGuard function according to the SkyGuard 2. Once sensor has been activated, ensure telescope out
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Function Table does not change. function stops then telescope in function operates for a
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short duration. Additionally, verify Soft Touch/SkyGuard
indicator light flashes and horn sounds. If machine is
equipped with SkyGuard beacon, ensure it flashes when
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sensor activates.
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3. With SkyGuard sensor still engaged, press and hold yel-
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low Soft Touch/SkyGuard override button. Operate a
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function to verify operation can be resumed.
or
4. Disengage SkyGuard sensor, release controls, and recy-
cle footswitch. Ensure normal operation available.
SkyGuard
0"$
toIn Ground Mode:
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1. Operation is allowed regardless of SkyGuard activation.
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BOTH SKYGUARD AND SOFT TOUCH

Perform this procedure if both SkyGuard and Soft Touch are
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selected in machine setup (refer to Table 6-2).

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From the Platform Control Console in an area free from

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obstructions:
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NOTE: Machine will treat Soft Touch/SkyGuard override switch as

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if it is a Soft Touch and SkyGuard switch.

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1. Operate the telescope out function, then activate Sky-

0"%
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Guard sensor.
SkyGuard SkyLine™
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2. Once sensor has been activated, ensure telescope out

function stops. Additionally, verify Soft Touch/SkyGuard
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indicator light flashes and horn sounds. If machine is

equipped with SkyGuard beacon, ensure it flashes when
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sensor activates.
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3. With SkyGuard sensor still engaged, press and hold yel-

low Soft Touch/SkyGuard override button. Operate a
function to verify operation can be resumed.
4. Disengage SkyGuard sensor, release controls, and recy-
cle footswitch. Ensure sure normal operation is available.
0"$
In Ground Mode:
SkyGuard SkyEye™ 1. Operation is allowed regardless of SkyGuard activation.
THE MACHINE OPERATOR IS REQUIRED TO PERFORM A DAILY FUNCTION TEST

TO ENSURE PROPER OPERATION OF THE SKYGUARD SYSTEM.
31215055 4-101
SOFT TOUCH ONLY Engage the SkyGuard sensor and observe the Analyzer to
If Soft Touch only is selected in machine setup (refer to Table determine if the switch/relay closes.
6-2), machine will treat the Soft Touch/SkyGuard override
If the status of the switch/relay remains OPEN while the Sky-
switch as if it is a Soft Touch switch.
Guard sensor is actively engaged, it is possible the sensor has
failed and should be replaced immediately.
SKYGUARD NOT SELECTED IN MACHINE SETUP
If the SkyGuard system is installed on the machine, but no If the status of the switch/relay remains CLOSED while the Sky-
option is selected in the machine setup (refer to Table 6-2), Guard sensor is actively engaged, a power or ground wire may
SkyGuard sensor status will be ignored. No function cutout or not be making good contact or may be loose or broken. Addi-
reversal will be implemented. tionally, there is a low probability that both relays may have
failed.
Diagnostics & Troubleshooting
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If the switch/relay status is in disagreement, then one may
If SkyGuard does not function when the sensor is engaged, have failed or is not installed correctly. In this case, the
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first verify the configuration under the machine will be inoperable.
MACHINE SETUP: SKYGUARD OPTION menu using the hand-
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held Analyzer. Ensure the selected configuration matches the FAULT CODES
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actual system installed on the machine. If not, select the cor- Refer to Table 6-9 for more fault code information
rect configuration, then verify operation.
• 0039 - SkyGuard switch activation fault
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Additionally, use the handheld analyzer to navigate to the • 2563 - switch disagreement fault
DIAGNOSTICS: FEATURES  SKYGUARD INPUTS menu to
or
determine additional SkyGuard fault information.
Table 4-3. SkyGuard Function Table

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Boom
Drive Drive Boom Boom Boom Jib Basket Basket
Steer Swing Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Swing Level Rotate
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Down
R*/C** R C R R R R C C C C C
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R = Indicates Reversal is Activated

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C = Indicates Cutout is Activated

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* DOS (Drive Orientation System) Enabled

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* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active
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Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing
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4-102 31215055
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SECTION 5 - BASIC HYDRAULIC INFORMATION & HYDRAULIC SCHEMATICS
SECTION 5. BASIC HYDRAULIC INFORMATION & HYDRAULIC 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-
When assembling connectors in the hydraulic that use o-ring rated.
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
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prior to assembly.
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Cup and Brush
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The following is needed to correctly oil the o-ring in this man-
ner:
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• A small container for hydraulic oil
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• Small paint brush 3. Turn the o-ring on the other side of the fitting and
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repeat the previous step, ensuring the entire o-ring is
coated with hydraulic oil.
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1. Hold the fitting in one hand while using the brush with
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the other hand to dip into the container. Remove excess

hydraulic oil from the brush so an even film of oil is
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applied on the o-ring.

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31215055 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 a suitable catch can.
ner:
3. Spray the entire o-ring surface with a medium coat of
• A small leak proof container oil.
• Sponge cut to fit inside the container
• A small amount of hydraulic oil to saturate the sponge.
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1. Place the sponge inside the container and add hydraulic
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oil to the sponge until it is fully saturated.
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2. Dip the fitting into the sponge using firm pressure.
Upon lifting the fitting, a small droplet will form and drip
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from the bottom of the fitting. This should signify an
even coating of oil on the fitting.
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or
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Brush-on Method
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This method requires a sealed bottle brush.
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1. Fill the bottle with hydraulic oil.

2. Using slight pressure to the body of the spray bottle,
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invert the bottle so the brush end is in the downward

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position.
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3. Brush hydraulic oil on the entire o-ring, applying an

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3. O-ring Boss type fittings will require more pressure in even coat of oil.
able to immerse more of the fitting into the saturated
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sponge. This will also cause more oil to be dispersed

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from the sponge.

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5-2 31215055
5.2 HYDRAULIC CONNECTION ASSEMBLY AND SAE = 45° flare per SAE J512
TORQUE SPECIFICATION
Tapered Thread Types

NPTF = national tapered fuel (Dry Seal) per SAE J476/J512
60°
30°
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Figure 5-4. SAE Thread
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ORFS = o-ring face seal per SAE J1453
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Figure 5-1. NPTF Thread
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BSPT = British standard pipe tapered per ISO7-1
or
55°
to Figure 5-5. ORFS Thread
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MBTL = metric flareless bite type fitting, pressure rating L
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(medium) per ISO 8434, DIN 2353

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

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Thread
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O.D.
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Figure 5-2. BSPT Thread

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Figure 5-6. MTBL-MBTS Thread

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Straight Thread Types, Tube and Hose BH = bulkhead connection – JIC, ORFS, MBTL, or MBTS types
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Connections
JIC = 37° flare per SAE J514
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Figure 5-3. JIC Thread Figure 5-7. Bulkhead Thread
31215055 5-3
Straight Thread Types, Port Connections Flange Connection Types

ORB = o-ring boss per SAE J1926, ISO 11926 FL61 = code 61 flange per SAE J518, ISO 6162
MPP = metric pipe parallel o-ring boss per SAE J2244, ISO FL62 = code 62 flange per SAE J518, ISO 6162
6149, DIN 3852
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Figure 5-10. ORB-MPP Thread
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Tightening Methods
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Torque = Application of a twisting force to the applicable con-
Figure 5-8. ORB-MPP Thread nection by use of a precise measurement instrument (i.e.
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torque wrench).
MFF = metric flat face port per ISO 9974-1
or
Finger Tight = The point where the connector will no longer
BSPP = British standard parallel pipe per ISO 1179-1, DIN 3852- thread onto the mating part when tightened by hand or fin-
2
to
gers. Finger Tight is relative to user strength and will have
some variance. The average torque applied by this method is 3
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ft-lbs [4 N-m] Also referred to as ‘Hand Tight.’
TFFT = Turns From Finger Tight; Application of a preload to a
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connection by first tightening the connection by hand (fin-

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gers) and applying an additional rotation counted by a

defined number of turns by use of a tool.
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FFWR = Flats from Wrench Resistance; Application of a pre-

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load to a connection by tightening to the point of initial

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wrench resistance and turning the nut a described number of

‘flats’. A ‘flat’ is one side of the hexagonal tube nut and
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equates to 1/6 of a turn. Also referred to as the ‘Flats Method.’

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Figure 5-9. MFF-BSPP Thread
5-4 31215055
Assembly And Torque Specifications 4. Take care to identify the material of parts to apply the
correct torque values.
Prior to selecting the appropriate torque from the tables
within this section, it is necessary to properly identify the con- a. Verify the material designation in the table head-
nector being installed. Refer to the Figures and Tables in this ings.
section. b. If specifications are given only for steel fittings and
components, the values for alternate materials shall
GENERAL TUBE TYPE FITTING ASSEMBLY
be as follows: Aluminum and Brass- reduce steel val-
INSTRUCTIONS ues by 35%; Stainless Steel- Use the upper limit for
1. Take precautions to ensure that fittings and mating steel.
components are not damaged during storage, handling 5. To achieve the specified torque, the torque wrench is to
or assembly. Nicks and scratches in sealing surfaces can
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be held perpendicular to the axis of rotation.
create a path for leaks which could lead to component
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contamination and/or failure.
2. When making a connection to tubing, compression or
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flare, inspect the tube in the area of the fitting attach-
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ment to ensure that the tube has not been damaged.
3. The assembly process is one of the leading causes for
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contamination in air and hydraulic systems. Contamina-
tion can prevent proper tightening of fittings and adapt-
or
ers from occurring.
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a. Avoid using dirty or oily rags when handling fittings.
b. If fittings are disassembled, they should be cleaned
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and inspected for damage. Replace fittings as nec-
essary before re-installing.
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c. Sealing compounds should be applied where speci-

Figure 5-11. Torque Wrench Angle
fied; however, care should be taken not to introduce
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sealant into the system.

6. Refer to the appropriate section in this manual for more
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d. Avoid applying sealant to the area of the threads specific instructions and procedures for each type of fit-
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where the sealant will be forced into the system. ting connection
This is generally the first two threads of a fitting.
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e. Sealant should only be applied to the male threads.

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f. Straight thread fittings do not require sealants. O-

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rings or washers are provided for sealing.

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g. When replacing or installing an O-ring, care is to be

taken while transferring the O-ring over the threads
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as it may become nicked or torn. When replacing an

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O-ring on a fitting, the use of a thread protector is

recommended.
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h. When installing fittings with O-rings, lubrication

shall be used to prevent scuffing or tearing of the O-
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ring. See O-ring Installation (Replacement) in this

section.
31215055 5-5
Assembly Instructions for American Standard NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-
MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
Pipe Thread Tapered (NPTF) Connections. ALIGNMENT.
1. Inspect components to ensure male and female port
5. Rotate male fitting the number of turns per Table 5-1,
threads are free of rust, splits, dirt, foreign matter, or
NPTF Pipe Thread. See FFWR and TFFT Methods for TFFT
burrs.
procedure requirements.
2. Apply a suitable thread sealant, such as High Tempera-
ture high thread sealant with PTFE, to the male pipe NOTE: TFFT values provided in Table 5-1, NPTF Pipe Thread are
threads if not already applied. Ensure the first 1 to 2 applicable for the following material configurations:
threads are uncovered to prevent system contamina-
tion. • STEEL fittings with STEEL mating components
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• STEEL fittings with ALUMINUM or BRASS mating compo-
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3. Assemble connection hand tight.
nents
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4. Mark fittings, male and female.
• ALUMINUM or BRASS fittings with STEEL mating compo-
nents
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• ALUMINUM or BRASS fittings with ALUMINUM or BRASS
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OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND mating components.
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR.
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Table 5-1. NPTF Pipe Thread
60°
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ØA dimension is measured
30° on the 4th pitch of the thread
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TYPE/FITTING IDENTIFICATION
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Turns From Finger

Thread Size ØA*
Tight (TFFT)**
-E
Material Dash Size

(UNF) (in) (mm)
nt
2 1/8 - 27 0.40 10.24 2 to 3

STEEL, ALUMINUM, OR BRASS FITTINGS WITH
ou
STEEL, ALUMINUM, OR BRASS MATING C
4 1/4 - 18 0.54 13.61 2 to 3

sc
6 3/8 - 18 0.67 17.05 2 to 3

Di
8 1/2 - 14 0.84 21.22 2 to 3

OMPONENTS
12 3/4 - 14 1.05 26.56 2 to 3

to
16 1 - 11 1/2 1.31 33.22 1.5 to 2.5

Go
20 1 1/4 - 11 1/2 1.65 41.98 1.5 to 2.5

24 1 1/2 - 11 1/2 1.89 48.05 1.5 to 2.5
32 2 - 11 1/2 2.37 60.09 1.5 to 2.5
* ØA thread dimension for reference only.

** See FFWR and TFFT Methods subsection for TFFT procedure requirements.
5-6 31215055
Assembly Instructions for British Standard Pipe 5. Rotate male fitting the number of turns per Table 5-2,
BSPT Pipe Thread. See FFWR and TFFT Methods for TFFT
Thread Tapered (BSPT) Connections procedure requirements.
1. Inspect components to ensure male and female port NOTE: TFFT values provided in Table 5-2, BSPT Pipe Thread are
threads are free of rust, splits, dirt, foreign matter, or applicable for the following material configurations:
burrs.
2. Apply a suitable thread sealant, such as High Tempera- • STEEL fittings with STEEL mating components
ture high thread sealant with PTFE, to the male pipe • STEEL fittings with ALUMINUM or BRASS mating compo-
threads if not already applied. Ensure the first 1 to 2 nents
threads are uncovered to prevent system contamina-
tion.
ts
nents
ar
3. Assemble connection hand tight.
rp
4. Mark fittings, male and female. mating components.
ou
ry
OVER TIGHTENING MAY CAUSE DEFORMATION OF THE PIPE FITTING AND
DAMAGE TO THE JOINING FITTING, FLANGE OR COMPONENT MAY OCCUR.
de
NEVER BACK OFF (LOOSEN) PIPE THREADED CONNECTORS TO ACHIEVE ALIGN-
or
MENT. MEET THE MINIMUM REQUIRED TURNS AND USE THE LAST TURN FOR
to
ALIGNMENT.
om
Table 5-2. BSPT Pipe Thread
t.c
en
m
ip
qu
-E
nt
ou
Turns From
Thread Size ØA* Finger Tight
sc
MATERIAL Dash Size (TFFT)**

(BSPT) (in) (mm)
Di
2 1/8 - 28 0.38 9.73 2 to 3

STEEL, ALUMINUM, OR BRASS FITTINGS WITH
to
4 1/4 - 19 0.52 13.16 2 to 3

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

MATING COMPONENTS
8 1/2 - 14 0.83 20.96 2 to 3

12 3/4 - 14 1.04 26.44 2 to 3
16 1 - 11 1.31 33.25 1.5 to 2.5
20 1 1/4 - 11 1.65 41.91 1.5 to 2.5
24 1 1/2 - 11 1.88 47.80 1.5 to 2.5
32 2 - 11 2.35 59.61 1.5 to 2.5
* ØA thread dimension for reference only.

** See Appendix B for TFFT procedure requirements.
31215055 5-7
Assembly Instructions for 37° (JIC) Flare Fittings 3. Torque assembly to value listed in Table Table 5-3, 37°
Flare (JIC)Thread - Steel or Table 5-4, 37° Flare
1. Inspect the flare for obvious visual squareness and con- (JIC)Thread - Aluminum/Brass while using the Double
centricity issues with the tube OD. Ensure surface is Wrench Method per Double Wrench Method. Refer to
smooth, free of rust, weld and brazing splatter, splits, FFWR and TFFT Methods for procedure requirements if
dirt, foreign matter, or burrs. If necessary replace fitting using the FFWR method.
or adapter.
NOTE: Torque values provided in Table Table 5-3, 37° Flare
(JIC)Thread - Steel and Table 5-4, 37° Flare (JIC)Thread -
Aluminum/Brass are segregated based on the material
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT configuration of the connection.
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK-
ts
AGE. ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
ar
COMPONENTS’ indicate either the following material configu-
2. Align tube to fitting and start threads by hand. rations:
rp
ou
nents
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
ry
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
nents
de
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
or
mating components.
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-8 31215055
Table 5-3. 37° Flare (JIC)Thread - Steel
Thread OD
A
B
ts
37°
ar
rp
Type/Fitting Identification Torque
Flats from
ou
Thread Wrench
MATERIAL
ØA* ØB* [Ft-Lb] [N-m]
ry
Dash Size Size Resistance
(F.F.W.R)**
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max
de
2 5/16-24 0.28 7.00 0.31 7.75 6 7 7 8 9 10 --
or
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
3 3/8-24 0.34 8.60 0.37 9.50 8 9 10 11 12 14 --
to
4 7/16-20 0.39 10.00 0.44 11.10 13 14 14 18 19 19 1-1/2 to 1-3/4
5 1/2-20 0.46 11.60 0.50 12.70 14 15 15 19 20 21 1 to 1-1/2
om
UN-LUBRICATED THREADS
6 9/16-18 0.51 13.00 0.56 14.30 22 23 24 30 31 33 1 to 1-1/2

t.c
8 3/4-16 0.69 17.60 0.75 19.10 42 44 46 57 60 63 1-1/2 to 1-3/4

10 7/8-14 0.81 20.50 0.87 22.20 60 63 66 81 85 89 1 to 1-1/2
en
12 1 1/16-12 0.97 24.60 1.06 27.00 84 88 92 114 120 125 1 to 1-1/2

m
14 1 3/16-12 1.11 28.30 1.19 30.10 100 105 110 136 142 149 1 to 1-1/2
ip
16 1 5/16-12 1.23 31.30 1.31 33.30 118 124 130 160 168 176 3/4 to 1
qu
20 1 5/8-12 1.54 39.20 1.63 41.30 168 176 185 228 239 251 3/4 to 1
-E
24 1 7/8-12 1.80 45.60 1.87 47.60 195 205 215 264 278 291 3/4 to 1
32 2 1/2-12 2.42 61.50 2.50 63.50 265 278 292 359 377 395 3/4 to 1
nt
* ØA and ØB thread dimensions for reference only.

ou
** See Appendix B for FFWR procedure requirements.

sc
Di
to
Go
31215055 5-9
Table 5-4. 37° Flare (JIC)Thread - Aluminum/Brass
Thread OD
A
B
ts
37°
ar
rp
TYPE/FITTING IDENTIFICATION Torque
Flats from
ou
Thread Wrench
MATERIAL
ry
Dash Size Size Resistance
(F.F.W.R)**
de
2 5/16-24 0.28 7.00 0.31 7.75 4 4 5 5 6 7 --
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
or
3 3/8-24 0.34 8.60 0.37 9.50 5 6 7 7 8 9 --
to
4 7/16-20 0.39 10.00 0.44 11.10 8 9 9 11 12 13 1-1/2 to 1-3/4
COMPONENTS; UN-LUBRICATED THREADS
5 1/2-20 0.46 11.60 0.50 12.70 9 10 10 12 13 14 1 to 1-1/2

om
6 9/16-18 0.51 13.00 0.56 14.30 14 15 16 19 20 21 1 to 1-1/2
t.c
8 3/4-16 0.69 17.60 0.75 19.10 27 29 30 37 39 41 1-1/2 to 1-3/4

10 7/8-14 0.81 20.50 0.87 22.20 39 41 43 53 56 58 1 to 1-1/2
en
12 1 1/16-12 0.97 24.60 1.06 27.00 55 57 60 74 78 81 1 to 1-1/2

m
14 1 3/16-12 1.11 28.30 1.19 30.10 65 68 72 88 93 97 1 to 1-1/2

ip
16 1 5/16-12 1.23 31.30 1.31 33.30 77 81 84 104 109 114 3/4 to 1

qu
20 1 5/8-12 1.54 39.20 1.63 41.30 109 115 120 148 155 163 3/4 to 1
-E
24 1 7/8-12 1.80 45.60 1.87 47.60 127 133 139 172 180 189 3/4 to 1
nt
32 2 1/2-12 2.42 61.50 2.50 63.50 172 181 189 234 245 257 3/4 to 1
ou

sc
** See FFWR and TFFT Methodsfor FFWR procedure requirements.

Di
to
Go
5-10 31215055
Assembly Instructions for 45° SAE Flare Fittings Torque fitting to value listed in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass while using
1. Inspect the flare for obvious visual squareness and con- the Double Wrench Method outlined in this section. Refer to
centricity issues with the tube OD. Ensure surface is FFWR and TFFT Methods for procedure requirements if using
smooth, free of rust, weld and brazing splatter, splits, the TFFT method.
dirt, foreign matter, or burrs. If necessary replace fitting
or adapter. NOTE: Torque values provided in Table 5-5, 45° Flare (SAE) - Steel
and Table 5-6, 45° Flare (SAE) - Aluminum/Brass are segre-
gated based on the material configuration of the connec-
tion.
DO NOT FORCE A MISALIGNED OR SHORT HOSE/TUBE INTO ALIGNMENT. IT
PUTS UNDESIRABLE STRAIN ONTO THE JOINT EVENTUALLY LEADING TO LEAK- ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS MATING
rts
AGE. COMPONENTS’ indicate either the following material configu-
rations:
pa
2. Align tube to fitting.
ur
3. Tighten fitting by hand until hand tight. nents
yo
nents
r
THE TORQUE METHOD SHOULD NOT BE USED ON LUBRICATED OR OILY FIT-
de
TINGS. NO LUBRICATION OR SEALANT IS REQUIRED. THE LUBRICATION
WOULD CAUSE INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. mating components.
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-12 31215055
Table 5-5. 45° Flare (SAE) - Steel
ts
ar
rp
Thread
MATERIAL

Dash Size Size
ou
ry
4 7/16-20 0.39 9.90 0.44 11.10 13 14 14 18 19 19
STEEL MATING COMPONENTS;
STEEL FITTINGS WITH
6 5/8-18 0.56 14.30 0.63 15.90 22 23 24 30 31 33
de
8 3/4-16 0.69 17.50 0.75 19.10 42 44 46 57 60 62
or
10 7/8-14 0.81 20.60 0.87 22.20 60 63 66 81 85 89
to
12 1 1/16-14 0.98 25.00 1.06 27.00 84 88 92 114 119 125
om
t.c
en
Table 5-6. 45° Flare (SAE) - Aluminum/Brass

m
ip
qu
-E
nt
ou
sc
Di

to
Thread
MATERIAL

Size
Go
Dash Size
4 7/16-20 0.39 9.90 0.44 11.10 8 9 9 11 12 12
MATING COMPONENTS;
OR ALUMINUM/BRASS
ALUMINUM/BRASS
6 5/8-18 0.56 14.30 0.63 15.90 14 15 15 19 20 20

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

10 7/8-14 0.81 20.60 0.87 22.20 39 41 43 53 56 58
12 1 1/16-14 0.98 25.00 1.06 27.00 55 58 61 75 79 83

** See FFWR and TFFT Methods for TFFT procedure requirements.
31215055 5-13
Assembly Instructions for O-Ring Face Seal (ORFS) 5. Torque nut to value listed in Table 5-7, O-ring Face Seal
(ORFS) - Steel or Table 5-8, O-ring Face Seal (ORFS) - Alu-
Fittings minum/Brass while using the Double Wrench Method.
Refer to FFWR and TFFT Methods for procedure require-
1. Ensure proper O-ring is installed. If O-ring is missing
ments if using the FFWR method.
install per O-ring Installation (Replacement).
2. Ensure surface is smooth, free of rust, weld and brazing NOTE: Torque values provided in Table 5-7, O-ring Face Seal
splatter, splits, dirt, foreign matter, or burrs. If necessary (ORFS) - Steel and Table 5-8, O-ring Face Seal (ORFS) - Alu-
replace fitting or adapter. minum/Brass are segregated based on the material config-
uration of the connection.
ts
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE COMPONENTS’ indicate either the following material configu-
ar
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE rations:
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE.
rp
3. Pre-lubricate the O-ring with Hydraulic Oil. nents
ou
4. Place the tube assembly against the fitting body so that
ry
nents
the flat face comes in contact with the O-ring. Hand
de
thread the nut onto the fitting body. • ALUMINUM or BRASS fittings with ALUMINUM or
BRASS mating components
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-14 31215055
Table 5-7. O-ring Face Seal (ORFS) - Steel
ts
Flats from Wrench
ar
TYPE/FITTING IDENTIFICATION Torque Resistance
rp
(F.F.W.R)**
ou
MATERIAL
Thread Size ØA* ØB* [Ft-Lb] [N-m] Swivel &

Tube
Dash Size Hose
Nuts
ry
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Ends
4 9/16-18 0.51 13.00 0.56 14.20 18 19 20 25 26 27 1/4 to 1/2 1/2 to 3/4
de
6 11/16-16 0.63 15.90 0.69 17.50 30 32 33 40 43 45 1/4 to 1/2 1/2 to 3/4
or
STEEL MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 40 42 44 55 57 60 1/4 to 1/2 1/2 to 3/4

STEEL FITTINGS WITH
to
10 1-14 0.94 23.80 1.00 25.40 60 63 66 81 85 89 1/4 to 1/2 1/2 to 3/4
12 1 3/16-12 1.11 28.20 1.19 30.10 85 90 94 115 122 127 1/4 to 1/2 1/2 to 3/4
om
16 1 7/16-12 1.34 34.15 1.44 36.50 110 116 121 149 157 164 1/4 to 1/2 1/2 to 3/4
t.c
20 1 11/16-12 1.59 40.50 1.69 42.90 150 158 165 203 214 224 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 230 242 253 312 328 343 1/4 to 1/2 1/2 to 3/4
en
32 2 1/2-12 2.43 61.67 2.50 63.50 375 394 413 508 534 560 1/4 to 1/2 1/2 to 3/4
m

ip

qu
-E
nt
ou
sc
Di
to
Go
31215055 5-15
Table 5-8. O-ring Face Seal (ORFS) - Aluminum/Brass
ts
Flats from Wrench
ar
TYPE/FITTING IDENTIFICATION Torque Resistance
rp
(F.F.W.R)**
Thread Swivel &
MATERIAL
ou
Dash ØA* ØB* [Ft-Lb] [N-m] Tube
Size Hose
Size Nuts
ry
(UNF) (in) (mm) (in) (mm) Min Nom Max Min Nom Max Ends
4 9/16-18 0.51 13.00 0.56 14.20 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
de
ALUMINUM/BRASS FITTINGS OR
6 11/16-16 0.63 15.90 0.69 17.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4
or
MATING COMPONENTS;
8 13/16-16 0.75 19.10 0.81 20.60 26 28 29 35 38 39 1/4 to 1/2 1/2 to 3/4

