User Manual

ManualsBrandsJLG ManualsSpecial machinery723A Service Manual

An Oshkosh Corporation Company

Service Manual

Models

L2906H, 2906H,

3507H, 619A,

723A

Agrovector

29.6LP, 29.6, 35.7

31200568

Revised

March 7, 2011

Summary of content (208 pages)

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Service Manual Models L2906H, 2906H, 3507H, 619A, 723A Agrovector 29.6LP, 29.6, 35.
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EFFECTIVITY PAGE May 30, 2009 - A - Original Issue Of Manual March 7, 2011 - B - Added Models 29.6LP, 29.6 & 35.7. Updated all Loctite® 242TM with Loctite® 243TM. Revised covers and pages 1-3 & 9-10 thru 9-100. L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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EFFECTIVITY PAGE b L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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SECTION CONTENTS Section Subject Section 1 Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Page 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual . . . . . . . .
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Section Subject Page Section 5 Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5-1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section Subject Section 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . .
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Section iv Subject Page L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Section 1 Safety Practices Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6 1.7 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Practices 1.1 INTRODUCTION 1.4 DO NOT OPERATE TAGS This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability. Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.
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Safety Practices 1.6 SAFETY INSTRUCTIONS Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs. For all safety messages, carefully read, understand and follow the instructions before proceeding. 1.6.
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Safety Practices 1.6.4 Operational Hazards ENGINE: Stop the engine before performing any service unless specifically instructed otherwise. VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation. SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.
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Section 2 General Information and Specifications Contents PARAGRAPH 2.1 2.2 2.3 2.4 2.5 2.6 TITLE Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . .
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General Information and Specifications 2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION L2906H, 2906H, 3507H, 29,6LP, 29.6 & 35.7 1 619A & 723A Model Serial Number Year Of Manufacture Maximum Weight Without Attachments (lbs/kg) Maximum Capacity (lbs/kg) ° Refer to load capacity chart for truck with attachment, and individual load ratings stamped on forks, if equipped. Use lowest capacity of all ratings. 1 As released from factory this truck meets specifications in ASME B56.6-2002 Part III.
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General Information and Specifications 2.2 TORQUES 2.2.1 SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTITETM 131) OR Vibra-TITE TM 111 or 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Clamp Load Stress Area See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.
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General Information and Specifications 2.2.1 SAE Fastener Torque Chart (Continued) SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
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General Information and Specifications 2.2.2 Metric Fastener Torque Chart CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS SizePITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® TM TM (Loctite® 262 242 or 271TM OR VibraOR VibraTITETM 131) TITETM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.
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General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* SizePITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 KN [N.m] [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.
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General Information and Specifications 2.2.2 Metric Fastener Torque Chart (Continued) Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Tensile Stress Area SizePITCH Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM TM TM (Dry or Loctite® Clamp Load 242 or 271 OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.
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General Information and Specifications 2.2.3 Hydraulic Hose Torque Chart O-Ring Face Seal & JIC Torque Chart Size ORFS JIC Flats Method 4 18 Nm (13 lb-ft) 18 Nm (13 lb-ft) 1.5 to 1.75 6 31 Nm (23 lb-ft) 31 Nm (23 lb-ft) 1 to 1.5 8 54 Nm (40 lb-ft) 54 Nm (40 lb-ft) 1.5 to 1.75 10 81 Nm (60 lb-ft) 81 Nm (60 lb-ft) 1.5 to 1.75 12 100 Nm (136 lb-ft) 115 Nm (85 lb-ft) 1.0 to 1.5 16 156 Nm (115 lb-ft) 156 Nm (115 lb-ft) .75 to 1.0 20 230 Nm (170 lb-ft) 230 Nm (170 lb-ft) .75 to 1.
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General Information and Specifications 2.3 SPECIFICATIONS 2.3.1 Travel Speed L2906H, 2906H, 29.9LP, 29.6 & 619A 3507H, 35.7 & 723A First Gear 10 kmph (6 mph) 7 kmph (4 mph) Second Gear 34 kmph (21 mph) 33 kmph (20 mph) 2.3.2 Hydraulic Cylinder Performance Specifications Note: Machine with no load, engine at full throttle, hydraulic oil above 54° C (130° F) minimum, engine at operating temperature. Function Approximate Times (sec.
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General Information and Specifications 2.3.4 Engine Performance Specifications Description Engine Make/Model Deutz TCD2012L04V02 Tier III Low Idle 925 ±50 rpm High Idle 2370 ±50 rpm Horsepower 74.9 kW/100.4 BHP @ 2200 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements Average Fuel Consumption (dependant on load/duty) 2.3.5 6,1 I/hr (1.6 gal/hr) Tires Note: Standard wheel lug nut torque is 300 Nm (220 lb-ft).
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General Information and Specifications 2.4 FLUIDS, LUBRICANTS AND CAPACITIES Engine Crankcase Oil Capacity w/Filter Change 10,4 liter (11 quart) Filter Capacity 1,0 liter (1.05 quart) Oil Type L2906H, 2906H, 3507H, 619A & 723A 29.6LP, 29.6 & 35.7 15W-40 CE DF Super ENGINE OIL 15W-40 Fuel Filters Primary Fuel Filter Capacity Fuel Filter Capacity Approx. 1,0 liter (1.05 quart) 0,6 liter (0.16 quart) Fuel Tank Capacity L2906H, 2906H, 29.6LP, 29.6 & 619A 95 liter (25 gallon) 3507H, 35.
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General Information and Specifications Axles Differential Housing Capacity - Front L2906H, 2906H, 29.6LP, 29.6 & 619A 9,5 liter (10 quart) 3507H, 35.7 & 723A 10 liter (10.6 quart) Differential Housing Capacity - Rear L2906H, 2906H, 29.6LP, 29.6 & 619A 3507H, 35.7 & 723A 5,5 liter (5,8 quart) 8 liter (8.5 quart) Wheel End Capacity L2906H, 2906H, 29.6LP, 29.6 & 619A 3507H, 35.7 & 723A 0,8 liter (0.8 quart) Front - 0,6 liter (0.6 quart) Rear - 0,7 liter (0.7 quart) Transfer Box Capacity 0,5 liter (0.
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General Information and Specifications 2.5 MAINTENANCE SCHEDULES 2.5.1 2.5.
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General Information and Specifications 2.6 2.6.1 LUBRICATION SCHEDULE 10 Hour Lubrication Schedule EVERY 10 OAH1900 2-16 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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General Information and Specifications 2.6.2 50 Hour Lubrication Schedule EVERY 50 OAH1910 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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General Information and Specifications This Page Intentionally Left Blank 2-18 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Section 3 Boom Contents PARAGRAPH 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 TITLE Boom System Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom System - Two Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Boom 3.1 BOOM SYSTEM COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.
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Boom 3.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 3.3 3.3.1 BOOM SYSTEM - TWO SECTION BOOM Boom System Description The boom operates via an interchange among the electrical, hydraulic and mechanical systems.
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Boom 10. Remove the lock bolt (3) and pin (4) from the rod end of the compensating cylinder on the first boom section. Rest the cylinder on the machine frame. 4. Remove the lock bolt (9) and pin (10) from the barrel end of tilt cylinder. Lift the tilt cylinder out of the boomhead. 11. Lower the boom to a level position and place a suitable support under the rear of the boom. Reposition the slings to each end of the boom. 5.
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Boom 3.4.3 Second Section Boom Installation 1. Insert the extend/retract cylinder through the rear of the second boom section and attach the pin and clip to the rod end. 2. Install the bottom rear wear pads, washers and bolts into the first boom section. Apply Loctite® 243TM and torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts).
