UGM (Universal Ground Module) Retrofit
Installation Instructions
An Oshkosh Corporation Company
For Kit: 1001149676
The purpose of this instruction is to install a UGM
(Universal Ground Module) on JLG boom lifts equipped
with ADE (Advance Design Electronics) 1600312,
1600327, 1600364, and 1600411 Ground Boards.
It is recommended that you read and thoroughly
understand these instructions before starting this
procedure.
CAUTION
Use all applicable Safety precautions
while working on, around or under any machinery.
Models Affected: (equipped with ADE)
• 400S
• 450A
• 600S
• 600A
• 740A
• 800A
• 800S
Options/Accessories Prohibited When Installing This
Kit:
• None
03/21/2016
Tools & Equipment Required:
• Standard mechanics tools
B
• Windows-compatible laptop computer with Windows
XP or Windows 7
• JLG Handheld Analyzer (JLG #2901443)
• Drill with 9/32” or 7mm diameter bit
3121461
• Small flat blade screwdriver
• 7/16” Open-End Wrench
• 7/16” Socket, Extension, and Ratchet Wrench
• JLG Software Download Cable (JLG #1060629 for
RS-232; JLG #1001137005 for USB)
Personnel Required:
• Qualified JLG equipment mechanic
An Oshkosh Corporation Company
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
Parts list: 3. Connect the JLG Analyzer to the Analyzer Port inside
Main Terminal Box.
Part
Item Description Qty
Number
1 1001103667 UGM-Universal Ground Module 1
2 0630548 Bolt, 1/4-20 x 2.50 GR2 5
3 4923591 Harness, Jumper 1
PROCEDURE:
This procedure will outline the steps necessary to fit a
#1001103667 UGM Module. This replacement is to
provide new features that were not a part of the
former device.
The new module will be pre-programmed. The
vehicle’s platform module software must be updated
to be compatible with the new module.
----------------------------------------------------------------
1. Open the Main Terminal Box and inspect the existing
module. The part number on the decal should be Figure 2: Analyzer Port in Main Terminal Box
“1600411”, “1600364”, “1600327” or “1600312” and
the blue connector should be vertical. (Refer to
4. Check the HELP Menu for active faults. Resolve any
Figure 1)
active faults before this upgrade.
5. Record all entries from the MACHINE SETUP and
PERSONALITIES Menus.
6. Use the JLG web site (www.jlg.com) to download the
necessary utility software.
7. Click My JLG, and then Online Express. Enter your
username and password, or sign-up for a new
account.
Figure 1: (example) Main Terminal Box with #1600411
Ground Module installed. Figure 3: Click on My JLG and then Online Express
2. Place the boom in the transport position (fully
telescoped in, platform fully lowered).
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
Figure 6: Select JLG Boom Lift & Model
Figure 4: Log-In to Online Express
11. Navigate to find 1001115685 Platform Module
8. Click on Service, and then Machine Control Software (800S only) Use version: P6.2 or later per
Software. Figure 7.
Figure 5:Click on Service -> Machine
Control Software
9. Select JLG Boom Lift Brand, and then the
appropriate Model. Click SEARCH to find the
software. Figure 7: Platform Module Software (800S only)
(Use software version: P6.2 or newer)
10. Select JLG Boom Lift & Model per Figure 6.
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
2. Remove the five 7/16” nuts that secure the existing
module to the Main Terminal Box.
3. Remove the existing module and lower two bolts,
nuts, and washers.
4. Temporarily fit the new module to the top three bolts
to locate two new bolt holes. Mark the location of the
two new lower holes using the new module as a
guide.
5. Remove the new module and drill the 9/32” or 7mm
holes. Do not drill into the fuel tank or components
behind the Main Terminal Box.
Figure 8: Navigate to find 1001106937 Platform
Module Software (all Models except 800S)
(Use version: P6.0 or newer)
GROUND BOARD REPLACEMENT:
1. Remove the harness connections from the existing
module. Use a small screw driver to carefully release
the AmpSeal connector latches. Squeeze the latch
on top of the MiniFit connector.