ALUMINUM/BRASS
to
10 1-14 0.94 23.80 1.00 25.40 39 41 43 53 56 58 1/4 to 1/2 1/2 to 3/4
12 1 3/16-12 1.11 28.20 1.19 30.10 55 58 61 75 79 83 1/4 to 1/2 1/2 to 3/4
om
16 1 7/16-12 1.34 34.15 1.44 36.50 72 76 79 98 103 107 1/4 to 1/2 1/2 to 3/4
t.c
20 1 11/16-12 1.59 40.50 1.69 42.90 98 103 108 133 140 146 1/4 to 1/2 1/2 to 3/4
24 2-12 1.92 48.80 2.00 50.80 12 13 13 16 18 18 1/4 to 1/2 1/2 to 3/4
en
32 2 1/2-12 2.43 61.67 2.50 63.50 20 21 22 27 28 30 1/4 to 1/2 1/2 to 3/4

m

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

qu
-E
nt
ou
sc
Di
to
Go
5-16 31215055
Assembly Instructions for DIN 24° Flare Bite Type

Fittings (MBTL and MBTS)
A NON-SQUARE TUBE END CAN CAUSE IMPROPERLY SEATED FITTINGS AND

LEAKAGE.
1. Inspect the components to ensure free of contamina-

tion, external damage, rust, splits, dirt, foreign matter, or
burrs. Ensure tube end is visibly square. If necessary
rts
replace fitting or tube.
pa
2. Lubricate thread and cone of fitting body or hardened
pre-assembly tool, as well as the progressive ring and
nut threads.
ur
yo
3. Slip nut and progressive ring over tube, assuring that
they are in the proper orientation.
r
de
4. Push the tube end into the coupling body.
5. Slide collet into position and tighten until finger tight.
or
Mark nut and tube in the finger-tight position. Tighten
to
nut to the number of flats listed in Table Table 5-9, DIN
24°Cone (MBTL & MBTS) while using the Double Wrench
om
Method. The tube must not turn with the nut.
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-18 31215055
Table 5-9. DIN 24°Cone (MBTL & MBTS)
ts
ar
DIN 24° CONE FLARELESS BITE FITTING
rp
(With or Without O-Ring)
ou
Tube Thread M Torque Flats from
MATERIAL
ØA* ØB* C* ØD* Wrench

TYPE
O.D. Size
ry
[Ft-Lb] [N-m]
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
de
6 M12 x 1.5 10.50 12.00 7.00 6.20 1.5 to 1.75
DIN 24° CONE FLARELESS BITE (MBTL) FITTING
or
8 M14 x 1.5 12.50 14.00 7.00 8.20 1.5 to 1.75
FFWR is the recommended
to
10 M16 x 1.5 14.50 16.00 7.00 10.20 1.5 to 1.75
method of fitting assembly.
12 M18 x 1.5 16.50 18.00 7.00 12.20 1.5 to 1.75
om
15 M22 x 1.5 20.50 22.00 7.00 15.20 Torque values are application 1.5 to 1.75
specific due to variability in the
t.c
18 M26 x 1.5 24.50 26.00 7.50 18.20 1.5 to 1.75

fitting supplier, coating,
22 M30 x 2 27.90 30.00 7.50 22.20 1.5 to 1.75
en
lubrication, and other physical

STEEL FITTINGS WITH STEEL MATING COMPONENTS
28 M36 x 2 33.90 36.00 7.50 28.20 characteristics of the connection. 1.5 to 1.75
m
35 M45 x 2 42.90 45.00 10.50 35.30 1.5 to 1.75

ip
Refer to the specific procedure

42 M52 x 2 49.90 52.00 11.00 42.30 1.5 to 1.75
in this service manual.
qu
Tube Thread M Torque Flats from

-E
ØA* ØB* C* ØD* Wrench

TYPE
O.D. Size [Ft-Lb] [N-m]

nt
Resistance
(mm) (Metric) (mm) (mm) (mm) (mm) Min Nom Max Min Nom Max (F.F.W.R)**
ou
6 M14 x 1.5 12.50 14.00 7.00 6.20 1.5 to 1.75

DIN 24° CONE FLARELESS BITE (MBTS) FITTING
sc
8 M16 x 1.5 14.50 16.00 7.00 8.20 1.5 to 1.75

Di
FFWR is the recommended

10 M18 x 1.5 16.50 18.00 7.50 10.20 1.5 to 1.75
method of fitting assembly.
12 M20 x 1.5 18.50 20.00 7.50 12.20 1.5 to 1.75
to
14 M22 x 1.5 20.50 22.00 8.00 14.20 Torque values are application 1.5 to 1.75
Go
16 M24 x 1.5 22.50 24.00 8.50 16.20 specific due to variability in the 1.5 to 1.75
fitting supplier, coating,
20 M30 x 2 27.90 30.00 10.50 20.20 lubrication, and other physical 1.5 to 1.75
25 M36 x 2 33.90 36.00 12.00 25.20 characteristics of the connection. 1.5 to 1.75
30 M42 x 2 39.90 42.00 13.50 30.20 1.5 to 1.75
Refer to the specific procedure
38 M52 x 2 49.90 52.00 16.00 38.30 1.5 to 1.75
in this service manual.
* ØA, ØB, C, & ØD thread dimensions for reference only.
** See Appendix B for FFWR procedure requirements.
31215055 5-19
Assembly Instructions for Bulkhead (BH) Fittings

1. Ensure threads and surface are free of rust, weld and
brazing splatter, splits, burrs or other foreign material. If
necessary replace fitting or adapter.
2. Remove the locknut from the bulkhead assembly.
3. Insert the bulkhead side of the fitting into the panel or
bulkhead bracket opening.
4. Hand thread the locknut onto the bulkhead end of the
fitting body.
ts
5. Torque nut onto fitting per Table 5-10 and Table 5-11
ar
while using the Double Wrench Method.
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-20 31215055
Table 5-10. Bulkhead Fittings (BH) - INCH
ts
ar
rp
FASTENING JAM NUT
ou
for Bulkhead Connectors
ry
Torque
MATERIAL
Thread Size
TYPE
Dash Size [Ft-Lb] [N-m]
de
(UNF) Min Nom Max Min Nom Max
or
4 9/16-18 15 16 17 20 22 23
O-RING FACE SEAL (ORFS) BULKHEAD FITTING
to
6 11/16-16 25 27 28 34 37 38
8 13/16-16 55 58 61 75 79 83
om
10 1-14 85 90 94 115 122 127
t.c
12 1 3/16-12 135 142 149 183 193 202

14 1 5/16-12 170 179 187 230 243 254
en
16 1 7/16-12 200 210 220 271 285 298

m
20 1 11/16-12 245 258 270 332 350 366

ip
24 2-12 270 284 297 366 385 403

qu
-E
Torque
Thread Size
STEEL FITTINGS
nt
TYPE
Dash Size [Ft-Lb] [N-m]

ou
(UNF) Min Nom Max Min Nom Max

sc
3 3/8-24 8 9 9 11 12 12
Di
4 7/16-20 13 14 14 18 19 19
5 1/2-20 20 21 22 27 28 30
37° FLARE (JIC) BULKHEAD FITTING
to
6 9/16-18 25 27 28 34 37 38
Go
8 3/4-16 50 53 55 68 72 75
10 7/8-14 85 90 94 115 122 127
12 1 1/16-12 135 142 149 183 193 202
14 1 3/16-12 170 179 187 230 243 254
16 1 5/16-12 200 210 220 271 285 298
20 1 5/8-12 245 258 270 332 350 366
24 1 7/8-12 270 284 297 366 385 403
32 2 1/2-12 310 326 341 420 442 462
31215055 5-21
Table 5-11. Bulkhead Fittings (BH) - METRIC
ts
ar
FASTENING JAM NUT
rp
for Bulkhead Connectors
ou
Connecting Torque
Thread M Size
Tube O.D.
ry
MATERIAL TYPE [Ft-Lb] [N-m]
(mm) (metric) Min Nom Max Min Nom Max
de
6 M12 x 1.5 14 15 16 19 20 22
or
8 M14 x 1.5 17 18 19 23 24 26
DIN 24° CONE FLARELESS BITE
(MBTL) BULKHEAD FITTING
to
10 M16 x 1.5 22 23 24 30 31 33
12 M18 x 1.5 35 37 39 47 50 53
om
15 M22 x 1.5 44 47 50 60 64 68
18 M26 x 1.5 70 75 80 95 102 108
t.c
22 M30 x 2 115 120 125 156 163 169

en
28 M36 x 2 150 157 164 203 213 222

m
35 M45 x 2 155 162 169 210 220 229

ip
42 M52 x 2 220 230 240 298 312 325

qu
STEEL FITTINGS
Connecting Torque
DIN 24° CONE FLARELESS BITE (MBTS) BULKHEAD FITTING
Thread M Size
-E
Tube O.D. [Ft-Lb] [N-m]

nt
(mm) (metric) Min Nom Max Min Nom Max

ou
6 M14 x 1.5 17 15 16 23 20 22
8 M16 x 1.5 22 18 19 30 24 26
sc
10 M18 x 1.5 35 23 24 47 31 33
Di
12 M20 x 1.5 40 35 37 54 47 50
to
14 M22 x 1.5 44 47 50 60 64 68
16 M24 x 1.5 70 75 80 95 102 108
Go
20 M30 x 2 115 120 125 156 163 169

25 M36 x 2 150 157 164 203 213 222
30 M42 x 2 155 162 169 210 220 229
38 M52 x 2 220 230 240 298 312 325
5-22 31215055
Assembly Instructions for O-Ring Boss (ORB) 6. Torque the fitting or nut to value listed in Table 5-12 thru
Table 5-17 while using the Double Wrench Method.
Fittings
a. The table headings identify the straight thread O-
1. Inspect components to ensure that male and female ring port and the type on the other side of the fit-
port threads are free of rust, splits, dirt, foreign matter, or ting. The torque will be applied to the straight
burrs. thread O-ring port.
2. Ensure proper O-ring is installed. If O-ring is missing b. Torque values provided in Table 5-12 thru Table 5-17
install per O-ring Installation (Replacement). are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ALUMINUM/BRASS MATING COMPONENTS’ indi-
cate either the following material configurations:
rts
CARE TO BE TAKEN WHEN LUBRICATING O-RING. AVOID ADDING OIL TO THE
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE
pa
nents
ur
yo
4. For Non-Adjustable and Plugs, thread the fitting by • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
hand until contact. mating components.
r
de
5. For Adjustable fittings, refer to Adjustable Stud End 7. Inspect to ensure the O-ring is not pinched and the
Assembly for proper assembly. washer is seated flat on the counterbore of the port.
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-24 31215055
Table 5-12. O-ring Boss (ORB) - Table 1 of 6
HEX TYPE PLUGS & STUD ENDS

with 37° (JIC) or L series DIN (MBTL) opposite end
ts
Thread Size ØA* Torque
ar
MATERIAL Dash Size
(UNF) (in) (mm) Min Nom Max Min Nom Max
rp
2 5/16-24 0.31 7.93 (85) (90) (94) 10 10 11
ou
3 3/8-24 0.37 9.52 (155) (163) (171) 18 18 19
4 7/16-20 0.44 11.11 22 23 24 29 31 33
ry
STEEL FITTINGS WITH STEEL MATING
5 1/2-20 0.50 12.70 23 25 26 32 34 35
de
6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
or
10 7/8-14 0.87 22.22 85 90 94 115 122 127
to
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
om
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
t.c
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

en
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

m
HEX TYPE PLUGS & STUD ENDS

ip
qu

MATERIAL Dash Size
-E
2 5/16-24 0.31 7.93 (55) (58) (61) 6 7 7

nt
ALUMINUM/BRASS FITTINGS OR ALUMINUM/BRASS
3 3/8-24 0.37 9.52 (101) (106) (111) 11 12 13

MATING COMPONENTS; UN-LUBRICATED THREADS
ou
4 7/16-20 0.44 11.11 14 15 16 19 20 22

5 1/2-20 0.50 12.70 15 16 17 20 22 23
sc
6 9/16-18 0.56 14.28 19 20 21 26 27 28

Di
8 3/4-16 0.75 19.10 34 36 37 46 49 50

to
10 7/8-14 0.87 22.22 55 58 61 75 79 83

12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
Go
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171

16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
* ØA Thread OD dimension for reference only.
**Removal Torque for Zero Leak Gold® Hollow Hex Plugs is significantly higher than install torque, typically 1.5-3.5X install torque.
31215055 5-25
STUD ENDS
with (ORFS) or S series DIN (MBTS) opposite end
ts
ar
MATERIAL Dash Size
rp
2 5/16-24 0.31 7.93 -- -- -- -- -- --
ou
3 3/8-24 0.37 9.52 -- -- -- -- -- --
4 7/16-20 0.44 11.11 26 27 28 35 37 38
ry
5 1/2-20 0.50 12.70 30 32 33 40 43 45
de
6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
or
10 7/8-14 0.87 22.22 100 105 110 135 142 149
to
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
om
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
t.c
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

en
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

m
STUD ENDS
ip
qu

MATERIAL Dash Size
-E
2 5/16-24 0.31 7.93 -- -- -- -- -- --

nt
3 3/8-24 0.37 9.52 -- -- -- -- -- --

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

5 1/2-20 0.50 12.70 20 21 21 27 28 28
sc
6 9/16-18 0.56 14.28 23 24 24 31 33 33

Di
8 3/4-16 0.75 19.10 39 41 43 53 56 58

to
10 7/8-14 0.87 22.22 65 69 72 88 94 98

12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
Go
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171

16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-26 31215055
ADJUSTABLE STUD END

ts
ar
MATERIAL Dash Size
rp
2 5/16-24 0.31 7.93 (60) (63) (66) 7 7 7
ou
3 3/8-24 0.37 9.52 (100) (105) (110) 11 12 12
4 7/16-20 0.44 11.11 15 16 17 20 22 23
ry
5 1/2-20 0.50 12.70 21 22 23 28 30 31
de
6 9/16-18 0.56 14.28 29 31 32 40 42 43
8 3/4-16 0.75 19.10 52 55 57 70 75 77
or
10 7/8-14 0.87 22.22 85 90 94 115 122 127
to
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
om
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
t.c
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

en
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

m
ADJUSTABLE STUD END

ip
qu

MATERIAL Dash Size
-E
2 5/16-24 0.31 7.93 (39) (41) (43) 4 5 5

nt
3 3/8-24 0.37 9.52 (65) (69) (72) 7 8 8

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

5 1/2-20 0.50 12.70 14 15 15 19 20 20
sc
6 9/16-18 0.56 14.28 19 20 21 26 27 28

Di
8 3/4-16 0.75 19.10 34 36 37 46 49 50

to
10 7/8-14 0.87 22.22 55 58 61 75 79 83

12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
Go
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171

16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
31215055 5-27
ADJUSTABLE STUD END

rts
MATERIAL Dash Size
pa
2 5/16-24 0.31 7.93 -- -- -- -- -- --
ur
3 3/8-24 0.37 9.52 -- -- -- -- -- --
yo
4 7/16-20 0.44 11.11 15 16 17 20 22 23
5 1/2-20 0.50 12.70 30 32 33 40 43 45
r
de
6 9/16-18 0.56 14.28 35 37 39 46 50 53
8 3/4-16 0.75 19.10 60 63 66 80 85 89
or
10 7/8-14 0.87 22.22 100 105 110 135 142 149
to
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175 184 193 235 249 262
om
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
t.c
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

en
32 2 1/2-12 2.50 63.50 375 394 413 510 534 560

m
ADJUSTABLE STUD END

ip
qu

MATERIAL Dash Size
-E
2 5/16-24 0.31 7.93 -- -- -- -- -- --

nt
3 3/8-24 0.37 9.52 -- -- -- -- -- --

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

5 1/2-20 0.50 12.70 20 21 21 27 28 28
sc
6 9/16-18 0.56 14.28 23 24 24 31 33 33

Di
8 3/4-16 0.75 19.10 39 41 43 53 56 58

to
10 7/8-14 0.87 22.22 65 69 72 88 94 98

12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
Go
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171

16 1 5/16-12 1.31 33.30 130 137 143 176 186 194
20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
5-28 31215055
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS
ts
MATERIAL Dash Size
ar
rp
2 5/16-24 0.31 7.93 (30) (32) (33) 3 4 4
3 3/8-24 0.37 9.52 (55) (58) (61) 6 7 7
ou
4 7/16-20 0.44 11.11 10 11 11 14 15 15
ry
5 1/2-20 0.50 12.70 14 15 16 19 20 22
6 9/16-18 0.56 14.28 34 36 38 46 49 52
de
8 3/4-16 0.75 19.10 60 63 66 80 85 89
or
10 7/8-14 0.87 22.22 100 105 110 135 142 149
12 1 1/16-12 1.06 27.00 135 142 149 185 193 202
14 1 3/16-12 1.19 30.10 175
to 184 193 235 249 262
om
16 1 5/16-12 1.31 33.30 200 210 220 270 285 298
20 1 5/8-12 1.63 41.30 250 263 275 340 357 373
t.c
24 1 7/8-12 1.87 47.60 305 321 336 415 435 456

32 2 1/2-12 2.50 63.50 375 394 413 510 534 560
en
TYPE/FITTING IDENTIFICATION HOLLOW HEX PLUGS

m

ip
MATERIAL Dash Size

qu
2 5/16-24 0.31 7.93 (20) (21) (21) 2 2 2

-E
3 3/8-24 0.37 9.52 (36) (38) (40) 4 4 5

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

5 1/2-20 0.50 12.70 9 10 10 12 14 14
ou
6 9/16-18 0.56 14.28 22 24 25 30 33 34

sc
8 3/4-16 0.75 19.10 39 41 43 53 56 58

Di
10 7/8-14 0.87 22.22 65 69 72 88 94 98

12 1 1/16-12 1.06 27.00 88 93 97 119 126 132
to
14 1 3/16-12 1.19 30.10 114 120 126 155 163 171

Go
16 1 5/16-12 1.31 33.30 130 137 143 176 186 194

20 1 5/8-12 1.63 41.30 163 171 179 221 232 243
24 1 7/8-12 1.87 47.60 198 208 218 268 282 296
32 2 1/2-12 2.50 63.50 244 256 268 331 347 363
31215055 5-29
ZERO LEAK GOLD®

ts
HOLLOW HEX PLUGS
ar
MATERIAL Dash Size
rp
2 5/16-24 0.31 7.93 2 3 4 3 4 5
ou
3 3/8-24 0.37 9.52 3 4 5 4 5 7
ry
4 7/16-20 0.44 11.11 7 8 9 9 11 12
5 1/2-20 0.50 12.70 9 10 11 12 14 15
de
6 9/16-18 0.56 14.28 11 12 13 15 16 18
or
8 3/4-16 0.75 19.10 28 30 32 38 41 43
10 7/8-14 0.87 22.22 46 48 50 62 65 68
12 1 1/16-12 1.06 27.00 51
to
54 57 69 73 77
om
14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
t.c
20 1 5/8-12 1.63 41.30

JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
en
32 2 1/2-12 2.50 63.50

m
ZERO LEAK GOLD®

ip
HOLLOW HEX PLUGS

qu

MATERIAL Dash Size
-E

2 5/16-24 0.31 7.93 2 3 4 3 4 5
nt
3 3/8-24 0.37 9.52 3 4 5 4 5 7

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

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

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

8 3/4-16 0.75 19.10 28 30 32 38 41 43
to
10 7/8-14 0.87 22.22 46 48 50 62 65 68

Go
12 1 1/16-12 1.06 27.00 51 54 57 69 73 77

14 1 3/16-12 1.19 30.10
16 1 5/16-12 1.31 33.30
Fitting size greater than -12 not typically specified on
20 1 5/8-12 1.63 41.30
JLG applications. Consult specific service procedure if encountered.
24 1 7/8-12 1.87 47.60
32 2 1/2-12 2.50 63.50
5-30 31215055
Assembly Instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-18,
Table 5-19, Table 5-20, Table 5-21, Table 5-22, or Table 5-
Metric (MFF) Fittings 23 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the Metric port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the Metric port.
2. If O-ring is not pre-installed, install proper size, taking b. Torque values provided in Table 5-18, Table 5-19,
care not to damage it. See O-ring Installation (Replace- Table 5-20, Table 5-21, Table 5-22, and Table 5-23
ment) for instructions. are segregated based on the material configuration
of the connection. ‘ALUMINUM/BRASS FITTINGS OR
ts
ar
rp
nents
ou
ry
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
de
by hand until contact.
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-32 31215055
Table 5-18. Metric Flat Face Port (MFF) - L Series - Table 1 of 3
rts
pa
ur
yo
FORM A (SEALING WASHER) FORM B (CUTTING FACE)
TYPE/FITTING IDENTIFICATION STUD ENDS STUD ENDS
r
with 37° (JIC) or L series DIN (MBTL) opposite end with 37° (JIC) or L series DIN (MBTL) opposite end
de
Thread M Connecting Torque Torque
or
MATERIAL Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
to
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
M10x1 6 7 8 8 9 11 11 13 14 14 18 19 19
om
M12x1.5 8 15 16 17 20 22 23 22 23 24 30 31 33
M14x1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
t.c
M16x1.5 12 33 35 36 45 47 49 48 51 53 65 69 72
en
M18x1.5 15 41 43 45 55 58 61 59 62 65 80 84 88
m
M22x1.5 18 48 51 53 65 69 72 103 108 113 140 146 153

M27x2 22 66 70 73 90 95 99 140 147 154 190 199 209
ip
M33x2 28 111 117 122 150 159 165 251 264 276 340 358 374
qu
M42x2 35 177 186 195 240 252 264 369 388 406 500 526 550
-E
M48x2 42 214 225 235 290 305 319 465 489 512 630 663 694
nt

ou

sc
M10x1 6 4 5 5 5 7 7 8 9 9 11 12 12
Di
M12x1.5 8 10 11 11 14 15 15 14 15 16 19 20 22
to
M14x1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
M16x1.5 12 21 22 23 28 30 31 31 33 34 42 45 46
Go
M18x1.5 15 27 28 29 37 38 39 38 40 42 52 54 57
M22x1.5 18 31 33 34 42 45 46 67 70 73 91 95 99
M27x2 22 43 45 47 58 61 64 91 96 100 123 130 136
M33x2 28 72 76 79 98 103 107 163 171 179 221 232 243
M42x2 35 115 121 127 156 164 172 240 252 264 325 342 358
M48x2 42 139 146 153 188 198 207 302 318 332 409 431 450
31215055 5-33
ts
ar
rp
ou
ry
de
or
to
M10x1 6 13 14 14 18 19 19 13 14 15 18 19 20
om
M12x1.5 8 18 19 20 25 26 27 18 19 20 25 26 28
M14x1.5 10 33 35 36 45 47 49 30 31 32 40 42 44
t.c
M16x1.5 12 41 43 45 55 58 61 41 43 45 55 58 61
en
M18x1.5 15 52 55 57 70 75 77 52 54 57 70 74 77
m
M22x1.5 18 92 97 101 125 132 137 66 70 73 90 95 99

M27x2 22 133 140 146 180 190 198 133 139 146 180 189 198
ip
M33x2 28 229 241 252 310 327 342 229 240 252 310 326 341
qu
M42x2 35 332 349 365 450 473 495 332 348 365 450 473 495
-E
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
nt

ou

sc
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12
Di
M12x1.5 8 12 13 13 16 18 18 12 13 13 16 18 18
to
M14x1.5 10 21 22 23 28 30 31 19 20 21 26 27 29
M16x1.5 12 27 28 29 37 38 39 26 28 29 36 38 39
Go
M18x1.5 15 34 36 37 46 49 50 34 35 37 46 48 50
M22x1.5 18 60 63 66 81 85 89 43 45 47 59 61 64
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
5-34 31215055
ts
ar
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS FORM E (EOLASTIC SEALING RING)
rp
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
Thread Connecting Torque Torque Torque
ou
MATERIAL M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
ry
(metric) (mm) Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max Min Nom Max
de
M10x1 6 13 14 14 18 19 19 13 14 14 18 19 19 9 10 10 12 14 14
M12x1.5 8 26 28 29 35 38 39 33 35 36 45 47 49 18 19 20 25 26 27
or
M14x1.5 10 37 39 41 50 53 56 41 43 45 55 58 61 26 28 29 35 38 39
to
M16x1.5 12 44 46 48 60 62 65 59 62 65 80 84 88 41 43 45 55 58 61
M18x1.5 15 59 62 65 80 84 88 74 78 81 100 106 110 48 51 53 65 69 72
om
M22x1.5 18 89 94 98 120 127 133 103 108 113 140 146 153 66 70 73 90 95 99
M27x2 22 96 101 106 130 137 144 236 248 260 320 336 353 100 105 110 135 142 149
t.c
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 166 175 183 225 237 248
en
M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 266 280 293 360 380 397
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 266 280 293 360 380 397
m
Torque Torque Torque

ip
Thread Connecting
qu
-E
M10x1 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
nt
M12x1.5 8 17 18 19 23 24 26 21 22 23 28 30 31 12 13 13 16 18 18
ou
M14x1.5 10 24 26 27 33 35 37 27 28 29 37 38 39 17 18 19 23 24 26
sc
M16x1.5 12 29 30 31 39 41 42 38 40 42 52 54 57 27 28 29 37 38 39
Di
M18x1.5 15 38 40 42 52 54 57 48 51 53 65 69 72 31 33 34 42 45 46
M22x1.5 18 58 61 64 79 83 87 67 70 73 91 95 99 43 45 47 58 61 64
to
M27x2 22 62 66 69 84 89 94 153 161 169 207 218 229 65 69 72 88 94 98

Go
M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 108 114 119 146 155 161
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 173 182 190 235 247 258
M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 173 182 190 235 247 258
31215055 5-35
Table 5-21. Metric Flat Face Port (MFF) - S Series - Table 1 of 3
ts
ar
rp
ou
ry
de
with (ORFS) or S series DIN (MBTS) opposite end with (ORFS) or S series DIN (MBTS) opposite end
or
(metric) (mm) Min Nom Max Min Nom Max to
Min Nom Max Min Nom Max
om
M12x1.5 6 15 16 17 20 22 23 26 28 29 35 38 39
M14x1.5 8 26 28 29 35 38 39 41 43 45 55 58 61
t.c
M16x1.5 10 33 35 36 45 47 49 52 55 57 70 75 77
en
M18x1.5 12 41 43 45 55 58 61 81 85 89 110 115 121

