Академический Документы
Профессиональный Документы
Культура Документы
Models
1200SJP
1350SJP
3128463
January 10, 2011
?
INTRODUCTION
SECTION A. INTRODUCTION
Follow the flow chart of Figure A-1. Troubleshooting Flowchart on Pg. 3. Only perform calibrations when indicated in proce-
dures or in section 5.1 Calibration Instructions on Pg. 207.
Each troubleshooting step setup is specified in the step instructions and applies only to that step. Any special wiring, dis-
connected connectors, programming modes, etc. should be removed, re-connected, restored, etc. after completing
the step unless directed otherwise. Some procedures call for swapping components, connections, etc. All instructions to
repair refer to the machine as assembled before the procedure started. Reinstall to proper locations all swapped compo-
nents, connections before repairing machine.
When a function will not operate with the same speed or power as a machine in good working condition, refer to the topic
which most closely describes the problem.
Conclude each session by rerunning the system test, checking for other problems.
If this method does not identify the problem, contact the factory for assistance.
Start
Using Analyzer,
Plug in Analyzer
Run Platform and Is Distress
Ground System
No Lamp Blinking?
Yes and read Help
Message
Tests
“Ground/
Everything OK”
No
No Yes
Troubleshoot by
Help Message in
Section 1
Using Analyzer,
find logged Help
Messages
Identify Fault
Repair Machine
Problem
Solved?
Yes
Done
Has the machine been serviced recently? Check that everything has been reconnected properly.
• Correct routing
• Pinches and kinks
• Splits, cuts, or breaks.
Inspect Wiring for:
• Corrosion on pins
• Moisture in the housing or on the contacts
• Bent or damaged pins
• Contacts not properly seated in housing
• Bad wire crimps to terminals
ADE service flash codes can also be read from the green LED on the face of the ground module or the system distress lamp
in the platform console, see Figure A-2. Ground Module and Platform Fault (System Distress) Lights on Pg. 4. Use the table
of contents to find possible faults based on the flashed code. Flash codes are the first two digits of Diagnostic Trouble
Codes or DTC’s. There is a unique DTC for each fault that occurs on the machine.
FAULT
CODE
LIGHT
1705744 A
J1 J4
J2 J3
1705745 B
Figure A-2. Ground Module and Platform Fault (System Distress) Lights
1
2 Vbatt from EMS 1
X169 Platform
3 J7 Module
12 Mode Select from
2
16 Ground Module X007.14
32
X166
Gateway Module X160
Diagnostic Connector J2
TCU Module
CAN HI 31 26 X171
X287 X288 X290 X289 28
29 Analyzer
Gray Black IGNITION BATT +
120 27
CAN 2 LO
IGNITION
GROUND
CAN 2 LO
CAN 2 LO
GROUND
IGNITION
CAN 2 HI
CAN 2 HI
CAN 2 HI
CAN LO
SHIELD
SHIELD
CAN HI
V BATT
V BATT
CAN LO 30
GND
12 10 9 8 7 12 11 16 15 22 7 23 A B E D C
Vbatt from Ground Module X008.4
X170
2 J8
Ground from Ground Module X008.3
12 16 1 2 3 X043 1
120
120
A Engine
B Module
C
X279 X240
X270
X269
X279
A B C X278 CAN HI
X086 12
C BA A
A A
6 J1 13
B CAN LO
7
B B
C CAN Shield 8
C C
C BA Ignition Power 5 Ground from Ground Module X001.8
1
X268
X014 Ignition Power
4
X089 14
J4
X090 1
2
CAN HI
A
B X062 C B A X084
Analyzer Power J5 D
X091 9 3
5 4 3 2 1 X083
E Load Pin
Analyzer RS232 Receive CAN LO
10 4
Analyzer Analyzer RS232 Transmit CAN Shield
11 5
Analyzer Ground 12 5 4 3 2 1 X216
Chassis Power
BLAM Module Relay
87
Ground Module 86 X266
85 30
Measures the total stroke of the main boom using a cable potentiometer. The sensor’s analog outputs are read by the BLAM
module. It increases as the boom length increases. The sensor is powered by a 5 volt reference and ground from the BLAM
module. Each sensor should measure 5k resistance between the A and B pins.
In transport position approximate typical values are:
MAIN BOOM LENGTH: 37.3"
MAIN BOOM A/D LENGTH: 395
April 25, 2008 - Original issue of fault guide for use with P7.2 or above Software and Telematics.
TABLE OF CONTENTS
SECTION A - INTRODUCTION
A.1 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.2 Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.3 Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A.4 Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
A.5 Ground Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
A.6 Control Module Power and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
A.7 Critical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
SECTION B - TROUBLESHOOTING SAFETY PRECAUTIONS
B.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B.2 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
B.3 Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 001 - EVERYTHING OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
DTC 002 - GROUND MODE OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
DTC 0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION . . . . . . . . . . . . . . . . . . . . . . 1-15
DTC 0011 - FSW OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
DTC 0012 - RUNNING AT CREEP - CREEP SWITCH OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
DTC 0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . 1-17
DTC 0014 - CHASSIS TILT SENSOR OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DTC 0015 - LOAD SENSOR READING UNDER WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DTC 0017 - OVER MOMENT - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
DTC 0018 - UNDER MOMENT - HYDRAULICS SUSPENDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
DTC 0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . 1-19
DTC 0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . 1-19
DTC 211 - POWER CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
DTC 212 - KEYSWITCH FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
DTC 213 - FSW FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 227 - STEER SWITCHES FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2211 - FSW INTERLOCK TRIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2215 - D/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2216 - D/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2217 - D/S JOY. CENTER TAP BAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2218 - L/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2219 - L/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2220 - L/S JOY. CENTER TAP BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
DTC 2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH. . . . . . . . . . . . . . . . 1-21
DTC 2222 - WAITING FOR FSW TO BE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
DTC 2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE . . . . . . . . . . . . . . . . . . 1-21
DTC 2224 - FOOTSWITCH SELECTED BEFORE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
DTC 234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM . . . . . . . . . . . . . . . . . . . 1-21
DTC 235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER . . . . . . . . . . . . . . . 1-21
DTC 236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH . . . . . . . . . . . . . 1-21
DTC 237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH . . . . . . . . . . . . . . . . . . . . . 1-21
DTC 259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS . . . . . . . . . . . . . . . . . . . . 1-21
DTC 2513 - GENERATOR MOTION CUTOUT ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
DTC 2514 - BOOM PREVENTED - DRIVE SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
DTC 2515 - DRIVE PREVENTED - BOOM SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
DTC 3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . .1-27
DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . .1-27
DTC 3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-27
DTC 3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
DTC 3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . .1-27
DTC 3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33100 - JIB LIFT UP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33101 - JIB LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33102 - JIB LIFT UP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33103 - JIB LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33104 - JIB LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33118 - SWING RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33119 - SWING RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
DTC 33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33121 - SWING RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33122 - SWING LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33130 - THROTTLE ACTUATOR - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33131 - THROTTLE ACTUATOR - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33132 - THROTTLE ACTUATOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33133 - PLATFORM CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33134 - PLATFORM CONTROL VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33150 - LIFT PILOT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
DTC 33151 - LIFT PILOT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33152 - LIFT PILOT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33153 - LIFT DOWN AUX VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33154 - LIFT DOWN AUX VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE -
SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
DTC 33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUIT. .1-32
DTC 33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33181 - MAIN LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
DTC 33183 - MAIN LIFT UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33207 - HORN - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33208 - HORN - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33209 - HORN - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33279 - GLOWPLUG - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
DTC 33280 - GLOWPLUG - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33281 - GLOWPLUG - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33295 - SWING LEFT VALVE - oPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33306 - SWING LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . .1-34
DTC 33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . .1-34
DTC 33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . .1-34
DTC 33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . .1-34
DTC 33329 - MAIN LIFT UP VALVE - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . .1-35
DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-35
DTC 431 - FUEL SENSOR SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 432 - FUEL SENSOR SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 433 - OIL PRESSURE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 434 - OIL PRESSURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 435 - COOLANT TEMPERATURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
DTC 437 - ENGINE TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
DTC 438 - HIGH ENGINE TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 439 - AIR FILTER BYPASSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4310 - NO ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4311 - LOW OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4313 - THROTTLE ACTUATOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4314 - WRONG ENGINE SELECTED - ECM DETECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4322 - LOSS OF ENGINE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 4323 - SPEED SENSOR READING INVALID SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 445 - BATTERY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
DTC 662 - CANBUS FAILURE - PLATFORM MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
DTC 666 - CANBUS FAILURE - ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
DTC 6610 - CANBUS FAILURE - BLAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
DTC 6611 - CANBUS FAILURE - CHASSIS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44
DTC 6612 - CANBUS FAILURE - CYLINDER LOAD PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46
DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47
DTC 6622 - CANBUS FAILURE - TCU MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-50
DTC 6623 - CANBUS FAILURE - GATEWAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51
DTC 6629 - TELEMATICS CANBUS LOADING TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
DTC 681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP . . . . . . .1-52
DTC 813 - CHASSIS TILT SENSOR NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
DTC 815 - CHASSIS TILT SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
DTC 825 - LSS HAS NOT BEEN CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
DTC 826 - RUNNING AT CREEP - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
DTC 827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . .1-53
DTC 828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . .1-53
DTC 831 - PLATFORM LEVELING OVERRIDE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
DTC 832 - PLATFORM LEVELING OVERRIDE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
DTC 833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . .1-53
DTC 834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . .1-54
DTC 837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
DTC 838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . .1-55
DTC 8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
DTC 8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . .1-55
DTC 8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56
DTC 8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56
DTC 8315 - PLATFORM LEVELING SENSOR - DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56
DTC 8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-57
DTC 8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-58
DTC 8318 - PLATFORM LEVELING SYSTEM TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
LIST OF FIGURES
LIST OF TABLES
is tilted. The machine is "Above Elevation" if the boom is greater than +15.0 (default) from gravity. This resets at 10.0. Sen-
sor failures can change these conditions..
