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Troubleshooting Manual

Models
1200SJP
1350SJP
3128463
January 10, 2011

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INTRODUCTION

SECTION A. INTRODUCTION

A.1 HOW TO USE THIS MANUAL


Troubleshooting system problems can be difficult. System wiring and hydraulic diagrams are provided in this book to help
isolate problems.

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

Figure A-1. Troubleshooting Flowchart

3128463 1200SJP 1350SJP A-3


INTRODUCTION

A.2 VISUAL INSPECTION


Perform a thorough visual and “hands on” inspection before starting any troubleshooting procedure. Also, perform a visual
inspection at every connector, sensor, hose, harness, etc. opened or accessed during the procedure. You can quickly find
the cause of many problems just by looking.

Has the machine been serviced recently? Check that everything has been reconnected properly.

Inspect Hoses for:

• Correct routing
• Pinches and kinks
• Splits, cuts, or breaks.
Inspect Wiring for:

• Contact with sharp edges


• Contact with hot surfaces
• Pinched, burned or chafed insulation
• Proper routing and connections
Check Sensors and Actuators for Damage.

Check Electrical Connectors 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

A.3 READING FAULT CODES


Current and logged system fault codes and ADE service flash codes can be read from the analyzer. Refer to 4.2 Using the
Analyzer on Pg. 177. Fault logs are separated by POWER CYCLE messages. In Troubleshooting, you may be asked to see
all of the currently active faults. This simply means all of the faults since the latest power cycle. Scroll through the chronolog-
ical faults on the analyzer, listing all the faults until the first “POWER CYCLE” message. Troubleshoot each of these items
separately unless instructed otherwise.

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

1705171 A 1702938 1705170 A

Figure A-2. Ground Module and Platform Fault (System Distress) Lights

A-4 1200SJP 1350SJP 3128463


INTRODUCTION

A.4 CONNECTOR REFERENCES


Electrical connectors are given a three digit identifier number preceded with “X”. See 2.1 Connector Index on Pg. 137 for a
list.
For Example:
[X004.21] refers to terminal 21 (pin and socket) of connector X004.
[X004.21.soc] refers to the socket side of terminal 21, connector X004.
[X004.21.pin] refers to the pin side of terminal 21, connector X004.

A.5 GROUND REFERENCE


Battery negative [X117] should be used as the ground reference for voltage measurements, unless stated otherwise.

3128463 1200SJP 1350SJP A-5


INTRODUCTION

A.6 CONTROL MODULE POWER AND COMMUNICATIONS


Always make sure that all of the control models are properly powered. See Figure A-3. Basic Electronic Module Connections
on Pg. 6
1. For Ground Module operation, Terminals [X001.24], and [X008.2] should have a voltage of Vbatt. Terminal [X008.1]
should be grounded.
2. CAN communication wires should have 60 resistance between CAN HI and CAN LO whenever both the Platform
Module and Chassis Module are connected or 120 when one of them are disconnected. Both CAN HI and CAN LO
should be isolated (show very high resistance or overload, OL) from the shield and ground. A CAN termination 120
resistor is located at both ends of the CAN bus. One is embedded in the platform module. The other terminator is jum-
pered in the chassis module.

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

X007 X001 Ground to Engine Module X240.1 X229 Chassis


CAN HI 13
CAN LO 24
J7 J1 8
J1 Module
CAN Shield 18 Analyzer Power CAN HI 6
28
Analyzer RS232 Receive
Vbatt from EMS
3
29
Analyzer RS232 Transmit X013 2 1 X263 120
30
Platform Mode Select Analyzer Ground Analyzer
14 31
Constant Battery (Vbatt)
24 CAN LO 7
X097 X280 X267
CAN Shield 8
3

Vbatt from Power X008 2 Ignition Power Chassis Power 5


Down Relay J8 9
2
Ground from B- 1
CAN Jumper 10
Platform Ground Constant Battery (Vbatt)
3 Battery +
Platform Power 4 Ground 4
Battery -
CAN HI CAN 2 HI
CAN LO CAN 2 LO
Analyzer Power
X233
Note: BLAM and Chassis Module Analyzer connections for download only X235 Analyzer RS232 Receive
9
10
J5
Analyzer Analyzer RS232 Transmit 11
Analyzer Ground 12

Figure A-3. Basic Electronic Module Connections

A-6 1200SJP 1350SJP 3128463


INTRODUCTION

A.7 CRITICAL SENSORS


Main Boom Angle Sensors
Main Boom Rotary Angle Sensor #1 (Right) [X099]
Main Boom Rotary Angle Sensor #2 (Left) [X100]
Measure the angle of the main boom with respect to the turntable. Power is supplied by the Ground Module so the sensors
can be turned on separately at startup for identification and diagnostic purposes. Once initialized, a constant 12 volts should
be supplied by the Power Down Relay [X011.87] to Main Boom Angle Sensor #1, [X099.1] and Main Angle Sensor #2,
[X100.1]. Each sensor communicates with the BLAM on its own serial bus.
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D ANGLE1: XXX.X
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D ANGLE2: XXX.X
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM ANGLE1: XX.X DEG
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM ANGLE1: XX.X DEG

In transport position approximate typical values are:


MAIN BOOM A/D ANGLE1: -38.0
MAIN BOOM A/D ANGLE2: -38.0
MAIN BOOM ANGLE1: -1.0
MAIN BOOM ANGLE2: -1.0

Main Boom Length Sensor


Main Boom Length Sensor #1 (Top Right) [X093]
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM LENGTH: XXX.X"
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D LENGTH: XXXXX

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

3128463 1200SJP 1350SJP A-7


INTRODUCTION

This Page Left Blank Intentionally

3128463 1200SJP 1350SJP A-8


SAFETY

SECTION B. TROUBLESHOOTING SAFETY PRECAUTIONS

B.1 GENERAL B.3 TROUBLESHOOTING SAFETY


This section contains the general safety precautions
which must be observed during troubleshooting of the
aerial platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
nance personnel pay strict attention to these warnings THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
and precautions to avoid possible injury to themselves or INJURY OR DEATH AND IS A SAFETY VIOLATION.
others, or damage to the equipment. A maintenance pro-
gram must be followed to ensure that the machine is safe • No smoking is mandatory. Never refuel during electrical
to operate. storms. Ensure that fuel cap is closed and secure at all
other times.
• Remove all rings, watches and jewelry when performing
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY any troubleshooting.
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST • Do not wear long hair unrestrained, or loose-fitting
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLA- clothing and neckties which are apt to become caught
TION. on or entangled in equipment.
• Observe and obey all warnings and cautions on
The specific precautions to be observed during trouble- machine and in service and operators manuals.
shooting are inserted at the appropriate point in the man-
• Keep oil, grease, water, etc. wiped from standing sur-
ual. These precautions are, for the most part, those that
faces and hand holds.
apply when servicing hydraulic and larger machine com-
ponent parts. • Use caution when checking a hot, pressurized coolant
system.
Your safety, and that of others, is the first consideration
• Never work under an elevated boom until boom has
when engaging in the troubleshooting of equipment.
been safely restrained from any movement by blocking
Always be conscious of weight. Never attempt to move
or overhead sling, or boom safety prop has been
heavy parts without the aid of a mechanical device. Do not
engaged.
allow heavy objects to rest in an unstable position. When
raising a portion of the equipment, ensure that adequate • A machine that is damaged or malfunctioning should
support is provided. immediately be tagged and removed from service.
• Repair any machine damage or malfunction before
SINCE THE MACHINE MANUFACTURER HAS NO
operating the machine.
DIRECT CONTROL OVER TROUBLESHOOTING,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF • Unless otherwise specified, perform any troubleshoot-
ing procedure with the machine parked on a flat level
THE OWNER/OPERATOR.
surface, boom stowed, key switch off and key removed,
park brake applied.
B.2 HYDRAULIC SYSTEM SAFETY • Battery should always be disconnected during replace-
It should be noted that the machines hydraulic systems ment of electrical components.
operate at extremely high potentially dangerous pres- • Keep all support equipment and attachments stowed in
sures. Every effort should be made to relieve any system their proper place.
pressure prior to disconnecting or removing any portion of • Use only approved, nonflammable cleaning solvents.
the system.

3128463 1200SJP 1350SJP B-9


REVISION LOG

April 25, 2008 - Original issue of fault guide for use with P7.2 or above Software and Telematics.