M20x1.5 14 41 43 45 55 58 61 111 117 122 150 159 165
m
M22x1.5 16 48 51 53 65 69 72 125 132 138 170 179 187

ip
M27x2 20 66 70 73 89 95 99 199 209 219 270 283 297

qu
M33x2 25 111 117 122 150 159 165 302 317 332 410 430 450
-E
M42x2 30 177 186 195 240 252 264 398 418 438 540 567 594
nt
M48x2 38 214 225 235 290 305 319 516 542 568 700 735 770
ou

sc
Di
M12x1.5 6 10 11 11 14 15 15 17 18 19 23 24 26
to
M14x1.5 8 17 18 19 23 24 26 27 28 29 37 38 39
M16x1.5 10 21 22 23 28 30 31 34 36 37 46 49 50
Go
M18x1.5 12 27 28 29 37 38 39 53 56 58 72 76 79
M20x1.5 14 27 28 29 37 38 39 72 76 79 98 103 107
M22x1.5 16 31 33 34 42 45 46 81 86 90 110 117 122
M27x2 20 43 45 47 58 61 64 129 136 142 175 184 193
M33x2 25 72 76 79 98 103 107 196 206 216 266 279 293
M42x2 30 115 121 127 156 164 172 259 272 285 351 369 386
M48x2 38 139 146 153 188 198 207 335 352 369 454 477 500
5-36 31215055
ts
ar
rp
ou
FORM E (EOLASTIC SEALING RING)
ry
FORM G/H (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS
STUD ENDS with (ORFS) or S series DIN (MBTS) opposite end
de
or
to
M10x1 6 26 28 29 35 38 39 26 28 29 35 38 39
om
M12x1.5 8 33 35 36 45 47 49 41 43 45 55 58 61
M14x1.5 10 52 55 57 70 75 77 52 55 57 70 75 77
t.c
M16x1.5 12 66 70 73 90 95 99 66 70 73 90 95 99
en
M18x1.5 15 92 97 101 125 132 137 92 97 101 125 132 137

m
M22x1.5 18 100 105 110 135 142 149 100 105 110 135 142 149
M27x2 22 133 140 146 180 190 198 133 140 146 180 190 198
ip
M33x2 28 229 241 252 310 327 342 229 241 252 310 327 342
qu
M42x2 35 332 349 365 450 473 495 332 349 365 450 473 495
-E
M48x2 42 398 418 438 540 567 594 398 418 438 540 567 594
nt

ou

sc
M10x1 6 17 18 19 23 24 26 17 18 19 23 24 26
Di
M12x1.5 8 21 23 23 29 31 32 27 28 29 37 38 39
to
M14x1.5 10 34 36 37 46 49 50 34 36 37 46 49 50
M16x1.5 12 43 45 47 58 61 64 43 45 47 58 61 64
Go
M18x1.5 15 60 63 66 81 85 89 60 63 66 81 85 89
M22x1.5 18 65 69 72 88 94 98 65 69 72 88 94 98
M27x2 22 86 91 95 117 123 129 86 91 95 117 123 129
M33x2 28 149 157 164 202 213 222 149 157 164 202 213 222
M42x2 35 216 227 237 293 308 321 216 227 237 293 308 321
M48x2 42 259 272 285 351 369 386 259 272 285 351 369 386
31215055 5-37
rts
pa
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end HOLLOW HEX PLUGS
ur
yo
r
M10x1 6 26 28 29 35 38 39 33 35 36 45 47 49 -- -- -- -- -- --
de
M12x1.5 8 37 39 41 50 53 56 41 43 45 55 58 61 -- -- -- -- -- --
or
M14x1.5 10 44 46 48 60 62 65 59 62 65 80 84 88 -- -- -- -- -- --
M16x1.5 12 59 62 65 80 84 88 74 78 81 100 106 110 -- -- -- -- -- --
M18x1.5 15 81 85 89 110 115 121 92 97 101
to
125 132 137 59 62 65 80 84 88
om
M22x1.5 18 89 94 98 120 127 133 100 105 110 135 142 149 -- -- -- -- -- --
M27x2 22 100 105 110 135 142 149 236 248 260 320 336 353 -- -- -- -- -- --
t.c
M33x2 28 -- -- -- -- -- -- 266 280 293 360 380 397 -- -- -- -- -- --

M42x2 35 -- -- -- -- -- -- 398 418 438 540 567 594 -- -- -- -- -- --
en
M48x2 42 -- -- -- -- -- -- 516 542 568 700 735 770 -- -- -- -- -- --

m

ip
qu
-E
M10x1 6 17 18 19 23 24 26 21 22 23 28 30 31 -- -- -- -- -- --
nt
M12x1.5 8 24 26 27 33 35 37 27 28 29 37 38 39 -- -- -- -- -- --
ou
M14x1.5 10 29 30 31 39 41 42 38 40 42 52 54 57 -- -- -- -- -- --
M16x1.5 12 38 40 42 52 54 57 48 51 53 65 69 72 -- -- -- -- -- --
sc
M18x1.5 15 53 56 58 72 76 79 60 63 66 81 85 89 38 40 42 52 54 57
Di
M22x1.5 18 58 61 64 79 83 87 65 69 72 88 94 98 -- -- -- -- -- --
to
M27x2 22 65 69 72 88 94 98 153 161 169 207 218 229 -- -- -- -- -- --

M33x2 28 -- -- -- -- -- -- 173 182 190 235 247 258 -- -- -- -- -- --
Go
M42x2 35 -- -- -- -- -- -- 259 272 285 351 369 386 -- -- -- -- -- --

M48x2 42 -- -- -- -- -- -- 335 352 369 454 477 500 -- -- -- -- -- --
5-38 31215055
Assembly Instructions for Metric ISO 6149 (MPP) 6. Torque the fitting or nut to value listed in Table 5-24
while using the Double Wrench Method.
Port Assembly Stud Ends
a. The table headings identify the Metric port and the
1. Inspect components to ensure that male and female type on the other side of the fitting. The torque will
threads and surfaces are free of rust, splits, dirt, foreign be applied to the Metric port.
matter, or burrs. b. Torque values provided in Table 5-24 are segregated
2. If O-ring is not preinstalled, install proper size, taking based on the material configuration of the connec-
care not to damage it. See O-ring Installation (Replace- tion. ‘ALUMINUM/BRASS FITTINGS OR ALUMINUM/
ment) for instructions. BRASS MATING COMPONENTS’ indicate either the
following material configurations:
ts
nents
ar
THREADED CONNECTION OF THE FITTING. THE LUBRICATION WOULD CAUSE • ALUMINUM or BRASS fittings with STEEL mating compo-
rp
INCREASED CLAMPING FORCE AND CAUSE FITTING DAMAGE. nents
ou
3. Pre-lubricate the O-ring with Hydraulic Oil.
mating components.
ry
4. For Non-Adjustable Fittings and Plugs, thread the fitting
7. Inspect to ensure the O-ring is not pinched and the
de
washer is seated flat on the counterbore of the port.
5. For Adjustable fittings, refer to Adjustable Stud End
or
Assembly for proper assembly.
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-40 31215055
Table 5-24. Metric Pipe Parallel O-Ring Boss (MPP)
Note: Metric O-ring

only style (ISO 6149)
requires o-ring
ts
chamfer in the port,
similar to ISO 11926
ar
(SAE ORB),but is not
interchangeable.
rp
STUD ENDS STUD ENDS
ou
with 37° (JIC) or L series DIN (MBTL) opposite end with (ORFS) or S series DIN (MBTS) opposite end
ry
Thread Connecting Torque Torque
MATERIAL
de
M Size Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m]
or
M8 x 1 4 6 7 7 8 9 9 8 9 9 10 12 12
M10 x 1 6 11 12 12 15 16
to 16 15 16 17 20 22 23
STEEL FITTINGS WITH STEEL MATING COMPONENTS;
om
M12 x 1.5 8 18 19 20 25 26 27 26 28 29 35 38 39
M14 x 1.5 10 26 28 29 35 38 39 33 35 36 45 47 49
t.c
M16 x 1.5 12 30 32 33 40 43 45 41 43 45 55 58 61
M18 x 1.5 15 33 35 36 45 47 49 52 55 57 70 75 77
en
M20 x 1.5 -- -- -- -- -- -- -- 59 62 65 80 84 88
m
M22 x 1.5 18 44 46 48 60 62 65 74 78 81 100 106 110

ip
M27 x 2 22 74 78 81 100 106 110 125 132 138 170 179 187
qu
M30 x 2 -- 95 100 105 130 136 142 175 184 193 237 249 262
M33 x 2 25 120 126 132 160 171 179 230 242 253 310 328 343
-E
M38 x 2 -- 135 142 149 183 193 202 235 247 259 319 335 351
nt
M42 x 2 30 155 163 171 210 221 232 245 258 270 330 350 366
ou
M48 x 2 38 190 200 209 260 271 283 310 326 341 420 442 462
sc
M60 x 2 50 230 242 253 315 328 343 370 389 407 500 527 552
M8 x 1 4 4 5 5 5 7 7 5 6 6 7 8 8
Di
M10 x 1 6 7 8 8 9 11 11 10 11 11 14 15 15
to
M12 x 1.5 8 12 13 13 16 18 18 17 18 19 23 24 26
M14 x 1.5 10 17 18 19 23 24 26 21 22 23 28 30 31
Go
M16 x 1.5 12 20 21 21 27 28 28 27 28 29 37 38 39
M18 x 1.5 15 21 22 23 28 30 31 34 36 37 46 49 50
M20 x 1.5 -- -- -- -- -- -- -- 30 40 42 41 54 57
M22 x 1.5 18 29 30 31 39 41 42 48 51 53 65 69 72
M27 x 2 22 48 51 53 65 69 72 81 86 90 110 117 122
M30 x 2 -- 62 65 68 84 88 92 114 120 125 155 163 169
M33 x 2 25 78 82 86 106 111 117 150 157 164 203 213 222
M38 x 2 -- 88 93 97 119 126 132 153 161 168 207 218 228
M42 x 2 30 101 106 111 137 144 150 159 168 176 216 228 239
M48 x 2 38 124 130 136 168 176 184 202 212 222 274 287 301
M60 x 2 50 150 157 164 203 213 222 241 253 265 327 343 359
31215055 5-41
Assembly instructions for Adjustable Port End 6. Torque the fitting or nut to value listed in Table 5-25,
Table 5-26, Table 5-27, Table 5-28, Table 5-29, or Table 5-
(BSPP) Fittings 30 while using the Double Wrench Method.
1. Inspect components to ensure that male and female a. The table headings identify the BSPP port and the
threads and surfaces are free of rust, splits, dirt, foreign type on the other side of the fitting. The torque will
matter, or burrs. be applied to the BSPP port.
2. If O-ring is not preinstalled, install proper size, taking b. Torque values provided in Table 5-25, Table 5-26,
care not to damage it. See O-ring Installation (Replace- Table 5-27, Table 5-28, Table 5-29, and Table 5-30 are
ment) for instructions. segregated based on the material configuration of
the connection. ‘ALUMINUM/BRASS FITTINGS OR
ts
ar
rp
nents
ou
ry
4. For Non-Adjustable Fittings and Plugs, thread the fitting • ALUMINUM or BRASS fittings with ALUMINUM or BRASS
mating components.
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-42 31215055
Table 5-25. British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
rts
pa
FORM A**(SEALING WASHER) FORM B** (CUTTING FACE)
ur
yo
BSPP Torque Torque
Connecting
r
Thread G
Tube O.D.
de
MATERIAL Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]
or
G 1/8A 6 7 8 8 9 11 11 13 14 14 18 19 19
to
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
om
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 33 35 36 45 47 49 52 55 57 70 75 77
t.c
G 1/2A 15 48 51 53 65 69 72 103 108 113 140 146 153

G 1/2A 18 48 51 53 65 69 72 74 78 81 100 106 110
en
G 3/4A 22 66 70 73 90 95 99 133 140 146 180 190 198

m
G 1A 28 111 117 122 150 159 165 243 255 267 330 346 362
ip
G 1-1/4A 35 177 186 195 240 252 264 398 418 438 540 567 594
qu
G 1-1/2A 42 214 225 235 290 305 319 465 489 512 630 663 694
BSPP Torque Torque
-E
Connecting
Thread G
MATERIAL Tube O.D.
nt
Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]

ou
G 1/8A 6 4 5 5 5 7 7 8 9 9 11 12 12
sc
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
Di
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
to
G 3/8A 12 21 22 23 28 30 31 34 36 37 46 49 50
G 1/2A 15 31 33 34 42 45 46 67 70 73 91 95 99
Go
G 1/2A 18 31 33 34 42 45 46 48 51 53 65 69 72
G 3/4A 22 42 45 47 57 61 64 86 91 95 117 123 129
G 1A 28 72 76 79 98 103 107 158 166 174 214 225 236
G 1-1/4A 35 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 42 139 146 153 188 198 207 302 318 333 409 431 451
* Typical for JLG Straight Male Stud Fittings

** Non typical for JLG Straight Male Stud Fittings, reference only.
*** Typical for JLG Adjustable Fittings
31215055 5-43
ts
ar
rp
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
ou
ry
BSPP Torque Torque
Connecting
Thread G
Tube O.D.
de
or
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19
to
G 1/4A 8 26 28 29 35 38 39 26 28 29 35 38 39
om
G 1/4A 10 26 28 29 35 38 39 26 28 29 35 38 39
G 3/8A 12 52 55 57 70 75 77 52 55 57 70 75 77
t.c
G 1/2A 15 66 70 73 90 95 99 66 70 73 90 95 99
G 1/2A 18 66 70 73 90 95 99 66 70 73 90 95 99
en
G 3/4A 22 133 140 146 180 190 198 133 140 146 180 190 198
m
G 1A 28 229 241 252 310 327 342 229 241 252 310 327 342
ip
G 1-1/4A 35 332 349 365 450 473 495 332 349 365 450 473 495
qu
G 1-1/2A 42 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
-E
Connecting
Thread G
MATERIAL Tube O.D.
nt

ou
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12
sc
G 1/4A 8 17 18 19 23 24 26 17 18 19 23 24 26
Di
G 1/4A 10 17 18 19 23 24 26 17 18 19 23 24 26
to
G 3/8A 12 34 36 37 46 49 50 34 36 37 46 49 50
G 1/2A 15 43 45 47 58 61 64 43 45 47 58 61 64
Go
G 1/2A 18 43 45 47 58 61 64 43 45 47 58 61 64
G 3/4A 22 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 28 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 35 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 42 259 272 285 351 369 386 259 272 285 351 369 386

5-44 31215055
ts
ar
with L series DIN (MBTL) opposite end with L series DIN (MBTL) opposite end HOLLOW HEX PLUGS
rp
BSPP Torque Torque Torque
Connecting
ou
Thread G
MATERIAL Tube O.D. [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
ry
de
G 1/8A 6 13 14 14 18 19 19 13 14 14 18 19 19 10 11 11 13 15 15
G 1/4A 8 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
or
G 1/4A 10 30 32 33 40 43 45 33 35 36 45 47 49 22 23 24 30 31 33
to
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77 44 46 48 60 62 65
G 1/2A 15 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
om
G 1/2A 18 66 70 73 90 95 99 89 94 98 120 127 133 59 62 65 80 84 88
G 3/4A 22 92 97 101 125 132 137 170 179 187 230 243 254 103 108 113 140 146 153
t.c
G 1A 28 -- -- -- -- -- -- 236 248 260 320 336 353 148 156 163 200 212 221
en
G 1-1/4A 35 -- -- -- -- -- -- 398 418 438 540 567 594 295 313.5 332 400 425 450
G 1-1/2A 42 -- -- -- -- -- -- 516 542 568 700 735 770 332 349 365 450 473 495
m

ip
Connecting
Thread G
qu

Size
-E
nt
G 1/8A 6 8 9 9 11 12 12 8 9 9 11 12 12 6 7 7 8 9 9
G 1/4A 8 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
ou
G 1/4A 10 20 21 21 27 28 28 21 22 23 28 30 31 14 15 16 19 20 22
sc
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50 29 30 31 39 41 42
Di
G 1/2A 15 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
G 1/2A 18 43 45 47 58 61 64 58 61 64 79 83 87 38 40 42 52 54 57
to
G 3/4A 22 60 63 66 81 85 89 111 117 122 150 159 165 67 70 73 91 95 99

Go
G 1A 28 -- -- -- -- -- -- 153 161 169 207 218 229 96 101 106 130 137 144
G 1-1/4A 35 -- -- -- -- -- -- 259 272 285 351 369 386 216 227 237 293 308 321
G 1-1/2A 42 -- -- -- -- -- -- 335 352 369 454 477 500 216 227 237 293 308 321

31215055 5-45
Table 5-28. British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
Bonded Washer
Seal
ts
Bonded
Washer
ar
Bonded Washer
(e.g. Dowty) Seal
rp
FORM A** (SEALING WASHER) FORM B** (CUTTING FACE)
ou
ry
BSPP Torque Torque
Connecting
Thread G
Tube O.D.
de
or
G 1/4A 6 26 28 29 35 38 39 41 43 45 55 58 61
to
G 1/4A 8 26 28 29 35 38 39 41 43 45 55 58 61
om
G 3/8A 10 33 35 36 45 47 49 66 70 73 90 95 99
G 3/8A 12 33 35 36 45 47 49 66 70 73 90 95 99
t.c
G 1/2A 14 48 51 53 65 69 72 111 117 122 150 159 165

G 1/2A 16 48 51 53 65 69 72 96 101 106 130 137 144
en
G 3/4A 20 66 70 73 90 95 99 199 209 219 270 283 297

m
G 1A 25 111 117 122 150 159 165 251 264 276 340 358 374
ip
G 1-1/4A 30 177 186 195 240 252 264 398 418 438 540 567 594
qu
G 1-1/2A 38 214 225 235 290 305 319 516 542 568 700 735 770
BSPP Torque Torque
-E
Connecting
Thread G
MATERIAL Tube O.D.
nt

ou
G 1/4A 6 17 18 19 23 24 26 27 28 29 37 38 39
sc
G 1/4A 8 17 18 19 23 24 26 27 28 29 37 38 39
Di
G 3/8A 10 21 22 23 28 30 31 43 45 47 58 61 64
to
G 3/8A 12 21 22 23 28 30 31 43 45 47 58 61 64
G 1/2A 14 31 33 34 42 45 46 72 76 79 98 103 107
Go
G 1/2A 16 31 33 34 42 45 46 62 66 69 84 89 94
G 3/4A 20 43 45 47 58 61 64 129 136 142 175 184 193
G 1A 25 72 76 79 98 103 107 163 171 179 221 232 243
G 1-1/4A 30 115 121 127 156 164 172 259 272 285 351 369 386
G 1-1/2A 38 139 146 153 188 198 207 335 352 369 454 477 500

5-46 31215055
ts
ar
rp
FORM E* (EOLASTIC SEALING RING) FORM G/H*** (O-RING W/ RETAINING RING) STUD ENDS & ADJUSTABLE
TYPE/FITTING IDENTIFICATION STUD ENDS AND HEX TYPE PLUGS STUD ENDS
ou
ry
BSPP Torque Torque
Connecting
Thread G
Tube O.D.
de
or
G 1/4A 6 41 43 45 55 58 61 26 28 29 35 38 39
to
G 1/4A 8 41 43 45 55 58 61 26 28 29 35 38 39
om
G 3/8A 10 59 62 65 80 84 88 52 55 57 70 75 77
G 3/8A 12 59 62 65 80 84 88 52 55 57 70 75 77
t.c
G 1/2A 14 85 90 94 115 122 127 66 70 73 90 95 99

G 1/2A 16 85 90 94 115 122 127 66 70 73 90 95 99
en
G 3/4A 20 133 140 146 180 190 198 133 140 146 180 190 198
m
G 1A 25 229 241 252 310 327 342 229 241 252 310 327 342
ip
G 1-1/4A 30 332 349 365 450 473 495 332 349 365 450 473 495
qu
G 1-1/2A 38 398 418 438 540 567 594 398 418 438 540 567 594
BSPP Torque Torque
-E
Connecting
Thread G
MATERIAL Tube O.D.
nt

ou
G 1/4A 6 27 28 29 37 38 39 17 18 19 23 24 26
sc
G 1/4A 8 27 28 29 37 38 39 17 18 19 23 24 26
Di
G 3/8A 10 38 40 42 52 54 57 34 36 37 46 49 50
to
G 3/8A 12 38 40 42 52 54 57 34 36 37 46 49 50
G 1/2A 14 55 58 61 75 79 83 43 45 47 58 61 64
Go
G 1/2A 16 55 58 61 75 79 83 43 45 47 58 61 64
G 3/4A 20 86 91 95 117 123 129 86 91 95 117 123 129
G 1A 25 149 157 164 202 213 222 149 157 164 202 213 222
G 1-1/4A 30 216 227 237 293 308 321 216 227 237 293 308 321
G 1-1/2A 38 259 272 285 351 369 386 259 272 285 351 369 386

31215055 5-47
Note: BSPP O-ring only

style (ISO 228-1) requires
o-ring chamfer in the
port, similar to ISO
11926 (SAE ORB),but is
rts
not interchangeable.
Not typically used on
pa
JLG machines.
ur
BANJO FITTINGS HIGH PRESSURE BANJO FITTINGS
TYPE/FITTING IDENTIFICATION JIS/BSPP O-RING ONLY
with S series DIN (MBTS) opposite end with S series DIN (MBTS) opposite end
yo
Connecting
Thread G
r
Tube O.D.
de
MATERIAL Size [Ft-Lb] [N-m] [Ft-Lb] [N-m] [Ft-Lb] [N-m]
or
G 1/4A 6 30 32 33 40 43 45 33 35 36 45 47 49
G 1/4A 8 30 32 33 40 43 45 33 35 36
to
45 47 49
G 3/8A 10 48 51 53 65 69 72 52 55 57 70 75 77
om
G 3/8A 12 48 51 53 65 69 72 52 55 57 70 75 77
t.c
G 1/2A 14 66 70 73 90 95 99 89 94 98 120 127 133

Fitting type not typically specified on
G 1/2A 16 66 70 73 90 95 99 89 94 98 120 127 133
en
JLG applications. Refer to the specific

G 3/4A 20 92 97 101 125 132 137 170 179 187 230 243 254 procedure in this Service Manual.
m
G 1A 25 -- -- -- -- -- -- 236 248 260 320 336 353

ip
G 1-1/4A 30 -- -- -- -- -- -- 398 418 438 540 567 594

qu
G 1-1/2A 38 -- -- -- -- -- -- 516 542 568 700 735 770

-E
Connecting
Thread G
nt
Size
ou
G 1/4A 6 20 21 21 27 28 28 22 22 23 30 30 31
sc
G 1/4A 8 20 21 21 27 28 28 22 22 23 30 30 31
Di
G 3/8A 10 31 33 34 42 45 46 34 36 37 46 49 50
G 3/8A 12 31 33 34 42 45 46 34 36 37 46 49 50
to
G 1/2A 14 43 45 47 58 61 64 58 61 64 79 83 87
Fitting type not typically specified on
Go
G 1/2A 16 43 45 47 58 61 64 58 61 64 79 83 87
JLG applications. Refer to the specific
G 3/4A 20 60 63 66 81 85 89 111 117 122 150 159 165 procedure in this Service Manual.
G 1A 25 -- -- -- -- -- -- 153 161 169 207 218 229
G 1-1/4A 30 -- -- -- -- -- -- 259 272 285 351 369 386
G 1-1/2A 38 -- -- -- -- -- -- 335 352 368 454 477 499

5-48 31215055
Assembly Instructions for Flange Connections:

(FL61 and FL62)
1. Make sure sealing surfaces are free of rust, splits,
scratches, dirt, foreign matter, or burrs.
2. See Figure for O-ring installation instructions.
3. Pre-lubricate the O-ring with Hydraulic Oil.
4. Position flange and clamp halves.
5. Place lock washers on bolt and bolt through clamp
ts
halves.
ar
6. Tighten all bolts by hand.
rp
7. Torque bolts in diagonal sequence in two or more incre-
ou
ments to the torque listed on Table Table 5-31and Table
5-32.
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
to
Go
5-50 31215055
Table 5-31. Flange Code (FL61 & FL62) -Inch Fasteners
ts
ar
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
rp
Bolt Fastener Torque for Flanges Equipped with Fastener Torque for Flanges Equipped with
Inch
ou
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws
Flange
TYPE
ry
SAE Dash Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
de
8 0.50 13 1.50 38.10 5/16-18 18 19 19 24 25 26 24 25 26 32 34 35
or
12 0.75 19 1.88 47.75 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
CODE 61 SPLIT FLANGE (FL61)
to
16 1.00 25 2.06 52.32 3/8-16 32 33 35 43 45 47 44 46 49 60 63 66
20 1.25 32 2.31 58.67 7/16-14 52 54 57 70 74 77 68 71 75 92 97 101
om
24 1.50 38 2.75 69.85 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
32 2.00 51 3.06 77.72 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
t.c
40 2.50 64 3.50 88.90 1/2-13 77 81 85 105 110 116 111 116 122 150 158 165
en
48 3.00 76 4.19 106.43 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
56 3.50 89 4.75 120.65 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
m
64 4.00 102 5.13 130.30 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
ip
80 5.00 127 6.00 152.40 5/8-11 155 163 170 210 221 231 218 228 239 295 310 325
qu
Inch
-E
Flange Size A* Thread GRADE 5 Screws GRADE 8 Screws

Flange
TYPE
nt
SAE Dash Size [Ft-Lb] [N-m] [Ft-Lb] [N-m]

Size
ou
(in) (mm) (in) (mm) (UNF) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
sc
8 0.50 13 1.59 40.39 5/16-18 -- -- -- -- -- -- 24 25 26 32 34 35

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

Di
16 1.00 25 2.25 57.15 7/16-14 -- -- -- -- -- -- 68 71 75 92 97 101

to
20 1.25 32 2.62 66.55 1/2-13 -- -- -- -- -- -- 111 116 122 150 158 165
20 1.25 32 2.62 66.55 -- -- -- -- -- -- -- -- -- -- -- -- --
Go
24 1.50 38 3.12 79.25 5/8-11 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 3/4-10 -- -- -- -- -- -- 332 348 365 450 473 495
* A dimension for reference only.
31215055 5-51
Table 5-32. Flange Code (FL61 & FL62) - Metric Fasteners
ts
ar
STEEL 4-BOLT FLANGE SAE J518
(INCH FASTENERS)
rp
Inch
ou
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws
Flange
TYPE Size
ry
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]
Size
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
de
8 0.50 13 1.50 38.10 (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
or
12 0.75 19 1.88 47.75 M8 x 1.25 18 19 19 24 25 26 18 19 19 24 25 26
16 1.00 25 2.06 52.32 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55

20 1.25 32 2.31 58.67 M10 x 1.5 37 39 41 50 to53 55 37 39 41 50 53 55
om
24 1.50 38 2.75 69.85 M10 x 1.5 37 39 41 50 53 55 37 39 41 50 53 55
32 2.00 51 3.06 77.72 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101
t.c
40 2.50 64 3.50 88.90 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101

en
48 3.00 76 4.19 106.43 M12 x 1.75 68 71 75 92 97 101 68 71 75 92 97 101

56 3.50 89 4.75 120.65 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
m
64 4.00 102 5.13 130.30 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
ip
80 5.00 127 6.00 152.40 M16 x 2 155 163 170 210 221 231 155 163 170 210 221 231
qu
Inch
-E
Flange Size A* Thread CLASS 8.8 Screws CLASS 10.9 Screws

Flange
TYPE Size
nt
SAE Dash [Ft-Lb] [N-m] [Ft-Lb] [N-m]

Size
ou
(in) (mm) (in) (mm) (Metric) Min Nom Max Min Nom Max Min Nom Max Min Nom Max
8 0.50 13 1.59 40.39 M8 x 1.25 -- -- -- -- -- -- 24 25 26 32 34 35
sc
12 0.75 19 2.00 50.80 M10 x 1.5 -- -- -- -- -- -- 52 54 57 70 74 77

Di
16 1.00 25 2.25 57.15 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
to
20 1.25 32 2.62 66.55 M12 x 1.75 -- -- -- -- -- -- 96 101 105 130 137 143
20 1.25 32 2.62 66.55 M14 x 2 -- -- -- -- -- -- 133 139 146 180 189 198
Go
24 1.50 38 3.12 79.25 M16 x 2 -- -- -- -- -- -- 218 228 239 295 310 325
32 2.00 51 3.81 96.77 M20 x 2.5 -- -- -- -- -- -- 406 426 446 550 578 605
* A dimension for reference only.
5-52 31215055
Double Wrench Method the ‘layline’ printed on the hose is a good indicator of proper
hose installation. A twisted lay-line usually indicates the hose
To prevent undesired hose or connector rotation, two
is twisted. See Figure 5-12. for double wrench method require-
wrenches must be used; one torque wrench and one Backup
ments.
wrench. If two wrenches are not used, inadvertent component
rotation may occur which absorbs torque and causes
improper joint load and leads to leaks. For hose connections,
ts
ar
rp
ou
ry
de
or
to
om
t.c
en
m
ip
qu
-E
nt
ou
sc
Di
Figure 5-12. Double Wrench Method

to
Go
31215055 5-53
FFWR and TFFT Methods Adjustable Stud End Assembly

For Adjustable Stud End Connections; the following assembly
FFWR (FLATS FROM WRENCH RESISTANCE METHOD) steps are to be performed:
1. Tighten the swivel nut to the mating fitting until no lat- 1. Lubricate the o-ring with a light coat of hydraulic oil.
eral movement of the swivel nut can be detected; finger
tight condition. 2. Position #1 – The o-ring should be located in the groove
adjacent to the face of the Backup washer. The washer
2. Mark a dot on one of the swivel hex nut flats and and o-ring should be positioned at the extreme top end
another dot in line on the connecting tube adapter. See of the groove as shown.
Figure B.1.
3. Position #2 – Position the locknut to just touch the
3. Use the double wrench method per Appendix A, turn Backup washer as shown. The locknut in this position
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the swivel nut to tighten as shown in Figure B.1. The nut will eliminate potential back up washer damage during
ar
is to be rotated clockwise the number of hex flats as the next step.
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defined by the applicable Table in Section 5.0.
4. Position #3 – Install the connector into the straight
4. After the connection has been properly tightened, mark
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thread box port until the metal Backup washer contacts
a straight line across the connecting parts, not covering the face of the port as shown.
ry
the dots, to indicate the connection has been properly
tightened. See Figure 5-13. 5. Position #4 – Adjust the connector to the proper posi-
de
tion by turning out (counterclockwise) up to a maxi-
mum of one turn as shown to provide proper alignment
or
with the mating connector, tube assembly, or hose
assembly.
to
6. Position #5 – Using two wrenches, use the backup
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wrench to hold the connector in the desired position
and then use the torque wrench to tighten the locknut
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to the appropriate torque.