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Boom 6. With the sling still in place, install the comp cylinder pin (1) and lock bolt (2). Apply Loctite® 243TM and torque to 90 Nm (66 lb-ft). Extend/Retract Cylinder Removal 1. Remove any attachment from the quick attach assembly. Refer to Section 3.6, “Quick Attach Assembly.” 2.
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Boom 3.4.6 Extend/Retract Cylinder Installation 1. Using a suitable sling, carefully install the extend/ retract cylinder into the rear of the boom and line up the barrel end of the cylinder with the pin bores on the first boom section. 9 8 2. Install the mounting pin (9) through the frame access hole on the chassis and the first boom section bore and cylinder barrel. Secure with snap rings. 3. Remove the plugs in the bottom of the extend/retract cylinder and install the previously removed fittings.
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Boom 3.5 BOOM WEAR PADS 5 A total of 14 wear pads are installed on the boom. Twelve of the fourteen wear pads on this boom are flat rectangular wear pads with metal inserts. Two wear pads on the bottom of the second section boom are channeled for tilt hose and auxiliary hose clearance. 3.5.1 Wear Pad Inspection 1 1 Ma2070 Inspect all wear pads for wear. If the angle indicators (1) on the ends of the wear pads are visible, the wear pads can be reused.
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Boom Boom Section Wear Pad Pathway Lubrication: • Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease. • Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease. 3.6 3.6.1 QUICK ATTACH ASSEMBLY Quick Attach Removal 1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch. 2.
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Boom 3.7 FORKS 3.8 Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately. Daily Inspection 1. Inspect forks (8) for cracks, paying special attention to heel (9) and mounting tubes (10). 2. Inspect forks for broken or bent tips (11) and twisted blades (12) and shanks (13). 3.8.
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Boom 3.9.1 NOTICE EQUIPMENT DAMAGE. DO NOT operate with the boom prop in place. Damage to the boom prop and/or the lift/lower cylinder could occur. Equipment and Supplies Required Auxiliary Hydraulic Power Supply: • Portable hydraulic unit or another machine with an auxiliary hydraulic power supply with a capacity to hold up to 11,4 L (3 gal) of hydraulic oil from the machine during lowering process. NOTICE b. Prop Removal 1.
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Boom 3. Label and disconnect both extend/retract hoses (4 & 5). Install plugs in hoses to prevent oil loss. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. Note: Loss of hydraulic oil is limited to the amount trapped within each hose. 4. Using the hoses and fittings specified previously, connect the jumper hoses between the auxiliary hydraulic power supply and the extend/retract hoses (4 & 5) of the affected machine.
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Boom 3.10 TROUBLESHOOTING This section provides an easy reference guide covering the most common problems that occur during operation of the boom. Problem 1. Boom will not extend or retract. Possible Causes Remedy 1. Broken hydraulic hose(s) or tube(s) and/or connections leaking. 1. Locate break, replace hose(s) or tube(s), tighten connections. 2. Extend/Retract hydraulic system not operating properly. 2. Refer to Section 8, “Hydraulic System.” 3. Faulty extend/retract cylinder. 3.
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Boom Problem 6. Rapid boom pad wear. 7. Auxiliary hydraulics will not operate. 3-14 Possible Causes Remedy 1. Incorrect wear pad gap. 1. Check wear pad gaps and correct as needed. Refer to Section 3.5.1, “Wear Pad Inspection.” 2. Rapid cycle times with heavy loads. 2. Reduce cycle times. 3. Contaminated, corroded or rusted wear pad sliding surfaces. 3. Remove contamination and/or corrosion from wear pad sliding surfaces and lubricate.
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Section 4 Cab and Covers Contents PARAGRAPH 4.1 4.2 4.3 4.4 4.5 4.6 TITLE Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Operator Cab Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Cab and Covers 4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section. LSI INDICATOR (L2906H, 2906H, 3507, 29.6LP, 29.6 & 35.
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Cab and Covers 4.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 4.3 4.3.1 OPERATOR CAB Operator Cab Description The welded metal cab features a modular design, allowing for a relatively quick, simple exchange of the entire cab and/or component parts. The cab is bolted directly to the frame. 4.4 CAB COMPONENTS 4.4.1 Steering Wheel a. Steering Wheel Removal 1.
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Cab and Covers 4.4.2 Steering Column/Valve Replacement a. Steering Column and Valve Removal 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. b. Steering Column and Valve Installation 1. Install the four hex-flange capscrews (three if machine is equipped with tilt column) through the steering column, mounting bracket and into the top of the orbitrol valve.
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Cab and Covers 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Open the engine covers. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. Remove the lower dash cover. 4.4.4 Throttle Pedal Replacement a. Throttle Pedal Removal 1.
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Cab and Covers 4.4.5 CE Machines Throttle Cable Adjustment 1. Start the machine and allow engine to low idle for approximately 30 seconds. 3 2. Verify low idle (900 ± 50 rpm). Low idle is a factory non-adjustable setting. 3. Bring engine to full throttle. If high idle rpm is greater than or equal to 2340 rpm, a thick throttle stop will need to be installed. If high idle rpm is less than 2340 rpm, a thin throttle stop will need to be installed. 2 1 4. Return engine to low idle and shut engine OFF.
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Cab and Covers 5. Start the engine and test the boom joystick for proper functions. WARNING 6. Close and secure the engine cover. Exhaust system components reach high temperatures and can cause severe burns. DO NOT come into contact with hot exhaust system components. 4.4.7 7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 4.4.8 Joystick Replacement a. Joystick Removal 1.
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Cab and Covers 8. Remove the seat/seat base. 9. Remove the seat plate (8) to expose the heater/ defroster element. noted, and make any necessary repairs before continuing. 10. Install the seat plate (8) in the cab. 11. Install the seat/seat base. 8 12. Check the coolant level. Add or remove fluid as required. 13. Verify the proper operation of the heating and air conditioning (if equipped) system. 14. Close and secure the engine covers. 15.
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Cab and Covers 3. Open the engine cover. Allow the system fluids to cool. 4. Properly disconnect the battery. 5. If equipped with a cab heater, Refer to Section 4.4.10, b. “Heater Assembly Installation.” 6. Working underneath the cab, label, disconnect and cap all hydraulic hoses at the cab fittings. Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. 7. In the cab, disconnect the throttle cable at the throttle lever bracket.
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Cab and Covers 13. Start the engine and check the operation of all controls. Check for hydraulic oil leaks. Check the hydraulic oil level in the tank and add oil as required NOTICE When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing. 14.
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Section 5 Axles, Drive Shafts, Wheels and Tires Contents PARAGRAPH 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 TITLE Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Axles, Drive Shafts, Wheels and Tires 5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.
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Axles, Drive Shafts, Wheels and Tires 5.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 5.3 Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.
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Axles, Drive Shafts, Wheels and Tires 5.4.4 Axle Removal WARNING Safely raise and adequately support the machine so that it will remain stable and in place before attempting to remove an axle. The front and rear axle assemblies differ in that the front axle assembly is equipped with a hydraulic drive pump, parking brake mechanism and a limited-slip feature; the rear axle has none of these.
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Axles, Drive Shafts, Wheels and Tires 2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation. 3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand.
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Axles, Drive Shafts, Wheels and Tires 5.4.6 Axle Assembly and Drive Shaft Troubleshooting Problem 1. Excessive axle noise while driving. 2. Intermittent noise when traveling. 3. Vibration or intermittent noise when traveling. 5-6 Possible Causes Remedy 1. Oil level too low. 1. Fill oil to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 2. Axle and/or wheel end housings filled with incorrect oil or oil level low. 2.