January 10, 2011 - Manual Revised

10 1200SJP 1350SJP 3128463


TABLE OF CONTENTS

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

3128463 1200SJP 1350SJP 11


TABLE OF CONTENTS (Continued)

DTC 2516 - DRIVE PREVENTED - ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22


DTC 2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
DTC 2521 - JIB SWING PREVENTED - IN 1000# MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
DTC 2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED. . . . . . . . . . . . . . . . . . . . .1-22
DTC 2523 - BACKUP BLAM COMMUNICATIONS ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
DTC 2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL . . . . . .1-22
DTC 331 - BRAKE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
DTC 332 - BRAKE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
DTC 3311 - GROUND ALARM - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
DTC 3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3336 - ALTERNATOR/ECM POWER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3338 - ALTERNATOR POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3339 - ALTERNATOR POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3340 - AUX POWER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3341 - AUX POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3342 - AUX POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3349 - ELECTRIC PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
DTC 3350 - ELECTRIC PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3351 - ELECTRIC PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3358 - MAIN DUMP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3359 - MAIN DUMP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3360 - MAIN DUMP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3361 - BRAKE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3362 - START SOLENOID - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3363 - START SOLENOID - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3364 - START SOLENOID - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3368 - TWO SPEED VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3369 - TWO SPEED VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
DTC 3370 - TWO SPEED VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3371 - GROUND ALARM - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3372 - GROUND ALARM - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3373 - GEN SET/WELDER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3374 - GEN SET/WELDER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3375 - GEN SET/WELDER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3376 - HEAD TAIL LIGHT - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3377 - HEAD TAIL LIGHT - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3378 - HEAD TAIL LIGHT - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3379 - HOUR METER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3380 - HOUR METER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
DTC 3381 - HOUR METER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . .1-27
DTC 3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .1-27
DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . .1-27
DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . .1-27

12 1200SJP 1350SJP 3128463


TABLE OF CONTENTS (Continued)

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

3128463 1200SJP 1350SJP 13


TABLE OF CONTENTS (Continued)

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

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TABLE OF CONTENTS (Continued)

DTC 841 - BOOM ANGLE SENSOR DISAGREEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-60


DTC 842 - BOOM LENGTH SWITCH FAILED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-61
DTC 843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-62
DTC 844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE . . . . . . . . . . . . . . . . . . . .1-62
DTC 845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-64
DTC 846 - BOOM LENGTH SENSOR - OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-65
DTC 847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . .1-66
DTC 848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . .1-67
DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . . .1-67
DTC 8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . .1-69
DTC 8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-70
DTC 8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-71
DTC 8413 - WRONG TELESCOPE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-72
DTC 8414 - WRONG LIFT RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73
DTC 851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73
DTC 852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
DTC 855 - MOMENT PIN - SENSOR FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
DTC 857 - NEW MOMENT PIN DETECTED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
DTC 861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESS. SWITCH DISAGREEMENT1-74
DTC 862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . .1-76
DTC 863 - AXLE EXTEND VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76
DTC 864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . .1-76
DTC 865 - AXLE RETRACT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76
DTC 866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT. . . . . . .1-76
DTC 867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-77
DTC 868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-77
DTC 869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-77
DTC 8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-77
DTC 8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-78
DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-78
DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-79
DTC 8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-79
DTC 8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-79
DTC 8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80
DTC 8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80
DTC 8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80
DTC 8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80
DTC 8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-80
DTC 8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . .1-80
DTC 8622 - FRONT RIGHT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-80
DTC 8623 - FRONT LEFT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-81
DTC 8624 - REAR RIGHT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-82
DTC 8625 - REAR LEFT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-83
DTC 8626 - FRONT LEFT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-84
DTC 8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . .1-85
DTC 8628 - REAR LEFT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-86
DTC 8629 - REAR RIGHT STEER SENSOR - NOT RESPONDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-87
DTC 8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT. . . . . . . . . .1-88
DTC 8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-89
DTC 8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-90
DTC 8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-91
DTC 8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-92
DTC 8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-93
DTC 8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . . .1-94
DTC 8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-95
DTC 8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
DTC 998 - EEPROM FAILURE - CHECK ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
DTC 9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER .1-96

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TABLE OF CONTENTS (Continued)

DTC 9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . .1-96


DTC 9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
DTC 9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
DTC 9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
DTC 9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
DTC 9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
DTC 9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
DTC 9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY. . . . . . . . . . . . . . .1-98
DTC 9922 - PLATFORM MODULE FAILURE - HWFS CODE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-98
DTC 9923 - GROUND MODULE FAILURE - HWFS CODE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
DTC 9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER. . .1-99
DTC 9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER. . . . . .1-99
DTC 9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . .1-99
DTC 9928 - ENVELOPE CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
DTC 9929 - MOMENT CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
DTC 9930 - STEER SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
DTC 9931 - BOOM SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
DTC 9932 - LIFT CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
DTC 9933 - TELESCOPE CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
DTC 9934 - DRIVE CRACKPOINTS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
DTC 9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-101
DTC 9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102
DTC 9937 - LENGTH SENSOR REF VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102
DTC 9938 - LENGTH SENSOR REF VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
DTC 9939 - BLAM HIGH RES A/D FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
DTC 9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
DTC 9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104
DTC 9944 - CURRENT FEEDBACK GAINS OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104
DTC 9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT. . . . . . . . . . . . . . . . . . .1-104
DTC 9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER. . .1-105
DTC 33xx - COMMON STB OR OC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-105
DTC 33XX - COMMON STG PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-106
SECTION 2 - ELECTRICAL REFERENCE
2.1 Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
2.2 BLAM Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2.3 Chassis Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2.4 Ground Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
2.5 Platform Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
2.6 Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
SECTION 3 - HYDRAULIC REFERENCE
SECTION 4 - JLG ANALYZER
4.1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
4.2 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
4.3 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-186
4.4 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-187
4.5 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-187
4.6 Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199
4.7 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199
SECTION 5 - CALIBRATIONS
5.1 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207
5.2 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-208
5.3 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-210
5.4 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-214
5.5 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-217

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5.6 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-221


5.7 Calibrating Lift Crack Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-222
5.8 Calibrating Telescope Crack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-225
5.9 Calibrating the Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-228
5.10 Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-240
SECTION 6 - GENERAL ELECTRICAL INFORMATION
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-245
6.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-245
6.3 Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
6.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-248
6.5 Working with AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-249
6.6 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254

LIST OF FIGURES

A-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3


A-2. Ground Module and Platform Fault (System Distress) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
A-3. Basic Electronic Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
2-1. Color Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-111
2-2. Platform Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113
2-3. Boom Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115
2-4. Engine Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117
2-5. Main Valve Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119
2-6. Ground Control Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121
2-7. Chassis Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123
2-8. Ground, Engine and BLAM Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-125
2-9. Platform Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127
2-10. Chassis Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129
2-11. Electrical Wiring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-131
2-12. Electrical Wiring (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-133
2-13. Telematics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135
3-1. Main Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-163
3-2. Pumps Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-164
3-3. Platform Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-165
3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-166
3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-167
3-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-168
3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-169
3-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-170
3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-171
3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-172
3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-173
3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-174
3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-175
4-1. Ground Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
4-2. Platform Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
4-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-179
4-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . .4-180
4-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . .4-181
4-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . . .4-182
4-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3. . . . . . . . . . .4-183
4-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3. . . . . . . . . . .4-184
4-9. Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3 . . . . . . . . . . .4-185
4-10. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-201

3128463 1200SJP 1350SJP 17


TABLE OF CONTENTS (Continued)

4-11. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-203


5-1. Boom Sensor Calibration Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-228
5-2. Boom Sensor Calibration Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-232
5-3. Boom Sensor Calibration Position 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-233
5-4. Boom Sensor Calibration Position 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-234
5-5. Boom Sensor Calibration Position 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-235
5-6. Boom Sensor Calibration Position 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-235
5-7. Boom Sensor Calibration Position 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-236
5-8. Boom Sensor Calibration Position 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-237
5-9. Boom Sensor Calibration Position 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-238
5-10. Boom Sensor Calibration Position 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-239
5-11. Wire Rope Tensioning Figure A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-240
5-12. Wire Rope Adjustment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-243
6-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-246
6-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-246
6-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
6-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
6-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-250
6-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-250
6-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-251
6-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-251
6-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-252
6-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-252
6-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-253
6-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
6-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
6-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
6-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255
6-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255
6-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255

18 1200SJP 1350SJP 3128463


TABLE OF CONTENTS (Continued)

LIST OF TABLES

1-1 Common Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36


2-1 Limit Switch States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109
2-2 Platform Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112
2-3 Main Valve Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118
2-4 Chassis Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122
2-5 Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
2-6 X086 (J1) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2-7 X087 (J2) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2-8 X088 (J3) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2-9 X089 (J4) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2-10 X090 (J5) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
2-11 X229 (J1) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2-12 X230 (J2) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2-13 X231 (J3) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2-14 X232 (J4) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2-15 X233 (J5) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
2-16 X001 (J1) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
2-17 X002 (J2) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
2-18 X004 (J4) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
2-19 X007 (J7) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
2-20 X008 (J8) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
2-21 X165 (J1) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
2-22 X166 (J2) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
2-23 X167 (J5) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
2-24 X168 (J6) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
2-25 X169 (J7) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
2-26 X170 (J8) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
2-27 Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
4-1 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-188
4-2 Machine Personality Settings and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-194
4-3 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-204
5-1 Calibrations Listed by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207
5-2 Calibrations Listed by Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207

3128463 1200SJP 1350SJP 19


TABLE OF CONTENTS (Continued)

This Page Left Blank Intentionally

20 1200SJP 1350SJP 3128463


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

SECTION 1. DTC DICTIONARY AND SELECTED TROUBLESHOOTING


For a list of Diagnostic Trouble Codes (DTC’s), see the table of contents.

DTC 001 - EVERYTHING OK


Everything OK. The "normal" help message when the analyzer is plugged into the platform. No problem is detected.