7. Visually inspect, where possible, the joint to ensure the
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o-ring is not pinched or bulging out from under the

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washer and that the backup washer is properly seated

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Figure 5-13. FFWR Method flat against the face of the port.
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TFFT (TURNS FROM FINGER TIGHT METHOD)

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1. Tighten the swivel nut to the mating fitting until no lat-

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eral movement of the swivel nut can be detected; finger

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tight condition.
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2. Mark a dot on one of the swivel hex nut flats and

another dot in line on the connecting tube adapter.
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3. Use the double wrench method per Appendix A, turn

to
the swivel nut to tighten. The nut is to be rotated clock-

wise the number of turns as defined by the applicable
Go
Table in Section 5.0.

4. After the connection has been properly tightened, mark
a straight line across the connecting parts, not covering
the dots, to indicate the connection has been properly
tightened.
5-54 31215055
Position #1 Position #2 Position #4

Locknut and Washer Locknut in position to Position #3 Connector backed Position #5
rts
backed off with o-ring protect the back-up Hand tightened into port Connector tightened
off for alignment
in position washer from damage until back-up to mating connector, to ?nal position
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during installation washer contacts tube assembly or
into the port port face hose assembly
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Adjustable Stud End Assembly Positions
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Locknut
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O-Ring
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Back-up Washer
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Figure 5-14. Adjustable Stud End Assembly

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

straight threads, ensure O-ring is seated all the way past
Go
Care must be taken when installing O-rings over threads dur-

the threads prior to installation.
ing replacement or installation. O-rings could become nicked
or torn. A damaged O-ring could lead to leakage problems. 5. Inspect O-ring for any visible nicks or tears. Replace if
found.
1. Inspect O-ring for tears or nicks. If any are found replace
O-ring.
2. Ensure proper O-ring to be installed. Many O-rings look
the same but are of different material, different hard-
ness, or are slightly different diameters or widths.
3. Use a thread protector when replacing O-rings on fit-
tings.
31215055 5-55
5.3 CYLINDER REPAIR

NOTE: The following are general procedures that apply to all of
the cylinders on this machine. Procedures that apply to a
specific cylinder will be so noted.
Disassembly
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK

SURFACE IN A DIRT FREE WORK AREA.
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1. Connect a suitable auxiliary hydraulic power source to
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the cylinder port block fitting.
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Figure 5-16. Cap Screw Removal
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DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.
de
2. Operate the hydraulic power source and extend the cyl- EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
or
inder. Shut down and disconnect the power source. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
Adequately support the cylinder rod, if applicable. CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
3. If applicable, remove the cartridge-type holding valve to

6. With the barrel clamped securely, apply pressure to the
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and fittings from the cylinder port block. Discard o- rod pulling device and carefully withdraw the complete
rings. rod assembly from the cylinder barrel.
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4. Place cylinder barrel in a suitable holding fixture. Tap

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around outside of cylinder head retainer with a suitable

hammer to break thread-locking compound.
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to
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Figure 5-17. Cylinder Rod Support
Figure 5-15. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch for

easy realignment. Using an allen wrench, loosen the
eight (8) cylinder head retainer cap screws, and remove
cap screws from cylinder barrel.
5-56 31215055
19 18
22
23
23
22
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22
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23
22
17
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19
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15
18
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16
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14
or
13
10
to
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11
12
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5
4
en
6
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7
8
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9
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3
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to
*Torque to 9 ft-lbs (12 Nm) 2

**Torque to 50-55 ft-lbs(67-74 Nm)
Go
1001251020-A
MAF28440A
1. Barrel 6. U-Packing 11. Backup Ring 16. Backup Ring 21. O-Ring
2. Rod 7. Back up Ring 12. O-Ring 17. Set Screw 22. Plug
3. Head 8. Dust Wiper 13. Piston 18. Counterbalance Valve 23. O-Ring
4. Spacer 9. Retaining Ring 14. Piston Seal 19. Dust Cap
5. Retaining Ring 10. O-Ring 15. O-Ring 20. Plug
Figure 5-18. Axle Extension Cylinder
31215055 5-57
11
6****
19 19***
11 1
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4
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18** 12
3
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14
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15
14
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or
17
16
13
to
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17 10
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9
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5
8
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7
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20*
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2
11
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*Torque to 84 ft-lbs (113 Nm)

to
**Torque to 9.5 ft-lbs (13 Nm) 11

***Torque to 13-15 ft-lbs (17-20Nm)(
Go
****Torque to 30-35 ft-lbs (40-47 Nm)
1001228019-C
MAE35830C
1. Barrel 6. Counterbalance Valve 11. Bushing 16. Seal

2. Rod 7. Wiper 12. O-ring Plug 17. Lock Ring
3. Piston 8. Rod Seal 13. Wear Ring 18. Capscrew.
4. Tapered Bushing 9. Backup ring 14. Backup ring 19. Bleeder Valve
5. Head 10. O- ring 15. O- ring 20. Capscrew
Figure 5-19. Axle Lockout Cylinder
5-58 31215055
19
20
21
19
17*
1
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21
22
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18*
12***
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14 13
23**
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16
or
15
to
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10
11
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3
9
7
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8
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5
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6
-E
4
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2
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*Torque to 50-55 ft-lbs (68-75 Nm)

**Torque to 9.6 ft-lbs (12 Nm) 19
to
***Torque to 74 ft-lbs (100 Nm)

Go
19
1001228053-B
MAF28460B
1. Barrel 7. Rod Seal 13. Piston Seal 19. Bushing

2. Rod 8. Backup Ring 14. O- ring 20. Plug
3. Head 9. Wear Ring 15. O- ring 21. Plug
4. Cap Cylinder 10. O- ring 16. Spacer 22. Tapered Bushing
5. Wiper 11. Backup Ring 17. Holding Valve Cartridge 23. Capscrew
6. Retainer 12. Piston 18. Counterbalance Valve Cartridge
Figure 5-20. Platform Level Cylinder (With Cold Weather Plus Package)
31215055 5-59
21
22 23
20***
21
23
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15 19***
11
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1
10
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9
16**
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10
11
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13
or
12
13
14
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7
8
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6
3
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5
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4
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18
-E
17*
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2
Di
21
to
*Torque to 84.82 ft-lbs (115 Nm)

**Torque to 9.6ft-lbs (13 Nm)
Go
***Torque to 50.15-54.58 ft-lbs (68- 21 1001228023-C

MAE35840C
1. Barrel 7. O-Ring 13. Backup Ring 19. Counterbalance valve

2. Rod 8. Backup Ring 14. Spacer 20. Cartridge Valve
3. Head 9. Piston 15. Tapered Bushing 21. Bushing
4. Wiper 10. Guide Ring 16. Capscrew 22. O-Ring
5. Rod seal 11. Lock Ring 17. Capscrew 23. O-Ring
6. Wear Ring 12. O-Ring 18. Ring washer
Figure 5-21. Platform Level Cylinder (Without Cold Weather Plus Package)
5-60 31215055
21
24****
21 23
22
1
19*****
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22
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16 20***
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17**
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10
11
or
12
9
to
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11
10 14
13
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14
15
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13
6
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3 5
4 7
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8
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18*
-E
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2 21
sc
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21
to

**Torque to 60 ft-lbs (82 Nm)
Go
***Torque to 30-34 ft-lbs (41-47 Nm)

****Torque to 25 ft-lbs (34 Nm)
1001228024-D
*****Torque to 50-55 ft-lbs (68-75 Nm) MAE35850D
1. Barrel 7. O-Ring 13. O-Ring 19. Holding Valve

2. Rod 8. Backup Ring 14. Back Up Ring 20. Check Valve
3. Head 9. Piston 15. Spacer 21. Bushing
4. Wiper 10. Lock Ring 16. Tapered Bushing 22. O-ring Plug
5. Rod Seal 11. Guide Ring 17. Capscrew 23. O-ring Plug
6. Wear Ring 12. Wear Ring 18. Capscrew 24. Pressure Regulator Valve
Figure 5-22. Lift Cylinder
31215055 5-61
21***
24
23
24
20 24
23
1
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24
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22****
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16 24
11 25
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10
11
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17** 13
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9
14
or
13
12
13
12 15
7 to
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8
6
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3
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5
4 19
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18*
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2
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23
to

**Torque to 5 ft-lbs (6.7 Nm)
Go
***Torque to 30-35ft-lbs (40-47 Nm) 23

****Torque to 17-20 ft-lbs (23-27 Nm)
1001228025-F
MAE35860F
1. Barrel 7. O-Ring 13. Backup Ring 19. Ring Washer 25. O-Ring
2. Rod 8. Backup Rig 14. Seal 20. Counterbalance valve
3. Head 9. Piston 15. Spacer 21. Cartridge Valve
4. Rod Wiper 10. Seal 16. Tapered Bushing 22. Cartridge Valve
5. Seal 11. Wear Ring 17. Capscrew 23. Bushing
6. Wear Ring 12. O-Ring 18. Capscrew 24. O-ring
Figure 5-23. Jib Cylinder
5-62 31215055
25
18
24
26
18
25
24
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15
10***
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21** 13 17*
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16 26
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12 14
11
or
12
3
to
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7
8
9
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20
en
6
4
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5
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22*
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2
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28
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19
Di
23
* Torque to 24.34 ft.lbs (33 Nm)
to
* *Torque to 30 ft.lbs (42 Nm)

*** Torque to 140.137 ft.lbs (190 Nm) 27 1001228026-B
Go
MAF28450B
1. Barrel 8. O-Ring 15. Tapered Bushing 22. Capscrew

2. Rod 9. Backup Ring 16. Spacer 23. Capscrew
3. Head 10. Piston 17. Capscrew 24. Bolt
4. Wiper 11. Seal 18. Wear Pad 25. Washer
5. Retaining Ring 12. Wear Ring 19. Valve Assembly 26. Plug
6. Rod seal 13. O-Ring 20. Bracket 27. Plug
7. Wear Ring 14. Backup Ring 21. Capscrew 28. Plug
Figure 5-24. Telescope Cylinder -1200SJP
31215055 5-63
25
18
24
26
18
25
24
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15
10
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21** 13 17
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16 26
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12 14
11
or
12
3
to
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7
8
9 20
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6
4
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5
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22*
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2
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28
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19
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23
* Torque to 30 ft.lbs (42 Nm)
to
** Torque to 115 ft.lbs (85 Nm)

27 1001228021-C
Go
MAF28430C
1. Barrel 8. O-Ring 15. Tapered Bushing 22. Capscrew

2. Rod 9. Backup Ring 16. Spacer 23. Capscrew
3. Head 10. Piston 17. Capscrew 24. Bolt
4. Wiper 11. Seal 18. Wear Pad 25. Washer
5. Retaining Ring 12. Wear Ring 19. Valve Assembly 26. O-Ring
6. Rod seal 13. O-Ring 20. Bracket 27. O-Ring
7. Wear Ring 14. Backup Ring 21. Capscrew 28. O-Ring
Figure 5-25. Telescope Cylinder -1350SJP
5-64 31215055
.
14. Remove the rod from the holding fixture. Remove the
cylinder head gland and retainer plate, if applicable. Dis-
card the o-rings, Backup rings, rod seals, and wiper seals.
Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning sol-
vent.
2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.
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3. Inspect threaded portion of rod for excessive damage.
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Dress threads as necessary.
4. Inspect inner surface of cylinder barrel tube for scoring
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or other damage. Check inside diameter for tapering or
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ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
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threads as necessary.
6. Inspect piston surface for damage and scoring and for
or
7. Using suitable protection, clamp the cylinder rod in a
vise or similar holding fixture as close to the piston as distortion. Dress piston surface or replace piston as nec-
to
possible. essary.
8. Loosen and remove the cap screw(s), if applicable, 7. Inspect threaded portion of piston for damage. Dress
om
which attach the tapered bushing to the piston. threads as necessary.
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9. Insert the cap screw(s) in the threaded holes in the outer 8. Inspect seal and o-ring grooves in piston for burrs and
piece of the tapered bushing. Progressively tighten the sharp edges. Dress applicable surfaces as necessary.
en
cap screw(s) until the bushing is loose on the piston.

9. Inspect cylinder head inside diameter for scoring or
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10. Remove the tapered bushing from the piston. other damage and for ovality and tapering. Replace as
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necessary.
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10. Inspect threaded portion of head for damage. Dress

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11. Inspect seal and o-ring grooves in head for burrs and
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sharp edges. Dress applicable surfaces as necessary.

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12. Inspect cylinder head outside diameter for scoring or

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other damage and ovality and tapering. Replace as nec-

essary.
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13. If applicable, inspect rod and barrel bearings for signs of

to
correct excessive wear or damage. Replace as necessary.

Go
a. Thoroughly clean hole, (steel bushing) of burrs, dirt

etc. to facilitate bearing installation.
b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
Figure 5-27. Tapered Bushing Removal be replaced.
c. Lubricate inside of the steel bushing with WD40
11. Screw the piston CCW, by hand, and remove the piston prior to bearing installation.
from cylinder rod. d. Using an arbor of the correct size, carefully press the
bearing into steel bushing.
12. Remove and discard the piston o-rings, seal rings, and
backup rings.
13. Remove piston spacer, if applicable, from the rod.
31215055 5-65
NOTE: Install pin into the composite bearing dry. Lubrication is Assembly
not required with nickel plated pins and bearings.
NOTE: Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual.
Apply a light film of hydraulic oil to all components prior to

assembly.
1. A special tool is used to install a new rod seal into the

applicable cylinder head gland groove.
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Figure 5-28. Composite Bearing Installation
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14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
ry
with Scotch Brite or equivalent.
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15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
or
16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.
to
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17. If applicable, inspect piston rings for cracks or other Figure 5-29. Rod Seal Installation
damage. Replace as necessary.
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en
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED

PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN-
m
TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAK-

ip
AGE AND IMPROPER CYLINDER OPERATION.

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Go
5-66 31215055
2. Use a soft mallet to tap a new wiper seal into the appli- 6. If applicable, correctly place new o-ring in the inner pis-
cable cylinder head gland groove. Install a new wear ton diameter groove. (The backup ring side facing the
ring into the applicable cylinder head gland groove. O-ring is grooved.)
7. If applicable, correctly place new seals and guide lock
rings in the outer piston diameter groove. (A tube, with
I.D. slightly larger than the O.D.of the piston is recom-
mended to install the solid seal.)
NOTE: The backup rings for the solid seal have a radius on one
side. This side faces the solid seal.(See magnified insert in
Figure 5-33.)The split of seals and backup rings are to be
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positioned so as not to be in alignment with each other.
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Figure 5-30. Poly-Pak Piston Seal Installation
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Figure 5-31. Wiper Seal Installation

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3. Place a new O-ring and Backup seal in the applicable

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outside diameter groove of the cylinder head.

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Figure 5-33. Piston Seal Kit Installation

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8. Using suitable protection, clamp the cylinder rod in a

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vise or similar holding fixture as close to piston as possi-

ble.
Go
9. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and Backup rings are not
damaged or dislodged.
Figure 5-32. Installation of Head Seal Kit
10. Thread piston onto rod until it abuts the spacer end and
4. Install washer ring onto rod, carefully install the head install the tapered bushing.
gland on the rod, ensuring that the wiper and rod seals
NOTE: When installing the tapered bushing, piston and mating
are not damaged or dislodged. Push the head along the
end of rod must be free of oil.
rod to the rod end, as applicable.
5. Carefully slide the piston spacer on the rod.
NOTE: Main telescope cylinder piston has an o-ring installed

inside the spacer.
31215055 5-67
b. Tap each space once; this means the tapered bush-

ing is tapped 3 times as there are 3 spaces between
WHEN REBUILDING THE TELESCOPE, LIFT, JIB, LEVEL, AXLE LOCKOUT OR AXLE the capscrews.
EXTENSION CYLINDERS, TIGHTEN SECURELY. (SEE TABLE 5-33)
11. Assemble the tapered bushing loosely into the piston

and insert JLG capscrews (not vendor capscrews)
through the drilled holes in the bushing and into the
tapped holes in the piston.
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Figure 5-35. Seating the Tapered Bearing
or
14. Retorque the capscrews evenly and progressively in
rotation to the specified torque value. (See Table 5-33,
to
Cylinder Head and Tapered Bushing Torque Specifica-
tions).
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Figure 5-34. Tapered Bushing Installation 15. Remove the cylinder rod from the holding fixture.
t.c
16. Place new guide locks and seals in the applicable out-
12. Tighten the capscrews evenly and progressively in rota- side diameter grooves of the cylinder piston. (See Figure
en
tion to the specified torque value. (See Table 5-33, Cylin- 5-33., Piston Seal Kit Installation)
der Head and Tapered Bushing Torque Specifications).
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17. Position the cylinder barrel in a suitable holding fixture.

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13. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
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(approximately 3/4" in diameter) as follows;

-E
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,

a. Place the shaft against the cylinder rod and in con- HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
nt
tact with the bushing in the spaces between the CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
ou
capscrews.
18. With barrel clamped securely, and while adequately sup-
sc
porting the rod, insert the piston end into the barrel cyl-
Di
inder. Ensure that the piston loading o-ring and seal ring
are not damaged or dislodged.
to
19. Continue pushing the rod into the barrel until the cylin-
der head gland can be inserted into the barrel cylinder.
Go
5-68 31215055
20. Secure the cylinder head gland using the washer ring Table 5-33. Cylinder Head and Tapered Bushing Torque
and socket head bolts. (See Table 5-33, Cylinder Head Specifications
and Tapered Bushing Torque Specifications and Table 5-
34, Holding Valve Torque Specifications) Tapered
Head Torque Value
Description Bushing Torque
(Wet)
Value (Wet)
Tele Cylinder (1200SJP) 120 ft. lbs. 30 ft. lbs.

(163 Nm) (40.5 Nm)
Tele Cylinder (1350SJP) 120 ft. lbs. 45 ft. lbs.

(163 Nm) (63 Nm)
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Level Cylinder 120 ft. lbs. 9 ft. lb.s
(163 Nm) (12.6 Nm)
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Jib Cylinder 30 ft. lbs. 5 ft. lbs.
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(41 Nm) (9 Nm)
Figure 5-36. Rod Assembly Installation
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Lift Cylinder 300 ft. lbs. 120 ft. lbs.
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(410 Nm) (168 Nm)
21. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
or
Axle Oscillation 120 ft. lbs. 9 ft. lb.s
reinstallation of any holding valve or valves. Cylinder (163 Nm) (12.6 Nm)
22. If applicable, install the cartridge-type holding valve and
fittings in the rod port block, using new o-rings as appli- to
Axle Extend 50 ft. lbs. 9 ft. lb.s
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Cylinder (70 Nm) (12.6 Nm)
cable. (See Table 5-34, Holding Valve Torque Specifica-
tions).
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Table 5-34. Holding Valve Torque Specifications

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Description Torque Value

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SUN - 7/8 HEX M20 X 1.5 THDS. 30-35 ft. lbs.

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(41-48 Nm)
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SUN - 1 1/8 HEX 1 -14 UNS THDS. 45-50 ft. lbs.

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(61-68 Nm)
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SUN - 1 1/4 HEX M36 X 2 THDS. 150-160 ft. lbs.

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(204-217 Nm)
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RACINE - 1 1/8 HEX 1 1/16 - 12 THDS. 50-55 ft. lbs.

(68-75 Nm)
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to
(102-109 Nm)
Go

(136-149 Nm)
31215055 5-69
Steer Cylinder 4. Mark cylinder cap and barrel with a center punch for
easy realignment. Unscrew the cylinder cap from the
DISASSEMBLY barrel.
5. Using a hook spanner, loosen the cylinder cap on Barrel.
Remove the cylinder head from the barrel and the rod.
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power source to

the cylinder port block fitting.
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ar
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
rp
SLIGHTLY TO AVOID TRAPPING PRESSURE.
ou
2. Operate the hydraulic power source and extend the cyl-
inder. Shut down and disconnect the power source.
ry
Adequately support the cylinder rod, if applicable.
de
3. Place cylinder barrel in a suitable holding fixture. Tap
or
around outside of cylinder head retainer with a suitable
hammer to break thread-locking compound. Figure 5-38. Cylinder Cap Removal
to
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Figure 5-39. Cylinder Cap Removal

Figure 5-37. Cylinder Barrel Support
to
Go
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,

HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
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.
5-70 31215055
15
15 1
17
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**Torque to 785 ft-lbs (1064 Nm)
1001228031-B
MAE35870B
1. Barrel 6. Piston Seal 11. Nut 16. Bushing

2. Rod 7. Wear Ring 12. Wiper 17. Plug
3. Head 8. O-Ring 13. Wear Ring
4. Cylinder Cap 9. Backup Ring 14. O-Ring
5. Wiper 10. Piston 15. Bushing
Figure 5-40. Steer Cylinder
31215055 5-71
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
11. Inspect seal and o-ring grooves in head for burrs and
12. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec-
essary.
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13. If applicable, inspect rod and barrel bearings for signs of
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correct excessive wear or damage. Replace as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs, dirt
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etc. to facilitate bearing installation.
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b. Inspect steel bushing for wear or other damage. If
steel bushing is worn or damaged, rod/barrel must
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be replaced.
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c. Lubricate inside of the steel bushing with WD40
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8. Using suitable protection, clamp the cylinder rod in a prior to bearing installation.
d. Using an arbor of the correct size, carefully press the
to
vise or holding fixture as close to the piston as possible.
bearing into steel bushing.
9. Loosen and remove the lock nut that secures the piston
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to the cylinder rod. NOTE: Install pin into the composite bearing dry. Lubrication is
not required with nickel plated pins and bearings.
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10. Remove the piston from the cylinder rod.

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11. Remove and discard the piston o-rings, seal rings.

12. Remove the rod from the holding fixture. Remove the
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cylinder head. Discard all seals on the cylinder head.

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Cleaning And Inspection

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1. Clean all parts thoroughly in an approved cleaning sol-

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vent.
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2. Inspect the cylinder rod for scoring, tapering, ovality, or

other damage. If necessary, dress rod with Scotch Brite
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or equivalent. Replace rod if necessary.

Figure 5-42. Composite Bearing Installation
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3. Inspect threaded portion of rod for excessive damage.

Dress threads as necessary.
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14. Inspect the oil ports for blockage or the presence of dirt
4. Inspect inner surface of cylinder barrel tube for scoring or other foreign material. Repair as necessary.
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or other damage. Check inside diameter for tapering or

ovality. Replace if necessary. 15. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
5. Inspect threaded portion of barrel for damage. Dress
6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec-
essary.
7. Inspect threaded portion of piston for damage. Dress
8. Inspect seal and o-ring grooves in piston for burrs and
5-72 31215055
Assembly 2. Use a soft mallet to tap a new wiper seal into the cylin-
der head gland groove. Install new wear rings into the
NOTE: Prior to cylinder assembly, ensure that the proper cylinder cylinder head gland groove.
seal kit is used. See your JLG Parts Manual.
NOTE: Apply a light film of hydraulic oil to all components prior to

assembly.
1. A special tool is used to install a new rod seal into the

applicable cylinder head gland groove.
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Figure 5-44. Poly-Pak Piston Seal Installation
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Figure 5-43. Rod Seal Installation
8*1&3
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."--&5 )&"%
WHEN INSTALLING NEW SEALS, ENSURE SEALS ARE INSTALLED PROPERLY.
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IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND

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IMPROPER CYLINDER OPERATION.

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Figure 5-45. Wiper Seal Installation

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3. Place a new O-ring and backup ring in the outside diam-

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eter groove of the cylinder head.