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Axles, Drive Shafts, Wheels and Tires 5.4.6 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem 4. Oil leaking from axle (differential housing and/or axle housings). 5. Oil leaking from wheel end housing (planet carrier). 6. Oil leaking from steering cylinder. Possible Causes Remedy 1. Drain plugs loose and/or o-rings damaged or missing. 1. Replace o-rings as needed and tighten plugs 80 Nm (59 lb-ft). 2. Hose fittings loose. 2. Tighten fittings. 3.
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Axles, Drive Shafts, Wheels and Tires 5.4.6 Axle Assembly and Drive Shaft Troubleshooting (Continued) Problem 7. Axle overheating. 8. High steering effort required. 9. Slow steering response. 10. Excessive noise when brakes are engaged. 11. Brakes will not engage. 12. Brakes will not hold the machine or braking power reduced. 5-8 Possible Causes Remedy 1. Oil level too high. 1. Fill oil to correct level. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”) 2.
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Axles, Drive Shafts, Wheels and Tires 5.5 5.5.1 DRIVE SHAFTS 6. Remove the four capscrews and four locknuts (1) securing the flange yoke (2) to the front axle flange. Drive Shaft Inspection Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time later. Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft.
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Axles, Drive Shafts, Wheels and Tires 5.6 WHEELS AND TIRES 5.6.1 WARNING Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over. It is recommended that a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information.
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Axles, Drive Shafts, Wheels and Tires 2. Install washers on the wheel studs. 3. Start all lug nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3 5 1 8 7 2 6 4 OAH0990 4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 300 Nm (221 lb-ft). 5. Remove machine from supports, 6. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 5.
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Axles, Drive Shafts, Wheels and Tires This Page Intentionally Left Blank 5-12 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Section 6 Transmission Contents PARAGRAPH 6.1 6.2 6.3 6.4 6.5 6.6 6.7 TITLE Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
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Transmission 6.1 TRANSMISSION ASSEMBLY COMPONENT TERMINOLOGY To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.
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Transmission 6.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 6.3 TRANSMISSION DESCRIPTION Instructions in this section pertain mainly to general specifications, towing, maintenance information, and transmission removal and installation procedures.
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Transmission 12. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts. 6.5.3 After Transmission Replacement 1. Install new hydraulic filters. 13. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so 2. Check the hydraulic oil level and add oil as required. 14.
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Transmission 6.6 TRANSMISSION FILTER REPLACEMENT 2 4 3 6 1 MZ5420 5 The hydrostatic pump filter is located on the left (inside) of the pump (1). Cleanliness is of extreme importance. Before attempting to remove the transmission filter, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission direction solenoids and other electrical components. 6.6.
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Transmission 6.7 TOWING A DISABLED MACHINE Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power. 2 Towing is only possible by using the "towing" feature built into the hydrostatic pump and disengaging the park brake on the front axle. 1. Securely block all four wheels. MZ5420 WARNING Block all four wheels when preparing the machine for towing to prevent any unexpected movement.
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Section 7 Engine: Deutz TCD 2012 Contents PARAGRAPH 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 TITLE Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . .
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Engine: Deutz TCD 2012 7.1 7.1.1 INTRODUCTION Disclaimer and Scope These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.
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Engine: Deutz TCD 2012 7.1.2 Component Terminology To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.
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Engine: Deutz TCD 2012 7.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 7.5 ENGINE COOLING SYSTEM 7.5.1 For a 110° C (230° F) system, use a 95 kPa (13 psi) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine. 7.5.2 7.3 ENGINE SERIAL NUMBER The Deutz TCD 2012 serial number is located on a tag on top of the engine.
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Engine: Deutz TCD 2012 8. Place a funnel at the base of the radiator to channel the drained coolant into the container. Open the radiator petcock and drain the coolant into the funnel. Transfer the fluid into a properly labeled container. Dispose of properly if coolant needs to be replaced. Close the radiator petcock. 9. Label, disconnect and cap all charge air tubes attached to the radiator. Cap all openings to keep dirt and debris from entering the cooling system. 10.
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Engine: Deutz TCD 2012 To clean the fuel/hydraulic oil tank: NOTICE Due to the precise tolerances of diesel injection systems, keep the fuel clean, and free of dirt and water. Dirt and water in the fuel system can cause severe damage to both the injection pump and the injection nozzles. Use #2 diesel fuel with a minimum Cetane rating of 40. #2 diesel fuel gives the best economy and performance under most operating conditions.
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Engine: Deutz TCD 2012 7.8 ENGINE EXHAUST SYSTEM 7.8.1 11. Remove the front exhaust pipe section (6) from the engine. Exhaust System Removal 7.8.2 1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the parking brake, and shut the engine OFF. 2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated. 3.
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Engine: Deutz TCD 2012 7.9 AIR CLEANER ASSEMBLY 2. Place the loosened clamp (8) over the air intake tube (9) and install elbow on the air cleaner assembly. 3. Adjust and tighten clamps before starting the machine. CAUTION 4. Properly connect the battery. NEVER run the engine with only the inner safety element installed. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.
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Engine: Deutz TCD 2012 14. Unbolt and remove the fan safety shroud. 7.10.2 15. Remove bolts securing the radiator and lift it clear of engine compartment. Refer to section Section 7.5.2, “Radiator/Oil and Charge Air Cooler Replacement.” 16. Mark the engine fan orientation. Remove the engine fan. 1 2 Engine disassembly, internal inspection, service, repair and assembly procedures are covered in the Deutz TCD 2012 service manual.
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Engine: Deutz TCD 2012 14. Refill the hydraulic reservoir (Refer to the appropriate Operation & Safety Manual for information concerning the hydraulic oil and filter change). 15. Reinstall the engine cover and radiator cover. 16. Reconnect the battery terminals, being sure to start with the positive (+) terminal. 17. Check that all hydraulic, electrical, cooling, fuel and exhaust system connections are correct and connected tightly. 18. Recharge the air conditioning system. Refer to Section 4.4.
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Section 8 Hydraulic System Contents PARAGRAPH 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 TITLE Hydraulic Component Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Hydraulic System 8.12 8-2 Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12.1 General Cylinder Removal Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12.2 General Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12.3 Cylinder Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12.4 Cylinder Inspection . . . . . . . . . . . . . . . . . .
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Hydraulic System 8.1 HYDRAULIC COMPONENT TERMINOLOGY To understand the safety, operation and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the hydraulic components of the machine. The following illustration identifies the components that are referred to throughout this section.
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Hydraulic System 8.2 SAFETY INFORMATION WARNING DO NOT service the machine without following all safety precautions as outlined in the “Safety Practices” section of this manual. 8.3 GENERAL INFORMATION Petroleum-based hydraulic oils are used in this machine. The temperature of hydraulic oil increases during the operation of various hydraulic functions. A heated petroleum-based hydraulic oil presents a fire hazard, especially when an ignition source is present.
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Hydraulic System NEVER replace a hydraulic hose or other component with a part not specifically designed for this machine. Use only factory approved parts for best performance and safety. Removal and replacement of hoses, tube lines, fittings, etc. usually involves straightforward procedures. When removing a hydraulic hose or other component, be aware that o-rings are used throughout the hydraulic system. ALWAYS replace a used o-ring with a new part.