DTC 002 - GROUND MODE OK


Ground mode OK. The "normal" help message when the analyzer is plugged into the ground module. No problem is
detected.

DTC 0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION


Running at cutback - out of transport position. Drive speed is limited to programmed maximum because the vehicle is out of
transport position. Maximum drive speed is set in the Personality of the machine. Transport position is defined as main boom
retracted, and the boom angle less than +15.0 (default) from gravity. Sensor failures can change these conditions. .

Note Pretest Instructions Test Result Corrective Action


Step 1 Read faults Are there any length sensor, boom angle sen- Yes Troubleshoot those faults first
sor, switch or transport length switch faults? No Go to step 2
Step 2 Return machine to transport Did fault clear? Yes Troubleshooting Complete
position No Go to step 3
Step 3 ANALYZER  DIAGNOS- Does it read OUT OF TRANSPORT? Yes Go to step 4
TICS  TRANSPORT DATA No Reprogram/replace ground module
 TRANSPORT MODE
Step 4 ANALYZER  DIAGNOS- Does it read STOWED, or can the main boom Yes Keep analyzer connected.
TICS  TRANSPORT DATA be lowered to make it read STOWED? Go to step 5
 MAIN LIFT STATUS No Calibrate boom sensors. See 5.9 Calibrating the
Boom Sensors on Pg. 228.
Step 5 ANALYZER  DIAGNOS- Does it read RETRACTED, or can the main Yes Normal operation. Troubleshooting complete.
TICS  TRANSPORT DATA boom be moved within the transport position No Calibrate boom sensors. See 5.9 Calibrating the
 MAIN TELESCOPE STA- envelope to make it read RETRACTED? Boom Sensors on Pg. 228.
TUS

DTC 0011 - FSW OPEN


Footswitch open. A drive or boom function has been selected but the platform footswitch [X152] is open. This could be
caused by operator not depressing the footswitch before utilizing a machine control in the platform.

Note Pretest Instructions Test Result Corrective Action


Step 1 Go to ANALYZER  DIAG- Does the analyzer read OPEN? -AND- Does the Yes If fault is clear, this is normal operation. Otherwise
NOSTICS  SYSTEM  analyzer read CLOSED with the footswitch reprogram/replace the ground module
FOOTSWITCH INPUT PLAT- depressed? No Go to step 2
FORM
Step 2 Locate platform passthru - Turn on machine. Is there about 12 VDC on Yes Keep the test setup in same condition.
15 pos [X164]. Ground platform passthru terminal 8 [X164.8]? Go to step 4
meter. See Grounding on No Go to step 3
Pg. 245 for details. Take the
following reading by back-
probing. See Backprobing
on Pg. 245 for details.

3128411 1200SJP 1350SJP 1-15


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Ground meter. Take the fol- Turn on machine. Is there about 12 VDC on Yes Repair/replace harness between platform mod-
lowing measurement by platform module J2 terminal 3 [X166.3]? ule J2 terminal 3 [X166.3] and platform passthru
backprobing. terminal 8 [X164.8]
No Replace platform module
Step 4 Locate platform passthru Turn on machine. Is there about 12 VDC on Yes Go to step 5
[X164]. Ground meter. Take platform passthru terminal 7 [X164.7]? No Repair/replace footswitch
the following reading by
backprobing.
Step 5 Disconnect platform Is there continuity between platform passthru Yes Go to step 6
passthru [X164] and plat- pin 7 [X164.7.pin] and platform module J7 No Repair/replace harness between platform
form module J7 [X169] socket 8 [X169.8.soc]? passthru pin 7 [X164.7.pin] and platform module
J7 socket 8 [X169.8.soc]
Step 6 Locate platform control box Turn on machine. Is there about 12 VDC on Yes Repair/replace footswitch
passthru - 19 pos [X160]. platform control box terminal 6 [X160.6]? No Keep test setup in place.
Ground meter. Take the fol- Go to step 7
lowing reading by backprob-
ing.
Step 7 Locate platform control box Turn on machine. Depress footswitch. Is there Yes Go to step 8
passthru - 19 pos [X160]. about 12 VDC on platform control box terminal No Repair/replace footswitch
Ground meter. Take the fol- 6 [X160.6]?
lowing reading by backprob-
ing.
Step 8 Disconnect ground module Turn on machine. Is there about 12 VDC on Yes Reprogram/replace platform module and/or
J7 [X007]. With a helper or ground module J7 terminal 15 [X007.15]? ground module
an object, hold the foot- No Go to step 9
switch down. Ground the
meter near the main terminal
box. Take the following mea-
surement by backprobing.
Step 9 Disconnect ground module Is there continuity between ground module J7 Yes Repair/replace harness between MTB passthru
J7 [X007] and MTB socket 15 [X007.15.soc] and MTB passthru socket 6 [X043.6.soc] and platform control box
passthru - 19 pos [X043] pin 6 [X043.6.pin]? passthru - 19 pos socket 6 [X160.6.soc]
No Repair/replace harness between ground module
J7 socket 15 [X007.15.soc] and MTB passthru
pin 6 [X043.6.pin]

DTC 0012 - RUNNING AT CREEP - CREEP SWITCH OPEN


Running at creep - creep switch open. All function speeds are limited to creep because the creep switch is open. This switch
is part of the hydraulic speed potentiometer operated by a knob on the platform console. The creep indicator will light when
in creep mode or blink in super creep mode. Circumstances that cause the machine to automatically enter creep/super
creep mode include encroachment of the operating envelope limit main boom, platform leveling fault, throttle actuator fail-
ure, stowed platform, software version faults, boom sensor failures, hydraulic warm-up mode, and hydraulic or electrical
retrieval mode.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are any of the circumstances that cause creep Yes Clear any condition present
or super creep mode automatically present? No Go to step 2
Step 2 Rotate function speed con- Is creep light on? Yes Go to step 7
trol knob fully CCW until it No Go to step 3
clicks.

1-16 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Watch creep light while turning on machine Yes Go to step 4
from both the platform and the ground. Is No Replace LED light panel with light that is bad.
creep light on for the lamp check?
Step 4 Disconnect hyd speed pot Is there about 12VDC at hyd speed pot Yes Keep hyd speed pot passthru - 6 pos. [X199] dis-
passthru - 6 pos. [X199]. passthru socket 3 [X199.3.soc]? connected.
Ground meter. See Ground- Go to step 6
ing on Pg. 245 for details. No Keep hyd speed pot passthru - 6 pos. [X199] dis-
Turn on machine. connected.
Go to step 5
Step 5 Disconnect hyd speed pot Is there continuity between hyd speed pot Yes Replace platform module
passthru - 6 pos. [X199] and passthru socket 3 [X199.3.soc] and platform No Replace/repair harness between hyd speed pot
platform module J1 [X165] module J1 socket 18 [X165.18.soc]? passthru socket 3 [X199.3.soc] and platform
module J1 socket 18 [X165.18.soc]
Step 6 Disconnect hyd speed pot Is there continuity between hyd speed pot Yes Repair/replace hyd speed pot and/or harness
passthru - 6 pos. [X199] and passthru pin 2 [X199.2.pin] and platform [X199]
platform module J1 [X165] module J1socket 32 [X165.32.soc]? No Repair/replace harness between hyd speed pot
passthru pin 2 [X199.2.pin] and platform module
J1socket 32 [X165.32.soc]
Step 7 Turn on machine. Rotate Does creep light turn off? Yes Keep machine in same condition.
function speed control knob Go to step 8
CW 1/4 turn to 9 o’clock No Go to step 9
position.
Step 8 Turn on machine. Rotate Does fault message clear? Yes Normal operation. Troubleshooting complete.
function speed control knob No Reprogram/replace ground module
CW 1/4 turn to 9 o’clock
position.
Step 9 Rotate function speed con- Is there a short between hyd speed pot Yes Repair/replace function speed control and/or
trol knob CW 1/4 turn to 9 passthru socket 2 [X199.2.soc] and pin 3 harness to hyd speed pot passthru - 6 pos.
o’clock position. Discon- [X199.3.pin]? [X199]
nect hyd speed pot passthru No Go to step 10
- 6 pos. [X199].
Step 10 Disconnect hyd speed pot Is there a short between platform module J1 Yes Repair/replace harness between platform mod-
passthru - 6 pos. [X199] and socket 32 [X165.32.soc] and socket 18 ule J1 socket 32 [X165.32.soc] and socket 18
platform module J1 [X165] [X165.18.soc]? [X165.18.soc]
No Keep hyd speed pot passthru - 6 pos. [X199] dis-
connected.
Go to step 11
Step 11 Disconnect hyd speed pot Is there about 12 VDC on hyd speed pot Yes Repair/replace harness between hyd speed pot
passthru - 6 pos. passthru pin 2 [X199.2.pin]? passthru pin 2 [X199.2.pin]
[X199].Ground meter. Turn No Reprogram/replace platform module
on machine.

DTC 0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATION


Running at creep - tilted and above elevation. All boom function speeds are limited to creep because the machine is tilted
and above elevation. The machine is "Tilted" if the chassis is greater than 5.0 in any direction. If Tilt calibration has not been
performed after the ground module or the main terminal box has been removed or replaced the machine will also indicate it

3128411 1200SJP 1350SJP 1-17


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

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..