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5,1*
Figure 5-46. Installation of Head Seal Kit
31215055 5-73
4. Place the cylinder cap over the rod and carefully install
the head gland on the rod, ensuring that the wiper and
rod seals are not damaged or dislodged. Push the head EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
along the rod to the rod end. HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
5. Place a new O-ring in the inner piston diameter groove.
6. Using suitable protection, clamp the cylinder rod in a 12. With barrel clamped securely, and while adequately sup-
vise or similar holding fixture as close to the piston porting the rod, insert the piston end into the barrel cyl-
threads as possible. inder. Ensure that the piston seals are not damaged or
dislodged.
7. Install the piston on the cylinder rod hand tight, ensur-
ing that the o-ring and Backup rings are not damaged or 13. Continue pushing the rod into the barrel until the cylin-
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dislodged. der head gland can be inserted into the barrel cylinder.
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8. Place a new wear ring in the outer piston diameter 14. Secure the cylinder head using Low Strength Thread-
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grooves. locking Compound and the cylinder cap.
15. After the cylinder has been reassembled, the rod should
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9. Carefully thread the lock nut onto the rod to secure the
piston in place. be pushed all the way in (fully retracted).
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10. Remove the cylinder rod from the holding fixture.
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11. Position the cylinder barrel in a suitable holding fixture.
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5-74 31215055
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1. Return Filter
2. Vented Fill Cap
3. Sight/Temperature Gauge
4. Suction Strainer
5. Magnetic Drain Plug
Figure 5-47. Hydraulic Tank
31215055 5-75
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A. Front Steer Valve/Axle Extend

B. Traction Valve
C. Rear Steer Valve/Axle Extend
D. Chassis Module Controller
E. Junction Manifold Valve
F. Axle Oscillation Valve
Figure 5-48. Chassis Control Valve Locations
5-76 31215055
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1. Level Up 6. Jib Swing Left 10. Level Up Relief 14. Main Pressure Check Port
2. Rotate Right 7. Jib Up 11. Jib Up/Down Relief 15. Level Up Test Port
3. Level Down 8. Jib Swing Right 12. Level Down Relief 16. Level Down Test Port
4. Rotate Left 9. Platform Dump 13. Filter or Plug 17. Jib Up/Down Test Port
5. Jib Down
Figure 5-49. Platform Valve Identification - JLG PN 4641266
31215055 5-77
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1. Level Up 5. Jib Down 9. Platform Dump 13. Main Pressure Check Port
2. Rotate Right 6. Jib Swing Left 10. Level Up Relief 14. Level Up Test Port
3. Level Down 7. Jib Up 11. Jib Up/Down Relief 15. Level Down Test Port
4. Rotate Left 8. Jib Swing Right 12. Level Down Relief 16. Jib Up/Down Test Port
Figure 5-50. Platform Valve Identification - JLG PN 4641460
5-78 31215055
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1. Aux Lift Down 5. Dump 9. Lift Up Relief 13. Tele Out Relief
2. Tele Out 6. Swing Relief 10. Lift Down Relief 14. Tele In Relief
3. Lift Up 7. Swing Left 11. Lift Flow 15. Tele Flow
4. Swing Right 8. Lift Down 12. Tele In 16. Lift Down/Aux Select
Figure 5-51. Main Valve Identification
31215055 5-79
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Table 5-35. Cartridge Torque Values

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Ft-Lbs. Nm Ft-Lbs. Nm
1 25-30 33.9-40.6 9 30-35 40.6-47.4
2 25-30 33.9-40.6 10 30-35 40.6-47.4
3 30-35 40.6-47.4 11 30 40.6
4 30-35 40.6-47.4 12 30-35 40.6-47.4
5 30-35 40.6-47.4 13 30-35 40.6-47.4
6 30-35 40.6-47.4 14 30-35 40.6-47.5
7 30-35 40.6-47.4 15 30-35 40.6-47.5
8 30 40.6
Figure 5-52. Main Valve Cartridge Torque Values
5-80 31215055
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Table 5-36. Plug Torque Values

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Ft-Lbs. Nm
1 115 156
2 100 135.5
3 40 54
4 13 17.5
Figure 5-58. Main Valve Plug Torque Values
31215055 5-81
5.4 HYDRAULIC TANK 5.5 PRESSURE SETTING PROCEDURE

The hydraulic tank has a capacity of 55 gallons (208 liters) and Cold temperatures have a significant impact on pressure read-
includes the hydraulic return filter and two suction strainers. It ings. JLG Industries Inc. recommends operating the machine
is normal for the oil level to appear low when the boom is until the hydraulic system has warmed to normal operating
raised and should only be checked with the machine on level temperatures prior to checking pressures. JLG Industries Inc.
ground and with the boom fully retracted and lowered. The also recommends the use of a calibrated gauge. Pressure read-
hydraulic oil should be maintained at the full level as shown by ings are acceptable if they are within ± 5% of specified pres-
the decal and hydraulic oil level gauge located on the side of sures.
the tank as shown in Figure 5-59., Hydraulic Oil Level Gauge.
This decal shows the proper full level for both hot and cold oil. To ensure all pressures are set correctly, the following proce-
Do not fill the hydraulic tank past the appropriate full mark. dures must be followed in order.
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Overfilling can cause the oil to overflow from the top of the
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1. All applicable steps in Section 5.11, Drive & Function
hydraulic tank during emergency lowering operations.
Pump Start Up Procedures must be followed.
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2. Set up of the function pump.
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3. Adjustments made at the main valve bank.
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4. Adjustments made at the platform valve.
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Set Up of the Function Pump
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HIGH PRESSURE RELIEF - 3400 PSI (234.4 BAR)
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1. Install a high pressure gauge at the MP port of the main
valve block.
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2. Using a screwdriver, remove the Din connector from the
lift down coil.
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3. Activate lift down. The gauge should read 3400 psi (234
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FULL LEVEL (HOT OIL)

bar).
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FULL LEVEL (COLD OIL)

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Figure 5-59. Hydraulic Oil Level Gauge

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5-82 31215055
4. To make an adjustment to this pressure, go back to the 3. To make an adjustment to this pressure, go to the
engine compartment to the function pump which is the engine compartment, locate the function pump. The
back pump. The high pressure relief adjustment is the stand by adjustment is the adjustment outside adjust-
adjustment closest to the pump. Using a 17 mm wrench, ment, closest to the turntable. Use the same tools that
remove the cover nut. Be careful not to lose the O-ring were used in the Hi pressure adjustment procedure.
washer inside the cover nut.
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5. Loosen the jam nut at the setscrew with the 17 mm Adjustments Made at the Main Valve Bank
or
wrench. Using a 3 mm allen wrench, adjust clockwise to LIFT UP - 2750 PSI (189.6 BAR)
increase, or counterclockwise to decrease.
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1. Install a high pressure gauge at the M5 port of the main
6. After adjusting the pressure, tighten the jam nut and the valve block. Plug and cap the hose on port 5.
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cover nut. This is the maximum relief pressure for all the 2. Activate lift up. The gauge should read 2750 psi (189.6
functions governed by this pump. Bar).
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STAND BY PRESSURE OR LOW PRESSURE RELIEF - 300 PSI 3. The adjustment cartridge is located below the M5
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(20.6 BAR) gauge port. Turn clockwise to increase, counterclock-

1. Install a low pressure gauge at port MP of the main valve wise to decrease.
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block capable of reading 300 psi (20.6 bar).

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LIFT DOWN - 1500 PSI (103.4 BAR)

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2. Start the engine, the gauge should read 300 psi (20.6 1. Install a high pressure gauge at the M4 port of the main
bar). valve block.
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2. Activate lift down to the end of the stroke. The gauge

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should read 1500 psi (103.4 bar).

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3. The adjustment cartridge is located to the left of the M4

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gauge port. Turn clockwise to increase, counterclock-

wise to decrease.
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31215055 5-83
SWING - 1500 PSI (103.4 BAR) STEERING, FRONT AND REAR

NOTE: Left and right are done with one adjustment. NOTE: The following procedure requires 2 people to perform. One
is needed for verifying / adjusting pressure readings and
1. Install a high pressure gauge at port MS. wheel spindle alignment the other for operating the steer
functions and using the Analyzer from the platform.
2. Lock the turntable pin.
3. Activate swing, the gauge should read 1500 psi (103.4 The Analyzer is required to perform the pressure check proce-
Bar). The adjustment cartridge is located below the MS dure through access of the calibration menu. The calibration
gauge port. menu will allow for extending and retracting the steer cylin-
ders individually, verifying pressures, and proper steer sensor
4. Turn clockwise to increase, counterclockwise to calibration. Verification of the steer sensor calibration will
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decrease. require one of two types of measuring methods; using a
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TELESCOPE OUT - 3000 PSI (206.8 Bar) square and ruler or using string as explained in Section 6 - JLG
Control System. The purpose of these measuring tools is to
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1. Install a high pressure gauge at the M8 port of the main assure that the wheel spindle is aligned “straight” with the
valve bank. Plug the telescope out hose either at the
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extended axle weldment.
valve bank (port #8) or at the inlet of the telescope cylin-
1. Position the machine with both front and rear axles fully
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der (V1).
extended.
2. Activate telescope out. The gauge should read 3000 psi
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(206.8 Bar). 2. Install the Analyzer in the platform control box and scroll
menu’s to Access Level 2 and insert password (33271) to
or
3. The adjustment cartridge is located below the M8 get into Access Level 1.
wise to decrease.
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TELESCOPE IN - 3200 PSI (220.6 BAR)
1. Install a high pressure gauge at the M7 port of the main
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valve block.
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2. Activate Telescope In. The gauge should read 3200 psi

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(220.6 Bar).
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3. The adjustment cartridge is located to the left of the M7

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wise to decrease.
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Adjustments Made at the Frame Valve Bank

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AXLE EXTEND AND RETRACT, FRONT AND REAR - 2500 PSI

(172.3 BAR)
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1. To extend the axles, drive the machine back and forth

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3. Scroll to the calibration mode. Once in the calibration

until extended. A machine that cannot be driven must
mode, press “ENTER” and scroll to steer. Once in the
be jacked up.
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steer calibration mode, the Analyzer is going to ask to

2. On both the front and rear frame valve banks, install a calibrate the steer sensors, this is going to allow extend-
Go
high pressure gauge on ports MA1 for extend and MA2 ing and retracting each steer cylinder individually dur-
for retract. The gauge should read 2500 psi (172.3 Bar) in ing this process. The JLG control system will ask to
both directions. calibrate the left front sensor, the left rear sensor, the
right front sensor and finally the right rear sensor in that
3. The axle extend/retract cylinders are connected hydrau- order. During this calibration mode each individual steer
lically in parallel. In order to get the correct pressure of cylinder will be extended and retracted to verify correct
the circuit being adjusted, unscrew the solenoid coil pressures with the marked MS (Measure Steer) ports on
from the circuit not being adjusted and pull it away from the steer / axle valve that pertains to that steer cylinder.
the valve. Refer to the Hydraulic Schematic in Section 7 - Schemat-
4. Turn clockwise to increase, counterclockwise to ics.
decrease.
5-84 31215055
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Figure 5-60. Steer Pressure Adjustments
31215055 5-85
4. Remove the front circular steer/axle access covers at the 6. Remove the pressure gauge from MS2 port and install
front of the chassis, and the rear square cover at the top on the MS1 port, which is on the right side of the front
rear of the chassis to gain access to the axle/steer valves. axle/steer valve, closest to the right front wheel spindle.
Position the steer switch to activate the left front steer
cylinder until the rod is in the fully retracted position
and hold the switch for a few seconds after the rod has
stopped. The MS1 port should read 2600 psi (179 Bar). If
the pressure is not correct, adjust relief valve next to
MS1 port, CW to increase or CCW to decrease.
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7. This step involves aligning the left front wheel spindle

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with the axle weldment. Position the left front wheel

spindle “straight” using a square and rule or string for
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proper alignment (Refer to Section 6 - JLG Control Sys-

5. Install a pressure gauge at the front axle/steer valve at
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tem). Once the left front wheel spindle has been prop-
MS2 port. This should be located on the left side of the
erly measured, press “ENTER” on the Analyzer. This is
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valve closest to the left front wheel spindle. Position the

calibrating data to the JLG Control System that the left
steer switch to activate the left front steer cylinder until
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front steer sensor is centered.

the rod is in the fully extended position and hold the
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switch for a few seconds after the rod has been fully
extended. The MS2 port should read 2000 psi (138 Bar).
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If the pressure is not 2000 psi (138 Bar) adjust relief valve
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mounted next to the MS2 port, CW to increase or CCW

to decrease.
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5-86 31215055
8. Checking the left rear steer cylinder is identical to the 9. Remove the gauge from MS1 port and install on MS2
procedure for left front steer cylinder, except now we are port, which is on the right side of the rear axle/steer
checking pressures at the rear axle/steer valve location. valve, closest to the right rear wheel spindle. Position
Install pressure gauge at MS1 port. This should be the steer switch to activate the left rear steer cylinder
located on the left side of the valve closest to the left until the rod is in the fully extended position and hold
rear wheel spindle. MS1 port should read 2600 psi (179 the steer switch for a few seconds after the rod has been
Bar) when the left rear steer cylinder is activated with fully extended. The MS2 port should read 2000 psi (179
the rod in the fully retracted position. If the pressure is Bar). If the pressure is not correct, adjust the relief valve
not 2600 psi (179 Bar) adjust relief valve mounted next mounted next to MS2 port CW to increase or CCW to
to MS1 port CW to increase or CCW to decrease. decrease.
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31215055 5-87
10. The next step is identical to the left front step men- 16. The next step is identical to the left front step men-
tioned above. Make sure the left rear wheel spindle is tioned above, make sure the right rear wheel spindle is
straight and press “ENTER” to accept the new calibration straight and press “ENTER” to accept the new calibration
settings, now press “ESC” (escape) and scroll to the right settings, now escape out of the calibration menu and
front steer calibration step. remove the Analyzer and pressure gauge.
11. Checking the right front steer cylinder is identical to the
procedure laid out for the left front steer cylinder, except Adjustments Made at the Platform Valve Bank
the pressures are now checked at MS3 port of the front PLATFORM LEVEL UP - 2500 PSI (172.3 BAR)
axle/steer valve. This should be at the right side of the
1. Install a high pressure gauge at the gauge port M1.
valve closest to the right front wheel spindle. Install the
gauge at MS3 port. Position the steer switch to activate 2. Activate level up to the end of stroke, it should read
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the right front steer cylinder until the rod is in the fully 2500 psi (172.3 Bar).
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retracted position and hold the steer switch for a few
3. All the relief valves are located on the same face. The
seconds after the rod has been fully retracted. If the
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level up relief valve is located closest to the M1 gauge
pressure is not 2600 psi (179 Bar), adjust the relief valve
port. Turn clockwise to increase, counterclockwise to
mounted next to the MS3 port CW to increase or CCW to
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decrease.
decrease.
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PLATFORM LEVEL DOWN - 1500 PSI (103.4 BAR)
12. Remove the gauge from MS3 port and install on MS4
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port, which is on the left side of the front axle/steer 1. Install a high pressure gauge at gauge port M2.
valve, closest to the left front wheel spindle. Position the
2. Activate level down to the end of stroke, it should read
or
steer switch to activate the right front steer cylinder
until the rod is in the fully extended position and hold 1500 psi (103.4 Bar).
the steer switch for a few seconds after the rod has
stopped extending. The MS4 port should read 2000 psi to
3. The level down relief valve is located to the left of the
level up relief valve. Turn clockwise to increase, counter-
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(138 Bar). If the pressure is not correct, adjust relief valve clockwise to decrease.
mounted next to the MS4 port CW to increase or CCW to
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decrease. ARTICULATING JIB UP AND DOWN - 2750 PSI (189.6 BAR)

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13. The next step is identical to the left front step men- 1. Install a high pressure gauge on gauge port M3. The jib
tioned above. Make sure the right front wheel spindle is relief valve is located below the level down relief valve.
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straight and press “ENTER” to accept the new calibration Activate jib up or down, it should read 2750 psi (189.6
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settings. Scroll over to right rear steer calibration step. Bar). Turn clockwise to increase, counterclockwise to
decrease.
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14. Checking the right rear steer cylinder is identical to the

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procedure laid out for the left rear steer cylinder. Install
gauge at MS4 port of the rear axle/steer valve. This
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should be at the right side of the valve closest to the

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right rear wheel spindle. Position the steer switch to acti-

vate the right rear steer cylinder until the rod is in the
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fully extended position and hold the steer switch for a

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few seconds after the rod has stopped extending. The

MS4 port should read 2000 psi (138 Bar. If the pressure is
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not correct, adjust relief valve next to the MS4 port CCW
to increase or CCW to decrease.
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15. Remove gauge from MS4 port and install on MS3 port,
which is on the left side of the rear axle/steer valve, clos-
est to the left rear wheel spindle. Position the steer
switch to activate the right rear steer cylinder until the
rod is in the fully retracted position and hold the steer
switch for a few seconds after the rod stops retracting. If
the pressure is not 2600 psi (179 Bar), adjust the relief
valve mounted next to the MS3 port CW to increase or
CCW to decrease.
5-88 31215055
5.6 DRIVE PUMPS (REXROTH) 2. Transmission does not propel the machine, diesel
engine running properly - Charge Pump/Relief Valve
Troubleshooting Procedure a. Is there any charge pressure at port G or indicated

by measuring pressure at Ma and Mb?
To aid in troubleshooting, refer also to the pressure measuring No - Proceed to step 2.d
port connections for test gauge installation information as Yes - Proceed to step 2.b
shown on the hydraulic circuit diagram. Procedure assumes
b. Is the charge pressure at least 500 psi while running
proper gauges are installed. (Minimum gauges required: (2) 0-
at high engine speed?
6000 psi, (1) 0-3000 psi & (1) 0-1000 psi [{2} 0-415 bar, {1} 0-210
No - Proceed to step 2.c
bar & {1} 0-70 bar]). This procedure was written to aid the trou-
Yes - Proceed to step 3.a
bleshooter in following a logical approach to a hydraulic sys-
c. Can the charge pressure be raised by removing dirt/
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tem fault.
debris from charge relief poppet or by adding or
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1. Transmission does not propel the machine, diesel removing shims from the charge pressure relief
engine running properly
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valve mounted in the second pump of the triple?
a. Is there oil in the reservoir? No - Proceed to step 2.d
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No - Fill reservoir Yes - Adjust pressure to 500 psi +50 psi, -0 psi (34.4
Yes - If yes, proceed to step 1.b bar +3.4 bar, -0 bar)
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b. Is the pump input shaft connected to the engine NOTE: The propulsion circuit uses a hot oil flushing valve to
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flex plate or rear of forward pump? obtain brake release pressure. The hot oil flushing valve
No - Connect pump input shaft cartridge (#120) is mounted in the Traction Control Mani-
or
Yes - If yes, proceed to step 1.c fold. The flushing valve receives its oil from the "left side"
c. Are the hydraulic hoses and tubing connected in wheel drive pump; the middle pump of the triple. With the
accordance with the hydraulic circuit diagram?
to engine running and propelling the machine forward or
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reverse, the "hot oil flushing valve" and the brake release
No - Correct the hoses/tubing pressure must be adjusted to 475 psi, +25 psi, -0 psi (32.7
Yes - If yes, proceed to step 1.d bar, +1.7 bar, -0 bar), as set by adjusting pressure relief car-
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d. Is the pump direction of rotation correct? (clockwise tridge (#130). The brake release pressure must be 25 psi less
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as looking at the shaft) than the charge pump pressure. Measure pressure at port
"MP" using a 0-1000 psi (0 - 70 bar) pressure gauge.
m
No - Fit pump having the correct direction of rota-

d. Is the transmission pumps suction hose pinched
ip
tion
shut?
qu
Yes - If yes, proceed to step 1.e

No - Proceed to step 2e
e. Are there "O"-rings missing from fittings (as exam-
-E
Yes - Repair damaged hose

ple - suction leak), pinched hoses, broken tubing,
e. Is the charge pump suction pressure/vacuum within
nt
etc?
recommended limits? (0.8 bar absolute or 6.3 inches
ou
of mercury)
No - Proceed to step 1.f
sc
Yes - Repair damage or fault

Yes - Proceed to step 2.g
Di
f. Are the electrical connectors/wiring intact and

f. Is the suction strainer inside the reservoir blocked,
secure to the pump control solenoids?
clogged, restricted?
to
No - Repair damage or fault

No - Proceed to step 2.g
Yes - If yes, proceed to step 1.g
Yes - Repair/replace with a clean suction strainer
Go
g. Does the engine "labor" when attempting drive, are

g. Is the reservoir air breather blocked or restricted?
the brakes released?
No - Proceed to step 2.h
No - Proceed to step 1.h
Yes - Clean or replace air breather
Yes - Check brake release circuit, measure pressure
at port "MP" on Traction Control manifold
h. Are all four wheel drive planetary reduction gear-
boxes engaged?
No - Engage wheel drive(s)
Yes - If yes, proceed to step 2.a
31215055 5-89
h. Remove charge pressure relief valve from the mid- f. Stroke pump in both directions, while measuring
dle pump and inspect. Is it damaged? pressure at Ma & Mb ports of the pump. Does any
No - Refit cartridge and proceed to step 2.i pressure greater than charge pressure alternate
Yes - Clean & inspect cartridge, poppet, springs, between ports Ma & Mb?
seals to determine cause of damage. Repair or fit a No - Verify that loading the pump will cause system
new cartridge and return to step 2.a pressure to increase above charge pressure. Proceed
i. Remove and inspect charge pump assemblies. Are to step 3.a
they damaged? Yes - Proceed to step 3.g
No - Proceed to step 2.j g. Is it possible to adjust high pressure relief valves
Yes - Repair and/or replace damaged components using 0-6000 psi (0 - 415 bar) gauges to monitor
and return to step 2.a pressure at Ma & Mb? (Refer to relief valve adjust-
ts
j. Is the charge pump installed for the clockwise rota- ment)
No - Replace high pressure relief valve and return to
ar
tion?
No - Refit charge pump. Return to step 2.a step 3.c
rp
Yes - With proper charge pressure and transmission Yes - Adjust high pressure relief valves to 5000 psi
still does not operate, proceed to step 3.a +50 psi, -0 psi (344.7 bar +3.4 bar, -0 bar)
ou
3. Transmission does not propel the machine, diesel h. Actuate control in both directions. Does transmis-
ry
engine running properly - Pump Control: (Insure Gener- sion operate?
ator Drive option is not turned "on") No - Check that minimum displacement stops on
de
the wheel drive motors are adjusted properly, check
a. Are the electrical connectors & wiring connected that the motors stroke between maximum to mini-
or
properly to the pump control solenoids? mum.
No - Connect a ammeter in series with solenoid wir- Yes - Operate the transmission
ing. Is a current of 400 mA to 1060 mA being
applied. (Current signal varies with joystick position) to
4. Transmission Drive is Sluggish or Erratic
om
Yes - Proceed to step 3.b a. Does the "EP" proportional pump control current
b. Are all four of the two-speed motors, mounted in vary with joystick movement?
t.c
the wheel drive planetary reduction gearboxes, No - Rectify the problem - broken wires, electrical
en
shifted to maximum displacement (high torque - connector, open solenoid coil, etc.
low speed)? Yes - Proceed to step 4.b
m
No - Select maximum displacement b. Are all four (4) brakes fully released?
ip
Yes - Proceed to step 3.c No - Check brake release pressure and insure each
qu
c. Actuate the pump control in both directions. Do the wheel receives correct release pressure.
pumps stroke? Do they go to full stroke? Yes - Proceed to step 4.c
-E
No - Refer to the pump service manual and then c. Are the pumps stroking time orifices installed tight
nt
proceed to step 3.d and clean?

Yes - Operate the transmission
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No - Remove the Plugs in ports X1 and X2. Remove

d. Remove stroking orifices in X1 and X2. Install pres- orifices with a 3mm allen wrench. Check that orifices
sc
sure gauges in X 1 and X 2 (0-500 psi [0 - 35 bar]). are clean & re-install.
Di
Stroke the pump in both directions. Do the pres- Yes - Proceed to step 4.d
sures at X1 and X2 alternate between 30 & 250 psi (2 d. Is an motor displacement stroking time orifice
to
& 17 bar)? plugged or is the two-speed shift hose pinched?