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Hydraulic System 8.6.3 Charge Pressure Checking 8.6.5 Boom Function Pressure Checking 3 5 7 4 6 MZ5520 Attach a pressure gauge to the test port (3) on the hydrostatic transmission (4) to check the system pressure. The pressure should be 26,2 ± 2 bar (380 ± 30 psi) with the engine at low idle. The charge pressure relief valve is preset at the factory and is not adjustable. 8.6.
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Hydraulic System 8.6.6 Steering Pressure Checking Attach a pressure gauge to the test fitting (7) at the main control valve. The pressure reading should be 186 ± 4 bar (2700 ± 50 psi) with the steering wheel fully turned to the steering stop in one direction. Do NOT adjust any relief settings. The unit is preset at the factory and should not be tampered with. If the proper pressure is not read, the unit may be defective. 8.6.
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Hydraulic System 8.7 HYDRAULIC SCHEMATIC 8.7.1 Gear Pump Schematic (Sheet 1) 8-8 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Hydraulic System 8.7.1 Gear Pump Schematic (Continued) (Sheet 2) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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8-10 A B C D E F ITEM A B1 B2 C D E F G H I J K L M N O P LOC D5 D3 D3 F5 F3 E3 G6 E5 G7 H7 E6 D6 D6 2,D8 2,E2 2,H5 H3 8 R B P T DESCRIPTION PUMP, DRIVE MOTOR, DRIVE - 2906 MOTOR, DRIVE - 3507 PUMP, IMPLEMENT - PISTON VALVE, MAIN CONTROL - PISTON VALVE, STEER SELECT VALVE, STEERING VALVE, BRAKE INCHING VALVE, PARK BRAKE VALVE, SERVICE BRAKE VALVE, 3 BAR CHECK - COOLER BYPASS COOLER, TRANSMISSION FILTER, MAIN RETURN VALVE, FRONT/REAR AUX - OPTIONAL VALVE, 1ST/2ND FRONT AUX - OPTIONAL VALVE, TRA
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L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 A B C B 280 8 FRONT AUX A 280 OPTIONAL REAR AUXILIARY M T REAR AUX B 280 REAR AUX H C A 280 7 B N M B 280 REAR AUX 5 6 5 2ND FRONT AUX 1ST OPTIONAL REAR AUX WITH ELECTRIC SECOND FRONT AUX 2ND L A 280 TO PUMP X-PORT TRAILER BRAKES O TRAILER BRAKE VALVE FRONT AUX 1ST OPTIONAL REAR AUX WITH MANUAL SECOND FRONT AUX M P T P D B Y AUXILIARY OPTIONS R G E F G I X RAP.PIL.
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Hydraulic System 8.8 HYDRAULIC RESERVOIR The hydraulic reservoir and fuel tank are part of the frame. For this reason, neither tank can be removed. For cleaning instructions, see Section 7.7.2, “Fuel/Hydraulic Oil Tank.” Occasionally, oil may seep, leak or be more forcefully expelled from the filter head when system pressure exceeds the rating of the filter head or filler cap.
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Hydraulic System 7. Label, disconnect and cap all hydraulic hoses attached to the pump, cap all fittings and plug hoses to keep dirt and debris from entering the hydraulic system. 8. Remove the two bolts that hold the pump in place. b. Implement Pump Installation 1. Position pump in the mounting position. a. Front Drive Motor Removal 1.
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Hydraulic System 8.11 CONTROL VALVES 8.11.1 7. Wipe up any hydraulic oil spillage in, on, near and around the machine and the work area. Main Control Valve The main control valve is mounted on the rear of the machine behind the rear access panel. 4 5 8. Remove the four bolts securing the main control valve to the frame bracket. b. Main Control Valve Disassembly 1. To disassemble the individual sections of the main control valve, remove the nuts from the end of the tie rods.
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Hydraulic System e. Main Control Valve Assembly Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. Assemble each Valve Section 6. Start the engine and run at approximately one-third to one-half throttle for about one minute without moving the machine or operating any hydraulic functions. 7. Inspect for leaks and check the level of the hydraulic oil in the reservoir. Shut the engine OFF. 8.
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Hydraulic System 8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. 8.11.3 Parking Brake 7 1 9 10 8 MZ5310 6. Remove the cotter key and pin (7) from the top of the brake valve (8). 7. Remove the bolts (9) that mount the service brake valve to the bracket support (10). Note: DO NOT disassemble the service brake valve. The service brake valve is not serviceable and must be replaced in its entirety, if defective. b.
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Hydraulic System Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil. 2. Use new oiled o-rings as required. Uncap, reattach and secure the three hoses. 3. Check the routing of all hoses for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. 4.
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Hydraulic System 8. Close and secure the engine cover. 9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. d. Parking Brake Valve Test. 1. Start the machine and engage the shift lever to the forward position. Slowly depress the throttle to mid idle. The parking brake will not allow the machine to move. b. Steer Select Valve and Manifold Disassembly, Cleaning, Inspection and Assembly 1. Place the steer select assembly on a suitable work surface. 2.
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Hydraulic System 2. Connect the hydraulic hoses, fittings, solenoid wire terminal leads, etc., to the steer select valve and manifold. 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Check the routing of all hoses, wiring and tubing for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all tube and hose clamps. 3. Open the engine cover.
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Hydraulic System 6. Install the cartridge in the inching valve housing. c. Inching Valve Installation 1. Attach the inching valve to the mounting plate on the frame using the socket head capscrews. 2. Connect the hydraulic hoses, fittings, etc., to the inching valve. 3. Check the routing of all hoses and wiring for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required. Tighten all hose clamps. 4.
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Hydraulic System 6. Remove the anti-kick valve from the machine. Wipe up any hydraulic oil spillage in, on, near and around the machine. 8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel. d. Anti-Kick Back Test b. Anti-Kick Back Disassembly, Cleaning, Inspection and Assembly 1. If further troubleshooting is required, refer to Section 8.7, “Hydraulic Schematic.” 1. Place the anti-kick valve assembly on a suitable work surface. 3 MZ5560 2.
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Hydraulic System 8.12 HYDRAULIC CYLINDERS 1 2 8.12.1 General Cylinder Removal Instructions 3 4 1. Park the machine on a firm, level surface, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF. 2. Chock the wheels. 3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 4. Open the engine cover. Allow the system fluids to cool. 1 5.
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Hydraulic System NOTICE When sliding the rod and piston assembly out of the tube, prevent the threaded end of the tube from damaging the piston. Keep the rod centered within the tube to help prevent binding. 6. Carefully pull the rod assembly along with the head gland out of the cylinder barrel. 7. Fasten the rod end in a soft-jawed vise, and put a padded support under and near the threaded end of the rod to help prevent damage to the rod. 8. Remove the set screw (3) from the piston (4).
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Hydraulic System 1. Grease the bushings at the ends of the hydraulic cylinder. Using an appropriate sling, lift the cylinder into it’s mounting position. NOTICE Avoid using excessive force when clamping the cylinder barrel in a vise. Apply only enough force to hold the cylinder barrel securely. Excessive force can damage the cylinder barrel. 5. Place the cylinder barrel (1) in a soft-jawed vise or other acceptable holding equipment if possible.
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Hydraulic System 8.12.8 Hydraulic Cylinder Torque Specifications Description L2906H, 2906H, 29.6 & 619A 3507H, 35.
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Hydraulic System This Page Intentionally Left Blank 8-26 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Section 9 Electrical System Contents PARAGRAPH 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 TITLE Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keypad and Display Screen . . . . . . . . . . . . . . . . .
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Electrical System 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.2 Window Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31 9.12.1 Windshield Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31 9.12.2 Rear Window Wiper Motor (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32 9.12.3 Windshield Washer Reservoir and Pump . . . . . . . . . . . . . . . . . . . . . . . . . 9.32 Cab Heater and Fan. . . .