DTC 2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL
Disconnect analyzer and cycle EMS to perform boom retrieval. This fault should never occur on properly configured
machines. Check model in MACHINE SETUP.
DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Platform down short to battery or open circuit. The platform module J7 platform level down output [X169.16] is shorted to
battery or open. If there are no open wires, the fault DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO
BATTERY on Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right front steer right valve output [X233.1]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
113.
DTC 868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right front steer left valve output [X233.2]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module left front steer left valve output [X233.3].
DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chas-
sis module left front steer left valve output [X233.4].
DTC 8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right rear steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right rear steer right valve output [233.5]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right rear steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right rear steer left valve output [233.6]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left rear steer right short to battery or open circuit. the control system detected a short to battery or open circuit on the chas-
sis module left rear steer right valve output [X233.7]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left rear steer left short to battery or open circuit. the control system detected a short to battery or open circuit on the chassis
module left rear steer left valve output [X233.8]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Front right wheel sensor short to ground or open circuit. The control system detected the front right steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
DTC 8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Front left wheel sensor short to ground or open circuit. The control system detected the front left steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
DTC 8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Rear right wheel sensor short to ground or open circuit. The control system detected the rear right steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
DTC 8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Rear left wheel sensor short to ground or open circuit. The control system detected the rear left steer angle sensor value was
below the electrical minimum. This may be due to an open circuit or a poor connection.
DTC 9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER
Functions locked out - platform module software version improper. Notification that the functions have been locked out
because the major version of the platform module software does not match the major version of the ground module soft-
ware. Load the same version of software in the platform and ground modules.
DTC 9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY
Ground module failure: high side driver cutout faulty. There is an internal problem with the ground module.
DTC 9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER
Functions locked out - chassis module software version improper. Notification that the functions have been locked out
because the major version of the chassis module software does not match the major version of the ground module software.
Load the same version of software in the chassis and ground modules.
DTC 9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER
Functions locked out - BLAM module software version improper. Notification that the functions have been locked out
because the major version of the BLAM module software does not match the major version of the ground module software.
Load the same version of software in the BLAM and ground modules.
DTC 9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER
Functions locked out - ground module software version improper. All functions are locked out because ground module soft-
ware version is improper for machine configuration...
Color Key
X198 X196 X195 X194 X193 X179 X285 X177 X175 X174
17 18 19 20 21 X190 X191 X182 X183 1 23 2 3 4
22
16 15 14 13 12 11 10 9 8 7 6 5
X197 X192 X189 X188 X187 X186 X185 X184 X180 X181 X178 X176
X154 VALVE
ROTATED
X153 FOR
CLARITY
PLATFORM DUMP
LEVEL UP
X135
X155 X136
LEVEL DOWN
X137
ROTATE RIGHT
X138 JIB SWING
RIGHT
ROTATE LEFT X140
X139
JIB SWING
X152 LEFT
X141
JIB UP
X142
JIB DOWN
X143
X150 X089
CABLE BREAK
PROXIMITY
X148 X062 SWITCH X282
PLATFORM LEVEL
SENSOR RIGHT
X146 TAILLIGHT
X104
X147 JIB (FAR SIDE)
STOW
SWITCH
TAILLIGHT
JIB
POSITION X105
SWITCH (NEAR SIDE)
BOOM LENGTH
SENSOR
BOOM
ANGLE
SENSOR X100
#2 LEFT
X099 BOOM
ANGLE X273
SENSOR
#1 RIGHT
BOOM AREA
Figure 2-3. Boom Area Connectors
X241
X240
X103
X084
X113
STARTER
7500W
GENERATOR
X250
X251
LOCATION
X057
APPROXIMATE
B.L.A.M.
X102
BATTERY GROUND
BUSSBAR BUSSBAR
X097 X098
BOOM ANGLE BOOM ANGLE
SENSOR SENSOR
1 PASSTHRU 2 PASSTHRU
(4 POS.) (4 POS.)
X095 X096
BLAM PUMP BOOM LENGTH
PASSTHRU SENSOR PASSTHRU
(6 POS.) (6 POS.)
X106 X272
VALVE PASSTHRU
(6 POS.)
X280
J1 X275
MAIN TELE
J4 X089 PROPORTIONAL
X072
X087
X090 J5 J2
MAIN
LIFT FLOW
LIFT DOWN CONTROL
X263 AUX SELECT
X286 X116
X091 X274
X110
ANALYZER
CONNECTION
X107
X117
X083
X017
X008 X007
X001
X271
X010
X043
X002 X004
X003
X012
X011
X024
X025
X023
X022
X021
X029
X026
X020
X028
X030
CHASSIS MODULE
X231
J3 X229
J1
J4 X232
X230
X233 J5 J2
X238
REAR LEFT
STEER ANGLE
ANALYZER FRONT LEFT
CONNECTION STEER ANGLE
X235 X203
X239 X225
REAR LEFT
AXLE SWITCH
REAR RIGHT
STEER ANGLE
X083 X205 FRONT LEFT
X200 AXLE SWITCH
AXLE LIMIT FRONT RIGHT
SWITCHES STEER ANGLE AXLE LIMIT
(REAR) SWITCHES
X226
(FRONT)
REAR REAR
AXLE SWITCH
AXLE
LOCKOUT 2 SPEED X204
X212 X214 FRONT REAR
X216 AXLE SWITCH
REAR
STEER FRONT
VALVE STEER
VALVE
AXLE
LOCKOUT
RETRACT X221 PRESSURE
X224 EXTEND SWITCH
X213 X206 EXTEND
RETRACT X209
REAR LEFT
X220
STEER LEFT X223 REAR LEFT X215
STEER RIGHT
BRAKE
FRONT LEFT X207 FRONT LEFT
STEER LEFT X210
STEER RIGHT
REAR RIGHT RELEASE
STEER LEFT X219 REAR RIGHT
X222 STEER RIGHT FRONT RIGHT
FRONT RIGHT X208 STEER RIGHT
TRACTION CONTROL VALVE STEER LEFT X211
CHASSIS AREA
Figure 2-7. Chassis Area Connectors
48-12(12)
WHT/YEL
7 30 TEMPERATURE 1 1 LINK
X012 9 ADC7(TEMP3)
5 13 SPEED 2 X125
ENGINE 2
X112
BRN/WHT 47-8
87a CAMSHAFT 1 12 GRD (SPEED) 10
POWER DOWN IN HEAD GLOW PLUG
RED 1-1(10)
86
BLACK
GROUND CONTROL MODULE X256 GLOW PLUGS NOT BOTH.
AIR 13 SENSING AND
3 25 +5Vref(ADC2)
PRESSURE SWITCHING
CIRCUITS
TO BATTERY NEG.