No - Remove the EP control module & replace it with Yes - Inspect and clean stroking orifice, check two-
Go
a new unit. Repeat step 3.c speed hose routing

Yes - Proceed to step 3.e. e. Is a flow divider/combiner cartridge stuck in the
e. Is the pressure at port "R", case pressure, less than 15 Traction Control Manifold? Flow divider/combiner
psi (1 bar) gauge pressure? cartridge # 111 controls the right side wheels, # 112
No - Correct problem restricting case drain oil flow controls the left side wheels. Also check to insure
(oil cooler blockage, pinched hoses, etc) bypass orifices #151 (right side) and # 152 (left side
Yes - Proceed to step 3.f are not plugged.
5-90 31215055
5. Transmission Drives in one direction only 7. Transmission Does Not Find or Hold Neutral
a. Are electrical connections to pump control propor- a. Does pump remain in neutral with electrical con-
tional solenoids correct, intact and without defects? nectors removed?
Yes - Proceed to step 5.b No - proceed to step 7.b
No - Rectify the problem Yes - Check electrical system for signal problem
b. Check hot oil flushing valve cartridge #120 located b. With electrical connectors removed and machines
in the Traction Control Manifold. wheels jacked off the ground and engine running,
Remove and inspect flushing valve cartridge for momentarily apply 12 volt DC signal (battery volt-
stuck spool or damaged cartridge "O"-ring seals & age) to a pump control solenoid. Does the pump
backup rings. return to neutral after the 12 volt signal is removed?
No - Apply 12 volts to opposite solenoid & recheck.
rts
c. Inspect "Make-Up" check valve cartridges, #190.1-
190.4, installed in the Traction Control Manifold. Is a No - Replace pump control module, repeat step 7.a
Yes - Possibly dirt was dislodged from control mod-
pa
cartridge "stuck" open with debris or is an "O"-ring
failed? ule, re-check thoroughly to determine problem has
definitely been resolved.
ur
No - Proceed to step 5.d
Yes - Clean/repair or replace Make-Up check car- c. Check mechanical centering of the pumps
yo
tridge. 8. Transmission Drives at a High Noise Level
d. Swap high pressure relief valves in the transmission.
r
a. Are the wheel drive planetary reduction gearboxes
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Does the transmission drive in the other direction? filled to the correct level and do they have the
No - Proceed to step 5.e
or
proper lubricant?
Yes - Repair/clean/adjust or replace high pressure No - Fill gearbox with correct grade of oil to the pre-
relief valve on the non-driving side
to
scribed level.
e. Replace "EP" control module. Does pump operate Yes - Proceed to step 8.b
om
properly? b. Is the engine flex plate and drive coupling correctly
No - Replace or repair pump installed and aligned with the transmission pump?
t.c
Yes - Operate the transmission No - Install flex plate and bell housing per manufac-
6. Transmission Drives in Wrong Direction turer's instructions
en
Yes - proceed to step 8.c

a. Check to see if electrical connectors or wiring have
m
been swapped on the pump. c. Is a rigid item or object contacting the resilient
ip
mounted engine/pump assembly?

b. Check to determine want end of the machine the No - Proceed to step 8.d
qu
boom is swung over. Yes - Insure no item is contacting the unit, transmit-
-E
ting air borne noise.

nt
d. Is the suction pressure/vacuum at the charge

pumps inlets within recommended limits?
ou
No - Return to step 1.h

Yes - Proceed to step 8.e
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e. Is there air in the hydraulic fluid? This may be indi-

Di
cated by foaming or milky colored oil.

to
Yes - Deaerate the oil and inspect system for cause

of air induction. Check for loose or missing "O"-rings
Go
on face seal connections.
31215055 5-91
f. Is a wheel drive hydraulic motor operating at exces- 11. Transmission Pump(s) Do Not Develop Maximum Horse-
sive speed? power (Flow & Pressure)
Yes - Check minimum displacement stop screw
adjustments on the motors. Should be 0.433" or a. Does the charge pump pressure meet specification?
11mm above the stop screw lock nut. Is one or more No - Return to step 2.a
motors "stuck" at minimum displacement, check for Yes - Proceed to step 11.b
plugged/blocked two-speed stroking orifice(s). b. Does the pump case pressure exceed 15 psi gauge
pressure?
9. Transmission Operates at a Higher than Normal Temper-
ature
Yes - Check case drain hoses, oil cooler, etc. for
a. Is the reservoir temperature above 195oF (90.5° C)? pinched or restricted oil flow
No - 195oF (90.5° C) is the upper limit. If temperature
ts
c. Are the pump(s) high pressure cross port relief
is over 195oF (90.5° C), the oil cooler may need to be valves adjusted to the required pressure (5000 psi)
ar
cleaned. so they do not bypass prematurely?
rp
Yes - Proceed to step 9.c No - Inspect/clean/adjust and or replace valve car-
tridge
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b. Are the hydraulic motor(s) stalling (wheels not turn-
Yes - Replace the pump, after blocking the "A" & "B"
ing) intermittently?
ports, running the pump and measuring pressure
ry
developed at "A" & "B". This must be done to insure
Yes - Hydraulic fluid is being heated through system
de
that flow & pressure loss in not elsewhere in the sys-
pressure relief valves. Shut down system and rectify
tem. (motors, swivel coupling, etc)
the cause of motor stall.
or
d. Is the diesel engine capable of developing horse-
c. Does oil temperature remain above 195oF (90.5° C), power at design rpm?
after cleaning the oil cooler?
No - Operate transmission. Check oil cooler more to Follow recommended troubleshooting procedures
to insure the engine is developing full power at
om
often. specified rpms.
Yes - Proceed to step 8.a
t.c
10. Transmission Operates at a Higher than Normal Temper- Charge Pressure Relief Valve Adjustment
en
ature
a. Check for differential temperature across the oil
m
cooler. Is there a temperature difference?

ip
No - Check to determine if the bypass check valve

qu
(10 psi [0.7 bar] crack pressure) is stuck open. Check

to determine if the oil cooler is restricted internally,
-E
causing oil flow to pass across the bypass check

nt
valve.
Yes - Proceed to step 8.b
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NOTE: Oil cooler flow is received from the transmission pumps

cases, max. continuous pump case pressure is 15 psi gauge
Di
pressure. Higher pressure will prematurely damage pump

shaft seals CHARGE RELIEF
to
b. Disconnect pump case drain from oil cooler & check With a low pressure (0 – 1000 psi [0 - 70 bar]) pressure gauge
Go
flow rate from charge pumps. Is the flow rate 3.8 tee’d into the ”G” port or two (2) low pressure gauges installed
GPM (14.4 LPM) with diesel idle speed of 1200 rpm? into ”Ma” and ”Mb”, run pump at engine idle speed. Do not
No - Refer to charge pump removal & inspection place the pump on stroke – low pressure gauges installed in
procedure ”Ma” & ”Mb” will be damaged! Prior to adjusting pressure,
insure charge pressure relief valve is clean of any dirt or debris.
The charge pressure relief valve does not wear appreciably
over time. If charge pressure was normal and then has
decayed, check for other causes of low charge pressure. If pres-
sure is low, remove relief valve and add shim(s). If pressure is
high, remove relief valve and take out shim(s).
5-92 31215055
NOTE: Shim thickness 1 mm = 56 psi (3.86 bar). Shims are avail- Hydraulic Centering of Control Modules
able in 0.3, 0.5, and 1.0 mm thickness.
PREPARATION FOR ADJUSTMENT
When control modules are exchanged or replaced, it is gener-
ally necessary to center the new module. This is done by run-
ning the pump with gauges installed at ports X1, X2, MA, and
MB Release the jam nut and turn the adjustment screw on top
of the control module valve body.
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Mechanical Centering of Pump
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PREPARATION FOR ADJUSTMENT
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The control piston has strong centering springs to ensure that
ry
once the pump is adjusted for the neutral position it will
always return to neutral. If an adjustment is necessary follow
de
the steps listed below.
To ensure there is equal pressure on both sides of the control
or
module during the centering operation, it is necessary to con-
to
nect the X1 and X2 ports together by means of hose or tubing.
(No less than a 1/4 inch ID) The port sizes are:
om
Pump Size Allen Wrench Wrench
t.c
28 5 mm 17 mm
en
With pressure gages installed at MA, and MB, and with A and B
The adjustment screw is an eccentric, therefore, turning more
m
ports blocked (or motor stalled), and with the pump running,
loosen the jam nut. Turn the mechanical centering adjusting than 90’ in either direction will have no further centering
ip
screw until 1000 psi is read on MA, or MB then turn screw effect, and could cause damage to the eccentric pin.
qu
opposite direction until 1000 psi is read on other pressure Pump Size Tool Required Wrench
port. Turn the screw back, splitting the distance between the
-E
28 Screwdriver 10 mm
previous two positions. This should be the neutral position.
nt
Pressure on MA, and MB should be equal.

CENTERING THE EP CONTROL MODULE
ou
With no electrical signal to solenoids A and B, (remove both

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plug-in connectors), the EP control module is correctly

Di
adjusted when any or all of the following conditions exist:

1. Approximately, when equal control pressures are
to
obtained at control pressure ports X1 and X2.

Go
2. The hydraulic motor does not turn when the brake is

released.
3. Charge pressure is registered equally at ports MA and
MB, when the flow output of the pump is deadheaded
against a locked motor or a valve.
Tighten jam nut, stop the pump drive, remove the hose con-
necting ports X1 and X2.
31215055 5-93
If difficulties are encountered in obtaining neutral position of Removal and Inspection of Charge Pump
the HD or EP control modules, check that the ends of the con-
trol spring are correctly located in the grooves near the end of Before removing cap screws, mark the position of the charge
the feedback lever arms. pump housing and separator plate in relation to the port
block.
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pa
ur
High Pressure Relief Valve Adjustments
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Loosen screws with metric allen wrench.
1. Remove relief valve cover from pump (ref. item 1).
r
Pump Size Allen Wrench
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28 8 mm
or
to
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t.c
en
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2. Loosen jam screw (ref. item 2).

-E
3. Holding spring loading nut (ref. item 4) rotate valve

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spindle (ref. item 3). For high range relief valve, one turn
ou
equals approximately 630 psi (44 bar). For low range

relief valve, one turn equals approximately 377 psi (26
sc
bar). Remove charge pump housing and inspect for wear or dam-
Di
4. After adjustment is completed torque jam screw (ref. age to gear set and 0-ring seals. Grease 0-rings prior to reas-
item 4) to 5 ft.lb. (7 Nm). sembly. Make sure 0-rings are completely seated in their
to
grooves.
5. Install relief valve assembly into pump, reinstall cover
Go
(ref. item 1) to proper torque.

Table 5-37. Torque Specs for Relief Valves into Port Block
Pump Size Wrench Size Torque

28 32 mm 66 ft.lb. (90 Nm)
5-94 31215055
Routine Maintenance
The Variable Displacement Hydrostatic Transmission Pumps
are relatively maintenance free. Maintenance work is confined
to the system, by way of maintaining hydraulic fluid condition,
the "life blood" of the machine. Oil monitoring, changes and
filter renewal promote system cleanliness. This will prevent
premature breakdown and repairs. Under normal application
conditions, the following maintenance intervals are sug-
gested:
1. Renewal of Filter Elements
ts
a. After commissioning or re-build.
ar
b. At every 500 operating hours or when filter indica-
rp
tor shows a dirty element.
c. With the suction strainer, the strainer should be
ou
renewed as soon as charge pump inlet pressure is
less than -3.2 psi, 6.3"Hg or 0.8 bar absolute.
ry
d. Only JLG recommended filter elements are to be
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Withdraw pinion shaft and inspect gear teeth and bearing sur- used. Paper elements cannot be cleaned; use throw-
faces for abnormal wear. away cartridges.
or
When reassembling, make sure chamfer (on outer edge of 2. Hydraulic Fluid Change
driven gear and drive gear) is installed into housing per illus-
tration.
to a. After 2000 operating hours (1st oil change)
om
b. Thereafter, every 2000 operating hours or annually,
irrespective of operating hours achieved.
t.c
c. Oil change should be performed with the system in

warm running condition. Before re-filling, the reser-
en
voir interior should be inspected and cleaned to

m
remove any sludge.

ip
d. Rags or threaded material must not be used.

qu
e. This machine has been designed & manufactured to

operate on an Exxon-Mobil Oil Co. hydraulic fluid,
-E
Mobilfluid #424, Product #52233-4. Consult JLG

nt
Industries prior to introducing any other type of

fluid to prevent interaction or possible contamina-
ou
tion.
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Torque value for bolts when replacing charge pump. f. The recommended interval between oil changes is
based on various factors and should be carried out
Di
Pump Size Torque according to the degree of aging, contamination

and water content.
to
28 18 ft.lb. (24 Nm)

g. Under application conditions with a heavy occur-
Go
NOTE: If serious wear or damage has occurred to one component, rence of dust or severe temperature fluctuations,
the complete charge pump assembly must be replaced the intervals between fluid maintenance should be
because they are matched components. shortened accordingly.
31215055 5-95
5. Oil Level Inspection

a. Inspect oil level in the reservoir daily.
PRACTICAL EXPERIENCE SHOWS THAT MOST FLUID MAINTENANCE ERRORS
OCCUR DURING AN OIL CHANGE DUE TO: b. If "topping off" is required, use only the same Mobil-
fluid #424, Product #52233-4.
• USE OF AN UNSUITABLE HYDRAULIC FLUID c. Do Not Mix Fluids.
• USE OF OIL CONTAMINATED DUE TO POOR STORAGE PRACTICES 6. Hydraulic Fluid - The "Life Blood" of the Machine
• FAILURE TO CLEAN THE RESERVOIR a. The type of hydraulic fluid supplied in the machine
from the factory was selected after extensive testing
• INADEQUATE CLEANLINESS WHEN FILLING THE RESERVOIR (DIRTY and development. The fluid was selected to perform
DRUMS, CONTAINERS, WATER, ETC) under "most" applications and conditions. Should
ts
3. Leakage Inspection this machine be in service for extended time peri-
ar
ods at the extremes (hot or cold), JLG should be con-
a. After commissioning
sulted for assistance in selection of the most
rp
b. The complete transmission drive system (pumps, suitable fluid type and grade for your application.
motors, hosing, filters, valves, etc) should be
ou
checked for leakage at regular intervals. b. When operating at temperatures below 0oF, allow a
warm-up period, if at all possible, to a temperature
ry
c. Leaking joints & connections must only be tight-
ened when pressureless. of 40oF.
de
4. Cleanliness Inspection c. When beginning motion of a "cold" machine, oper-
ate all functions at reduced speeds until the "cold"
or
a. The oil tank breather should be regularly cleaned of oil has circulated out of the drive loop.
dirt and dust to prevent clogging. With each cylin-
der movement, gallons of oil pumped, an equal
amount of air exchange occurs across the reservoir to
om
breather. A dirty or clogged breather will affect all
machine functions!
t.c
b. The air/oil cooler surfaces and engine radiator

en
should be cleaned at the same time.

c. If hose connections are disassembled, it is impera-
m
tive that the utmost care be taken that no foreign

ip
bodies infiltrate the oil circuit. Catastrophic compo-

qu
nent failure may occur.

-E
nt
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Di
to
Go
5-96 31215055
Removal and Installation of Shaft Seal Press in shaft seal with bushing to the stop. Then replace snap
ring.
Remove the retaining ring with snap ring pliers.
rts
pa
ur
r yo
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Screw in sheet metal screw into the holes fitted with rubber.
Pull out shaft seal with pliers.
or
to
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t.c
en
m
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-E
nt
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Di
to
Go
31215055 5-97
5.7 FUNCTION PUMP (REXROTH)
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rp
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or
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t.c
en
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Figure 5-61. Function Pump - Sectional View

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Spare Parts 2. Drive Shaft

-E
1. Sealing kit, existing spare parts: shaft sealing ring, o-

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rings, and a circlip.

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sc
Di
to
Go
3. Bearing set, miscellaneous parts.
5-98 31215055
4. Rotary Group complete: 9 pistons, cylinder subassem- Sealing the Drive Shaft
bly, valve plate, retaining plate, and retaining ball.
BE VERY CAREFUL SO THE DRIVE SHAFT IS NOT DAMAGED DURING THE

REMOVAL OF THE SHAFT SEALING RING.
1. Remove the snap ring.
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5. Swash Plate.
rp
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ry
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2. Change the shaft seal and check its’ sliding surface
(drive shaft) and housing. Grease the sealing ring.
or
to
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6. Parts of the control valve: control piston, piston rod,
plug, spring stopper max flow, hex nut, and hex head
t.c
nut.
en
m
ip
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3. Be careful while you seal the drive shaft. Use an adhesive

tape to prevent the shaft splines from damaging the
-E
seal.
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sc
7. DFR pilot valve.

Di
to
Go
31215055 5-99
4. Assemble the sealing ring, fitting tool holds the correct 2. Mark the position of the port plate and remove the
position of the sealing ring in the pump housing. socket screw of the port plate.
ts
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5. Assemble the snap ring. 3. Remove the port plate together with the valve plate
rp
(hold the valve plate so the plate can’t fall down).
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ry
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or
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6. Assemble the snap ring in the correct position.

t.c
4. Remove the o-ring.

en
m
ip
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-E
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sc
Disassembly and Assembly of the Complete Unit 5. Disassemble the taper roller bearing (nearby port plate).
Di
1. Disassemble the pilot valve.

to
Go
5-100 31215055
6. Remove the adjustment shim. 10. Disassemble the rotary group in horizontal position.
ts
ar
7. Unscrew the cap nut and remove it. 11. Disassemble the stopper max flow.
rp
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ry
de
or
to
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8. Loosen the fixing nut of the stopper max flow and disas- 12. Remove the threaded pin.
semble it.
t.c
en
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-E
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13. Disassemble the plug.

9. Turn in the stopper max flow to get swivel angle zero.
sc
Di
to
Go
31215055 5-101
14. Disassemble the control piston while moving the swash 18. Remove both bearing shells.
plate.
ts
ar
19. Remove the drive shaft.
15. The swash plate must be lifted a little bit to disassemble
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the piston rod.
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ry
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or
to
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20. Disassemble the snap ring.
t.c
16. Remove the swash plate.

en
m
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-E
nt
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21. Disassemble the sealing ring.

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17. Remove the spring.

Di
to
Go
5-102 31215055
22. The external front bearing ring is pulled out of the pump 25. The spring has additional pretension while you disas-
housing. semble the three pressure pins inside the cylinder.
ts
ar
23. Remove the o-ring. Lifting of the valve plate isn’t shown.
rp
Assembly
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1. Measurement of the taper roller bearing pretention.
ry
de
or
to
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24. A bearing puller is used to disassemble the external

t.c
bearing ring of the taper roller bearing inside the port

en
plate. Take care of the surface of the port plate. 2. Ensure there is a correct connection of the piston rod
and the swash plate.
m
ip
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-E
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to
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31215055 5-103
3. Pumps clockwise driven must have a position of the Adjustments

valve plate 4 degrees out of center in the same direction
TAPER ROLLER BEARING INITIAL TENSION
decentered like drive direction.
Cast Iron pump housing must have initial tension of the bear-
ings: 0 to 0.05 mm.
rts
pa
4. Pumps counterclockwise driven must have a position of
ur
the valve plate 4 degrees decentered in the ccw posi-
yo
tion.
r
de
or
to
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MECHANICAL FLOW LIMITER
t.c
Differential volume if you are rotating the threaded pin - each

rotation is approximately 3.1 cm3.
en
5. Note the correct position of the drilling that connects

Tightening Torques
m
high pressure to the control valve. Check control valve

ip
drilling position at the pump housing and fit together. For break-off plugs, use High Strength Anaerobic Retaining
Compound.
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For all other parts, use Medium Strength Threadlocking Com-

-E
pound.
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Table 5-38. Tightening Torques

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M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

Di
8.8 2.3 5.0 8.5 21 41 72 115 176 240 350 600 1220
10.9 3.2 7.2 12 29 58 100 165 250 350 490 840 1670
to
12.9 4.1 8.5 14.5 35 70 121 195 300 410 590 990 2000
Go
5-104 31215055
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rp
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or
Figure 5-62. Function Pump, Pressure and Flow Control - Sheet 1
to
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t.c
en
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31215055 5-105
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rp
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or
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t.c
en
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-E
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Pump Control Disassembly For Cleaning 3. Hydraulic fluid may drip from the pump. Wiping the sur-
face clean and installing some adhesive tape should pre-
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NOTE: If the Function Pump does not perform correctly after

vent oil from seeping from the pump control.
following the pre-start start-up procedures, it is possible that a
sc
contaminate particle has lodged in the pump control prevent- 4. Work on a clean, lint free area.
ing proper operation. The pump control’s internal parts are
Di
not provided as spare parts due to the close tolerances NOTE: The pump control can be equipped with either O-rings or a
sealing plate. These components are NOT interchangeable.
to
required between the mating parts. However, the control can

be disassembled, cleaned and placed back in service should 5. Remove the three (3) ”0”-rings (Parker # 2-011, Viton 90
Go
the only problem prove to be contamination. Disassembly, shore)

inspection, cleaning and reassembly MUST BE done in a clean
well-illuminated area. 6. Remove both the adjustment hex caps and bonded seal
rings. (17 mm wrench)
Pump Control removal:
7. Remove both the adjustment lock nuts and bonded seal
1. Disconnect plug the hose attached to the pump control rings. (17 mm wrench)
Port ”X”.
8. Remove both the adjusting screws. (3-mm Allen
2. Remove the four (4) socket head cap screws that attach wrench)
the control to the pump. Insure that the three (3) ”0”-
rings are also removed with the control.
5-106 31215055
9. Remove the spring cover hex cap for the ”outer” flow 21. Inspect the housing for contamination or plugged ori-
regulation adjustment this requires a 19-mm wrench. fices. Clean orifices carefully with a dead soft steel wire
to insure they are open. Inspect all parts for burrs, scor-
10. Remove the spring disc.
ing, debris, etc.
11. Remove the adjusting springs (two springs, one
NOTE: On the mounting surface of the control housing, between
”nested” inside the other) and spring follower.
the oil ports is what appears to be a slotted head screw. IT
12. The flow regulation spool should slide from the control IS NOT A SCREW. This is a bleed orifice, which must be ori-
housing, (a magnet should aid in removal). If it does not, entated to allow proper control operation. The slot in the
remove the hollow hex head plug at the rear of the flow head should be oriented to fall in-line with the oil ports,
regulation spool and carefully push the spool from the NOT PERPENDICULAR to the oil ports. If the slot is oriented
housing - do not scratch/mar the spool’s bore. perpendicular to the three ports, the pump pressure will
ts
not return from load pressure to stand-by pressure at the
13. Remove the spring cover hex cap for the ”inner” pres-
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end of operating a function! The pump pressure will
sure compensation adjustment – this requires a 30-mm
remain at the last highest pressure generated.)
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wrench.
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14. Remove the spring disc. 22. After all parts are clean and dry, lightly oil a control
spool and install in its bore. The spool must slide
15. Remove the adjusting springs (two springs, one
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smoothly and easily within the housing. If it does not,
”nested” inside the other). check for contamination. If contamination cannot be
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16. Remove the spring follower. found check for ”scoring” or ”burring” of the control
housing. If the spool does not slide smoothly & freely,
or
17. The pressure compensation spool should slide from the the control must be replaced with a new unit.
control housing, (a magnet should aid in removal). If it
does not, remove the hollow hex head plug at the rear
of the flow regulation spool and carefully push the spool to23. Lightly oil and check operation of the second spool. The
spools are installed correctly when there ”pointed” end
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from the housing - do not scratch/mar the spool’s bore. faces the spring followers
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18. The spools are identical. 24. Re-assemble in reverse order.

25. Bench set the pressure adjustments as described in ”C.
en
19. Wash the housing and all parts in a clean JLG approved
solvent such as non-chlorinated brake cleaner, Stoddard 4” of the Operating Instructions.
m
solvent, etc.
NOTE: The pump control can be equipped with either O-rings or a
ip
20. Blow off all the parts with clean, dry compressed air. sealing plate. These components are NOT interchangeable.
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26. Re-install on the Function Pump, insure the ”0”-rings are

-E
installed properly and tighten the four (4) M6 socket

head cap screws to 105 inch pounds.
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31215055 5-107
5.8 DRIVE PUMPS (SAUER)
Electric displacement control Electric displacement control
Servo piston Servo piston
Swashplate feedback pin Swashplate feedback pin

Valve plates
Piston
Piston
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Slipper
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Slipper Front shaft bearing
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Rear shaft bearin
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Shaft seal
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Rear shaft
to Front shaft
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Swashplate bearing Shaft coupling Swashplate bearing
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Swashplate Center shaft bearings Swashplate

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Cylinder block Cylinder block

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Figure 5-65. Piston Pump Cross Sectional View

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Port Locations and Gauge Installation

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Table 5-39. Port Information

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Port identifier Port size Wrench size Reading Gauge size, bar [psi]
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L1, L2, L3 1 1/16-12 UNF 2B 9/16 internal hex Case drain 10 bar [100 psi]
Di
MA, MB, MC, MD 9/16-18 UNF 1/4 internal hex System pressure 600 bar [10,000 psi]
to
M3 9/16-18 UNF 2B 1/4 internal hex Charge pressure 50 bar [1000 psi]
Go
M4, M5 7/16-20 UNF 2B 3/16 internal hex Servo pressure 50 bar [1000 psi]
X7 9/16-18 UNF 2B 1/4 internal hex Brake pressure 50 bar [1000 psi]
5-108 31215055
Servo gauge port M5 Charge inlet port E

ISO 11926-1 - 7/16-20 ISO 11926-1 - 1 5/16-12
Case drain port L3 Servo gauge port M4
ISO 11926-1 - 1 1/16-12 ISO 11926-1 - 7/16-20
Case drain port L1

ISO 11926-1 - 1 1/16-12
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System port B
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System port C ISO 11926-1 - 1 5/16-12
ISO 11926-1 - 1 5/16-12
or
System port D System port MD
ISO 11926-1 - 1 5/16-12 ISO 11926-1 - 9/16-18
System port A
ISO 11926-1 - 1 5/16-12 toSystem gauge port MA
ISO 11926-1 - 9/16-18
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Figure 5-66. Port Locations - Sheet 1 of 2

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31215055 5-109
System gauge port MB System gauge port MC

ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18
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Brake gage port X7
Charge constr port M3
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ISO 11926-1 - 9/16-18
ISO 11926-1 - 9/16-18
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or
Servo gauge port M5 Servo gauge port M4
ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
to
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Charge pressure gauge port M3

ISO 11926-1 - 9/16-18
to
Case drain port L2

ISO 11926-1 - 1 1/16-12
Go
Figure 5-67. Port Locations - Sheet 2 of 2
5-110 31215055
Initial Startup Procedures tions and listen for cavitation. Check for proper fluid
level in reservoir.
Follow this procedure when starting-up a new pump or when
restarting a pump that has been removed. Ensure the pump is 9. When adequate charge pressure is established (as
thoroughly tested on a test stand before installing. shown in model code), increase engine speed to normal
operating rpm to further purge residual air from the sys-
Prior to installing the pump, inspect for damage that may have tem.
occurred during shipping.
10. Shut the off engine. Connect the pump control signal.
1. Ensure that the machine hydraulic oil and system com- Start the engine, checking to be certain the pump
ponents (reservoir, hoses, valves, fittings, and heat remains in neutral. Run the engine at normal operating
exchanger) are clean and free of any foreign material. speed and carefully check for forward and reverse con-
trol operation.
rts
2. Install new system filter element(s) if necessary. Check
that inlet line fittings are properly tightened and free of 11. Continue to cycle between forward and reverse for at
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air leaks. least five minutes to bleed all air and flush system con-
taminants out of the system loop.
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3. Install the pump. Install a 50 bar [1000 psi] gauge in the
charge pressure gauge port M3. NOTE: Normal charge pressure fluctuation may occur during for-
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4. Fill the housing by adding filtered hydraulic fluid to the ward and reverse operation.
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upper case drain port. If the controls are installed on top,
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open the construction plugs in the top of the controls to 12. Check that the reservoir is full. Remove charge pressure
assist in air bleed. gauge and cap port. The pump is now ready for opera-
or
tion.
5. Fill the reservoir with hydraulic fluid of the recom-
mended type and viscosity. Use a 10-micron filler filter.
Ensure construction plug is closed after filling is com- to
Troubleshooting
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plete.
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6. Disconnect the pump from all control input signals. HIGH INLET VACUUM CAUSES CAVITATION WHICH CAN DAMAGE INTERNAL
PUMP COMPONENTS.
en
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AFTER START-UP THE FLUID LEVEL IN THE RESERVOIR MAY DROP DUE TO
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SYSTEM COMPONENTS FILLING DAMAGE TO HYDRAULIC COMPONENTS MAY

OCCUR IF THE FLUID SUPPLY RUNS OUT. ENSURE RESERVOIR REMAINS ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN HAVE
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FULL OF FLUID DURING START-UP. SUFFICIENT FORCE TO PENETRATE YOUR SKIN CAUSING
SERIOUS INJURY AND/OR INFECTION AND MAY BE HOT
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ENOUGH TO CAUSE BURNS. RELIEVE PRESSURE IN THE

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SYSTEM BEFORE REMOVING HOSES, FITTINGS, GAUGES,

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AIR ENTRAPMENT IN OIL UNDER HIGH PRESSURE MAY DAMAGE HYDRAU- OR COMPONENTS. SEEK IMMEDIATE MEDICAL ATTENTION
LIC COMPONENTS. CHECK CAREFULLY FOR INLET LINE LEAKS. IF YOU ARE CUT OR BURNED BY HYDRAULIC FLUID.
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CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS. TAKE PRECAU-

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DO NOT RUN AT MAXIMUM PRESSURE UNTIL SYSTEM IS FREE OF AIR AND TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND REIN-
FLUID HAS BEEN THOROUGHLY FILTERED. STALLING SYSTEM COMPONENTS AND LINES
Go
7. Use a common method to disable the engine to prevent

it from starting. Crank the starter for several seconds. Do
not to exceed the engine manufacturer’s recommenda-
tion. Wait 30 seconds and then crank the engine a sec-
ond time as stated above. This operation helps remove
air from the system lines. Refill the reservoir to recom-
mended full oil level.
8. When the gauge begins to register charge pressure,
enable and start engine. Let the engine run for a mini-
mum of 30 seconds at low idle to allow the air to work
itself out of the system. Check for leaks at all line connec-
31215055 5-111
Table 5-40. Electrical Troubleshooting
Item Description Action

Control operates pump in one direction only Control coil failure. Measure resistance at coil pins. Resistance
should be 14.2W (24V) or 3.66W (12V) at 20° C
[70° F]. Replace coil.
No pump function No power to controller. Restore power to controller.
Erratic pump function Electrical connection to pump is bad. Disconnect connection, check wires, recon-
nect wires.
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Erratic or no machine function External controller malfunction or Verify external controller problem using spare
hydraulic system problem. controller. Replace controller. Check hydraulic
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system fluid level/pressures/filters/etc. Fix
hydraulic system problems.
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ry
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Table 5-41. Neutral Difficult or Impossible to Find
or
to
Input to pump control Input to control module is operating Disconnect input and check to see if pump comes back to neu-
improperly. tral. If Yes, input fault, replace/repair external controller. If No,
om
go to next step.
Pump control neutral Neutral set improperly. Shunt servo gauge ports M4 and M5 together with external
t.c
hose and see if pump comes back to neutral. If Yes: control neu-
tral improperly set. If no: balance swashplate (see Mechanical
en
neutral adjustment). If you still cannot set neutral, replace con-

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trol.
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Table 5-42. System Operating Hot

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Oil level in reservoir Insufficient hydraulic fluid will not meet cooling Fill reservoir to proper level.
demands of system.
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Heat exchanger Heat exchanger not sufficiently cooling the system. Check air flow and input air temperature for heat
Di
exchanger. Clean, repair or replace heat exchanger.

to
Charge pressure Low charge pressure will overwork system. Measure charge pressure. Inspect and adjust or
replace charge relief valve. Inspect charge pump.
Go
Repair or replace charge pump.