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Electrical System 9.1 ELECTRICAL COMPONENT TERMINOLOGY To understand the safety, operation, and service information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the electrical components of the machine. The following illustration identifies the components that are referred to throughout this section.
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Electrical System 9.2 SPECIFICATIONS Electrical system specifications are listed in Section 2.3, “Specifications.” 9.3 a. Help - Displays active fault code. Depress OK button again and use keypad arrows to cycle through the last 25 fault codes. Active fault codes are denoted with an asterisk. Refer to Section 9.18.2, “Fault Code Table,” for the complete list of codes.
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Electrical System 9.5 SOFTWARE LEVEL 2 ACCESSIBILITY The following parameters can be altered in the 2nd level of access to the machine’s software. Refer to Section 9.17.2, “Analyzer Software - Version 3.5,”for detailed software information. 9.5.1 Operator Tools Function Description Change Anti Theft Code Allows the owner to change the Anti Theft Code Perform Hardware Exchange Allows the owner to restore machine data (anti theft code, engine hours, machine personalities, etc.
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Electrical System 9.6 9.6.1 OPERATOR TOOLS Resetting the Anti theft Code To reset the anti theft code: 1. Turn the engine to the ON position. 2. Press the "C" and "OK" buttons on the dash simultaneously to enter the analyzer mode. 3. Scroll to "Access Level Code". Enter the code "33271" to go into access level 2. 4. Scroll to and select the "Operator Tools" screen. 5. Scroll to and select the "Change Anti Theft Code" screen. 6. Enter the current anti theft code.
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Electrical System 9.7 INSTRUMENT PANEL 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 9.8 9.8.1 FUSES AND RELAYS Engine Compartment Relays and Fuses 2 MY3360 a. Removal 1. Park the machine on a firm, level surface with the machine level, retract and level the boom. Place the transmission control lever in the (N) NEUTRAL position and engage the parking brake. Shut the engine OFF. 2.
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Electrical System 9.8.2 Power Distribution Module MZ5360 Fuse/Relay 9.8 Function Amp Rating F01 Right Headlight Low 7.5 F02 Rear Wiper 15 F03 Right Headlight High 7.5 F04 Left Headlight Low 7.5 F05 Left Headlight High 7.5 F06 Fan 20 F07 Front Wiper 25 F08 A/C 7.5 F09 Key 2 15 F10 Key 1 15 F11 Radio 10 F12 Lights Bat 1 15 F13 Lights Bat 2 15 F14 Left Marker Lights 7.
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Electrical System Fuse/Relay Function Amp Rating F20 Beacon 15 F21 Rear Worklights 15 F22 Controller 25 F23 Display/Joystick 10 F24 Fuel 15 F25 Socket 15 F26 Seat 15 F27 Key Bat 15 F28 Spare Bat 15 F29 Shift/Steer 15 F30 Spare Key 15 K1 Reverse Travel K2 1/2 Aux K3 Flasher K4 Ignition Power 1 K5 Ignition Power 2 K6 Work Lights K7 Ignition Power 3 K8 Fuel L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9 ELECTRICAL SYSTEM SCHEMATICS For more detailed schematics, contact your local authorized service distributor. 9.9.1 Cab Harness Electrical Schematic 1 of 2 Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 2) Note: Sheet 1 of 7 not included in electrical schematic intentionally. 9.10 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 2 - Continued) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 2) Note: Sheet 1 of 7 not included in electrical schematic intentionally. 9.12 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 2 - Continued) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9.2 Cab Harness Electrical Schematic 2 of 2 Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 3) 9.14 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 3 - Continued) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 3) 9.16 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 3 - Continued) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9.3 Cab Roof and Boom Schematic Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 4) 9.18 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 4) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9.4 Front and Rear Frame Schematic Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 5) 9.20 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 5) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9.5 Engine Compartment Schematic Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 6) 9.22 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 6) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.9.6 Power Ground, ANSI Shifter and Oil Gauge Schematic Before S/N 1160005989 excluding 116005189, 1160005314 & 1160005414 (Sheet 7) 9.24 L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System S/N 1160005989 & After including 116005189, 1160005314 & 1160005414 (Sheet 7) L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.7 9.
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Electrical System 9.10 9.10.1 CIRCUIT BREAKDOWNS Alternator Charge Circuit ENGINE HARNESS CAB HARNESS 1 ENGINE ALTERNATOR W 1 X40-W X40-D+ X40-B+ 1 1 B+ D+ ALTERNATOR 1 2 2 3 3 4 4 5 5 6 6 7 7 8 9 9 ALT D+ WHT ALT BAT RED (16.
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Electrical System 9.10.
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Electrical System 9.10.3 9.28 Constant Power Circuit L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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Electrical System 9.11 9.11.1 ENGINE ELECTRICAL COMPONENTS flywheel. The starter drive or solenoid that pushes the drive forward to engage the flywheel may be defective. Missing or damaged teeth on the flywheel can also prevent the starter from cranking the engine. Starter 3. If the starter only “clicks” it may indicate that the battery is discharged, or that there is a loose or corroded battery cable connection.
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Electrical System e. Starter Periodic Maintenance A starter requires no routine maintenance beyond the occasional inspection of the electrical connections, which must be clean and tight. Note: DO NOT disassemble the starter. The starter is not serviceable and must be replaced in its entirety, if defective. f. Starter Installation 1. Position the starter in its mounting opening on the flywheel housing. Position the ground cable over the correct starter mounting bolt. Secure the starter with fasteners.
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Electrical System b. Alternator Installation 1. Position the alternator and align with the upper alternator mount on the engine bracket. Insert the upper mounting hardware (1) through the alternator mount. DO NOT tighten completely at this time. 2. Align the lower alternator mount hole with the lower mounting bracket on the engine, and insert the lower mounting hardware (2) through the alternator mount. DO NOT tighten completely at this time. 1.
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Electrical System 7. Turn ignition key switch to the RUN position, and operate windshield wiper in both LOW and HIGH speeds to ensure proper operation and that correct wiper travel is achieved. b. Disassembly 8. Install right side defroster hose to the dash panel hose connector. c. Inspection and Replacement 9. If previously removed, install hydraulic hoses under the dash. 10. Install the lower dash panel. 11. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 9.12.
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Electrical System a. Removal 1. Park the machine on a firm, level surface with the machine level, retract and level the boom. Place the transmission control lever in the (N) NEUTRAL position and engage the parking brake. Shut the engine OFF. 9.13 9.13.1 CAB HEATER AND FAN Cab Heater/Air Conditioning Controls 2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated. 3. Allow the engine and all system fluids to cool. 4.
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Electrical System 9. Remove the hex locknut from the suspect control shaft. 9.14 SOLENOIDS, SENSORS AND SENDERS 10. Remove the control from the panel. b. Disassembly DO NOT disassemble the cab heater and fan controls. The controls are not serviceable. Replace controls if found to be defective. c. Installation and Testing 1. Check that the variable speed fan control is in the OFF position. 2. If installing the temperature control, attach the cable connector to the back of the control. 9.14.
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Electrical System d. Ignition Switch Installation 1. Connect the ignition key switch to the cab harness connectors. 2. Reach up and under the dash to work the ignition switch into the ignition switch-mounting hole on the lower right side of the dash. 3. Align the ignition switch so that when it is in the OFF position, the key slot is positioned vertically (straight up and down). Install the hex nut securing the ignition switch to the dash. DO NOT overtighten. 4. Install the lower dash panel. 5.