X017 D+
24 4 24 ADC2 WHT/YEL 48-11 (10)
G G
WHT/YEL 48-3
14
BROWN 13-2 7 HORN GND
WHT/YEL 48-9
RIGHT WHITE 22-2 35 X274 X241 X240
X018 SWING J2 10 TAN 55-21 LIFT DOWN AUX. SELECT
LEFT WHITE 21-2 34 (GRAY)
12 TAN 55-22 LIFT DOWN AUX. X275
BLACK
22 TAN 4-3 DOWN X277
11
35 WHITE 22-3 RIGHT X069
22 SWING
34 WHITE 21-3 LEFT X070 YEL/RED 2-1-99
2-40 25 CAN SHIELD BLACK 0-1 B
19 TAN 55-20 LIFT FLOW CONTROL X286
DEUTZ
32 CAN LO ORN/RED 49-199 L
20 BLACK (18) DIANOSTICS
X028 HOURMETER
12 14 CAN HI ORN/RED 49-198 K PLUG
BLACK (10)
CAN LO
CAN HI
29 BLACK
X036 NO CHARGE 87 87a 1
BRN/WHT 47-8-1 26 ORN/RED 5
26 BLU/ORN 52-12 86 2
85 X273
X033 GLOW PLUGS 6
WHT/YEL 48-6 15
YEL/RED 2-40-9
30
MOMENT CONTROL X101
X040 18 7 YEL/RED 2-80 1 RED A
13
CAN SHIELD
ORN/RED 49-103
BLACK (18)
TEST BOOM LENGTH SENSOR
RED (18)
24 8 ORN/RED 49-110 3 BLUE C
X032 AXLES SET 1 STRING POT
WHT/YEL 39-1-1 9 BLACK 2
PLATFORM 28 BLACK B
X038 14 4
OVERLOAD ORN/RED 49-100 BRN/WHT 47-12 FUEL SENSOR (SIGNAL) BRN/BLK BRN/BLK
25
E 500# CAP 12 E
X031 RED/YEL 54-2-1 2 6 BLACK SENSOR (GROUND) X272 X106
23
X037 1000# CAP J5 BROWN
RED/YEL 54-3-1 27 6
BOOM SYSTEM 11 WHT/YEL 48-3 X090
3 5
X039 CONTROL ORN/RED 49-101 12 WHT/YEL 48-9
1 ORANGE 8-3 2 ORANGE 8-3 LEFT FORWARD DRIVE PUMP X121
BLACK 31 10
2 ORANGE 8-2 1 ORANGE 8-2 LEFT REVERSE DRIVE PUMP X119
8
GND FROM BATTERY 12
1 A B C X084
X008 3 3 ORANGE 7-2 RIGHT REVERSE DRIVE PUMP X118
MTB EMS input 23
2 X010
GND TO PLATFORM 6 J1 GRAY 4 ORANGE 7-3 RIGHT FORWARD DRIVE PUMP X120
BLACK (12) 3 J8
16 X279
BLACK 5 X086
A B C 1
YEL/RED 2-1-2(12) MTB EMS TO PLATFORM
12 4 24 YEL/RED 20-70-1
2
5 RED A 9 RED ANALYZER POWER 1
A RED CAN HI 6
YEL/RED 2-3-2 1 18
BLACK B B BLACK CAN LO 7 10 GREEN ANALYZER RECEIVE 2
YEL/RED 2-2-1 2 19
SHIELD SHIELD 8 11 WHITE ANALYZER TRANSMIT 3
C C CAN SHIELD
27 4
9 12 BLACK/SHIELD ANALYZER GROUND 4
2
X268 X278
FOOTSWITCH 12 X091
YEL/RED 2-21 15 9 3
D 6 D
MTB MODE SELECT 1 5
YEL/RED 2-30 3 YEL/RED 2-70-2 (14)
2 6 BLACK (16) 4
X001
MTB MODE OUTPUT 3
11 YEL/RED 2-30-1 14 28 RED ANALYZER POWER 1
4 29 GREEN ANALYZER RECEIVE 2
J1 4
16 ANALYZER TRANSMIT ORANGE 60-1
(WHITE) 30 WHITE 3
ORN/RED 49-102 21 V-BAT + X097 J2 BLACK X087
31 BLACK/SHIELD ANALYZER GROUND 4
BOOM CONTROL SYSTEM 26 X280
TEST SWITCH 9 10 12 ORANGE 7-2
X013
X283, X284 17 11 ORANGE 7-3
14 2 X096 X100
30 YEL/RED 2-70-3 (14)
CAN SHIELD
3 19 27 BLACK 3 SERIAL OUTPUT
YEL/RED 2-70-5
BLACK 3 BLACK
YEL/RED 2-70-4
BLACK (18)
22
20
RED (18)
BRN/BLK 4 BRN/BLK
BOOM LENGTH LIMIT SWITCH X281 34 X099
17 BLACK (14) X095
14 X017 33 J4 GRAY
13 34
19
35 5 1 RED A
X271 BLACK 5 (16)
20
32 2 BLACK B
LIFT
DEUTZ ENGINE
WHITE 1 YEL/RED 2-60 29
33 3 GREEN D
21 22 X089 CYL. PIN
19 E
BLACK 2 ORN/RED 49-64 11 4 WHITE
ORANGE 55-45
ORANGE 55-47
YELLOW
BRN/ORN 53-3
BLACK (14)
13 5 SHIELD
RED 6 ORN/RED 49-65 35
X266
X062
25 87
2 87a CHASSIS POWER
7 86
X014 X007 85 DISTRIBUTION X267 X110
X270 4 AUXILIARY POWER
8 4 5 6 7 1 2 3 30 RELAY
X083 PUMP MOTOR
3 RED(18) A A RED CAN HI 13 J7 8
B+
M
30 AMP
BLACK B B BLACK CAN LO (BLACK) SLIP RING CONNECTOR TO CHASSIS X108
2 24 9 X116
B 1 SHIELD C C SHIELD CAN SHIELD 18 B
6
5 2500W
7 BLU/ORN 52-6 (12)
C B A GENERATOR
8 13 12 VDC
87
28 87a X127 BATTERY
14
X269 86
85
3 GENERATOR
30
10 RED 1-3 (12) 14 GA. FUSE LINK X117
V REF
11
7500 W GENERATOR X248
1
5 AMP X109
5 BLU/ORN 52-6 B
V BAT GENERATOR
12 YEL/RED 2-20 A BRN/WHT 47-20
BLACK
CONTROL
BLACK C BOX
RED
87 87a
SHEILD
86 X246
85
30
A RED A
BLACK (14)
87 87a
86 X247
85
30
RED
8 7 6 5 4 3 2 1
Pleatform Schematic
29 BLACK 12 BLACK
6 BRN/WHT 47-4 35 23
FUEL GAGE
FULL
3 BRN/WHT 47-3 23 24
3/4 J1
BLU/ORN 52-3
2 BRN/WHT 47-2 24
1/2 X190 11 BLU/BLK 11
1/4 1 BRN/WHT 47-1 22
14 HOLE PLUG (12) 14
4 BLACK 25
17 HOLE PLUG (18) 17
5 X187 SOFT TOUCH ORN/RED 49-42 16
19 HOLE PLUG (18) 19
2
4 X166
D D
5 GND FROM GND MODULE
J8 1 BLACK (12) 16 BLACK (12) 16
CREEP 1 ORN/RED 49-15 9 GND EMS
(BLACK) 2 YEL/RED 2-1-2 (12) 12 RED (12)
J2 12
FOOTSWITCH/ENABLE 2 YEL/RED 2-21 7 (GRAY)
J2 X170
3 BRN/WHT 47-13 21
X191
6 BLACK 18
YEL/RED 2-16-1
YEL/RED 2-16-2 8
A 6 YEL/RED 2-16-3 A
8 7 6 5 4 3 2 1
X083
H H
DRIVE ORIENTATION
SWITCH
ORANGE (16)
YELLOW (16)
RED 14GA
BLK 14GA
YEL/RED 2-1-7 1
VIOLET
SHIELD
BLK
BLK
RED
X216
BLK
X213
BLACK 2
J4 GRAY
1 2 3 4 5 6 7 8 9 10 11 12
1 OSC. AXLE
3
X205 X204
YEL/BLK 14G
ORANGE 55-45
RED
SHIELD
ORANGE 55-47
ORANGE 60-2
BLK 14GA
BLK
LOCK-OUT
YEL/RED
ORN/RED 49-106
G PRESSURE G
2 LEFT FRONT AXLE
EXTEND LIMIT SWITCH
RIGHT FRONT AXLE
EXTEND LIMIT SWITCH
SWITCH 4
OSC. AXLE
X232
BLK WHT BLK WHT YEL/RED 2-1-3 LOCK-OUT
3 VALVE 5
J2 BLACK
BLK WHT BLK WHT YEL/RED 2-1-2 X212
5 ORN/RED 49-105
X225
LEFT REAR AXLE
EXTEND LIMIT SWITCH
RIGHT REAR AXLE
EXTEND LIMIT SWITCH
ORN/RED 7
X226
6 ORN/RED 49-106 8
X230
F 7 ORN/RED 49-107 F
8 1
X215 2
6 PIN
9 2
BRAKE
VALVE
3
BUSS
SPD 4
X214 VALVE CONNECTOR
10 YEL/WHT 39-2 FRONT AXLE EXTEND X206 5
6 X227
X200
1 RED 1 RED A
X201
RIGHT FRONT
2 WHT 2 BLUE B
STEER SENSOR
3 BLK 3 BLK C
J3 GREEN
X202
LEFT FRONT
BLK 14GA
BLK BRN/BLK 4 BRN/BLK
X239
4 YEL 9-1 LEFT FRONT STEER LEFT X210 7 RED 1 RED A
J5 RUST
X236
RIGHT REAR
5 YEL 12-2 RIGHT REAR STEER RIGHT X222 8 WHT 2 BLUE B
STEER SENSOR
C C
6 YEL 11-2 RIGHT REAR STEER LEFT X219 9 BLK 3 BLK C
BLK BRN/BLK 4 BRN/BLK
X233 X238
7 YEL 12-1 LEFT REAR STEER RIGHT X223 10 RED 1 RED A
X237
LEFT REAR
8 YEL 11-1 LEFT REAR STEER LEFT X220
11 WHT 2 BLUE B
STEER SENSOR
YEL/RED 2-1-5
YEL/RED 2-1-6
9 RED 12 BLK 3 BLK C
SHIELD
BLACK
BLK
10 GRN
B
11 WHT B
1 2 3 4 5 6 7 8 9 10 11 12
12 BLK
J1 GRAY X229
4 3 2 1 X235
A A
8 7 6 5 4 3 2 1
X141 X139
X143 X140 X138 X137
X158 X159 X142 2500W
PLATFORM GENERATOR X129
FLOODLIGHTS X156 X132
X133 X130
X128
GENERATOR
X157 X127 CONTROL BOX
X249 X250
GENERATOR
PLATFORM RELAY 7500W
CONTROL GENERATOR X247 X251
VALVE CONTROL BOX
X253 7500W
X254 X248 GENERATOR 7500W
JIB STOW RELAYS SKYPOWER
X160 SWITCH X113 X264 X265 GENERATOR
X161 X162 X246
X163
X174 X144 X146 7500W
DUAL CAPACITY GENERATOR X252
X175 JIB POSITION PLATFORM
SWITCH BOX ENGINE
X176 STARTER X118 X119
X145 X147 HARNESS
X112 (DEUTZ)