Note Pretest Instructions Test Result Corrective Action


Step 1 Return machine to Trans- Is fault still active? Yes Go to step 2
port position and level No Troubleshooting complete
ground
Step 2 Are there any boom sensor or Chassis tilt sen- Yes Troubleshoot those faults
sor faults? No Go to step 3
Step 3 Return machine to Trans- Does MAIN LIFT read STOWED? Yes Go to step 4
port position and level No Perform 5.9 Calibrating the Boom Sensors on
ground. ANALYZER  Pg. 228
DIAGNOSTICS  TRANS-
PORT DATA
Step 4 Is the Tilt indicator on? Yes Perform 5.6 Calibrating Tilt Sensor on Pg. 221
No Repair/reprogram ground module

DTC 0014 - CHASSIS TILT SENSOR OUT OF RANGE


Chassis tilt sensor out of range. Chassis tilt sensor has indicated a tilt angle greater than 19 for more than 4 seconds.

Note Pretest Instructions Test Result Corrective Action


Step 1 Put machine on level surface Did fault clear? Yes Normal operation. Troubleshooting complete.
No Go to step 2
Step 2 Perform Tilt calibration. See Did it calibrate successfully? Yes Troubleshooting complete
5.6 Calibrating Tilt Sensor No Replace ground module
on Pg. 221.

DTC 0015 - LOAD SENSOR READING UNDER WEIGHT


Load sensor reading under weight. The load sensor is reading 20% or more under the calibrated zero point. This fault may
occur if the platform is resting on the ground. Not reported during the 2 second power-up.

Note Pretest Instructions Test Result Corrective Action


Step 1 Safely ensure platform is not Does fault clear? Yes Troubleshooting complete
resting on anything. No Go to step 2
Step 2 Perform 5.9 Calibrating the Does calibration complete successfully? Yes Troubleshooting complete
Boom Sensors on Pg. 228. No Troubleshoot according to calibration fault

DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED


Envelope encroached - hydraulics suspended. The system detected a violation of the safe operating area envelope. If plat-
form is stuck in the air call JLG for help.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the platform stuck in the air? Yes Call JLG for help
No Go to step 2
Step 2 Calibrate boom sensors. Did calibration complete successfully? Yes Go to step 3
See 5.9 Calibrating the No Troubleshoot according to calibration fault
Boom Sensors on Pg. 228
for details.

1-18 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Calibrate chassis tilt. See Did calibration complete successfully? Yes Troubleshooting complete
5.6 Calibrating Tilt Sensor No Troubleshoot according to calibration fault
on Pg. 229 for details.

DTC 0017 - OVER MOMENT - HYDRAULICS SUSPENDED


Over moment - hydraulics suspended. Notification that the system has detected too much force applied to the moment pin,
and suspended hydraulics to prevent further encroachment. While the boom is in over-moment violation, the system will pre-
vent all jib, lift down, telescope out, drive, steer and swing functions until the over-moment violation clears. All remaining
functions are limited to super creep. The BCS indicators are on continuously. The system will flash the BCS indicators and
sound the platform alarm while the user commands a disallowed function. Use the APU to telescope in or lift up to return the
platform to the ground. See DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.

DTC 0018 - UNDER MOMENT - HYDRAULICS SUSPENDED


Under moment - hydraulics suspended. The system has detected too little force on the moment pin. If the engine is running,
the system suspends all jib, lift up, telescope in, drive, steer and swing functions until the under-moment violation clears. In
APU mode, the system suspends swing functions only, but flashes the BCS lamp and sounds the alarm during any com-
mand of the jib, lift up, telescope in or swing functions. If the platform is stuck in the air call JLG for help.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the platform stuck in the air? Yes Call JLG for help
No Go to step 2
Step 2 Return boom to transport Does fault clear and not return repeatedly? Yes Troubleshooting complete
position No Go to step 3
Step 3 Perform boom sensor cali- Did calibration complete successfully? Yes Go to step 4
bration No Troubleshoot according to calibration fault
Step 4 Perform Chassis Tilt calibra- Did calibration complete successfully? Yes Troubleshooting complete
tion No Troubleshoot according to calibration fault

DTC 0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED


Main envelope encroached - hydraulics suspended. Notification that the system has detected a main envelope violation and
suspended hydraulics to prevent further encroachment. Use the APU to telescope in or lift down inside the envelope. See
DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.

DTC 0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED


Tower envelope encroached - hydraulics suspended. This fault does not occur on a properly configured 1200/1350 SJP.
Ensure Machine Setup has proper model configured.

DTC 211 - POWER CYCLE


Power cycle. Normal message that appears in DTC stack when power is turned off then on. DTC’s before a power cycle are
active, i.e. they occured after power was turned on.

DTC 212 - KEYSWITCH FAULTY


Keyswitch faulty. Both platform [X007.2] and ground [X007.3] modes are selected simultaneously. This could be due to a
bad keyswitch [X030], wiring, or bad diodes at the power down relay [X011].

3128411 1200SJP 1350SJP 1-19


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 213 - FSW FAULTY


Footswitch faulty. The two footswitch inputs [X169.8 X007.15] have read the same state for more than one second. These
signals should always be opposite. Check the footswitch and wiring for shorts or open circuits.

DTC 227 - STEER SWITCHES FAULTY


Steer switches faulty. Notification that both left and right steer switch inputs [X168.5 X168.6] are active at the same time. This
could be due to a faulty steer switch [X176] or wiring.

DTC 2211 - FSW INTERLOCK TRIPPED


Footswitch interlock tripped. Notification that the footswitch was closed for seven seconds with no function selected.
Release the footswitch, close the footswitch again, then activate the desired function with seven seconds.

DTC 2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH


Drive locked - joystick moved before footswitch. Notification that drive was selected before and during footswitch signal
[X007.15] closure. Can be reported during power-up sequence. Allow the joystick to return to neutral before activating the
footswitch. This may also indicated a problem with the footswitch wiring.

DTC 2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCH


Steer locked - selected before footswitch. Notification that one of the platform steer inputs [X168.5 X168.6] was selected
before the footswitch was closed. Steering will be prevented. Close the footswitch before steering. This could also be due to
a faulty steer switch [X176] or wiring.

DTC 2215 - D/S JOY. OUT OF RANGE LOW


Drive/Steer joystick out of range low. The drive joystick input [X168.3] is below the working voltage range.

DTC 2216 - D/S JOY. OUT OF RANGE HIGH


Drive/Steer joystick out of range high. The drive joystick input [X168.3] is above the working voltage range.

DTC 2217 - D/S JOY. CENTER TAP BAD


Drive/Steer joystick center tap bad. The drive joystick center tap input [X168.2] is not reading the correct voltage, +/- 10%
from the reference voltage middle point.

DTC 2218 - L/S JOY. OUT OF RANGE LOW


Lift/Swing joystick out of range low. The lift and/or swing joystick input [X167.3 X167.4] is below the working voltage range.

DTC 2219 - L/S JOY. OUT OF RANGE HIGH


Lift/Swing joystick out of range high. The lift and/or swing joystick input [X167.3 X167.4] is above the working voltage range.

DTC 2220 - L/S JOY. CENTER TAP BAD


Lift/Swing joystick center tap bad. The lift and/or swing joystick center tap inputs [X167.2 X167.5] are not reading the correct
voltage, +/- 10% from the reference voltage middle point.

1-20 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH


Lift/swing locked - joystick moved before footswitch. Notification that the platform lift and/or swing joystick was not centered
before the footswitch was closed. Lift and swing will be prevented. Close the footswitch before selecting any function or
moving the joystick. This could also be due to faulty joystick not returning to center.

DTC 2222 - WAITING FOR FSW TO BE OPEN


Waiting for footswitch to be open. Notification that the platform footswitch input [X169.8] was open when the platform mode
was selected. This indicates that the footswitch [X152] was engaged before platform power-on and may be blocked or
stuck. This can also be reported during the power-up sequence. The footswitch or its wiring may be faulty.

DTC 2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE


Pump switches locked - selected before footswitch. A platform boom function switch input (lower lift, telescope, platform
level, platform rotate, jib) was selected before key switch or footswitch input [X169.8] closure. The footswitch must be acti-
vated before any function. This may be caused by a problem with a switch or its wiring. Run ANALYZER  SYSTEM TEST
from the platform controls to find the specific switch.

DTC 2224 - FOOTSWITCH SELECTED BEFORE START


Footswitch selected before start. Notification that the footswitch was selected before starting the machine. Release the foot-
switch before starting the machine.

DTC 234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM


Pump switches faulty - check diagnostics/boom. A ground control or platform control boom function switch (lower lift, tele-
scope, platform level, platform rotate, jib, etc.) has both directions selected together. This may be caused by a problem with
a switch or its wiring. Run ANALYZER  SYSTEM TEST from the ground controls and platform controls to find the specific
switch.