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Electrical System 7. Check the fuel level sender. The resistance of the fuel level sender are: Fuel Tank Capacity L2906H, 2906H, 29.6 & 619A 3507H, 35.7 & 714A 100% 4 ohms 10 ohms 50% 162 ohms 185 ohms 0% 314 ohms 297 ohms 8. A defective fuel level sender in the fuel tank may also prevent the fuel level indicator from moving. 9.14.
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Electrical System 9.14.6 2. Install the fuel shut-off solenoid on the engine. Do Not Over Tighten. Fuel Shut-off Solenoid 1 3. Connect the wiring connector at the fuel shut-off solenoid lead. 1 4. Properly connect the battery. 5. Start the engine. If the engine starts, the fuel shutoff solenoid is functioning. If the engine fails to start, the fuel shut-off solenoid may have a poor ground connection.
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Electrical System 4. Start the engine, and observe the operator’s display for warning indication. If the sender is not defective, the problem could be elsewhere; possibly in a shorted wire, improper-running engine, low oil, obstructed or faulty oil pump, defective instrument display. 5. Close and secure the engine cover. 6. Remove the Do Not Operate Tag from the ignition key switch and the steering wheel. 9.14.8 Oil Temperature Sensor The oil pressure sensor is located on the side of the engine oil pan.
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Electrical System 9.14.10 b. Boom Angle Sensor Inspection and Replacement Boom Angle Sensor The boom angle sensor is located at the top left inside rear of the boom. Inspect the sensor and the wiring harness connector terminals for continuity. Replace a defective or faulty sensor with a new sensor. a. Boom Angle Sensor Removal 1.
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Electrical System 9.15 9.15.1 LOAD STABILITY INDICATOR - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (Before S/N 1160005993 excluding 1160005943, 1160005945 & 1160005414) Load Stability Indicator WARNING TIP OVER HAZARD. The LSI considers only longitudinal stability limitations, observe all operating parameters. Failure to follow operating parameters of the telehandler could damage the equipment and/or cause tip over. Note: The Load Stability Indicator is NOT a serviceable item.
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Electrical System 9.15.2 b. LSI Sensor Installation LSI Sensor Note: If the rear axle is removed or replaced, the LSI Sensor must be installed AFTER the rear axle is installed and setting on all four wheels. 1. Ensure threads of both bolt holes are clean and free from rust, water and debris. 2. Clean the bare metal with a degreasing agent, Loctite® 7063TM. 3. Remove any excessive degreasing agent and allow to dry. 6 4.
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Electrical System 9.15.3 LSI System Calibration a. Standard Calibration To calibrate the LSI, certain conditions must be met: • The sensor must be installed according to Section 9.15.2, “LSI Sensor.” • The machine control system must be powered on for at least 10 minutes before calibration. • The calibration shall be conducted with the standard carriage and forks attached for the machine and weights as necessary.
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Electrical System Note: If the test weight is not known, follow steps 1 & 2. Model Test Weight (W) Xtip (1) Xcal (2) L2906H, 29.6LP 2100 kg (4630 lb) 1256 mm (49 in) 698 mm (27 in) 2906H, 29.6 2100 kg (4630 lb) 1256 mm (49 in) 698 mm (27 in) 3507H, 35.7 2100 kg (4630 lb) 1758 mm (69 in) 1043 mm (41 in) 1 L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 1. With ignition key in OFF position, press and hold SYSTEM CHECK button on LSI display and turn ignition key to engine START position.
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Electrical System 9.16 LOAD STABILITY INDICATOR - LSI L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 (S/N 1160005993 & After including 1160005943, 1160005945 & 1160005414) 9.16.1 Load Stability Indicator • In some instances the LSI system may slow down or stop boom functions if operated close to forward stability limitations. When LEDs begin to flash, certain functions can not be operated.
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Electrical System 9.16.2 b. LSI Sensor Installation LSI Sensor Note: If the rear axle is removed or replaced, the LSI Sensor must be installed AFTER the rear axle is installed and setting on all four wheels. 7 1. Ensure threads of both bolt holes are clean and free from rust, water and debris. 2. Clean the bare metal with a degreasing agent, Loctite® 7063TM. 3. Remove any excessive degreasing agent and allow to dry. 4.
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Electrical System 9.16.3 LSI System Calibration a. Standard Calibration To calibrate the LSI, certain conditions must be met: • The sensor must be installed according to Section 9.15.2, “LSI Sensor.” • The machine control system must be powered on for at least 10 minutes before calibration. • The operator must remain in the cab. • The calibration shall be conducted with the standard carriage and forks attached and weights as necessary ( a range of 60-80% of maximum weight capacity).
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Electrical System 6. Lower boom and without moving the machine, pick up the proper test weight (W) listed in the table. Pressing the LMI Override button may be required to lower the boom. 1 2 L2906H, 2906H, 3507H, 29.6LP, 29.6 & 35.7 MZ5990 1. With the estimated test weight on the forks, start the machine and extend the boom horizontally until the machine starts to tip. This point should be at an extension of Xtip (1) of the second boom section.
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Electrical System 9.16.5 500 Hour - LSI CAN SYSTEM CHECK 1. Start machine 2. Press the “C” and “OK” buttons simultaneously on the keypad or the analyzer. 9.17 HAND HELD ANALYZER The hand held analyzer can be used in place of the cab display panel. 3. Go to “ACCESS LEVEL 2 or 1” and press “OK”. 4. Enter the proper access code and press “OK”. 5. Go to “OPERATOR TOOLS” menu, press “OK”. 1 6. Scroll to “LSI_CAN SYSTEM CHECK”. 7.
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L2906H, 2906H, 3507H, 619A, 723A, 29.6LP, 29.6, 35.
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9.
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Electrical System 9.18 FAULT CODES Active faults and fault memory will be displayed at the operator level of access. Active faults will also be displayed as a blink code at the controller on-board LED. The 25 previous faults are logged in fault memory, which can be accessed by choosing ENTER while viewing active fault messages. 9.18.