Platform Level X258
Sensor (Left) AIR FILTER CHARGE
X177 X148 X255 PRESSURE ENGINE CONTROL PRESSURE
SWITCH (DEUTZ EMR2)
X285 X256
X178 X169 X241 X240 HYDRAULIC
X179 OIL PUMPS
X165 Platform Level X134 THROTTLE PRESSURE X257 X120 X121
X181 Sensor (Right) ACTUATOR X126
J7
X184 FOOTSWITCH
X185 X125 X245 X122
J2
X073 CONTROL
X024 VALVE
J1
X043 AUX
X029 GLOW POWER
LIGHTS X108
RELAY PLUG RELAY
X028 FUEL RELAY
X030 TAILLIGHTS LEVEL
SENSOR X111 X109
X020 X242
X022 X002
X018 X011 X012 X004 X017 X270
Figure 2-11. Electrical Wiring (Sheet 1 of 2)
STEER STEER
ANGLE ANGLE
SENSOR SENSOR
X200 X239
DIAGNOSTIC
CONNECTION
TO ANALYZER
SWIVEL
X227 X228
X235
X206 X207 X208 X219 X220 X221 CHASSIS
MODULE
X201 X236
TRACTION X214
VALVE
X230 X233
X232
STEER STEER
VALVE VALVE
J2 J5
X212
FRONT X216 J4 REAR
J1 J3
X237
X229 X231
X202
STARTER X113
STEER START RELAY AUX STEER
ANGLE POWER ANGLE
SENSOR RELAY SENSOR
X112
Figure 2-12. Electrical Wiring (Sheet 2 of 2)
Telematics System
GATEWAY
MODULE
CAN SHIELD
X288
X291, X292
BATTERY +
BATTERY +
CAN 1 LO
CAN 2 LO
GROUND
GROUND
IGNITION
CAN 1 HI
CAN 2 HI
CAN LO
CAN LO
SHIELD
CAN HI
CAN HI
CAN
B+
B-
ANTENNA
10 9 12 11 8 7 3 C D E B A 16 15 23 7 22
1-100-2
1-100-1
YEL/RED
2-100-1
RED
RED
RED
BLK
X098
RED
BLK
MTB GROUND BUS BLACK BLK
YEL/RED
MTB BATTERY BUS 2-100-2
X097
10 A 10 A
X291 X295 X293
X296
TELEMATICS A B C
X029 GROUND E-STOP
A B C
SWITCH BATTERY SIDE
COMMUNICATION UNIT
A A RED A A
RED
BLK
120 120
B B BLK B B
X289 TELEMATICS Ohms Ohms
C C SHIELD C C
DIAGNOSTIC CONNECTOR
X292 X294
A A
TO MTB CAN TO ENGINE
HARNESS B B CAN HARNESS
X279 X279
C C 1001102417 A
X290
CELLULAR CABLE
GPS CABLE
Table 2-18. X004 (J4) Ground Module Pinout Table 2-19. X007 (J7) Ground Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
17 Basket Level Up Switch Input Vbatt 25 Not Used -- --
18 Basket Rotate Right Switch Input Vbatt 26 Not Used -- --
19 Jib Up Switch Input Vbatt 27 Not Used -- --
20 Jib Right Switch Input Vbatt 28 Not Used -- --
21 Not Used -- -- 29 V Bat Battery Vbatt
22 Not Used -- -- 30 Not Used -- --
23 Boom Lift Up Switch Input Vbatt 31 Not Used -- --
24 V Bat Battery Vbatt 32 V Bat Battery Vbatt
25 V Bat Battery Vbatt 33 Not Used -- --
26 No Charge Lamp Output Vbatt 34 Not Used -- --
27 1000# Capacity Lamp Output Vbatt 35 Boom Length Limit Switch Open Input Vbatt
28 Engine High Temperature Lamp Output Vbatt
29 Engine Low Oil Pressure Lamp Output Vbatt Table 2-20. X008 (J8) Ground Module Pinout
30 Boom Telescope Out Switch Input Vbatt Pin Function Type Range (V)
31 Ground Ground 0VDC 1 Ground from Battery Ground 0VDC
32 Not Used -- -- 2 Ground EMS Output Vbatt
33 Main Boom Lift Down Input Vbatt 3 Ground to Platform Ground 0VDC
34 Swing Left Switch Input Vbatt 4 Ground EMS Out to Platform Output Vbatt
35 Swing Right Switch Input Vbatt
Table 2-24. X168 (J6) Platform Module Pinout Table 2-26. X170 (J8) Platform Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
1 Steer & Drive Joystick Supply Vref 7VDC 1 Ground from Ground Module Ground 0VDC
2 Drive Center Tap Input 7VDC 2 Ground EMS Ground 0VDC
3 Drive Signal Input 7VDC
4 Not Used -- --
5 Steer Left Switch Input 7VDC
6 Steer Right Switch Input 7VDC
7 Ground Ground 0VDC
8 Not Used -- --
4
3
2
1
4
3
654
AMP06R Amp 6 position recepta-
cle 1 2 3
45 6
1 3
6 8
3 1
6 4
9 7
12 10
15 13
14
AMP15R Amp 15 position recep-
tacle 2
1 3
4 6
7 9
10 12
13 15
14
AMP25LP Amp Rectangular 25
position plug with key for
13 12 11 10 9 8 7 6 5 4 3 2 1
left
25 24 23 22 21 20 19 18 17 16 15 14
1 5
10 AMP 14
1 8
16 23
AMP354P
(Gray)
AMP355P
(Blue) 24 AMP 35
1 4
9 12
10 11
4 1
12 9
11 10
DEUTZ12R Deutz Supplied 12 posi-
tion receptacle 2 3
1 4
9 12
10 11
DEUTZ16P Deutz Supplied 16 posi-
tion plug 2 3
1 4
5 8
9 12
13 16
1415
4 1
8 5
12 9
16 13
15 14
DEUTZE Deutz Supplied 4 posi-
tion charge air pressure
sensor Plug
1 2
Rear View
DHD14R Deutsch 14 position HD
series alum. Receptacle
Rear View
DHD19P Deutsch 19 position HD
series alum. Plug
C
DT03R Deutsch 3 position DT
series receptacle
B A
C
DT03P032GP Deutsch 3 position DT A
B
(Green) series plug with over- B A
DT03P032BP mold adaptor
(Blue) C
DT03P032OP
(Orange) C
DT04P Deutsch 4 position DT
series plug
3 2 1
DTM03R Deutsch 3 position DTM
series mini receptacle
12 3
DTM04P Deutsch 4 position DTM
series mini plug
4 1
3 2
6 5 4 3 2 1
6 5 4 3 2 1
1 2
2 1
1 4
2 5
3 6
4
3
2
1
Rear View
MMF10P Molex Mini Fit 10 posi-
tion plug
6
7
8
9
10
1
2
3
4
5
7 8 9 10 11 12
1 2 3 4 5 6
13
14
15
16
17
1 18
2 19
3 20
4 21
5 22
6 23
7 24
8
9
10
11
12
A B
C BA
1 2
SUM06N Sumitomo 6 position
natural
4 1
5 2
6 3
M5
MS
M8
M7
TELE OUT M4 MP
LIFT UP SWING
RELIEF LIFT
RELIEF RELIEF
ADJ TELE IN DOWN
ADJ ADJ
RELIEF RELIEF MAIN VALVE
ADJ ADJ
PUMPS
FUNCTION PUMP
LOW PRESS
RELIEF ADJ.
HIGH PRESS
RELIEF ADJ.
P
L2
MP L1
M1 R2
R1
M2
S2
M3 S1
2.0 GPM T
J2
75 PSI
J1
CHECK
VALVE
PLATFORM LEVEL
UP RELIEF ADJUST
0.2 GPM
PLATFORM LEVEL
DOWN RELIEF
ADJUST
0.3 GPM
JIB UP/DOWN
2.0 GPM
JIB UP/DOWN
RELIEF ADJUST
JIB UP/DOWN
SHUTTLE 10 MICRON
VALVE FILTER
BASKET SUPPORT
SWIVEL PORT
#5
b a
Ps G (Fa) (Fe) B
Ma
5000 PSI
THROTTLE
POSITION
3
1.7in
3
.37in
5000 PSI
1.2mm
Mb
R T1 T2 X1 X2 S A
P - #2 #2 - P
B1 - #5 #5 - B1
B2 - #4 #4 - B2
A2 - #3 #3 - A2
A1 - #6 #6 - A1
PUMP CIRCUIT.
1200SJP, 1350SJP, 1250AJP
CD - #7 #7 - CD 2792771 C
SWIVEL
SET AT
300
PSI
b a
Ps G (Fa) (Fe) B
SET AT
3400
PSI
Ma
5000 PSI
B
3
1.7in
3
.37in
3
2.74in
5000 PSI
550 PSI
S L1 L
Mb
R T1 T2 X1 X2 S A
RESERVOIR
"T3" 2792771 C
SHT. #1
LEVEL CYLINDER
1200SJP-1350SJP
Bore: 5.00" 19.63 sq. in.
Rod: 2.00" 3.14 sq. in.
Annulus: 16.49 sq. in.
Cyl. Area Ratio: 1.19:1
Stroke: 13.375"
PLATFORM ROTATOR
Displacement: 14 c.i.r.
C1 C2
V1 V2
M1 L1 L2 M2 R1 R2
2 4 2 4
S1 S2 S1 S2
3 1 3 1
2 1 75 PSI 2
0.2 GPM
2
1 1
T
"T2"
SHT. #1
3 2.0 GPM
MP 1
1
10 MICRON ABS
B10 >= 1000
P 2
IN OUT
100 PSI
BYPASS
"P3"
SHT. #1
PLATFORM CONTROL
1200SJP,1350SJP,1250AJP 2792771 C
Displacement: 74.2 cu. in. for 244 degrees Bore: 3.00" 7.06 sq. in.
Displacement: 54.7 cu. in. for 180 degrees Rod: 1.50" 1.76 sq. in.
Annulus: 5.3 sq. in.