Charge pump inlet vacuum High inlet vacuum will overwork system. A dirty fil- Check charge inlet vacuum. If high, inspect inlet filter
ter will increase the inlet vacuum. Inadequate line and replace as necessary. Check for adequate line
size will restrict flow. size, length or other restrictions.
System relief pressure settings If the system relief valves are worn, contaminated, or Verify settings of high pressure relief valves and
valve settings are too low, the relief valves will be replace valves as necessary.
overworked.
System pressure Frequent or long term operation over system relief Measure system pressure. If pressure is too high,
setting will create heat in system. reduce loads.
5-112 31215055
Table 5-43. System Will not Operate

Oil level in reservoir Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level.
Control orifices Control orifices are blocked. Clean control orifices.
Control screens Control screens are blocked. Clean or replace control screens.
Charge pressure with pump in neutral Low charge pressure insufficient to recharge sys- Measure charge pressure with the pump in neu-
tem loop. tral. If pressure is low, go to next step.
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Pump charge relief valve A pump charge relief valve that is leaky, contami- Adjust or replace pump charge relief valve as nec-
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nated, or set too low will depressurize the sys- essary.
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tem.
Charge pump inlet filter A clogged filter will under supply system loop. Inspect filter and replace if necessary.
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Charge pump A malfunctioning charge pump will provide Repair or replace the charge pump.
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insufficient charge flow.
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System pressure Low system pressure does not provide enough Measure system pressure. Continue to next step.
power to move load.
or
Charge check / HPRVs Defective charge check / HPRVs cause system Repair or replace charge check / HPRVs.
to
pressure to be low.
Input to control Input to control module is operating improperly. Repair or replace control.
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Optional control cutoff valve Control cutoff valve coil not energized. Ensure charge pressure to control via port X7. If
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none, confirm control cutoff valve coil is ener-

gized. If still no pressure, repair or replace control
en
cutoff valve.
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Table 5-44. System Noise or Vibration

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Reservoir oil level Low oil level leads to cavitation. Fill reservoir.
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Aeration of the oil/pump inlet vacuum Air in system decreases efficiency of units and con- Find location where air is entering into the system
trols. Air in system is indicated by excessive noise in and repair. Check that inlet line is not restricted and
sc
pump, foaming in oil, and hot oil. is proper size.

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Cold oil If oil is cold, it may be too viscous for proper function Allow the oil to warm up to its normal operating
and pump cavitates. temperature with engine at idle speed.
to
Pump inlet vacuum High inlet vacuum causes noise/cavitation. Check that inlet line is not restricted and is proper
Go
size. Check filter and bypass switch.

Shaft couplings A loose input shaft to prime mover coupling will Replace loose shaft coupling.
cause excessive noise.
Shaft alignment Misaligned input and prime mover shafts create Correct misalignment.
noise.
Charge/system relief valves Unusual noise may indicate sticking valves. Possible Clean/replace valves and test pump. May be a nor-
contamination. mal condition.
31215055 5-113
Table 5-45. Sluggish System Response

Oil level in reservoir Low oil level will cause sluggish response. Fill reservoir.
Charge check / HPRVs Incorrect pressure settings will affect system Replace charge check / HPRVs.
reaction time.
Low prime mover speed Low engine speed will reduce system perfor- Adjust engine speed.
mance.
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Charge and control pressures Incorrect pressures will affect system perfor- Measure and adjust charge and control pres-
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mance. sures.
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Air in system Air in system will produce sluggish system Fill tank to proper level. Cycle system slowly for
response. several minutes to remove air from system.
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Contaminated control orifices Control orifices are plugged. Clean control orifices.
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Contaminated control screens Control screens are plugged. Clean or replace control screens.
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Pump inlet vacuum Inlet vacuum is too high resulting in reduced Measure charge inlet vacuum. Inspect line for
system pressure. proper sizing. Replace filter. Confirm proper
or
bypass operation.
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5-114 31215055
Adjustments NOTE: Listed pressures assume a pump speed of 1800 min-1 (rpm)
and charge flow of 26.5 l/min [7 US gal/min]. At higher
pump speeds or higher charge flows the charge pressure
will rise over the rated setting.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS AND VOID YOUR
WARRANTY. TAKE PRECAUTIONS TO ENSURE SYSTEM CLEANLINESS WHEN 3. Loosen the locknut and rotate the adjusting screw
REMOVING AND REINSTALLING SYSTEM LINES clockwise to increase the setting; counterclockwise to
decrease it. Subtract the case pressure reading to com-
1. Thoroughly clean the outside of the pump. pute the actual charge pressure.
2. If removing the pump, tag each hydraulic line. When you NOTE: Pressure change per turn is dependent on charge flow
disconnect hydraulic lines, cap them and plug each entering pump.
ts
open port to prevent contamination.
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4. While holding the adjusting screw, torque locknut to 12
3. Ensure the surrounding area is clean and free of contam-
Nm [9 lbft].
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inants like dirt and grime.
5. When you achieve the desired charge pressure setting,
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4. Inspect the system for contamination.
remove the gauges and plug the ports.
5. Check the hydraulic fluid for signs of contamination: oil
ry
discoloration, foam in the oil, sludge, or metal particles. DISPLACEMENT LIMITER ADJUSTMENT
de
6. If there are signs of contamination in the hydraulic fluid, 1. Mark servo cylinder location in case it rotates during dis-
replace all filters and drain the hydraulic system. Flush placement limiter adjustment.
or
the lines and refill the reservoir with the correct filtered
2. Loosen the locknut (E550).
to
hydraulic fluid.
7. Before reinstalling the pump, test for leaks.
om
CHARGE PRESSURE RELIEF VALVE.

t.c
1. Install a 50 bar [1000 psi] pressure gauge in charge pres-

en
sure gauge port M3. Install a 10 bar [100 psi] gauge at

case pressure port L1, L2, or L3. Operate the system with E450
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4 mm
the pump in neutral (zero displacement) when measur-
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ing charge pressure.

E550
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2. The table below shows the acceptable pump charge 13 mm

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pressure range for some nominal charge relief valve set- 23 N•m
tings (refer to model code located on serial number [17 lbf•ft]
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plate). These pressures assume 1800 min-1 (rpm) pump

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speed and a reservoir temperature of 50°C [120°F], and 3. Rotate the adjusting screw (E450) based on the follow-
are referenced to case pressure. ing table. Rotating the adjusting screw clockwise
sc
decreases the maximum displacement of the pump

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while rotating the adjusting screw counterclockwise

increases the maximum displacement.
to
Charge pressure gauge port M3

Go
0 - 50 bar [0 - 1000 psi]

1/4 in
24 N•m [17 lbf•ft]
Locknut Case drain port L2

19 mm
12 N•m 0 - 10 bar [0 - 100 psi]
[9 lbf•ft] 9/16 in
115 N•m [85 lbf•ft]
Adjusting screw
5 mm
Figure 5-68. Charge Pressure Adjustment
31215055 5-115
4. After establishing the desired maximum displacement 3. Observe pressure gauges. If necessary, turn adjusting
setting, hold adjusting screw in place and tighten the screw to reduce any pressure differential.
locknut. Torque to 23 Nm [17 lbft]. C
NOTE: Adjustment of the EDC is very sensitive. Be sure to hold the
hex wrench steady while loosening the locknut. Total
adjustment is less than 120 degrees.
BE SURE SERVO CYLINDER DOES NOT ROTATE WHEN DISPLACEMENT LIM-
ITER LOCKNUT (E550) IS TORQUED. 4. Rotate the neutral adjusting screw clockwise until the
pressure increases on the gauge. Note the angular posi-
5. One turn of the adjusting screw will change the maxi- tion of the wrench. Then rotate the neutral adjusting
mum displacement approximately as follows. screw counterclockwise until the pressure increases by
an equal amount on the other gauge. Again note the
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Table 5-46. Displacement Limiter Adjustment Data angular position of the wrench.
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Approximate Solenoid shaft
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displacement Control spool
Locknut wrench Adjusting screw
Displacement change per
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size and torque size
revolution of
adjusting screw
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45 13 mm 23 Nm [17 lbft] 4 mm internal hex 5.1 cc / turn
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CONTROL NEUTRAL ADJUSTMENT
All functions of the Electric Displacement Control (EDC) are
preset at the factory. Adjust the pump to neutral with the
pump running on a test stand or on the vehicle/machine with to
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the prime mover operating. If adjustment fails to give satisfac-
tory results, you may need to replace the control or coils. Adjusting
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screw
1. Install a 50 bar [1000 psi] gauge in each of the two servo (cam)
en
gauge ports (M4 and M5). Disconnect the external con- Feedback pin
trol input (electrical connections) from the control. Start

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Maximum
the prime mover and operate at normal speed. adjustment
ip
less than 120°

2. Use a 4mm internal hex wrench to hold the neutral
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adjusting screw stationary while loosening the locknut

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with a 13mm wrench.

Illustration shows how eccentric cam on
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adjusting screw rotates to adjust neutral.

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Neutral adjusting screw

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4 mm
Servo pressure gauge port M4
Di
0 - 50 bar [0 - 1000 psi]

Locknut 3/16 in
to
13 mm 12 N•m [9 lbf•ft]
10 N•m
Go

[7 lbf•ft]
Servo pressure gauge port M5 0 - 50 bar [0 - 1000 psi]
3/16 in
0 - 50 bar [0 - 1000 psi] 12 N•m [9 lbf•ft]
3/16 in
12 N•m [9 lbf•ft]

0 - 50 bar [0 - 1000 psi]
3/16 in
12 N•m [9 lbf•ft]
Figure 5-69. Control Neutral Adjustment
5-116 31215055
5. Rotate the neutral adjusting screw clockwise half the PUMP SETUP
distance between the wrench positions noted above.
The gauges should read the same pressure, indicating 1. Attach a 50 bar [1000 psi] gauge to each servo pressure
that the control is in its neutral position. port M4 and M5.
6. Hold the neutral adjusting screw stationary and tighten 2. Attach a 600 bar [10 000 psi] gauge to each system pres-
the lock nut. Torque to 10.Nm [7 lbft]. Do not over sure port (MA and MB for front pump, MC and MD for
torque the nut. rear pump).
7. When the neutral position is set, stop the prime mover, 3. Remove servo cylinder locking screws (E350) and plates
remove the gauges, and install the gauge port plugs. (E300) from both sides of the pump.
Reconnect the external control input. 4. Disconnect the control solenoids from the vehicle wir-
rts
ing harness.
NOTE: A small pressure differential of 1.5 bar [22 psi] or less is
acceptable. Zero differential is usually not possible. 5. If using a PWM signal to set mechanical neutral, connect
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the control solenoids C1 and C2 to the signal source.
MECHANICAL NEUTRAL ADJUSTMENT Ensure the source supplies no current to the solenoids
ur
Mechanical neutral is set with the pump running at 1800 min until required in the following procedure.
yo
(rpm). To set neutral, you must stroke the pump in each direc-
tion.
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This procedure details setting neutral for the entire pump, one
side at a time. The procedure is the same for each side of each
or
pump so you will need to repeat it four times to set mechani-
cal neutral for both the front and rear sections. Alternate M4/
M5 and MA/MB to zero out forward and reverse directions of
the front unit, then move the gauges to M4/M5 of the rear unit to
om
and MC/MD (system gauge ports for the rear unit). Refer to the
drawing that follows to identify all ports. The front and rear
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sections are basically mirror images of each other. The control

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solenoids C1 and C2 are marked on each control.

While performing this adjustment, you monitor the following
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pressures.:
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• Servo pressure at M4 and M5

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• System pressure at MA and MB or MC and MD

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• Pressure differential between M4 and M5 (optional)

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• Pressure differential between A and B or C and D (optional)

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31215055 5-117
System gauge port MC System gauge port MB
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ISO 11926-1 - 9/16-18 ISO 11926-1 - 9/16-18
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Rear servo gauge port M5 Front servo gauge port M4
Servo cylinder (4 pl.) ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
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E300 Servo cylinder
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locking clip
E350 Servo cylinder
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locking screw
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10mm
or
14.5 N•m [11 lbf•f t]
to
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System port B
System port C
ISO 11926-1 - 1 5/16-12
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ISO 11926-1 - 1 5/16-12

System port D
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ISO 11926-1 - 1 5/16-12 System port MD

System port A ISO 11926-1 - 9/16-18
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ISO 11926-1 - 1 5/16-12 System gauge port MA

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ISO 11926-1 - 9/16-18

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Rear servo gauge port M4 Front servo gauge port M5

ISO 11926-1 - 7/16-20 ISO 11926-1 - 7/16-20
Figure 5-70. Servo and System Pressure Gauge Port Locations
5-118 31215055
SERVO ADJUSTMENT Removing The Pump

6. Run prime mover at 1800 min (rpm). Before working on the pump, thoroughly clean the outside. If
7. If using a PWM signal, ensure the signal is off. Check the the pump has an auxiliary pump attached, remove both
servo pressure gauges. Ensure the differential between pumps as a single unit. Tag and cap all hydraulic lines as you
M4 and M5 is less than 1.5 bar [22 psi]. disconnect them, and plug all open ports to ensure that dirt
and contamination do not get into the system.
8. Using a 3/4 in deep socket, unthread both servo cylin-
ders 2-3 turns. This step ensures the servo cylinders have
no contact with the servo piston.
CONTAMINATION CAN DAMAGE INTERNAL COMPONENTS. TAKE PRECAU-
9. Stroke the pump by turning the control eccentric screw TIONS TO ENSURE SYSTEM CLEANLINESS WHEN REMOVING AND INSTALL-
ts
(or supplying current to solenoid C1) until the servo ING SYSTEM LINES.
pressure at port M4 is 1 to 2 bar [14 -29 psi] greater than
ar
at port M5 and the system pressure gauges indicate dis- 1. Thoroughly clean all dirt and grime from the outside of
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placement. Pressure should be greater at port MA for the pump.
clockwise rotation, or MB for counterclockwise rotation.
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This also indicates the servo piston is in contact with the 2. Tag, disconnect, and cap each hydraulic line connected
servo cylinder on side M5. to the pump. As hydraulic lines are disconnected, plug
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each open port, to ensure that dirt and contamination
10. Slowly thread the servo cylinder on the M5 side in until do not get into the pump.
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the system pressure differential starts to decrease. Main-
3. Remove the pump and its auxiliary pump (if applicable)
or
tain servo pressure differential between 1-2 bar [14-29
psi] during this step. Continue turning the servo cylinder as a single unit.
to
in until the system pressure differential (between ports NOTE: Be careful, do not damage solenoids and electrical connec-
MA/MB or MC/MD) is less than 1.5 bar [22 psi]. This pro- tions when using straps or chains to support the pump.
om
cedure sets the servo and swashplate to mechanical
neutral on the M5 side.
Inspection
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11. To complete setting neutral, repeat steps 1-5 but stroke

1. Ensure the work surface and surrounding area are clean
en
the pump in the opposite direction by turning the

eccentric screw in the opposite direction, or by supply- and free of contaminants such as dirt and grime.
m
ing current to solenoid C2. Reverse gauge locations (M4 2. Inspect the system for contamination.
ip
for M5, MB for MA etc.) from those stated above since

the pump is now stroking the other direction. 3. Look at the hydraulic fluid for signs of system contami-
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nation, oil discoloration, foam in the oil, sludge, or metal

12. Set neutral for the rear pump by repeating steps 1-6 on
-E
particles.
the rear pump. Remember that the rear pump is a mirror
nt
image of the front pump and therefore the locations of Replacement

the servo gauge ports (M4/M5) and the control sole-
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noids (C1/C2) are opposite. 1. Before replacing the pump, replace all filters and drain
sc
the hydraulic system. Flush the system lines and fill the
13. Remove all gauges and replace gauge port plugs.
reservoir with the correct, filtered hydraulic fluid.
Di
2. Fill the pump with clean, filtered hydraulic fluid.

to
3. Attach the pump to the prime mover. Torque mounting

Go
screws according to the manufacturers recommenda-

tion.
4. Replace all hydraulic lines. Ensure the charge inlet line is
filled with fluid.
31215055 5-119
Electric Control Module REASSEMBLY

NOTE: Ensure you install dowel pins (D300) in housing before
REMOVAL installing control.
Refer to exploded diagram, next page.
1. Using a 5 mm internal hex wrench, remove the six cap 1. Install a new gasket (D150).
screws (D250). 2. If you removed screen (D084), install a new one. Install
2. Remove the control module and gasket (D150). Discard with the mesh facing outward.
the gasket. D084
D084
3. If necessary, remove orifices (F100) using a 3 mm inter-

nal hex wrench. Tag and number them for reinstallation.
ts
Incorrect screen
Correct screen
orientation orientation
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4. Inspection
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5. Inspect the machined surfaces on the control and top of
the pump. If you find any nicks or scratches, replace the
ou
component. 3. If previously removed, install orifices (F100) using a 3
mm internal hex wrench. Torque to 2.5 Nm [1.8 lbft].
ry
NOTE: Remove plug on top of control to ensure the swashplate
feedback pin is properly positioned in the center of the con- 4. Install the control module and six cap screws (D250).
de
trol module when installing control. 5. Using a 5 mm internal hex wrench, torque the cap
or
screws (D250) to 13.5 Nm [10.lbft].
to
om
D050 (3X)
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4 mm
en
5 N•m [4 lbf•f t] D1
m
D250
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D025A
5 mm
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13.5 N•m
[10 lbf•ft]
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nt
D025A D050 (3X)

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D084 4 mm
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5 N•m
Torque sequence
[4 lbf•ft]
Di
2 1 D150
to
6 5
Go
F100 (2X)
3 mm
2.5 N•m
4 3 [1.8 lbf•ft]
D300 (2X)
Figure 5-71. Control Module And Solenoid Removal/installation
5-120 31215055
CONTROL SOLENOIDS REMOVAL Shaft, Seal, and Bearing

1. Disconnect electrical connection and remove the three The front pump input shaft assembly is serviceable without
cap screws (D050) using a 4.mm internal hex wrench. disassembling the pump, the rear shaft is not. Orient the
2. Remove the solenoid (D025) and O-ring (D025A). Dis- pump on the work surface so the shaft is pointing to the side.
card the O-ring.
REMOVAL
3. If necessary, remove the coil using a 12 point 26 mm
socket. 1. Unwind the spiral ring (J300) from the housing to
release the shaft/seal/bearing subassembly.
CONTROL SOLENOIDS INSPECTION 2. Pry on the lip of the seal carrier (J275) to remove it from
the pump. Remove the seal carrier. Remove and discard
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1. Inspect the machined surface on the control. If you find
any nicks or scratches, replace the component. O-ring (J260). Press the seal (J250) out of the carrier and
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discard.
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CONTROL SOLENOIDS REASSEMBLY 3. Pull the shaft (J100) with bearing (J150) out of the
pump. If necessary, tap lightly on the shaft to dislodge it
ou
1. Lubricate new O-ring (D025A) using petroleum jelly and
install. from the cylinder block. C
ry
2. Install solenoid with three cap screws (D050) using a 4
de
mm internal hex wrench. Torque screws to 5 Nm [4 lbft].
DO NOT DAMAGE THE HOUSING BORE, SHAFT OR BEARING WHEN REMOV-
3. Install coil using a 12 point 26 mm socket. Torque coil
or
ING THE SHAFT AND BEARING.
nut to 5 Nm [3.7 lbft].
4. Reconnect electrical connections and test the pump for
proper operation. to 4. Remove the retaining ring (J200) using retaining ring
pliers. Press the bearing off the shaft.
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en
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Protective
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sleeve
J100
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J150
J200
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J250
to
J260
J150
Go
J275
J300
Figure 5-72. Shaft Assembly
31215055 5-121
INSPECTION Charge Pump

1. Inspect the shaft journals for wear, scratching, and pits. Position pump with front shaft pointing downward. Attach
Check the splines for fretting; replace if damaged. securely to a proper work stand. If an auxiliary pump is
Rotate the bearing, if it does not rotate smoothly, attached, remove auxiliary pump before servicing charge
replace it. pump.
REASSEMBLY REMOVAL
1. Press the bearing (J150) onto the shaft (J100) and 1. Remove screws (K351), and hangers (K975).
replace the retaining ring (J200). Ensure the retaining
ring diameter is less than 38.84 mm [1.53.in] when 2. Remove running cover (K301). Remove and discard seal
installed on the shaft. ring (K250).
ts
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2. Install the shaft/bearing assembly into the pump. 3. Using a 10 mm internal hex, remove screws (K400).
Remove cover (K101).
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3. Lubricate and install a new O-ring (J260) onto seal car-
rier (J275). Press a new seal (J250) into the seal carrier. 4. Remove charge pump assembly with shaft.
ou
Press the seal until it is flush within +0.12mm [0.005 in]
NOTE: Note position of alignment pin (S500) in housing. Align-
or -0.72 mm [0.0028 in] of the inside lip of the carrier: see
ry
ment pin position will change for clockwise or counter-
illustration.
clockwise rotation.
de
Press ?ush to this sur face
+0.12 mm [ 0.005 in] / -0.72 mm [ 0.028 in] 5. Remove and discard seal (S300).
or
6. Using a snap ring pliers, remove two clips (K205).
to
Seal
7. Remove geroter cover (S200). Remove geroter assembly
om
(S100).
4. Cover the shaft with a protective sleeve while installing
the seal carrier. Hand press the seal carrier into the hous- 8. Remove and discard gasket (K151). Remove alignment
t.c
ing. Ensure the seal carrier clears the spiral ring groove pins (K450).
en
in the housing. Remove the protective sleeve.

9. If it is necessary to remove housing (K300), use a 10 mm
5. Wind the spiral ring into the housing. Ensure the inside internal hex to remove screws (K350).
m
diameter of the spiral ring is greater than 68 mm [2.677

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10. Remove housing (K300).

in] after installation.
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11. Remove and discard seal (K150).

-E
INSPECTION
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1. Inspect all machined surfaces. If you find any nicks or

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scratches, replace the component.

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2. Inspect geroter and cover for wear or damage. If wear or

damage is found, replace geroter kit.
Di
3. Inspect shaft for wear or damage. If found, replace shaft.

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4. Inspect journal bearings in aux pad and housing. If worn

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or damaged, replace journal bearings or aux pad or

housing assembly.
5-122 31215055
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or
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to
Go
Figure 5-73. Charge Pump
31215055 5-123
REPLACING CHARGE PUMP JOURNAL BEARINGS 10. Install screws (K351) and brackets (K975). Torque screws
Use a suitable press to remove and replace the journal bear- per listing in the table.
ings. Refer to the drawings below for installation dimensions.
Charge Check / HPRV
The high pressure relief and charge check valve assembly may
be removed for cleaning and replacement of the O-rings.
These valves are factory set and are not field adjustable. Refer
to the pump model code for the factory setting when ordering
replacements.
REMOVAL
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1. Using an 8 mm internal hex wrench, remove the valve
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seat plugs (K007).
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ASSEMBLY 2. Carefully lift the valve (H002) and spring (H003) assem-
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blies from the center section using a magnet.
1. Lubricate and install new seal (K150).
ry
2. Install housing (K300). Install screws (K350). Using a 10 INSPECTION
mm internal hex, torque screws per listing in table.
de
1. Inspect the valves and mating seats in the valve seat
3. Install alignment pins (K450). Install new gasket (K151). plugs (K007) for damage or foreign material.
or
4. Lubricate and reassemble charge pump assembly [shaft REASSEMBLY
to
(K201), pin (S500), geroter (S100), cover (S200), two clips
(K205)]. 1. Lubricate and install new O-rings (K008, K010) and
om
backup ring (K009) on valve seat plug (K007).
5. Install charge pump assembly into housing in original
position. 2. Verify that the conical springs (H003) are properly
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retained on the check relief valves (H002). Install the

6. Lubricate and install seal (S300). valve assemblies into the center section. Ensure each
en
7. Install aux pad (K101). valve assembly moves freely in its bore.
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8. Using a 10 mm internal hex, install screws (K400). Torque 3. Install the valve seat plugs into the center section and
ip
screws per listing in table. torque to 80 Nm [59.lbft].

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9. Lubricate and install seal (K250). Install running cover 4. Operate machine through full range of controls to
-E
(K301). ensure proper operation. Check for leaks.