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Electrical System 9.18.2 Fault Code Table Message Fault Code HELP COMMENT 00XXX EVERYTHING OK 001 POWER UP Indicators Other Actions Taken Trigger for Fault Latch Until The system detects no problems exist. 21XXX POWER CYCLE 211 FUNCTION ENABLE INPUTS – INVALID SIGNAL STATES 214 1 Ignore and inhibit all function requests from the platform station. Output J2-19 Function Enable Relay of the platform module will be deactivated.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until JOYSTICK S3 BUTTON ACTIVE AT POWER UP 219 1 Ignore command signals from the joystick S3 button that was active during the power-up. At system power-up, if the S3 button is activated on JLG models only. A CAN message is received indicating the joystick S3 button is not activated.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until APU SWITCH INPUT INVALID – INPUT HIGH AT POWER UP 2116 1 Still allow APU function request. If J7-4 Boom Angle reading is less than 10° and the J3-8 Boom Retracted input is HIGH, cutout the Main Lift Up and Telescope Out functions. If a platform is configured as ENABLED and the UGM detects J4-16 Auxiliary Power Unit (APU) Enable is HIGH at system power up.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CONTINUOUS AUXILIARY HYDRAULICS SWITCH HIGH AT POWER UP 2122 1 Inhibit operation of the Continuous Auxiliary Hydraulics feature/logic. The UGM has detected the Continuous Auxiliary Hydraulics switch is HIGH at system power up. The input goes LOW for a period of at least 1 second.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until FUNCTION ENABLE INTERLOCK – ENABLE SWITCH NOT SELECTED FIRST 2227 1 The requested function will be ignored. If the PLATFORM STATION is active and a platform is configured as ENABLED and a platform is detected as attached and a hydraulic function request is detect at the platform station before the function enable signal was received. The hydraulic function request is no longer active.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until PLATFORM OPTION NOT CONFIGURED 2311 1 The UGM will also disregard all commands from the platform station. The UGM will use the platform attached response curves. If the PLATFORM ATTACHED option has not been configured in the MACHINE SETUP menu and a platform attached state is detected or the UGM detects a HIGH on J7-1 or J7-2. Power cycle.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK STABILIZERS NOT DEPLOYED 2315 1, 15 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK CHASSIS NOT LEVEL 2317 1, 16 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until OPERATING MODE INTERLOCK - PARK BRAKE NOT SET 2320 1 J2-26 Engage Starter output will be deactivated and engine start will not be permitted if the PLATFORM STATION is active and CABIN MODE was the last valid operating mode. Changeover to PLATFORM MODE will not be permitted. Changeover to CABIN MODE will not be permitted. All hydraulic function requests from the platform station will be ignored.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until HYDRAULIC FILTER RESTRICTION 2332 1, 6 N/A J2-24 Hydraulic Filter Restriction input is HIGH for a period of 3 seconds or more after system power has been ON for at least 10 minutes. J2-24 Hydraulic Filter Restriction input is LOW for 1 second. ALL WHEEL STEER INPUT – INVALID SIGNAL 2333 1 Not recognize any steer mode requests on input J4-35 All Wheel Steer.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until KEYPAD CANCEL BUTTON – INVALID SIGNAL 2340 1 Disregard all signal changes until switch state transitions to LOW. The UGM detects the keypad CANCEL button is HIGH at power up or for a period of 7 seconds or longer. Power cycled. KEYPAD UP BUTTON – INVALID SIGNAL 2341 1 Disregard all signal changes until switch state transitions to LOW.
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Electrical System Message BOOM ANGLE SENSOR – NOT RESPONDING Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until 2346 1 Display the fixed boom angle value of ‘99’ on the operator’s cabin display. Temporarily assign a fixed boom angle value of 99×. Disallow boom angle sensor calibration (“BOOM ANGLE: CALIBRATION FAIL”). Ignore all hydraulic function requests from the platform module.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until SYSTEM INTERLOCK – SET JOYSTICK INPUTS TO NEUTRAL 2347 1 Deactivate and inhibit all joystick functionality. The UGM has detected one of the following conditions: The hydraulic quick connect switch is activated when any of the other auxiliary hydraulics functions is active.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CABIN JOYSTICK – LEFT ROLLER FAULT 2350 1 Left roller function requests will be ignored by the UGM. The CAT cabin joystick detects a fault with the left roller on the joystick. Power cycled. CABIN JOYSTICK – RIGHT ROLLER FAULT 2351 1 Right roller function requests will be ignored by the UGM. The CAT cabin joystick detects a fault with the right roller on the joystick. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ERRATIC PLATFORM COUPLED SIGNAL 2385 1 The platform will be considered coupled. The UGM detects three signal transitions on J3-13 within a 5 second period. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until PLATFORM ATTACHED HYDRAULIC QUICK CONNECT CUTOUT 2528 1 Deactivate output J1-23 Hydraulic Quick Connect. Ignore auxiliary hydraulic requests when the S4 button is engaged on the cabin’s joystick. If hydraulic quick connect feature is configured in the MACHINE SETUP menu and the platform attached conditions have been met and J7-35 is HIGH and J3-10 is LOW and the CABIN STATION is active.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TELESCOPE POSITION SWITCHES – CONFLICTING STATES 2558 1 Illuminate the vehicle system distress indicator in the cabin’s display. Activate the buzzer for a period of 5 seconds in the cabin’s display. Illuminate the vehicle system distress indicator at the platform station. Activate the buzzer for a period of 5 seconds at the platform station.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until MAIN LIFT DOWN VALVE – OPEN CIRCUIT 33184 1 Deactivate output J2-22 Main Lift Down Valve. The UGM detects an open circuit at this output or the UGM detects a CURRENT FEEDBACK LOST condition and sets an internal flag to determine if this fault condition is the reason for the fault. Power cycled. MAIN LIFT DOWN VALVE – SHORT TO GROUND 33185 1 Deactivate output J2-22 Main Lift Down Valve.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until FORK TILT VALVES – SHORT TO BATTERY 33192 1 Deactivate output J2-8 Fork Tilt Up Valve. Deactivate output J2-19 Fork Tilt Down Valve. Decouple/disable current feedback input J3-6 Tilt Return (Disables Fork Tilt Up and Down). The UGM detects a short to battery at this output. Power cycled. FORK TILT UP VALVE – SHORT TO GROUND 33193 1 Deactivate output J2-8 Fork Tilt Up Valve.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until AUXILIARY FUNCTION-A VALVE– SHORT TO GROUND 33198 1 Deactivate output J2-9 Auxiliary Function-A Valve. Decouple/disable current feedback input J3-14 Aux Return (Disables Auxiliary Function-A and Function-B). Deactivate and inhibit the Continuous Auxiliary Hydraulics feature. Turn OFF the Continuous Auxiliary Hydraulics indicator.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until HYDRAULIC QUICK CONNECT SELECT – OPEN CIRCUIT 33204 1 Deactivate output J1-23 Hydraulic Quick Connect Select. If hydraulic quick connect feature is configured in the MACHINE SETUP menu and the UGM detects an open circuit at this output. Power cycled. HYDRAULIC QUICK CONNECT SELECT – SHORT TO BATTERY 33205 1 Deactivate output J1-23 Hydraulic Quick Connect Select.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until DUMP VALVE – SHORT TO BATTERY 33214 1 Deactivate output J2-13 Dump Valve. Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-5 Frame Level Right Valve. Deactivate output J2-7 Frame Level Left Valve. Deactivate output J2-8 Fork Tilt Up Valve. Deactivate output J2-9 Auxiliary Function-A Valve. Deactivate output J2-10 Left Stabilizer Up Valve.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until AUXILIARY ELECTRICS – OPEN CIRCUIT 33219 1 Deactivate output J2-1 Auxiliary Electrics. The JLG brand is configured for the UGM, the PLATFORM STATION is not active, and the UGM detects an open circuit at this output. Power cycled. AUXILIARY ELECTRICS – SHORT TO BATTERY 33220 1 Deactivate output J2-1 Auxiliary Electrics.