Cyl. Area Ratio: 1.33:1
Stroke: 23.5"
C1 C2
V1 V2
.047
S1 S2 M3 J1 J2
1 2
2750 PSI
3
2 4 2 4
S1 S2 S1 S2
3 1 3 1
2 2
1 1
PLATFORM CONTROL
1200SJP,1350SJP,1250AJP
2792771 C
T P
MS4 b
1
P3
TRACTION CONTROL
S4 (PAGE 5)
B T
A P
S3
RIGHT 1
MS3 a
2600 PSI
REAR STEER 2
RIGHT 2
2000 PSI
b
MS2
LEFT SIDE
S2
B T
A P
S1
LEFT
1
MS1 a
2600 PSI
2
V2
RIGHT SIDE
2
MA4
2500 PSI
b
A4 1
V1
A2 B T
REAR AXLE
A1 A P
V1 1
A3
a
LEFT SIDE
2500 PSI
MA3
2
V2 AXLE
STEER
2792771 C
P
V2
LEFT SIDE
T
2
MA3
2500 PSI
P4 a
TRACTION CONTROL A3
(PAGE5) 1 V1
A1
P A
FRONT AXLE
T B A2
1 V1
A4
RIGHT SIDE
b
2500 PSI
MA4
2
V2
2
2600 PSI
a MS1
LEFT
S1
P A
LEFT SIDE
T B
S2
1
b MS2
2000 PSI
RIGHT
2 FRONT STEER
2600 PSI
a MS3
RIGHT
S3
P A
RIGHT SIDE
T B S4
1
b MS4
2000 PSI
LEFT
AXLE
2792771 C
Figure 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2
P1 P2
PLANETARY GEAR
88.2 : 1 RATIO
LEFT
REDUCTION
A3
4
P3 3 3
2
P4
Br
L1 G 1 2 4
L B3
2.74 CU. IN. MAX G1
1.0 CU. IN. MIN
1 3
A B .025 DIA. .047
ORIFICE
Speed
REAR 2 Two Shift
TS
1 2
MBR
Brake 2
1
Release
2 3
BR 1 1 2
1 2
LOP 3 .047
2
1
AXLE LOCKOUT
MLOP
A B
A5 4 2
2.74 CU. IN. MAX
1.0 CU. IN. MIN G1
L
L1 G
Br 3
B5
B2 B1 A1
PLANETARY GEAR
RIGHT
88.2 : 1 RATIO
REDUCTION
2792771 C
TRACTION CONTROL
Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2
LEFT
OSC. AXLE L.O. CYL.
PLANETARY GEAR
88.2 : 1 RATIO
REDUCTION
A4
Br
L1 G
B4
L
2.74 CU. IN. MAX
1.0 CU. IN. MIN
G1
A B
FRONT
2 4
3
"OPTION"
AXLE LOCK OUT CYLINDERS
BORE: 5.00" 19.63 SQ. IN.
ROD: 2.00" 3.14 SQ. IN.
MP
A B
L1 G
Br
A6
B6
A2 D
PLANETARY GEAR
88.2 : 1 RATIO
REDUCTION
#3 #1 SWIVEL PORT
#7
SWINGDRIVE SWING
BearingtoPinionRatio:103:20 A
GearboxRatio:54.58:1
MotorDisc.:6.00c.i.r. LIFTCYLINDER
Bore:9.00"63.61sq.in.
Rod:4.00"12.56sq.in.
BOOMCONTROL B
Annulus:51.05sq.in.
Cyl.AreaRatio:1.24:1
Stroke:62.125"
1200SJP/1350SJP
2792771C
M1 1 2 3 MS
1500PSI
1 3 2
2
1500PSI
EMERGENCY
LOWER 2
A B
2
a b
RESERVOIR
SHT.#2 P T
3 1 SWING
T3 LIFTDOWN
AUXSELECT
FROMGRPORT
GR
OFGENERATOR
P2
MAIN
DUMP
B
P
M
S
AUX.PUMP
TOGRPORT W LS
OFMAINVALVE MP
GR
LS1 3
TO "X" PORT OF
FUNCTION PUMP
SHT.#2 P
A
"OPTION"
TO RESERVOIR
G GENERATOR CONTROL
L B
LIFT
TELESCOPE
TELESCOPE CYLINDER
Bore:5.00"19.63sq.in.
Rod:4.00"12.56sq.in.
Annulus:7.07sq.in.
Cyl.AreaRatio:2.77:1
Stroke:344.625"
5GPM
V2 V1
M4 4 5 M5 6 M7 7 8 M8
75PSI
1 1 1
2 2 2
LIFT
A B
A B
a b
P T a b
P T
2
TELESCOPE
2
LIFT DOWN
AUXILIARY
2 1
T2
15PSI
1
"T"
SHT.#3
2
1
5PSI
P3
MP3
2
75PSI
"P"
1
SHT.#3
P1
"B"
2792771C
SHT.#2
4.1 TO CONNECT THE JLG CONTROL SYSTEM 4.2 USING THE ANALYZER
ANALYZER With the machine power on and the analyzer connected
properly, the analyzer will display the following:
1. Connect the cable supplied with the analyzer, to the
controller module located in the platform box or at
the controller module in the ground control box and
connect the remaining end of the cable to the ana-
lyzer.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
Figure 4-1. Ground Analyzer Connection Point
menu item.
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
LOGGED HELP
1: POWER CYCLE (0/0)
At this point, the analyzer will display the last fault the sys-
tem has seen, if any are present. You may scroll through
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To
return to the beginning, press ESC. two times. POWER
CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu
items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ESC. key.
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
4-180
ACCESS LEVEL 1
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
MAX FORWARD X% MAX UP X% MAX LEFT X% MAX UP X% MAX IN X% MAX IN X%
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
SECTION 4 - JLG ANALYZER
MIN REVERSE X% CREEP UP X% CREEP LEFT X% MIN DOWN X% MIN OUT X% MIN OUT X%
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
MAX REVERSE X% MIN DOWN X% MIN RIGHT X% MAX DOWN X% MAX OUT X% MAX OUT X%
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE: GEN SET/WELDER:
ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS MAIN UP: XXX% ENGINE 1800 RPM
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL X.XS MAIN DOWN: XXX%
1200SJP 1350SJP
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE:
MIN UP X% MIN LEFT X% MIN UP X% MIN LEFT X% SWING: XXX%
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE:
MAX UP X% MAX LEFT X% MAX UP X% MAX LEFT X% PLT LEVEL: XXX%
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE:
MIN DOWN X% MIN RIGHT X% MIN DOWN X% MIN RIGHT X% PLT ROTATE: XXX%
PLATFORM LEVEL: PLATFORM ROTATE: JIB LIFT: JIB LIFT: GROUND MODE:
MAX DOWN X% MAX RIGHT X% MAX DOWN X% MAX RIGHT X% MAIN TELE: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
TOWER UP: XXX%
Figure 4-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present)
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
JIB (U/D): XXX%
GROUND MODE:
JIB (L/R): XXX%
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
3128463
FROM:
PERSONALITIES
MENU: MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN:
MACHINE SETUP 1200S 1350S: 135' MAX ANSI USA DEUTZ F4 TIER1 NO GLOW PLUGS DISABLED ENABLED
3128463
MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG: STARTER LOCKOUT: ENGINE SHUTDOWN:
TO: 1250A 1350S: 125' MAX ANSI EXPORT DEUTZ F4 TIER2 AIR INTAKE ENABLED DISABLED
CALIBRATIONS
MODEL NUMBER: ENVELOPE HEIGHT: MARKET: ENGINE: GLOW PLUG:
1350S 1350S: 120' MAX CSA DEUTZ ECM IN-CYLINDER*
ENVELOPE HEIGHT: MARKET:
1350S: 110' MAX CE
ENVELOPE HEIGHT: MARKET:
1200S: 120' MAX AUSTRALIA
ENVELOPE HEIGHT: MARKET:
1200S: 110' MAX JAPAN
ENVELOPE HEIGHT:
1250A: 125' MAX
ENVELOPE HEIGHT:
1250A: 100' MAX
ENVELOPE HEIGHT:
1250A: 80' MAX
1200SJP 1350SJP
CHASSIS TILT: TILT: LOAD SYSTEM:
3 DEGREES + CUT 5=3 DEG PLUS CUT SPECIAL 1
Figure 4-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present)
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
SECTION 4 - JLG ANALYZER
4-181
4-182
FROM:
MACHINE SETUP
SECTION 4 - JLG ANALYZER
CALIBRATE CALIBRATE CALIBRATE CALIBRATE LEVEL CALIBRATE LEVEL CALIBRATE MAIN CALIBRATE MAIN
STEER? DRIVE? BOOM VALVES? UP CRACKPOINT? DOWN CRACKPOINT? LIFT CRACKPOINT? TELE CRACKPOINT?