DTC 235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER


Pump switches locked - selected before aux power. A ground function switch input (lower lift, telescope, platform level, plat-
form rotate, jib) was selected before the ground auxiliary power switch input [X004.16]. The auxiliary power (enable) switch
must be activated before the desired function switch. This also may be caused by a problem with a switch or its wiring. Run
ANALYZER  SYSTEM TEST from the ground controls to find the specific switch.

DTC 236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH


Pump switches locked - selected before start switch. A ground control or platform control boom function switch (lower lift,
telescope, platform level, platform rotate, jib, etc.) input was selected before the start switch input [X165.14 X004.4]. The
start switch may only be activated when no function is commanded. This also may be caused by a problem with a switch or
its wiring. Run ANALYZER  SYSTEM TEST from the ground controls and platform controls to find the specific switch.

DTC 237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH


Start switch locked - selected before keyswitch. The start switch input [X004.4] was selected at startup. The engine start
switch [X026] is likely stuck or the wiring is shorted.

DTC 259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS


Model changed - hydraulics suspended - cycle emergency stop switch. Notification that the model number was changed
using the analyzer. The hydraulics will be suspended until the power is cycled.

3128411 1200SJP 1350SJP 1-21


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 2513 - GENERATOR MOTION CUTOUT ACTIVE


Generator motion cutout active. Notification that the generator motion cutout is configured and the machine is in platform
mode with the generator active and a function was engaged. Do not engage functions while the generator is active or
change the machine configuration.

DTC 2514 - BOOM PREVENTED - DRIVE SELECTED


Boom prevented - drive selected. Notification that ANALYZER  MACHINE SETUP  FUNCTION CUTOUT is set to BOOM
CUTOUT and the machine is driving above elevation and a boom function is being attempted. Operate drive and boom sep-
arately or change the machine setup.

DTC 2515 - DRIVE PREVENTED - BOOM SELECTED


Drive prevented - boom selected. Notification that drive was selected while a boom function was selected and drive cutout is
configured to prevent simultaneous drive & boom operation.

DTC 2516 - DRIVE PREVENTED - ABOVE ELEVATION


Drive prevented - above elevation. Notification that drive was selected while above elevation and drive cutout is configured to
prevent drive.

DTC 2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATION


Drive prevented - tilted & above elevation. Notification that drive was selected while tilted and above elevation and tilt is con-
figured to cutout drive.

DTC 2521 - JIB SWING PREVENTED - IN 1000# MODE


Jib swing prevented - in 1000 pound mode. Notification that the machine is in 1000# mode and the jib swing function was
engaged. Swinging the jib is not allowed in 1000# mode.

DTC 2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED


CAN dongle attached - hydraulics not restricted. Notification the production dongle control tool is connected.

DTC 2523 - BACKUP BLAM COMMUNICATIONS ACTIVE


Backup BLAM communications active. This fault should never occur on properly configured machines. Check model in
MACHINE SETUP.

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 331 - BRAKE - SHORT TO BATTERY


Parking brake short to battery. The parking brake output [X001.23] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 113.

DTC 332 - BRAKE - OPEN CIRCUIT


Parking brake open circuit. The parking brake output [X001.23] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 113.

1-22 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3311 - GROUND ALARM - SHORT TO BATTERY


Ground alarm short to battery. The ground alarm output [X002.27] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.

DTC 3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND


Right forward drive pump short to ground. The right forward drive pump output [X087.1] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT


Right forward drive pump open circuit. The right forward drive pump output [X087.1] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 113.

DTC 3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY


Right forward drive pump short to battery. The right forward drive pump output [X087.1] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND


Right reverse drive pump short to ground. The right reverse drive pump output [X087.12] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT


Right reverse drive pump open circuit. The right reverse drive pump output [X087.12] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.

DTC 3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY


Right reverse drive pump short to battery. The right reverse drive pump output [X087.12] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUND


Left forward drive pump short to ground. The left forward drive pump output [X090.1] is shorted to ground. See DTC 33XX -
COMMON STG PROCEDURE on Pg. 106.

DTC 3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT


Left forward drive pump open circuit. The left forward drive pump output [X090.1] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.

DTC 3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY


Left forward drive pump short to battery. The left forward drive pump output [X090.1] is shorted to battery. See DTC 33xx -
COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUND


Left reverse drive pump short to ground. The left reverse drive pump output [X090.2] is shorted to ground. See DTC 33XX -
COMMON STG PROCEDURE on Pg. 106.

3128411 1200SJP 1350SJP 1-23


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT


Left reverse drive pump open circuit. The left reverse drive pump output [X090.2] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.

DTC 3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY


Left reverse drive pump short to battery. The left reverse drive pump output [X090.2] is shorted to battery. See DTC 33xx -
COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3336 - ALTERNATOR/ECM POWER - SHORT TO GROUND


Alternator power short to ground. The alternator power output [X001.10] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 114.

DTC 3338 - ALTERNATOR POWER - OPEN CIRCUIT


Alternator power - open circuit. The alternator power output [X001.10] is shorted to ground. See common OC/STB .

DTC 3339 - ALTERNATOR POWER - SHORT TO BATTERY


Alternator power short to ground. The alternator power output [X001.10] is shorted to ground. See common OC/STB.

DTC 3340 - AUX POWER - SHORT TO GROUND


Auxiliary power short to ground. The auxiliary power output [X001.13] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.

DTC 3341 - AUX POWER - OPEN CIRCUIT


Auxiliary power open circuit. There is an open circuit in the auxiliary power output [X001.13]. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 113.

DTC 3342 - AUX POWER - SHORT TO BATTERY


Auxiliary power short to battery. The auxiliary power output [X001.13] is shorted to battery voltage. See DTC 33xx - COM-
MON STB OR OC PROCEDURE on Pg. 113.

DTC 3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUND


Cold start advance solenoid short to ground. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.

DTC 3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUIT


Cold start advance solenoid open circuit. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.

DTC 3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERY


Cold start advance solenoid short to battery. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.

DTC 3349 - ELECTRIC PUMP - SHORT TO GROUND


Electric pump short to ground. This fault should never occur on properly configured machines. Reload ground module soft-
ware or replace the ground module.

1-24 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3350 - ELECTRIC PUMP - OPEN CIRCUIT


Electric pump open circuit. This fault should never occur on properly configured machines. Reload ground module software
or replace the ground module.

DTC 3351 - ELECTRIC PUMP - SHORT TO BATTERY


Electric pump short to battery. This fault should never occur on properly configured machines. Reload ground module soft-
ware or replace the ground module.

DTC 3358 - MAIN DUMP VALVE - SHORT TO GROUND


Main dump short to ground. The main dump output [X002.13] is shorted to ground. See DTC 33XX - COMMON STG PRO-
CEDURE on Pg. 106.

DTC 3359 - MAIN DUMP VALVE - OPEN CIRCUIT


Main dump open circuit. The main dump output [X002.13] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on
Pg. 105.

DTC 3360 - MAIN DUMP VALVE - SHORT TO BATTERY


Main dump short to battery. The main dump output [X002.13] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 3361 - BRAKE - SHORT TO GROUND


Parking brake short to ground. The parking brake output [X001.23] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.

DTC 3362 - START SOLENOID - SHORT TO GROUND


Start solenoid short to ground. The engine start solenoid output [X001.11] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 114.

DTC 3363 - START SOLENOID - OPEN CIRCUIT


Start solenoid open circuit. The engine start solenoid output [X001.11] is open. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 113.

DTC 3364 - START SOLENOID - SHORT TO BATTERY


Start solenoid short to battery. The engine start solenoid output [X001.11] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.

DTC 3368 - TWO SPEED VALVE - SHORT TO GROUND


Two speed short to ground. The two speed valve output [X001.20] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.

DTC 3369 - TWO SPEED VALVE - OPEN CIRCUIT


Two speed open circuit. The two speed valve output [X001.20] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 113.

3128411 1200SJP 1350SJP 1-25


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3370 - TWO SPEED VALVE - SHORT TO BATTERY


Two speed short to battery. The two speed valve output [X001.20] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 113.

DTC 3371 - GROUND ALARM - SHORT TO GROUND


Ground alarm short to ground. The ground alarm output [X002.27] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 106.

DTC 3372 - GROUND ALARM - OPEN CIRCUIT


Ground alarm open circuit. The ground alarm output [X002.27] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 105.

DTC 3373 - GEN SET/WELDER - SHORT TO GROUND


Generator set/welder short to ground. The output for the generator [X001.22] is shorted to ground. See DTC 33XX - COM-
MON STG PROCEDURE on Pg. 106.

DTC 3374 - GEN SET/WELDER - OPEN CIRCUIT


Generator set/welder open circuit. The output for the generator [X001.22] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 3375 - GEN SET/WELDER - SHORT TO BATTERY


Generator set/welder short to battery. The output for the generator [X001.22] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.

DTC 3376 - HEAD TAIL LIGHT - SHORT TO GROUND


Head tail light short to ground. The head and tail light output [X002.26] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.

DTC 3377 - HEAD TAIL LIGHT - OPEN CIRCUIT


Head tail light open circuit. The head and tail light output [X002.26] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 105.

DTC 3378 - HEAD TAIL LIGHT - SHORT TO BATTERY


Head tail light short to battery. The head and tail light output [X002.26] is shorted to battery. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.