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LEFT STABILIZER UP VALVE – SHORT TO GROUND 33227 1 Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-15 Right Stabilizer Down Valve. Deactivate output J2-10 Left Stabilizer Up Valve. Deactivate output J2-21 Left Stabilizer Down Valve. The stabilizers are configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until RIGHT STABILIZER UP VALVE – SHORT TO GROUND 33233 1 Deactivate output J2-3 Right Stabilizer Up Valve. Deactivate output J2-15 Right Stabilizer Down Valve. Deactivate output J2-10 Left Stabilizer Up Valve. Deactivate output J2-21 Left Stabilizer Down Valve. The stabilizers are configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION C COIL – SHORT TO GROUND 33242 1 Deactivate output J1-10 Transmission C Control Coil. 3rd, 2nd, and 1st will be the only available gear selections. Flash the “Gear Selection” symbol on the LCD of the cabin’s display. A TRANSMISSION configuration of POWERSHIFT is configured and a GEAR SELECTION of 4F/3R is configured and the UGM detects a short to ground at this output. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION A COIL – SHORT TO GROUND 33251 1 Deactivate output J2-33 Transmission A Control Coil. Flash the “Gear Selection” and the “Drive Direction” symbols on the LCD of the cabin’s display. A TRANSMISSION configuration of POWERSHIFT is configured and the UGM detects a short to ground at this output. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until TRANSMISSION 1 COIL – SHORT TO GROUND 33260 1 Deactivate output J1-7 Transmission 1 Coil. Deactivate and inhibit activation of J1-20 Transmission 2 Coil. Flash the “Gear Selection” symbol on the LCD of the cabin’s display. A TRANSMISSION configuration of HYDROSTATIC is configured and the UGM detects a short to ground at this output. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ENGINE FUEL RELAY – SHORT TO BATTERY 33268 1 Deactivate output J2-31 Engine Fuel Relay. Deactivate and inhibit output J2-26 Engage Starter. The UGM detects a short to battery at this output. Power cycled. ENGINE FUEL RELAY – SHORT TO GROUND 33269 1 Deactivate output J2-31 Engine Fuel Relay. Deactivate and inhibit output J2-26 Engage Starter. The UGM detects a short to ground at this output.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ALL WHEEL STEER VALVE – SHORT TO GROUND 33275 1 Deactivate output J2-4 All Wheel Steer Valve. Try to complete any pending steer mode changes. Display the “Steer Valve Failure” screen on the LCD of the cabin’s display. The UGM detects a short to ground at this output. Power cycled. APU PUMP RELAY – OPEN CIRCUIT 33276 1 Inhibit operation of J1-13 APU Pump Relay.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LIFT – CURRENT FEEDBACK READING TOO LOW 33287 1 Do not detect or report the BOOM ANGLE SENSOR – NOT RESPONDING fault. The UGM detects the actual current has deviated more than 250 mA from the commanded current for more than 1 second. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until REAR AUXILIARY HYDRAULICS VALVE – SHORT TO GROUND 33328 1 Deactivate output J2-23 Rear Auxiliary Hydraulics Valve. Deactivate output J2-9 Auxiliary Function-A Valve until input J7-23 is LOW. Deactivate output J2-20 Auxiliary Function-B Valve until input J7-23 is LOW. If the rear auxiliary hydraulics feature is configured in the MACHINE SETUP menu and the UGM detects a short to ground at this output.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until ENGINE TROUBLE CODE: (SPN):(FMI) 437 1, 2, 3* (ECM will determine the proper action to take.) * - The UGM will illuminate just the engine warning fault indicator if the DM1 message indicates a warning or derate condition. The UGM will illuminate the engine warning and engine critical fault indicators if the DM1 message indicates a critical (shutdown) condition.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LOW ENGINE OIL PRESSURE WARNING 4318 1, 2, 9 N/A The ECM detects the engine oil pressure is getting low, the ECM will transmit a J1939 CAN bus DM1 message, or use the J1939 Transfer Protocol in the event multiple engine faults exist, on CAN1 to communicate low engine oil pressure (SPN:FMI 100:17 or 100:18). Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN 441 1 Inhibit all output drivers except engine start. The UGM or platform module has detected the battery voltage is at or below 9V. Power cycled. (Replace/fix battery.) BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN 442 1 Inhibit all output drivers. The UGM or platform module has detected the battery voltage is at or above 16V. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until DRIVE DIRECTION SIGNAL LOST 463 1 Command an ‘N’ in the cabin’s display. Broadcast the TC1 J1939 CAN message on CAN1 to command the TCM to the neutral gear selection if MODELS: TH336, TH337, TH406, TH407, TH414, TH417, TH515 are configured. Deactivate and inhibit output J2-33 Transmission Forward. Deactivate and inhibit output J2-32 Transmission Reverse.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until INVALID TRANSMISSION CONFIGURATION 466 1 Deactivate output J1-20 Transmission D / 2 Coil. Deactivate output J1-7 Transmission E / 1 Coil. Deactivate output J2-33 Transmission A / Forward Coil. Deactivate output J2-32 Transmission B / Reverse Coil. Deactivate output J1-10 Transmission C Coil. Deactivate output J2-5 Frame Leveling Right Valve. Deactivate output J2-7 Frame Leveling Left Valve.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until COMMUNICATIONS 66XXX CANBUS FAILURE – PLATFORM MODULE 662 1 Disregard any CAN messages with the platform module source addresses. The PLATFORM OPTION is configured as ENABLED and a platform is detected as attached and the UGM does not detect the platform module on the CAN bus for a period of 250msec. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CANBUS FAILURE – CABIN JOYSTICK 6617 1 Disregard any CAN messages with the cabin joystick source addresses. Deactivate and inhibit all hydraulic functions. The UGM does not detect the cabin’s joystick on the CAN bus for a period of 250msec and an ENGINE STOPPED or ENGINE RUNNING state exists for a period of one second. Valid CAN bus communication is re-established with the joystick.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CANBUS FAILURE – BOOM RIDE/BOOM FLOAT MODULE 6631 1 If active, deactivate and then inhibit operation of Boom Ride Valve, Boom Float Valve, and Boom Tank Valve. The UGM has lost communications with the Boom Ride/Boom Float (Accessory) Module. Power cycled. CANBUS FAILURE BOOM EXTENSION LIMIT MODULE 6637 1 The UGM has lost communications with the Accessory Module. Power cycled.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS CELL #1 ERROR 821 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS CELL #3 ERROR 823 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSS HAS NOT BEEN CALIBRATED 825 1, 14 Deactivate and inhibit the Lift Up output. Deactivate and inhibit the Lift Down output. Deactivate and inhibit the Telescope Out output. Deactivate and inhibit the Telescope In output. Deactivate and inhibit the Platform Rotate Left output. Deactivate and inhibit the Platform Rotate Right output. Deactivate and inhibit the Platform Level Up output.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until LSI DETECTED BUT NOT CONFIGURED 8515 1 Inhibit all hydraulic functions. Set CAN message bit to permit LSI System display control of its alarm. The UGM has detected the CAN bus LSI system is present on the machine; however it has not been configured properly in the MACHINE SETUP - LOAD MOMENT menu selection. Use analyzer and correct parameter that is improperly configured.
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Electrical System Message Fault Code Indicators LSS EEPROM ERROR 992 1 Power cycle. (Replace board) LSS INTERNAL ERROR – PIN EXCITATION 993 1 Power cycle. (Replace board) LSS INTERNAL ERROR – DRDY MISSING FROM A/D 994 1 Power cycle. (Replace board) EEPROM FAILURE – CHECK ALL SETTINGS 998 1 Suspend all hydraulic function, engine, and transmission operation. The UGM has detected an anomaly in EEPROM. Power cycle.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT 9945 1 The UGM will not permit engine start. The UGM will not permit any hydraulic function operation. The UGM has detected the current feedback calibration checksum is incorrect. Power cycle. (Replace board) CABIN DISPLAY EEPROM WRITE FAILURE 9946 1 N/A The UGM was not able to write/ reprogram the cabin display’s EEPROM. Power cycle.
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Electrical System Message Fault Code Indicators Other Actions Taken Trigger for Fault Latch Until GROUND MODULE VLOW FET FAILURE 9986 1 Suspend all hydraulic function and engine operation, and command the transmission to neutral. The UGM has detected an anomaly in a mosfet. Power cycle.
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31200568 An Oshkosh Corporation Company JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: +1-717-485-5161 Customer Support Toll Free: 1-877-554-5438 Fax: +1-717-485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: +61 265 811 111 Fax: +61 265 810 122 JLG Latino Americana Ltda. Rua Eng.