DEUTZ SETUP:
SETUP 2
1200SJP 1350SJP
DEUTZ SETUP:
SETUP 3
DEUTZ SETUP:
SETUP 4
Figure 4-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present)
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
3128463
FROM:
HELP:PRESS ENTER
3128463
MENU: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: TO:
DIAGNOSTICS DRIVE BOOM FUNCTIONS ENGINE SYSTEM SHEET 2
STEER OUTPUT: SWING OUTPUT: ENGINE OIL PLATFORM SELECT SOFT TOUCH
LEFT XXX% LEFT XXX% PRESSURE:XXXXPSI KEYSWITCH:CLOSED OVERRIDE: OPEN
CREEP MODE: TOWER TELESCOPE: ENGINE SPEED FOOTSWITCH INPUT PLATFORM TILT2
1200SJP 1350SJP
HIGH ENGINE JIB SWING: CREEP OSCILATING AXLE
SWITCH: OPEN LEFT XXX% SWITCH: CLOSED PRES. SW.: OPEN
DRV. ORIENTATION
SWITCH: CLOSED
DRV. ORIENTATION
Figure 4-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3
OVERRIDE: OPEN
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
SECTION 4 - JLG ANALYZER
4-183
4-184
FROM: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: TO:
SHEET 1 TRANSPORT DATA BCS ENVELOPE BOOM SWITCHES BOOM SENSORS LOAD PIN SHEET 3
TRANSPORT MODE: BCS STATUS: MAIN BOOM MAIN BOOM LENGTH TOWER LENGTH 1 LOAD PIN MOMENT
OUT OF TRANSPORT NORMAL LENGTH: XXX.X" SWITCH NC: OPEN SENSOR: X.X" VALUE: XXXX
MAIN LIFT 2 RAW
TOWER LIFT ELEC. RETRIEVAL: MAIN BOOM MAIN BOOM LENGTH TOWER LENGTH 2 ANGLE: XXX.X LOAD PIN RATIO
STATUS: STOWED NOT ACTIVE ANGLE1: XX.X DEG SWITCH NO:CLOSED SENSOR: X.X" VALUE: XX.XXX
TOWER RETRACTED
TOWER TELESCOPE HYD. RETRIEVAL: MAIN BOOM MAIN BOOM LENGTH TOWER ANGLE 1 LENGTH 1: XXXXXX LOAD PIN ANGLE
STATUS:RETRACTED NOT ACTIVE ANGLE2: XX.X DEG ZONE: A/D SENSOR: XX.X VALUE: XXX.X
TOWER RETRACTED
MAIN LIFT MAIN ENVELOPE MAIN BOOM A/D DUAL CAPACITY TOWER ANGLE 2 LENGTH 2: XXXXXX LOAD PIN VECTOR
STATUS: ELEVATED STATUS: NOMINAL LENGTH: XXXXX SWITCH NC: OPEN SENSOR: XX.X FORCE: XXXXXX
TOWER EXTENDED
MAIN TELESCOPE MAIN ENVELOPE MAIN BOOM A/D DUAL CAPACITY TOWER CYLINDER LENGTH 1: XXXXXX LOAD PIN MOMENT
STATUS:RETRACTED LOW: NOMINAL ANGLE1: XXX.X SWITCH NO:CLOSED ANGLE: XX.X RAW: XXXXX
TOWER EXTENDED
PLATFORM TOWER ENVELOPE MAIN BOOM A/D DUAL CAPACITY MAIN ANGLE 1 TO LENGTH 2: XXXXXX LOAD PIN RATIO
SECTION 4 - JLG ANALYZER
STOWED: NO STATUS: NOMINAL ANGLE2: XXX.X LENGTH ZONE: A/B TOWER: XX.X RAW: XX.XXX
TOWER TRIP POINT
AXLE STATUS: MAIN BOOM ANGLE BOOM CONTROL: TOWER TELESCOPE MAIN ANGLE 2 TO LENGTH: XXXX.X" LOAD PIN ANGLE
EXTENDED ZONE: 4 AUTOMATIC SWITCH NC: OPEN TOWER: XX.X RAW: XXX.X
TOWER ANGLE 1
JIB STOWED LIMIT MAIN BOOM LENGTH TOWER TELESCOPE MAIN ANGLE L TO LOW CAL: XXX.X LOAD PIN V-FORCE
SWITCH: CLOSED ZONE: A MODE SW: OPEN SWITCH NO:CLOSED GRAVITY: XXX.X RAW: XXXXXXXX
TOWER ANGLE 2
JIB STOWED LIMIT TOWER TELESCOPE MAIN ANGLE H TO LOW CAL: XXX.X LOAD PIN ANGLE
OVERRIDE: OPEN STATUS:RETRACTED GRAVITY: XXX.X CAL POINT: XXX.X
TOWER ANGLE 1
AXLE INPUT SW.: TOWER LIFT ANGLE TOWER LENGTH 1 HIGH CAL: XXX.X LOAD PIN V-FORCE
EXTEND CLOSED SWITCH: OPEN A/D: XXXXX CAL: XXXXX
1200SJP 1350SJP
LOW CAL: XXXXXX
ANGLE A/D: XXXXX VALUE: XXX
MAIN ANGLE 2
MAIN LIFT 1 LOW CAL: XXXXXX LOAD PIN X-AXIS
ANGLE A/D: XXXXX RAW VALUE: XXX
MAIN ANGLE 1
MAIN LIFT 2 HIGH CAL: XXXXXX LOAD PIN Y-AXIS
ANGLE A/D: XXXXX RAW VALUE: XXX
MAIN ANGLE 2
MAIN LIFT 1 RAW HIGH CAL: XXXXXX
ANGLE: XXX.X MAIN TRIP POINT
ANGLE: XXX.X
Figure 4-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
3128463
3128463
FROM: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS: DIAGNOSTICS:
SHEET 2 MOMENT LOAD CAN STATISTICS CALIBRATION DATA DATALOG VERSIONS
ACTUAL MOMENT PLATFORM CAN STATISTICS PLATFORM UP DATALOG: GROUND MODULE
XXXXXXXX LB*IN CAPACITY:1000 LB RX/SEC: X CAL: X ON XXH XXM SOFTWARE: P7.X
OVER MOMENT DUAL CAPACITY CAN STATISTICS PLATFORM DOWN MAIN ANGLE 1 DATALOG: GROUND MODULE
XXXXXXXX LB*IN SWITCH NC: OPEN TX/SEC: X CAL: X LO CAL: X ENGINE XH XM CNST DATA: P7.X
UNDER MOMENT DUAL CAPACITY CAN STATISTICS LEFT FORWARD MAIN ANGLE 1 DATALOG: GROUND MODULE
XXXXXXXX LB*IN SWITCH NO:CLOSED BUS OFF X DRIVE CAL: XXXX HI CAL: X DRIVE XH XM HARDWARE: REV 4
UNDER MOMENT CAL DUAL CAPACITY CAN STATISTICS RIGHT FORWARD MAIN ANGLE 2 DATALOG: GROUND MODULE
POINT: X LENGTH ZONE: A/B PASSIVE XXXXX DRIVE CAL: XXXX LO CAL: X LIFT XH XM S/N: XXXXXX
YELLOW WITNESS JIB IN-LINE CAN STATISTICS LEFT REVERSE MAIN ANGLE 2 DATALOG: PLATFORM MODULE
CAL: XXXXXXXX SWITCH: OPEN MSG ERROR: XXXX DRIVE CAL: XXXX HI CAL: X SWING XH XM SOFTWARE: P7.X
GREEN WITNESS PLATFORM LOAD RIGHT REVERSE LENGTH RETRACTED DATALOG: PLATFORM MODULE
CAL: XXXXXXXX STATE: OK DRIVE CAL: XXXX CAL: XXXXX TELE XH XM HARDWARE: REV 2
LOAD PIN RATIO L FRONT STEER LENGTH EXTENDED DATALOG: PLATFORM MODULE
1200SJP 1350SJP
INSTALLED: NO CAL: XXXXX ERASE RENTAL? S/N: XXXXXX
SKY BRIGHT MAIN LIFT DOWN MAIN ANGLE 1
INSTALLED: NO CAL: XXXX S/N: XXXXXX
PIPE RACKS MAIN TELESCOPE MAIN ANGLE 1
INSTALLED: NO IN CAL: XXXXX REV X.X
CAMERA MOUNT MAIN TELESCOPE MAIN ANGLE 2
INSTALLED: NO OUT CAL: XXXXX S/N: XXXXXX
MAIN ANGLE 2
REV X.X
VERSIONS:
ANALYZER V6.3
Figure 4-9. Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
SECTION 4 - JLG ANALYZER
4-185
SECTION 4 - JLG ANALYZER
4.3 CHANGING THE ACCESS LEVEL OF THE Once the correct password is displayed, press ENTER.
The access level should display the following, if the pass-
HAND HELD ANALYZER word was entered correctly:
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting can-
not be accidentally altered. To change the access level,
the correct password must be entered. To enter the pass-
word, scroll to the ACCESS LEVEL menu. For example:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the pass-
word.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
Continue using the arrow keys until all the remaining digits
of the password is shown.
GROUND ALARM:
2 = LIFT DOWN
PERSONALITIES:
The effect of the machine digit value is displayed along
DRIVE ACCEL 1.0s
with its value. The above display would be selected if the
There will be a minimum and maximum for the value to machine was equipped with a ground alarm and you
ensure efficient operation. The Value will not increase if wanted it to sound when lifting down. There are certain
the UP arrow is pressed when at the maximum value nor settings allowed to install optional features or select the
will the value decrease if the DOWN arrow is pressed and machine model.
the value is at the minimum value for any particular per-
sonality. If the value does not change when pressing the When selection the machine model to match the size of
up and down arrows, check the access level to ensure the machine, the personality settings will all default to the
you are at access level 1. factory recommended setting.
ELEVATION CUTBACK
Default
Configuration Digit Number Description
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing
the personality settings first and then changing the model number of the machine configuration will cause
the personality settings to return to default
3 1350S
NOTE: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial
default setting.
2 CSA
3 CE
4 AUSTRALIA
5 JAPAN
Default
Configuration Digit Number Description
Number
STARTER LOCKOUT: 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; 0
6 engine start can be attempted at any time during pre-glow.
TILT: 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when 1
8 tilted more than 5 degrees and above elevation; also reduces drive speed to
creep.
2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also reduces drive speed to creep.
3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also reduces drive speed to creep.
4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep
when tilted more than 4 degrees and above elevation; also disallows tower lift up,
tower telescope out, drive, main telescope out and main lift up.
5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep
when tilted more than 3 degrees and above elevation; also disallows tower lift up,
tower telescope out, drive, main telescope out and main lift up.
NOTE: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform
alarm when the machine is also above elevation.
Default
Configuration Digit Number Description
Number
GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
11*
1 MOTION CUTOUT: Motion cutout in platform mode only.
2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5
sec ON, 2 sec OFF).
3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), plat-
form alarm beeps (5 sec ON, 2 sec OFF).
4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main
lift up, platform alarm beeps (5 sec ON, 2 sec OFF).
* Certain market selections will limit load system options or alter default setting.