DTC 3379 - HOUR METER - SHORT TO GROUND


Hour meter short to ground. The hourmeter output [X004.12] is shorted to ground. See DTC 33XX - COMMON STG PROCE-
DURE on Pg. 106.

DTC 3380 - HOUR METER - OPEN CIRCUIT


Hour meter open circuit. The hourmeter output [X004.12] has an open circuit. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 105.

1-26 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3381 - HOUR METER - SHORT TO BATTERY


Hour meter short to battery. The hourmeter output [X004.12] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND


Platform up override short to ground. The ground module J2 platform level up override output [X002.5] is shorted to ground.
If there are no open wires, the fault DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND on Pg. 35 should also be
active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT


Platform up override open circuit. The ground module J2 platform level up override output [X002.5] is open. If the open is in
or near the platform up solenoid [X136], the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN
CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY


Platform up override short to battery. The ground module J2 platform level up override output [X002.5] is shorted to battery.
If there are no open wires, the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on
Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND


Platform down override short to ground. The ground module J2 platform level down override output [X002.7] is shorted to
ground. If there are no open wires, the fault DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND on Pg. 35
should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT


Platform down override open circuit. The ground module J2 platform level down override output [X002.7] is open. If the open
is in or near the platform down solenoid [X137], the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY


Platform down override short to battery. The ground module J2 platform level down override output [X002.7] is shorted to
battery. If there are no open wires, the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN
CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND


Platform left short to ground. The platform module J7 platform rotate left output [X169.5] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT


Platform left open circuit. The platform module J7 platform rotate left output [X169.5] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.

DTC 3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY


Platform left short to battery. The platform module J7 platform rotate left output [X169.5] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.

3128411 1200SJP 1350SJP 1-27


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND


Platform right short to ground. The platform module J7 platform rotate right output [X169.6] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT


Platform right open circuit. The platform module J7 platform rotate right output [X169.6] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.

DTC 3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY


Platform right short to battery. The platform module J7 platform rotate right output [X169.6] is shorted to battery. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33100 - JIB LIFT UP VALVE - SHORT TO GROUND


Jib up short to ground. The jib up output [X169.25] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on
Pg. 106.

DTC 33101 - JIB LIFT UP VALVE - OPEN CIRCUIT


Jib up open circuit. The jib up output [X169.25] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33102 - JIB LIFT UP VALVE - SHORT TO BATTERY


Jib up short to battery. The jib up output [X169.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 105.

DTC 33103 - JIB LIFT DOWN VALVE - SHORT TO GROUND


Jib down short to ground. The jib down output [X169.26] is shorted to ground. See DTC 33XX - COMMON STG PROCE-
DURE on Pg. 106.

DTC 33104 - JIB LIFT DOWN VALVE - OPEN CIRCUIT


Jib down open circuit. The jib down output [X169.26] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
105.

DTC 33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERY


Jib down short to battery. The jib down output [X169.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 105.

DTC 33118 - SWING RIGHT VALVE - SHORT TO GROUND


Swing right valve short to ground. The swing right valve output [X002.35] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.

DTC 33119 - SWING RIGHT VALVE - OPEN CIRCUIT


Swing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 105.

1-28 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERY


Main telescope in short to battery. The main telescope in output [X002.4] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.

DTC 33121 - SWING RIGHT VALVE - SHORT TO BATTERY


Swing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCE-
DURE on Pg. 105.

DTC 33122 - SWING LEFT VALVE - SHORT TO GROUND


Swing right valve short to ground. The swing right valve output [X002.34] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.

DTC 33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY


Main telescope out short to battery. The main telescope out output [X002.16] is shorted to battery. See DTC 33xx - COM-
MON STB OR OC PROCEDURE on Pg. 105.

DTC 33130 - THROTTLE ACTUATOR - SHORT TO GROUND


Throttle actuator short to ground. This fault should only occur on machines configured with non-ECM engines. The engine
throttle actuator output [X001.1] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 33131 - THROTTLE ACTUATOR - OPEN CIRCUIT


Throttle actuator open circuit. This fault should only occur on machines configured with non-ECM engines. The engine throt-
tle actuator output [X001.1] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33132 - THROTTLE ACTUATOR - SHORT TO BATTERY


Throttle actuator short to battery. This fault should only occur on machines configured with non-ECM engines. The engine
throttle actuator output [X001.1] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33133 - PLATFORM CONTROL VALVE - SHORT TO GROUND


Platform control valve short to ground. The platform dump valve output [X002.3] is shorted to ground. See DTC 33XX - COM-
MON STG PROCEDURE on Pg. 114.

DTC 33134 - PLATFORM CONTROL VALVE - OPEN CIRCUIT


Platform control valve open circuit. The platform dump valve output [X002.3] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 113.

DTC 33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERY


Platform control valve short to battery. The platform dump valve output [X002.3] is shorted to battery. See DTC 33xx - COM-
MON STB OR OC PROCEDURE on Pg. 113.

DTC 33150 - LIFT PILOT VALVE - SHORT TO GROUND


Lift Pilot Valve Short to Ground. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

3128411 1200SJP 1350SJP 1-29


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 33151 - LIFT PILOT VALVE - OPEN CIRCUIT


Lift Pilot Valve Open Circuit. The lift down auxiliary select valve output, ground module J2 -10 [X002.10], is open. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33152 - LIFT PILOT VALVE - SHORT TO BATTERY


Lift Pilot Valve Short to Battery. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to bat-
tery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33153 - LIFT DOWN AUX VALVE - SHORT TO GROUND


Lift Down Auxiliary Valve Short to Ground. The lift down auxiliary valve output, ground module J2 - 12 [X002.12] is shorted to
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33154 - LIFT DOWN AUX VALVE - OPEN CIRCUIT


Lift Down Auxiliary Valve Open Circuit. The lift down output, ground module J2 - 12 [X002.12], is open. See DTC 33xx - COM-
MON STB OR OC PROCEDURE on Pg. 105.

DTC 33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERY


Lift Down Auxiliary Valve Short to Battery. The lift down auxiliary valve output, ground module J2 - 12 [X002.12], is shorted to
battery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR


OPEN CIRCUIT
Restricted to transport - Axle lockout valve short to battery or open circuit. The control system detected a short to battery or
an open circuit on the PWM output for the Axle Lockout valve.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the resistance of the axle lockout valve sole- Yes Go to step 2
noid [X212] about 6.2 No Replace the axle lockout valve solenoid
Step 2 Disconnect the axle lockout Does the voltage between the positive battery Yes Go to step 10
valve solenoid DIN connec- terminal [X116] and terminal 2 of the Axle No Go to step 3
tor [X212] Lockout valve solenoid DIN connector
[X212.2.soc] measure 12VDC?
Step 3 Does the voltage between the positive battery Yes Repair/replace the black wire between terminal 2
terminal [X116] and terminal 2 of the chassis of the axle lockout valve solenoid DIN connector
module J4 connector [X232.2.pin] measure [X212.2.soc] and terminal 2 of the chassis mod-
12VDC? ule J4 connector [X232.2.soc]
No Go to step 4
Step 4 Does the voltage between the positive battery Yes Replace the chassis module
terminal [X116] and terminal 4 of the chassis No Go to step 5
module J1 connector [X229.4] measure
12VDC?
Step 5 Does the voltage between the positive battery Yes Repair/Replace the black wire between terminal 5
terminal [X116] and terminal 5 of the chassis of the chassis (bottom) swivel connector
(bottom) swivel connector [X216.5] measure [X216.5] and terminal 4 of the chassis module J1
12VDC? connector [X229.4]
No Go to step 6