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to
Go
Figure 5-74. Charge Check / HPRV
5-124 31215055
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Figure 5-75. Charge Check / HPRV

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Charge Pressure Relief Valve REASSEMBLY

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Replace the charge pressure relief valve (V10-1) or (V10-2) as a 1. Lubricate and install new O-rings (V10A).
complete unit. Do not attempt to repair the internal compo-
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2. Install the charge pressure relief valve (V10). Torque to

nents of the valve. 52 Nm [38 lbft].
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REMOVAL 3. Operate vehicle/machine through full range of controls

ou
to ensure proper operation.

1. Using a 27 mm (V10-1) or a 1 in (V10-2) wrench, remove
sc
the charge pressure relief valve. Discard the O-rings

Di
(V10A).
to
INSPECTION
Go
1. Inspect the sealing surfaces of the pump and charge

pressure relief valve for nicks or scratches, replace com-
ponents as necessary.
31215055 5-125
rts
pa
ur
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or
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Figure 5-76. Charge Pressure Relief Valve

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Control Cutoff Valve REASSEMBLY

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ip
Replace the control cutoff valve as a complete unit. Do not 1. Lubricate and install new O-rings (G10A) onto the valve.
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attempt to repair the internal components of the valve. 2. Install the control cutoff valve (G10). Torque to 46 Nm
[34 lbft]. Slide the coil (G20) onto the valve.
-E
REMOVAL
3. Install the coil nut (G30). Torque to 9 Nm [7.lbft]. Do not
nt
1. Disconnect the coil from the vehicle/machine wire har- overtorque.

ou
ness.
4. Operate vehicle/machine through full range of controls
2. Using a 24 mm hex wrench, remove the control cutoff
sc
to ensure proper operation

valve coil nut (G30). Remove the coil (G20).
Di
3. Use a 1 1/16 in hex wrench to remove the control cutoff

to
valve (G10). Remove and discard the O-rings and backup

rings (G10A).
Go
INSPECTION
1. Inspect the sealing surfaces of the pump and control
cutoff valve for nicks or scratches. Replace components
as necessary.
5-126 31215055
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Figure 5-77. Control Cutoff Valve
or
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Table 5-47. Fastener Size and Torque Chart
om
Item Fastener Wrench size Torque
D015 Neutral adjust screw 4 mm internal hex NA
t.c
D050 Control coil mounting screw 4 mm internal hex 8 Nm [5.9 lbft]

en
D060 Neutral adjust locking nut 13 mm hex 10 Nm [7 lbft]

m
D200 Swash plate feedback pin (not shown) 13 mm hex 25 Nm [18.4 lbft]
ip
D250 Electric control mounting screw 5 mm internal hex 13 Nm [9.5 lbft]

qu
E350 Servo cylinder locking screw 10 mm hex 14.5 Nm [11 lbft]

-E
G10 Control cutoff valve 1 1/16 in hex 45 Nm [33 lbft]

nt
G10B Control cutoff valve coil nut 24 mm hex 9 Nm [7 lbft]

ou
K007 Charge check / HPRV 8 mm internal hex 80 Nm [60 lbft]

sc
K350 A pad cover mounting screw 17 mm hex 70 Nm [52 lbft]

Di
B pad cover mounting screw 8 mm hex 111 Nm [82 lbft]

to
V10-1 Charge relief valve 27 mm hex 52 Nm [38 lbft]

V10-2 Charge relief valve 1 in hex 52 Nm [38 lbft]
Go
Table 5-48. Plug Size and Torque Chart
Item O-ring plug Wrench size Torque

B015 7/16 - 20 3/16 internal hex 20 Nm [15 lbft]
B020 1-1/16 - 12 9/16 internal hex 48 Nm [35 lbft]
D065 7/16 - 20 3/16 internal hex 12 Nm [9 lbft]
G250 9/16 - 18 1/4 internal hex (hardened plug) 45 Nm [33 lbft]
31215055 5-127
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Figure 5-78. Fastener and Plug Locations
5-128 31215055
5.9 FUNCTION PUMP (SAUER) 6. Remove the bearing cup (B010), bearing cone (B020)
and housing O-ring (K060). Discard the O-ring.
Disassembly 7. Tilt the housing on its side to allow fluid to drain.
1. Remove the control from the endcap by removing the 4 8. Remove the cylinder block kit while holding onto the
control bolts (C300), using a 4 mm internal hex wrench. front shaft.
C200
rts
s K041
C300
pa
I4 mm
ur
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2. Remove and discard the 4 O-rings (C200). P101 368
r
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3. Remove the 4 endcap screws (J030) using a 10 mm 9. Set cylinder block on a clean dry surface.
internal hex wrench.
or
10. Rotate pump back to a position so that the shaft is
J030 pointing down.
10 mm
to
11. Pull the shaft (J010) from the shaft seal.
om
J020
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en
pJ010 P020
m
B090
ip
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B010 B025
-E
nt
B020 B044
B040
ou
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K060
B043
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K030
to
Go
E101 17 E101 176
4. Carefully remove the endcap (J020). Prevent the valve 12. Compress the bias spring (B025) and rotate the servo
(B090) plate from falling off. piston assembly (P020) towards the swashplate (B040).
5. Place the endcap and valve plate in a clean area, pro- 13. Lift the swashplate/servo piston assembly up at an
tecting them from contamination. angle and remove it from the housing.
31215055 5-129
14. Remove the servo piston (P020) and bias spring (B025) rings. Remove the 2 set screws (C102). Remove the
from the swashplate by removing the clevis pin (B043) spools (C112, C132). Note which bore each spool came
and snap ring (B044). Discard the snap ring. out of. Also note the orientation of each spool for rein-
sertion. There may be differences in reinserting into the
15. Pull to remove the front tapered roller bearing cup
same bore.
(B060) and cone (B070).
C104
B071
C104A
C103
C103A
C112
R C132
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pB070
C105
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pB060
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C106A C106 C105A
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C113
or
E101 178
C102
C115
to C133 C114
om
16. Examine the cradle bearings (B030) to determine if they C117
need replacement. C135
C116
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NOTE: Removing the pins (B071) will likely damage the cradle
bearings, so make sure you have replacement bearings C134 C117 d
en
before you remove them. C118

m
dC138A
17. If cradle bearings need replacing, remove the 2 pins
ip
C138 E101 180

(B071) holding the cradle bearings, and then remove the
qu
cradle bearings. Note the location and orientation of the

22. Remove the adjusting screw (C138) and the O-ring
-E
bearings for re-installation.

(C138A). Discard the O-ring. Remove the springs (C134,
nt
18. Orient the housing with the flange facing up. C135) and spring guide (C133).
ou
19. Using snap-ring pliers, remove the snap ring (K010). 23. Remove the adjusting screw (C118), O-ring (C116) and 2
backup rings (C117). Discard the O-ring and backup
sc
K010 rings. Remove the springs (C114, C115) and spring guide
Di
(C113).
K020
24. Pull to remove the slipper retainer (K049) with the pis-
to
tons (K050) from the cylinder kit.

Go
20. Carefully pry out the shaft seal (K020).
If you are unable to pull the shaft seal out, try to push
the seal out by going through the inside of the housing.
21. Remove the 4 plugs (C103, C104, C105, C106) and their
O-rings (C103A, C104A, C105A, C106A). Discard the O-
5-130 31215055
NOTE: The pistons are not selectively fitted, however units with pressed air. Conduct inspection in a clean area and keep all
high hourly usage may develop wear patterns. Number the parts free from contamination. Clean and dry parts again after
pistons and bores for reassembly if they are to be reused. any rework or resurfacing.
PISTONS AND SLIPPERS

K050 Inspect the pistons for damage and discoloration. Discolored
pistons may indicate excessive heat; do not reuse.
K049 Inspect the running surface of the slippers. Replace any piston
assemblies with scored or excessively rounded slipper edges.
K047 Measure the slipper foot thickness. Replace any piston assem-
blies with excessively worn slippers. Check the slipper axial
ts
end-play. Replace any piston assemblies with excessive end-
K046
ar
play.
rp
P010 Maximum end play
K041
ou
Minimum Slipper
slipper foot
ry
K042 thickness
K050
de
K043
or
K044
K045 to
Minimum slipper foot thickness and maximum axial end-play
are given in the table below.
om
t.c
J Frame
25. Remove the ball guide (K047).
Slipperfoot thickness 3.23 mm
en
26. Remove the 3 pins (K046).

[0.127 in]
m
NOTE: Most repairs do not require block spring removal. Perform Piston/slipper end play 0.05 mm
ip
this procedure only if you suspect problems with the block [0.002 in]
spring.
qu
BALL GUIDE, SLIPPER RETAINER, AND HOLD-DOWN

-E
27. Turn the block over. Using a press, apply pressure on the
block spring washer (K044) to compress the block spring PINS
nt
(K043). Compress the spring enough to safely remove The ball guide should be free of nicks and scratches, and
ou
the spiral retaining ring (K045). While maintaining pres- should not be excessively scored. Examine for discoloration
sure, unwind the spiral retaining ring. Carefully release that may indicate excessive heat or lack of lubrication. The slip-
sc
the pressure and remove the outer block spring washer, per retainer should be flat, and slippers should fit in the
retainer with minimal side play. Place the hold-down pins on a
Di
block spring, and inner block spring washer (K042) from

the cylinder block. flat surface and roll them to make sure they are straight. Dis-
to
card and replace any damaged parts.

Go
Slipper
RISK OF PERSONAL INJURY: COMPRESSING THE BLOCK retainer
SPRING REQUIRES ABOUT 350 TO 400 N [80 TO 90.LBF ].
USE A PRESS SUFFICIENT TO MAINTAIN THIS FORCE WITH
REASONABLE EFFORT. ENSURE THE SPRING IS SECURE
BEFORE ATTEMPTING TO REMOVE. THE SPIRAL RETAINING Ball guide
R I N G. R EL E A S E T H E P RE S S U RE S L O W L Y A F T E R T H E
RETAINING.RING IS REMOVED.
Hold down pins
Inspection
After disassembly, wash all parts (including the end-cap and
housing) thoroughly with clean solvent and allow to air dry.
Blow out oil passages in the housing and endcap with com-
31215055 5-131
BLOCK SPRING, AND WASHERS for scratches and / or burrs. Clean and coat all spools, bores,
If cylinder kit was fully dissembled, visual inspection of the cyl- and seals with a light coating of hydraulic oil.
inder block, spring, and washers should indicate minimal wear. C104
Replace if cracks or other damage is present.
C103
C104A
C103A
Washer
C112i
C132
Cylinder block spring
Spring retainer
ts
C105
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Retaining ring C106A
C105A
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C106
ou
CYLINDER BLOCK
C113
ry
Examine the running face of the cylinder block. The surface C102
should be smooth and free of nicks and burrs. Ensure that no C115
de
scratches or grooves exist; these may drastically reduce output
C133 C114
flow.
or
B C117
C135
to
C116
K041 C117
om
C134
C118
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A C138A
en
C138
m
?at to 0.002 mm
[0.000079 in]
INPUT SHAFT
ip
Check to see that the shaft (J010) and its splines are straight
qu
J Frame 45-60 cc 65-75 cc and free of damage or heavy wear. Inspect the shaft surface
where it meets the shaft seal. Replace the shaft if a groove
-E
Minimum cylinder block height (A) 62.25 mm exists at the sealing land surface that may let dirt into or
nt
[2.45 in] hydraulic fluid out of the unit. Clean the sealing area with a
ou
Maximum block bore diameter (B) 19.8 mm 21.57 mm nonabrasive material if necessary. Lubricate the shaft with a
[0.785 in] [0.85 in] light coat of hydraulic fluid.
sc
J010
Di
CONTROL
Carefully examine the plug(s) for signs of wear. Also check the
to
small tip of the plug(s) for heavy wear and replace if necessary.
Inspect each spool’s springs to make sure they are intact.
Go
Check the inside and outside surfaces of the springs for wear
and replace if necessary. Check the spool’s outside diameter
5-132 31215055
SWASHPLATE Measure the thickness of the valve plate. Ensure that valve
Carefully inspect each surface of the swashplate for wear. All plate parallelism is equal to or less than 0.025 mm [0.001 in].
swashplate surfaces should be smooth. Inspect the swash- Appearance should be flat and smooth on both the running
plate’s slipper running surface for damage and brass transfer. face and the bottom surface. The valve plate should be flat to
Excessive brass transfer from slippers may indicate that the 0.005 mm [0.0002.in] convex. A magnetic particle inspection is
slippers should be replaced. Finally, check the swashplate recommended to detect cracks. The valve plate must be
bearing journal for scratches. Replace swashplate if necessary. replaced if any cracks exist.
3.88 mm [0.153 in] min.
B040
B090 0.025 mm
[0.001 in]
rts
pa
0.005 mm
JOURNAL BEARINGS [0.0002 in]
ur
convex max
Inspect the journal bearings for damage or excessive wear.
yo
Replace journal bearings if scratched, warped, or excessively
worn. The polymer wear layer must be smooth and intact.
r
de
or
ENDCAP
Inspect the endcap. Remove the check valve (B092) to expose
B030
to
the spring (B091). Check and record orientation of the timing
pin (J050) The split in the timing pin should be facing into or
om
out of the slot in the valve plate. Inspect the check valve for
wear on its sealing face and replace if necessary. Make sure the
t.c
spring is undamaged. Replace any components if excess wear

VALVE PLATE is present.
en
Inspect the valve plate for scratches and grooves. Check the
plate for evidence of any cavitation along the running face of
m
the valve plate. If pitting from cavitation exists, replace the

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valve plate. Check for excess wear on the brass running face. If
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any discoloration or burn marks are observed, replace the

valve plate.
-E
Run a fingernail or pencil tip across the diameter of the sealing

nt
J050
land surface (see illustration). No deep or outstanding grooves
ou
should be felt, as these may decrease pump flow. Lap or

replace if grooves or nicks are present. Inspect the mating sur-
sc
faces of the endcap and valve plate for any possible contami-
Di
nation; even a few thousandths of an inch may affect pump

operation. B091
to
B092
Go
SERVO PISTON
Check the servo piston assembly (P020) for any obvious wear
or damage. Check the corresponding endcap bore for galling
or excessive wear. Discard the piston if damaged. Replace the
servo piston-rings.
P020
31215055 5-133
HOUSING NOTE: If journal bearings are reused, reinstall them in their origi-
Inspect the housing to ensure that it is clean and free of for- nal orientation and position.
eign material. Inspect the swashplate bearing surfaces, and
endcap mating surfaces.
P020
J010
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B025
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lB040
B044
ou
ry
SHAFT BEARING KITS
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The tapered roller bearing kit consists of a cup and cone. Make B071
sure the cup and cone are free of excessive wear or contamina- B043
or
tion. Rotate the bearings to check for smoothness. If a contam-
inated bearing is suspected, clean with a solvent and lubricate
with hydraulic fluid.
to
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NOTE: Replace the bearing if the problem is not remedied by lB030
cleaning.
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Inspect for uneven wear. If abnormal wear is found, replace the B070
en
bearing kit.
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B060
ip
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nt
ou
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Assembly
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to
1. Coat the journal bearings (B030) with hydraulic fluid and

install them into the pump housing. Punch in retaining
Go
pins (B071) a minimum of 0.5 mm [0.002 in] below the

bearing surface.
2. Reinstall shaft bearing cup (B060) and cone (B070).

Before replacing the bias spring (B025), coat the curved
surface of the swashplate with hydraulic fluid.
5-134 31215055
3. Reinstall the swashplate/servo piston/bias spring 8. Install the pistons (K050) to the slipper retainer (K049).
assembly in its original orientation in the housing. Install the piston/retainer assembly into the cylinder
Rotate the servo piston perpendicular to the swash- block. Ensure the concave surface of the retainer seats
plate, and at the same time compress the bias spring to on the ball guide. If you’re reusing the pistons, install
fit into housing pocket. Lubricate all sides of the servo them to the original block bores. Lubricate the pistons,
piston and its respective bore liberally with hydraulic oil. slippers, retainer, and ball guide before assembly. Set
Also, lubricate the flat face of the swashplate to prevent the cylinder kit aside on a clean surface until needed.
premature wear during start-up.
NOTE: Be sure to install the slipper retainer so it mates correctly
4. Insert the input shaft (J010) through the bearing into with the ball guide (concave side of the slipper retainer
the housing. You may need to push on the servo piston against the convex side of the ball guide).
to rotate the swashplate in order to put the shaft in
ts
properly. 9. Set the pump on its side. Secure the end of the shaft
ar
with one hand and keep it horizontal. Insert the cylinder
5. Coat all parts with hydraulic fluid prior to reassembly.
kit onto the shaft. While holding the shaft still, slightly
rp
rotate the cylinder block kit to help start the shaft
ou
splines over the ball guide and align it with the block
COMPRESSING THE BLOCK SPRING REQUIRES ABOUT 350 splines. When the cylinder block kit slides completely
ry
TO 400 N [80 TO 90 LBF ]. USE A PRESS SUFFICIENT TO over the shaft splines, reposition the unit with the flange
MAINTAIN THIS FORCE WITH REASONABLE EFFOR T. facing downward.
de
ENSURE THE SPRING IS SECURE BEFORE ATTEMPTING TO Fix the shaft
INSTALL.THE SPIRAL RETAINING RING. RELEASE THE PRES-
or
on this end
SURE SLOWLY AFTER THE RETAINING RING IS INSTALLED.
6. Install the inner block spring washer (K042), block spring
(K043), and outer washer (K044) into the cylinder block. to
om
Using a press, compress the block spring enough to
expose the retaining ring groove. Wind the spiral retain- Slightly rotate
t.c
ing ring (K045) into the groove in the cylinder block. cylinder block
en
K050
m
ip
K049
qu
-E
K047
nt
ou
K046
sc
P010
Di
K041
to
K042
Go
K043
K044
K045
7. Turn the block over and install the hold-down pins

(K046), and ball guide (K047) to the cylinder block.
31215055 5-135
10. Clean the valve plate (B090) and endcap. Install the tim- 11. Install the bearing cone (B020) onto the shaft. Using
ing pin (J050) in the endcap and verify that it is properly assembly grease to hold the seal (K060), install the end-
oriented with the split facing into or out of the slot in the cap to the housing. Ensure that seals remain properly
valve plate. The timing pin should be installed to 3.61 ? seated and are not pinched during assembly. With a 10
0.25.mm [0.14.?.0.01 in] above the valve plate surface. mm internal hex wrench, install and torque endcap
Apply a liberal amount of assembly grease to the back- screws at 127 to 155 Nm [94.to.114.lbft], using the criss
side of the valve plate surface to hold it in position. cross pattern. Retorque the first screw to ensure proper
Install the valve plate over the timing pin, check valve torque retention.
(B092), and bearing cup (B010).
J030
B090 10 mm
127 to 155 N·m
ts
[94 to 114 lbf·ft]
ar
rp
J050
J020
ou
B092
B010
ry
B091
de
B020
or
to K060
om
t.c
NOTE: To insure proper pump operation, it is extremely important

en
to ensure that there is no contamination between the end-

cap and valve plate.
m
ip
qu
-E
nt
12. Lubricate the lip of the new shaft seal (K020) with clean
ou
hydraulic fluid. Place a protective sleeve over the shaft

end to prevent damage to the seal during installation.
sc
Keeping the seal perpendicular to the shaft, press the

Di
new seal into the housing just far enough to clear the
retaining ring groove. Install seal with the cupped side
to
toward the shaft bearing. Do not damage the seal dur-

ing installation. Using the appropriate snap ring pliers,
Go
install the seal retaining ring (K010). Remove the instal-

lation sleeve.
5-136 31215055
15. Hold the control in a horizontal position. Install the

K010 spherical end of the LS spool (C112) into the LS bore (see
illustration). Using a new O-ring, install the LS plug
K020 (C104), torque at 10.8 to 13.5 Nm [8 to 10 lbft]. Place the
2 LS springs (C114, C115) onto the LS spring guide
(C113) and install into the LS bore. Place a new O-ring
(C116) and Backup rings (C117) onto the LS adjustment
screw (C118). Install the LS plug assembly so that it sits
one turn below the surface of the control housing.
Install and tighten set screw (C102) at 7.5 to 10.8 Nm
[5.5.to 8.0 lbft]. Also, install the plugs (C105, C106) with
new O-rings. Torque the plugs at 10.8 to 13.5 Nm [8 to
ts
10 lbft].
ar
C103 C104
rp
C103A C104A
ou
13. Clean all control parts and cover with a light coating of
ry
hydraulic fluid prior to reassembly. C132 C112
14. Install the spherical end of the PC spool (C132) into the
de
PC bore (refer to illustration). Install the PC plug (C103) C105
or
using a new O-ring (C103A). Torque at 10.8 to 13.5 Nm
[8.to.10.lbft]. Place the two PC springs (C134, C135) onto C106A
the PC spring guide (C133) and install into the PC bore.
Place a new O-ring onto the PC plug and install it so that to C106
C105A
om
it sits one turn below the surface of the control housing.
Install and tighten set screw (C102) at 7.5 to 10.8 Nm [5.5
C113
t.c
to 8.0 lbft] to retain the adjusting plug.

C102
10.8 to 13.5 N•m C115
en
[8.0 to 10.0 lbf•f

t]
C133 C114
m
C103
C103A C117
ip
C135
qu
C116
C132
-E
C134 C117
nt
C118
C136
ou
7.5 to 10.8 N•m

C138
[5.5 to 8.0 lbf•f
t]
sc
C102
Di
NOTE: PC and LS spools need to be adjusted to proper setting

according to tag nomenclature.
to
C133
Go
C135
C134
C136
C138
31215055 5-137
16. Using petroleum jelly to retain them, install 4 new seal PROCEDURE
rings (C200) in the recesses on the control housing.
Install the control assembly onto the endcap using the 4 1. Clamp the unit.
screws (C300). Torque at 5.4 to 7.5 Nm [4.0 to 5.5 lbft]
using a criss cross pattern and retorque the first screw to Clamp the unit in a vice from the flange side.
ensure proper torque retention.
Make sure the vice jaws are clean and have smooth sur-
faces to prevent damage to the pump.
5.4 to 7.5 N• m C200

[4 to 5.5 lbf•f
t]
4 mm
rts
C300
pa
ur
r yo
5.10 GEAR PUMP (SAUER)
de
or
Disassembly NOTE: Clamping the pump on the body is not recommended
because serious damage to the surfaces, on which the
to
Prior to proceeding it may be necessary to prepare some sub- ports are located, may occur.
assemblies separately.
om
2. Remove capscrews. (Except Units with 03 Flange).
The details for preparing each subassembly are given in the
following section.
t.c
Use a 17 mm socket wrench and loosen the four cap-

Also, some general recommendations are given below. screws on the cover. Next completely unscrew the cap-
en
screws and remove them.

CLEANLINESS
m
Cleanliness is a primary factor for reliable pump performance. Inspect the threads of the capscrews for damage.
ip
Wash the outside of the pump thoroughly before disassembly

qu
and all pieces prior to assembly. Cleaning parts with clean

shop solvent and air drying is usually adequate.
-E
LUBRICATION OF MOVING PARTS

nt
During assembly, it is imperative to provide lubrication with

ou
clean hydraulic oil to all the running parts of the pump.

sc
It is also necessary to coat the seals with grease. The absence

Di
of lubrication during assembly can cause the unit to seize after

a few minutes of running.
to
CARE OF SURFACE TREATMENT

Go
Be careful when handling all the internal surfaces, especially

bearings, gears, and body faces. Do not touch or score them
with metal tools or cutting edges.
MARKING THE PARTS

Mark the parts before completely disassembling a pump. The
marks allow components to be reassembled in the same rela-
tive position. This action should be applied to the body, bear-
ings, and gears. Scribing, bluing, or using a felt tip pen to mark
the outside of the body on the inlet side is suggested to indi-
cate the relative position of the front flange and the rear cover
to the body. Mark the bearing blocks also on the inlet side and
the gears position relative to each other. DO NOT scribe inter-
nal surfaces.
5-138 31215055

1200 SJP Part 2

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SECTION 4 - BOOM & PLATFORM

Support Installation 5. Position the platform on the platform support and

NOTE: The platform support weighs approximately 81.6 lb

2. Install the rotator center bolt and locknut.

6. Connect the electrical cables to the platform control

eight bolts securing the support to the rotator and

install the bolts.

A Torque to 35 ft. lbs. (50 Nm)

B Medium Strength Threadlocking Compound

D Check torque every 150 hours of operation

Figure 4-1. Platform Support Torque Values

3. Place blocking under lift cylinder to hold it in place.

5. Remove the boom end cover.

Figure 4-3. Boom Assembly - Sheet 2 of 7

Figure 4-4. Boom Assembly - Sheet 3 of 7

Figure 4-5. Boom Assembly - Sheet 4 of 7

Figure 4-6. Boom Assembly - Sheet 5 of 7

Figure 4-7. Boom Assembly - Sheet 6 of 7

1.438 .062 rts

Figure 4-8. Boom Assembly - Sheet 7 of 7

1. Position the boom so that it is horizontal. If the boom is

2. Use an adequate lifting device to support the weight of

the jib and platform assembly.

3. Tag and disconnect the hoses and electrical harnesses

that run to the platform. Cap or plug all openings.

5. Remove the bolt and keeper pin securing the platform

level pivot pin and remove the pin.

11. Remove the boom pivot pin.

8. Attach a lifting device to the powertrack for support and

unbolt the upper powertrack tube from the fly boom.

11. Attach a strap or other similar device around the pow-

ertrack and boom to keep the powertrack secure

15. Remove the rear boom cover.

25. Remove the trunnion blocks that secure the telescope

cylinder rod to the boom base section.

front of the inner mid boom sections.

38. Pull the sections out enough to allow easy removal of

boom retract cables at the front of the inner mid boom

minimum depth of 3 to 4 feet (1 to 1.25 m). The fly boom

section only needs Super Lube applied to the insertion end.

Super Lube is also to be moderately applied to all outer sur-

faces of interior wear pads after they are installed to the

avoid application on exposed painted surfaces of the fully

extended boom. Refer to Section 1 - Remove the Platform

JLG PARTS MANUAL. OUTER MID RETRACT NUTS, LOCATED ON BOTTOM OF

2. Fabricate a special fixture as shown below to keep four

extend wire ropes from crossing over each other.

Figure 4-9. Boom Assembly Torque Values - Sheet 1 of 2

NOTE: If any rotator bolts are replaced, all bolts

on the rotator should be retorqued. Check

torque on the bolts every 150 hours of

Figure 4-10. Boom Assembly Torque Values - Sheet 2 of 2

9. Apply Medium Strength Threadlocking Compound to

sembly. Torque the bolts to 50 ft.lbs. (68 Nm).

outer mid boom section, leaving enough of the fly out

so there is adequate slack in the fly boom extend cables

outer mid boom section. Torque the bolts to 50 ft.lbs.

14. Apply Medium Strength Threadlocking Compound to

17. Using an adequate lifting device, align the outer mid