Default
Configuration Digit Number Description
Number
* Certain market selections will limit function cutout options or alter default setting.
4150364-15
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.
1200SJP
GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
ANSI USA 1 5 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
ANSI EXPORT 1 5 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CSA 1 5 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CE 1 5 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
AUSTRALIA 1 5 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
JAPAN 1 5 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
1200SJP
FUNCTION CUTOUT
OSCILLATING AXLE
GROUND ALARM
TEMPERATURE
LOAD SYSTEM
ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1
ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1
CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1
AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.
1350SJP
GLOW PLUGS
SOFT TOUCH
MARKET
ENGINE
TILT
ANSI USA 3 1 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
ANSI EXPORT 3 1 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CSA 3 1 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
CE 3 1 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
AUSTRALIA 3 1 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
JAPAN 3 1 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1
1350SJP
FUNCTION CUTOUT
OSCILLATING AXLE
GROUND ALARM
TEMPERATURE
LOAD SYSTEM
ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1
ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1
CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1
AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1
NOTE: Machine personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum
machine performance.
Stop watch should start when the function is activated. Not with the controller or switch.
Unless noted, function speeds should be measured from platform.
Platform speed knob must be at full speed (fully clockwise).
All test should be done with the oil temp above 100° F (38° C).
Test Notes
1. Personality settings can be adjusted anywhere
4.6 MACHINE ORIENTATION WHEN SETTING within the adjustment range in order to achieve opti-
SPEEDS mum machine performance
Lift Up: From platform control, lowest elevation up to max- 2. Stop watch should start when the function is acti-
imum elevation, boom retracted. vated.Not with the controller or switch.
Lift Down: From platform control, maximum elevation 3. Unless noted, function speeds should be measured
down to minimum elevation, boom retracted. from platform.
4. Platform speed knob must be at full speed (fully
Swing Right (Max): 360 Degrees, from platform control,
clockwise).
boom approximately 45° elevation, boom retracted.
5. All test should be done with the oil temp above 100°
Swing Left (Max): 360 Degrees, from platform control, F (38° C).
boom approximately 45° elevation, boom retracted.
Telescope Out: From platform control, boom horizontal, 4.7 SYSTEM TEST
500 lb. (230 kg) capacity selected.
The Control System Incorporates a built-in system test to
Telescope In: From platform control, boom horizontal, check the system components and functions. To use this
500 lb. (230 kg) capacity selected. function, use the following procedures.
Drive Forward (Max): Test should be done on a smooth Test from the Platform
level surface. High Speed - Low Torque setting, drive 200
1. Position the Platform/Ground select switch to the
ft. (61 m) front wheels to front wheels. Timed after
Platform position.
machine has obtained maximum speed.
2. Plug the analyzer into the connector at the base of 4. The analyzer screen should read:
the platform control box.
Test from the Ground Station 4. The analyzer screen should read:
SECTION 5. CALIBRATIONS
This machine incorporates a variety of sensors and a high Service Action Calibration
degree of function interaction. For safety and proper
BLAM removal Boom Sensors
machine functionality, the calibration procedures must be
repeated for any control module replacement, system cal- BLAM replacement Boom Sensors
ibration related fault, or removal or replacement of any Drive
sensors, valves, coils, motors, or pumps. The chart below Boom angle sensor removal or replace- Boom Sensors
lists the calibrations required and potential reasons for re- ment
calibration. Boom length sensor removal or replace- Boom Sensors
All calibration procedures are menu driven through the ment
use of the standard JLG analyzer. With the exception of Boom lift flow control valve/coil replace- Lift Crack Point
steering calibration, no external tools are required to com- ment
plete the calibration procedures. The user is prompted to Boom telescope flow control valve/coil Tele Crack Point
exercise the machine in a specific order to use the replacement
machines physical properties to consistently establish
Chassis Module replacement Steering
sensor response and the interaction of valves, pumps,
and motors. Steering calibration also uses the analyzer Drive pump/coil replacement Drive
and is performed on one side of the machine at a time Ground Module removal Boom Sensors
requiring the use of a string or other means to determine Chassis Tilt
when the tires are in line with each other. With the excep- Ground Module replacement Boom Sensors
tion of the load control calibration, all calibrations are Chassis Tilt
accessed by connecting the analyzer into the control sys- Drive
tem inside the main terminal box or on the bottom of the Lift Crack Point
platform control box. Calibration of the platform load sens- Tele Crack Point
ing system is accessed by connecting the analyzer Platform Level Crack Point
directly into the LSS module. Steering
Table 5-1. Calibrations Listed by Symptom Load cell removal or replacement Platform Load Sensing
LSS module replacement Platform Load Sensing
Symptom Calibration
Main terminal box removal or replacement Chassis Tilt
Boom control system inaccuracy Boom Sensors
Moment pin removal or replacement Boom Sensors
Boom telescope problems Wire Rope Tensioning
Platform level valve/coil replacement Platform Level Crack Point
Drive lugs engine Drive
Platform module replacement Platform Level Crack Point
Drive pulls to one side Drive
Steer Angle Sensor replacement Steering
Load control inaccuracy Platform Load Sensing
Platform leveling erratic Platform Level Crack Point
Speed control for slow speed is poor Drive
Tilt indication inaccuracy Chassis Tilt
Wheel misaligned persistently Steering
4. The analyzer screen should read: 8. Use the arrow keys to reach Steer. The screen will
read:
10. Hit Enter. The screen will read: 13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave
off the control. The display will read FRT LEFT =
and show the numeric calibration value for that
wheel.
2. Plug the analyzer into the connector at the base of 4. The analyzer screen should read:
the platform control box.
8. Use the arrow keys to reach DRIVE. 10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read:
13. Hit Enter. The number displayed will be the value 15. Repeat steps 10 thru 12 for left reverse drive.
that the crack point is set to. The screen will show:
16. Left Reverse Drive Calibration will be followed by
Right Forward Drive Calibration which will be fol-
lowed by Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC
twice to go back to CALIBRATIONS.
When the unit is in the transport position and driving and In each of the cases above it shall be necessary to re-
the current setpoint varies by ± 5.5° for more than 8 sec- cycle the EMS to clear the fault. Operable functions shall
onds the events 1,2,3 & 4 above will occur. (note function be in the creep mode except while below elevation.
speeds will operate normally). Cycling the EMS will clear TILT SENSOR ERRORS
the fault and allow the operator to operate the machine as
a new level setpoint is taken. If the secondary tilt sensor is faulty, the control system will
continue to utilize information from the primary sensor.
VALVE DRIVER ERRORS
If the primary sensor is faulty, the control system will
There are three possible level valve driver errors, short to switch to the backup sensor for control.
battery, short to ground, and open circuit.
In both cases above the following will occur:
1. In the case of a short to ground or an open circuit,
the platform valve cannot be turned on and the fol- 1. The Electronic Leveling System Fault Lamp will flash
lowing will occur: (to indicate that there is a leveling fault).
a. All interactions with platform leveling shall cease 2. The platform alarm will sound.
3. A system fault will be logged. cycle will be the same as would otherwise have been
commanded to the flow control valve.
4. All function speeds (lift, swing, telescope, jib and
drive) will be placed in creep mode (except when Only one platform or jib function is allowed at one time to
the platform is in the transport position). limit the amount of current draw, minimizing the voltage
drop on the supply to the Platform Module.
5. Automatic leveling remains active.
The function is enabled first shall remain active until it is
Lift, swing, drive and telescope will continue to operate. released. Any other function commanded while another
In each of the cases above it will be necessary to re-cycle function is active is ignored.
the EMS to clear the fault. Operable functions shall be in
the creep mode except while below elevation. Platform Leveling Calibration Procedure
When both sensors appear to be working but have mea- STEP 1: SETTING THE PLATFORM VALVE MINIMUMS
surements that disagree by ±5.5° The following will occur:
1. Put machine into “Ground Mode”.
1. All interactions with platform leveling shall cease.
2. Start machine and plug in Analyzer.
2. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has been 3. Go to the “Access Level 2” screen.
lost). 4. Enter “33271” to get into Access Level 1 mode.
3. The platform alarm will sound. 5. Go to the “Personalities” menu and adjust the fol-
4. A system fault will be logged. lowing personalities. Refer to Table 4-2. Machine
Personality Settings and Speeds on page 202 for
5. All function speeds (lift, swing, telescope and drive) proper setting values.
will be placed in creep mode (except when the plat-
form is in the transport position) Basket Level Up Min
Basket Level Up Max
At this point, the operator must use the level up and down
Basket Level Down Max
toggle switch to manually level during descent. It shall be
Jib Up Min
necessary to re-cycle the EMS to clear the fault.
Jib Down Min
CAN Errors 6. Recycle EMS.
The Ground Module has two direct outputs dedicated to STEP 2: CALIBRATING THE PLATFORM LEVEL
overriding the Platform Module’s control of the leveling SENSORS
valves. The Ground Module “Platform Level Up/Down”
outputs are used to control the platform level up and 1. Put machine into “Ground Mode”.
down valves. 2. Start machine and plug in Analyzer.
When in ground mode, if the Ground Module reads a plat- 3. Manually level the platform with the switch on the
form leveling switch command, the switch command is MTB.
communicated over CAN to the Platform Module where it
is handled normally. 4. Go to the “Access Level 2” screen.
If Ground Module determines that CAN communication is 5. Enter “33271” to get into Access Level 1 mode.
inoperable, it turns on the platform control valve and the
6. Go to the “Calibrations” menu and hit ENTER.
appropriate platform leveling override outputs while the
switch is engaged. 7. Use RIGHT ARROW go to “Plat. Leveling” screen.