1-30 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Does the voltage between the positive battery Yes Replace the Collector Ring and swivel harness
terminal [X116] and terminal 5 of the Turntable No Go to step 7
(top) Swivel connector [X083.5] measure
12VDC?
Step 7 Does the voltage between the positive battery Yes Replace the valve harness
terminal [X116] and any terminal of the 12 No Go to step 8
position MTB ground buss connector [X009]
measure 12VDC?
Step 8 Does the voltage between the positive battery Yes Repair/Replace the Black wire between terminal
terminal [X116] and terminal 3 of the ground 3 of the ground module J8 connector [X008.3]
module J8 connector [X008.3] measure and the MTB ground buss connector [X009]
12VDC? No Go to step 9
Step 9 Does the voltage between the positive battery Yes Replace the ground module
terminal [X116] and terminal 1 of the ground No Repair/Replace the Black wire from the battery
module J8 connector [X008.1] measure
12VDC?
Step 10 Disconnect the axle lockout Does the voltage on terminal 1 of the axle lock- Yes Go to step 11
valve solenoid DIN connec- out valve solenoid DIN connector No Go to step 15
tor [X212] [X212.1.soc] measure 12VDC?
Step 11 Remove terminal 8 of the Does the voltage on terminal 1 of the axle lock- Yes Repair/replace the ORANGE 60-2 wire between
chassis (bottom) swivel out valve solenoid DIN connector terminal 1 of the axle lockout valve solenoid con-
connector [X216.8] [X212.1.soc] measure 12VDC? nector [212.1] and terminal 8 of the chassis (bot-
tom) swivel connector [X216.8]
No Go to step 12
Step 12 Remove terminal 8 of the Does the voltage on terminal 1 of the axle lock- Yes Replace the collector ring and swivel harness
turntable (top) swivel con- out valve solenoid DIN connector No Go to step 13
nector [X083.8] [X212.1.soc] measure 12VDC?
Step 13 Remove terminal 4 of the 6 Does the voltage on terminal 1 of the axle lock- Yes Repair/Replace the ORANGE 60-1 wire between
position BLAM-Valve har- out valve solenoid DIN connector terminal 4 of the 12 position BLAM-Valve harness
ness passthru connector [X212.1.soc] measure 12VDC? passthru connector [X280.4] and terminal 8 of
[X280.4] the Turntable (top) swivel connector [X083.8]
No Go to step 14
Step 14 Remove terminal 3 of the Does the voltage on terminal 1 of the axle lock- Yes Repair/Replace the ORANGE 60-1 wire between
BLAM module J5 connector out valve solenoid DIN connector terminal 3 of the BLAM module J5 connector
[X090.3] [X212.1.soc] measure 12VDC? [X090.3] and terminal 4 of the 12 position BLAM-
Valve harness passthru connector [X280.4]
No Replace the BLAM module
Step 15 Remove terminal 8 of the Is there continuity between terminal 8 of the Yes Go to step 16
chassis (bottom) swivel chassis (bottom) swivel connector No Repair/replace the ORANGE 60-2 wire between
connector [X216.8] and dis- [X216.8.pin] and terminal 1 of the axle lockout terminal 1 of the axle lockout valve solenoid con-
connect the axle lockout valve solenoid DIN connector [X212.1.soc]? nector [212.1] and terminal 8 of the chassis (bot-
valve solenoid DIN connec- tom) swivel connector [X216.8]
tor [X212]
Step 16 Remove terminal 8 of the Is there continuity between terminal 8 of the Yes Go to step 17
Turntable (top) swivel con- Turntable (top) swivel connector [X083.8] No Replace the Collector Ring and swivel harness
nector [X083.8] and discon- and terminal 1 of the axle lockout valve sole-
nect the axle lockout valve noid DIN connector [X212.1.soc]?
solenoid DIN connector
[X212]

3128411 1200SJP 1350SJP 1-31


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 17 Remove terminal 4 of the 6 Is there continuity between terminal 4 of the 6 Yes Go to step 18
position BLAM-Valve har- position BLAM-Valve harness passthru con- No Repair/Replace the ORANGE 60-1 wire between
ness passthru connector nector [X280.4] and disconnect the axle lock- terminal 4 of the 12 position BLAM-Valve harness
[X280.4] and disconnect the out valve solenoid DIN connector [X212] and passthru connector [X280.4] and terminal 8 of
axle lockout valve solenoid terminal 1 of the axle lockout valve solenoid the Turntable (top) swivel connector [X083.8]
DIN connector [X212] DIN connector [X212.1.soc]?
Step 18 Remove terminal 3 of the Is there continuity between terminal 3 of the Yes Replace the BLAM module
BLAM module J5 connector BLAM module J5 connector [X090.3] and ter- No Repair/Replace the ORANGE 60-1 wire between
[X090.3] and disconnect the minal 1 of the axle lockout valve solenoid DIN terminal 3 of the BLAM module J5 connector
axle lockout valve solenoid connector [X212.1.soc]? [X090.3] and terminal 4 of the 6 position BLAM-
DIN connector [X212] Valve harness passthru connector [X280.4]

DTC 33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUIT


Restricted to transport - parking brake short to battery. The parking brake output [X001.23] is shorted to battery so the boom
cannot go above the transport position. See DTC 331 - BRAKE - SHORT TO BATTERY on Pg. 22.

DTC 33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUIT


Jib left open circuit. The jib swing left output [X169.28] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
105.

DTC 33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERY


Jib left short to battery. The jib swing left output [X169.28] is shorted to battery. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 105.

DTC 33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUND


Jib left short to ground. The jib swing left output [X169.28] is shorted to ground. See DTC 33XX - COMMON STG PROCE-
DURE on Pg. 106.

DTC 33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUIT


Jib right open circuit. The jib swing right output [X169.27] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on
Pg. 105.

DTC 33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERY


Jib right short to battery. The jib swing right output [X169.27] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUND


Jib right short to ground. The jib swing right output [X169.27] is shorted to ground. See DTC 33XX - COMMON STG PROCE-
DURE on Pg. 106.

DTC 33181 - MAIN LIFT UP VALVE - OPEN CIRCUIT


Main cylinder lift up open circuit. The main boom cylinder lift up output [X002-11] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.

1-32 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 33183 - MAIN LIFT UP VALVE - SHORT TO GROUND


Main cylinder lift up valve - short to ground. The main boom cylinder lift up output [X002-11] is shorted to battery (-) terminal/
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUIT


Main cylinder lift down open circuit. The main boom cylinder lift down output [X002.22] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.

DTC 33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUND


Main cylinder lift down short to ground. The main boom cylinder lift down output [X002.22] is shorted to battery (-) terminal/
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT


Main telescope out open circuit. The main telescope out output [X002.16] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUND


Main telescope out short to ground. The main telescope out output [X002.16] is shorted to ground. See DTC 33XX - COM-
MON STG PROCEDURE on Pg. 106.

DTC 33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUIT


Main telescope in open circuit. The main telescope in output [X002.4] is open. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 105.f

DTC 33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUND


Main telescope in short to ground. The main telescope in output [X002.4] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.

DTC 33207 - HORN - OPEN CIRCUIT


Horn open circuit. The ground module horn output [X002.2] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE
on Pg. 105.

DTC 33208 - HORN - SHORT TO BATTERY


Horn short to battery. The ground module horn output [X002.2] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.

DTC 33209 - HORN - SHORT TO GROUND


Horn short to ground. The ground module horn output [X002.2] is shorted to ground. See DTC 33XX - COMMON STG PRO-
CEDURE on Pg. 106.

DTC 33279 - GLOWPLUG - OPEN CIRCUIT


Glow plug open circuit. The glow plug / intake heater output [X001.12] is open. See DTC 33xx - COMMON STB OR OC PRO-
CEDURE on Pg. 105.

3128411 1200SJP 1350SJP 1-33


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 33280 - GLOWPLUG - SHORT TO BATTERY


Glow plug short to battery. The glow plug / intake heater output [X001.12] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.

DTC 33281 - GLOWPLUG - SHORT TO GROUND


Glow plug short to ground. The glow plug / intake heater output [X001.12] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.

DTC 33295 - SWING LEFT VALVE - OPEN CIRCUIT


Swing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.

DTC 33306 - SWING LEFT VALVE - SHORT TO BATTERY


Swing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.

DTC 33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND


Main cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control flow control output
[X002.9] is open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT


Main cylinder telescope flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY


Main cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERY


Main cylinder lift down short to battery. The main boom cylinder lift down output [X002.22] is shorted to battery (+) terminal.
See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND


Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT


Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY


Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

1-34 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 33329 - MAIN LIFT UP VALVE - SHORT TO BATTERY


Main cylinder lift up short to battery. The main boom cylinder lift up output [X002-11] is shorted to battery (+) terminal. See
DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND


Platform up short to ground. The platform module J7 platform level up output [X169.15] is shorted to ground. If there are no
open wires, the fault DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND on Pg. 27 should also be
active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT


Platform up short to battery or open circuit. The platform module J7 platform level up output [X169.15] is shorted to battery
or open. If there are no open wires, the fault DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY on
Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND


Platform down short to ground. The platform module J7 platform level down output [X169.16] is shorted to ground. If there
are no open wires, the fault DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND on Pg. 27
should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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 431 - FUEL SENSOR SHORT TO BATTERY


Fuel sensor short to battery. Indicates that the fuel sensor signal [X002.25] may be shorted to battery. See DTC 33xx - COM-
MON STB OR OC PROCEDURE on Pg. 105.

DTC 432 - FUEL SENSOR SHORT TO GROUND


Fuel sensor short to ground. Indicates that the fuel sensor signal [X002.25] may be shorted to ground. See DTC 33XX -
COMMON STG PROCEDURE on Pg. 106.

DTC 433 - OIL PRESSURE SHORT TO BATTERY


Oil pressure short to battery. This fault should only occur on machines configured with non-ECM engines. The engine oil
pressure input [X001.15] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 434 - OIL PRESSURE SHORT TO GROUND


Oil pressure short to ground. This fault should only occur on machines configured with non-ECM engines. The engine oil
pressure input [X001.15] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 435 - COOLANT TEMPERATURE SHORT TO GROUND


Coolant temperature short to ground. This fault is only active for machines configured with older non-ECM Deutz engines.
The engine coolant temperature input [X001.14] is shorted to ground.