Figure 10: Drill New Mounting Holes in
Main Terminal Box
Figure 9: AmpSeal (Left) & MiniFit (Right)
Connector Latches
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
Tilt
Switch
Plug
Figure 12: P/Q Tilt Switch Plug
8. Re-install the harness connections to the new
module.
NOTICE
If Ground Module being replaced is
P/N:1600327, P/N:1600364, or P/N:1600312
wiring changes are required as follows. No other
Figure 11: New Holes for UGM Module modules (i.e. propulsion module or added upright
module) should be disturbed or removed.
6. Install the lower two bolts, nuts, and washers in the
new location and tighten.
• Before reconnecting the black J7 connector, carefully
7. Fit the new module to the Main Terminal Box and
using a screwdriver on opposing corners of red
install the five 7/16” nuts to secure it. faceplate, unlock and slide the faceplate up. Do not
completely remove it.
• Twist and pull the 2 ground wires to remove them
NOTICE from pin locations J7-6 and J7-17. (Note: Some
machines may only have wire in one of these
If Ground Module being replaced is P/N: 1600312 locations)
tilt switch removal is required as follows • Re-route and re-connect these 2 ground wires to pins
J2-28 and J4-32.
After installing the replacement module, remove the • Insert CAN Terminator Enable jumper P/N: 4923591
external P/Q tilt switch by disconnecting the wiring at the (#3) between pins J7-6 and J7-17 per Figure 13.
plug closest to the external tilt switch, stowing the wiring
harness under the valve body and removing the external
tilt switch refer to Figure 12. The external tilt switch is not
required as the replacement module contains an internal
tilt switch.
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
SOFTWARE UPATE:
1. Turn the Main Terminal Box’s key switch to Platform
Mode (purple icon) and pull the emergency stop out.
2. Connect the Software Download Cable to the laptop
and the Analyzer Port at the Platform Console Box
(see arrow in image below).
Figure 13: UGM Wire #3 Placement Figure 15:
• Apply steady pressure to both ends of the red 3. Pull the Platform Console Box’s EMS (emergency
faceplate to re-lock it. (Do not force faceplate back
stop switch) out to power the vehicle.
into locking position)
• Reconnect the black J7 connector. 4. For 800S models, use the “#1001115685vP62.exe”
(or newer) utility to update the platform module. For
all other models, use the “#1001106937vP60.exe”
(or newer) utility.
5. Click the utility’s COM Port drop-down and make the
proper selection for the RS-232 or USB port that is
connected to the vehicle.
Figure 16:
6. Click the utility’s Program Platform Module button
begin downloading.
7. A prompt will appear to display the present software
version. Click Yes to begin downloading.
8. Close the application when Progress bar reaches
Figure 14: Install 7/16” Nuts to Secure UGM Module
100%.
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UGM (Universal Ground Module) Retrofit For Kit: 1001149676
9. Cycle vehicle power off and then back on (push / pull
emergency stop).
CONFIGURATION:
1. Connect the JLG Analyzer to the Analyzer Port at the
Platform Console Box.
2. Navigate to the ACCESS LEVEL Menu and enter the
Access Level 1 password (33271).
3. Navigate to the MACHINE SETUP menu and select
MODEL: “600S” and MARKET: “CE”. This will force a
reset of all machine modules for configuration
purposes
4. Cycle vehicle power.
5. Re-enter the Access Level 1 password.
6. Restore the settings in the MACHINE SETUP menu
that were recorded in the Preparation step.
7. Restore the settings in the PERSONALITIES menu
that were recorded in the Preparation step.
8. Cycle vehicle power and ensure there are no active
HELP messages.
RE-CALIBRATION REQUIRED:
• 800A - Tilt Sensor and UMS (Upright Monitoring
System)
• 800S - Tilt Sensor and Platform Crack Points
• All Others - Tilt Sensor
Refer to the applicable Service and Maintenance manual
for re-calibration instructions.
Note: Service and Maintenance manuals may be
accessed using “www.jlg.com” and/or “JLG Online
Express”
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