If the Platform Module is still running when CAN is down 8. Hit ENTER. “Calibrate?” prompt should appear.
nothing will operate when in platform mode. When the
operator switches to ground mode, the platform will not 9. Hit ENTER again to calibrate level sensors.
control any of its valve outputs and a CAN error message 10. When calibration has been successful “Cal. Com-
is signaled. plete” should appear.
Additional Platform and Jib Valves 11. Cycle power to the machine.
The high side drivers for the platform left and right and the STEP 3: BLEEDING THE PLATFORM VALVES
jib up and down valves are be located in the Platform
1. Put machine into “Ground Mode”.
Module and are proportional. Flow through the valves is
individually controllable. The individually controlled duty 2. Start machine and plug in Analyzer.
3. Go to the “Access Level 2” screen. STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
4. Enter “33271” to get into Access Level 1 mode.
1. Put machine into “Ground Mode”.
5. Go to the “Personalities” menu.
2. Start machine and plug in Analyzer.
6. Using the left arrow button, go to the “Ground
Mode” menu. 3. Go to the “Access Level 2” screen.
7. Hit ENTER. 4. Enter “33271” to get into Access Level 1 mode.
8. Using the UP/DOWN arrows, adjust the following 5. Go to the “Calibrations” menu and hit ENTER.
personalities to 100%.
6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
Basket Rotate 7. “Calibrate?” prompt should appear. Hit ENTER
Basket Level again.
Jib U/D (if configured)
8. You will hear engine go to 1800 rpm.
Start up the machine and exercise each above plat- 9. Using UP ARROW, increase the value until you see
form function (from the ground) eight (8) to ten (10) the basket up movement.
times for 5 seconds in each direction.
10. Hit ENTER again. “Cal. Complete” message should
9. Return the personality settings back to the values as appear
shown in Table 4-2. Machine Personality Settings
and Speeds on page 202. 11. Engine should again return to idle.
10. Recycle EMS. 12. Hit ESC should return to “Basket U Crkpt” screen.
13. Hit RIGHT ARROWto get to the “Basket D Crkpt”
screen. Hit ENTER.
14. “Calibrate?” prompt should appear. Hit ENTER
again.
15. You will hear engine go to 1800 rpm.
Using DOWN ARROW, decrease the value until you see
the basket down movement.
Hit ENTER again. “Cal. Complete” message should
appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
STEP 2: CALIBRATING THE PLATFORM LEVEL 5. The analyzer screen should read:
SENSORS
1. Position the Platform/Ground select switch to the
Ground position.
11. Hit ENTER again to calibrate level sensors. 4. The analyzer screen should read:
12. When calibration has been successful CAL. COM-
PLETE should appear.
13. Cycle power to the machine.
Basket Rotate
Basket Level
Jib U/D (if configured)
STEP 4: CALIBRATING THE PLATFORM LEVEL 4. The analyzer screen should read:
5.6 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the
Ground control box.
9. Use the arrow keys to reach the TILT SENSOR. The 5.7 CALIBRATING LIFT CRACK POINT
screen should read:
1. Position the Platform/Ground select switch to the
Platform position.
3. Pull out the Emergency Stop switch and Start the 8. Use the arrow keys to reach Upper Lift Crack Point
engine. (UPPER LIFT CRKPT). The screen will read:
10. Hit Enter. The screen will read: 13. Hit enter. The number displayed will be the value
that the crack point is set to. The screen will show:
5.8 CALIBRATING TELESCOPE CRACK POINT 3. Pull out the Emergency Stop switch and Start the
engine.
1. Position the Platform/Ground select switch to the
Platform position.
8. Use the arrow keys to reach Upper Telescope Crack 10. Hit Enter. The screen will read:
Point (UPPER TELE CRKPT). The screen will read:
12. Activate the Tele Out function until the boom starts to
move, then leave off immediately. The display will
read CRK PT = and show the numeric crack point
value.
13. Hit enter. The number displayed will be the value 15. Hit Enter. The screen will read:
that the crack point is set to. The screen will show:
9. Use the arrow keys to reach BOOM SENSORS. The 11. After verifying all the conditions listed in step 1 are
screen should read: met, hit Enter. The screen will read:
10. Hit Enter. The screen will read: 12. After verifying all load (personnel or material) is
removed from the platform, hit Enter. The screen will
read:
13. After visually verifying that the jib is horizontal, hit 15. After visually verifying the platform is centered, hit
Enter. The screen will read: Enter. The screen will read:
14. After visually verifying the platform is level, hit Enter. 16. After operating telescope in to verify the boom is
The screen will read: fully retracted, hit Enter. The screen will read:
17. Use the up/down arrows to select YES if the acces- 19. Use the up/down arrows to select YES if the acces-
sory is installed, NO if it is not installed and hit enter. sory is installed, NO if it is not installed and hit enter.
The screen will read: The screen will read:
18. Use the up/down arrows to select YES if the acces- 20. Use the up/down arrows to select YES if the acces-
sory is installed, NO if it is not installed and hit enter. sory is installed, NO if it is not installed and hit enter.
The screen will read: The screen will read:
21. Use the up/down arrows to select YES if the acces- 23. After making sure the machine is in Calibration Posi-
sory is installed, NO if it is not installed and hit enter. tion 1, hit Enter. The screen will read:
The screen will read:
The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:
25. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:
27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:
When the machine is in the proper position, hit When the machine is in the proper position, hit Enter. The
Enter. The screen will read: screen will read as follows:
29. Lift down to stop (boom must be on boom rest) for When Position 7 Calibrating is complete, the screen will
Calibration Position 7. read:
Press Enter. The screen read: When the machine is in the proper position, hit Enter. The
screen will read:
ter line on decal within 0.25" [6 mm]) for Calibration When Position 9 calibrating is complete, the screen will
Position 9. read:
32. Telescope in to green witness mark (controller will Press Enter. The screen will read:
find the position - operator must visually verify the
position).
5.10 WIRE ROPE TENSIONING PROCEDURE 1. Remove the lock plates and nylon collar locknuts
from the wire rope fittings.
With the boom assembly in the fully retracted position and 2. Extend the boom 5 to 6 feet (1.5 to 1.8 m) from fully
before making any adjustments to the wire ropes of the retracted position while maintaining a horizontal (+/-
boom assembly, remove any covers necessary to visually 5°) position of boom.
inspect the threaded fittings, taking note of the amount of
adjustment that is left for both the extend and retract wire 3. Using tool P/N 4120043, torque outer mid retract
ropes for the fly and outer mid booms. Also, take note of adjuster nuts to 80 ft.lb. (112 Nm), alternating
between the two ropes until both maintain the
the position of each boom section while the assembly is in
required torque.
the fully retracted position. Take preliminary measure-
ments and compare them to Figure 5-11., Wire Rope Ten-
sioning Figure A.
8.0 ± 0.5”
203 ± 13 mm 9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
FLY BOOM
BASE BOOM OUTER MID BOOM
INNER MID BOOM
4. Using tool P/N 4120043, torque fly retract adjuster NOTE: Ensure the boom is not fully retracted for following
nuts to 80 ft.lb. (112 Nm), alternating between the steps.
two ropes until both maintain the required torque.
6. Using tool P/N 4120043, torque outer mid extend
adjuster nuts to 80 ft.lb. (112 Nm), alternating
between the two ropes until both maintain the
required torque.
1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt
6.1 GENERAL
This section contains schematics to be used for locating and correcting most of the operating problems which may develop.
If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, tech-
nically qualified guidance should be obtained before proceeding with any maintenance.
Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch
it to a good ground. A good ground will be a short circuit to the battery negative terminal or known good ground such as the
platform grounding bolt. Check this with a multimeter on continuity measurement or resistance. If the meter lead won’t reach
a good ground "walk" the meter back to one, finding shorts along the way.
Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically
designed for this technique. Whenever possible insert probes into the side of the connector such that the test also checks
both terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sides
of a connector terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still
attached to the contact and contacts are seated in the connector.
Min/Max
Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while
alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the
solenoid and meter, is held down.
Polarity
Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and that the leads are connected to the device under test cor-
rectly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other
port goes to the positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
Example: 50 mA = 0.05 A
• If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together.
(See multimeter’s operation manual) Resistance should read a short circuit (very low resis-
• Use firm contact with meter leads tance)
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
• Some meters require a separate button press to • Set up the meter for the expected current range
enable audible continuity testing • Be sure to connect the meter leads to the correct
• Circuit power must be turned OFF before testing con- jacks for the current range you have selected
tinuity • If meter is not auto ranging, set it to the correct range
• Disconnect component from circuit before testing (See multi meter’s operation manual)
• Use firm contact with meter leads • Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
Requirements:
• Harness with at least three separate wires including the wire under test.
Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate mea-
surement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach
of the jumper.
1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not com-
pletely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
6.4 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. De-energize the circuit.
2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an
open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will
be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two
terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.
Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually oper-
ated switches except that the moving object operates the switch. These switches can be tested the same way as a stan-
dard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive
proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do
not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform
position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find
the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch
as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the
switch and object sensed.
Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener-
gized to actuate.
1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.
2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do
this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for exam-
ple. The state indicated in the control system should change.
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and
female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by
using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside
the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus
preventing the housing latch from engaging.
2. Open one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Pro-
ceed as follows:
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector
Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Fig-
ure 6-7. Connector Assembly (2 of 4)).
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the lock-
ing latches by squeezing them inward (See Figure 6-8. Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)).
Disassembly
1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The
resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies
the effectiveness of the connector seals and could result in system failure.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in
place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedge-
lock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
1. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it
away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may displace the seal.
3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly
locked in place.
NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Technology Equipment Pte Ltd.
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0) 421 69 350 20 Hong Kong +39 029 359 5210 639379 - Singapore
+49 (0) 421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591-9030
(852) 2639 5797 +65-6591-9031
www.jlg.com