3128411 1200SJP 1350SJP 1-35


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 437 - ENGINE TROUBLE CODE


Engine trouble code. This fault text is followed by the engine’s specific fault code. This code could represent engine faults
like low oil pressure warning, high coolant temperature warning, etc. See Table 1-1. Common Deutz Engine Fault Codes on
Pg. 36 or consult the engine control module manual to interpret the engine specific fault code.
Table 1-1. Common Deutz Engine Fault Codes

Fault Code using Fault Code using Troubleshooting Troubleshooting


Fault Description Cause Results
JLG Analyzer Deutz SERDIA Engine Machine
190:8 1 Speed sensor Engine speed sen- Loss of engine Check distance
sor failure OR Gap speed signal will from sensor to ring
from sensor tip to cause the engine to gear. Check for
ring gear too large shut down or not contamination on
OR Additional start. sensor end. Check
incorrect impulses wiring connection.
received OR Wiring Check sensor
to sensor inter- located at flywheel
rupted. housing and
replace if required.
100:2 8 Oil Pressure Fault at corre- The engine will con- Check relevant sen-
110:2 9 Coolant tempera- sponding sensor tinue operating with sor replace if
ture OR wiring connec- the failure of either required. Check rel-
tion has a short cir- Oil Pressure or evant wiring and
cuit or open circuit. Coolant Tempera- connections
ture sensors. How- between sensor
ever with a failure of and ECU.
the sensor, the
associated moni-
toring function is
de-activated
100:1 30 Oil Pressure warn- Engine Oil Pressure Fault message Check engine oil Depending on
ing has fallen below occurs. Engine may level. Check oil Machine Program-
acceptable value. also shutdown pressure sensor ming the engine will
depending on JLG and wiring. Check either Shutdown OR
Machine program- engine for other only give a warning
ming possible mechani-
cal causes. The
engine has a 12
second monitoring
delay on startup, so
proceed carefully
not to cause further
low oil pressure
damage to engine
on repeated start
attempts
110:0 31 Coolant Tempera- Engine Oil Temper- Fault message Check engine oil Depending on
ture warning ature has exceeded occurs. Engine may level. Check Oil Machine Program-
acceptable value. also shutdown temperature sen- ming the engine will
depending on JLG sor and wiring. either Shutdown OR
Machine program- Check cooling sys- only give a warning
ming. Fault will dis- tem for leaks or
appear when Oil contamination, etc.
Temperature drops
below preset recov-
ery temperature.

1-36 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Table 1-1. Common Deutz Engine Fault Codes

Fault Code using Fault Code using Troubleshooting Troubleshooting


Fault Description Cause Results
JLG Analyzer Deutz SERDIA Engine Machine
702:14 35 Overspeed warning Engine RPM was or If engine exceeds If condition per- Check for external
(with thrust mode is above maximum maximum RPM set sists: Check fuel environmental con-
operation). allowed RPM limit point (3300 RPM) rack. Check actua- ditions that could
limit. "Thrust mode" the fuel rack is set to tor and replace if cause engine over-
function is active zero position until required. Check speed condition
engine speed wiring to actuator.
returns below Check engine
acceptable recov- speed sensor, ring
ery speed (2810 gear teeth, etc.
RPM).
100:1 40 Oil pressure switch Oil pressure below Normally this would See Oil Pressure
off switch-off limit. cause an Emer- Warning info
gency stop of the
engine. But EMR is
not programmed to
directly shutdown
the engine in JLG
machines. Only if
the JLG machine is
programmed to
shutdown will this
occur
110:0 41 Coolant tempera- Oil temperature has Normally this would See Coolant Tem-
ture switch-off exceeded switch off cause an Emer- perature Warning
limit gency stop of the info
engine. But EMR is
not programmed to
directly shutdown
the engine in JLG
machines. Only if
the JLG machine is
programmed to
shutdown will this
occur
91:11 67 Error Hand Setp1 Loss of CAN bus Engine will only run Check CAN con- Check relevant wir-
898:2 68 Error CAN Setp1 input. at constant speed nection and wiring ing and connec-
of 1835 RPM connection entering tions between
743:12 70 CAN-Bus controller Controller for CAN- Engine will shut- engine ECU from machine and ECU
bus is faulty. Fault down or not restart machine. Check for open or short
removal despite OR Engine will only ECU for proper CAN circuit. Check Ter-
reinitializing contin- run at constant bus data flow and minating resistor in
uously not possi- speed of 1835 RPM correct program- machine wiring
ble. ming.
743:9 71 CAN interface SAE J Overflow in input
1939 buffer or a trans-
mission cannot be
placed on the bus.
743:14 74 CAN Passive error Open or Short cir- Engine will shut- Check CAN con-
cuit in wiring down or not restart nection and wiring
OR engine will only connection entering
run at constant engine ECU from
speed of 1835 RPM machine.

3128411 1200SJP 1350SJP 1-37


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 438 - HIGH ENGINE TEMP


High engine temperature. This fault should only occur on machines configured with non-ECM engines. The engine tempera-
ture is above 130°C.

DTC 439 - AIR FILTER BYPASSED


Air filter bypassed. This fault should never occur on properly configured machines. Reload ground module software or
replace the ground module.

DTC 4310 - NO ALTERNATOR OUTPUT


No alternator output. Notification that the engine has been running for 15 seconds or more and the battery voltage is still
below 11.5 volts. This probably indicates a problem with the alternator or its wiring.

DTC 4311 - LOW OIL PRESSURE


Low oil pressure. This fault should only occur on machines configured with non-ECM engines. Notification that the oil pres-
sure input [X001.15] is below 8 PSI and the engine has been running for at least 10 seconds.

DTC 4313 - THROTTLE ACTUATOR FAILURE


Throttle actuator failure. This fault should only occur on machines configured with non-ECM engines. The engine is over-
speeding, reading over 3050 RPM. This probably indicates the throttle actuator has failed.

DTC 4314 - WRONG ENGINE SELECTED - ECM DETECTED


Wrong engine selected - ECM present. The machine is configured to be a non-ECM engine, but an ECM signal is detected
on the CAN bus. Change the machine engine configuration.

DTC 4322 - LOSS OF ENGINE SPEED SENSOR


Speed input lost. This fault should only occur on machines configured with non-ECM engines. Notification that there is no
engine speed detected on the engine flywheel speed sensor input [X001.16], but the oil pressure input [X001.15] reads
above 8 PSI for more than 3 seconds.

DTC 4323 - SPEED SENSOR READING INVALID SPEED


Speed sensor reading invalid speed. This fault should only occur on machines configured with non-ECM engines. Notifica-
tion that the engine flywheel speed sensor input [X001.16] is indicating a speed that greater than 4000 RPM or approxi-
mately 8875 Hz.

DTC 441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN


Battery too low - system shut down. A warning that the voltage at ground module J8 [X008.2] is below 9 volts. The system
will shut down after about 5 seconds. Remove any corrosion on battery terminals and battery cable terminals. Recharge or
replace battery.

DTC 442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN


Battery too high - system shut down. The voltage at ground module J8 [X008.2] is above 18.6 volts. The system will shut
down. Check battery and battery connections or replace battery.

DTC 445 - BATTERY VOLTAGE LOW


Battery voltage is too low. A warning that the voltage at ground module J8 [X008.2] is below 11 volts. Remove any corrosion
on battery terminals and battery cable terminals. Recharge or replace battery. Check battery charging system.

1-38 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 662 - CANBUS FAILURE - PLATFORM MODULE


Platform CAN communications lost. The system cannot communicate with the platform module. This may be due to wiring
problems between platform and ground modules.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check fault log for other Have most modules lost communications? Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE
modules having lost com- CANBUS ERRORS on Pg. 55
munication No Go to step 2
Step 2 Disconnect the platform Is there 11VDC or more between platform Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE
module J8 connector module J8 socket 2 [X170.2.soc] and socket CANBUS ERRORS on Pg. 55 fault step 3
[X170]. Turn machine on in 1 [ X170.1.soc]? No Keep machine on. Go to step 3
platform mode
Step 3 Disconnect the platform Is there zero VDC between platform module J8 Yes Keep machine on. Go to step 5
module J8 connector connector socket 1 [X170.1.soc] and socket No Go to step 4
[X170]. Turn machine on in 2 [X170.2.soc]?
platform mode
Step 4 Remove any corrosion on Does battery still exhibit low power? Yes Replace battery
battery terminals and battery No Retry normal vehicle operation
cable terminals. Run
machine to recharge bat-
tery.
Step 5 Turn machine on in platform Is there 11VDC or more between the 19 posi- Yes Repair/replace harness between the 19 position
mode. Backprobe to take the tion platform control box passthru connector platform control box passthru connector [X160]
following measurement. terminal 12 [X160.12] and terminal 16 and the platform module J8 connector [X170]
See Backprobing on Pg. [X160.16]? No Go to step 6
245 for details.
Step 6 Take the following measure- Turn machine on in platform mode. Is there Yes Repair/replace harness between the MTB pass
ment by backprobing 11VDC or more between MTB pass thru - 19 thru - 19 position connector [X043] and the plat-
position connector pin 12 [X043.12.pin] and form control box passthru - 19 position connec-
pin 16 [X043.16.pin]? tor [X160]
No Go to step 7
Step 7 Take the following measure- Turn machine on in platform mode. Is there Yes Repair/replace harness between the ground
ment by backprobing 11VDC or more between ground module J8 module J8 connector [X008] and the MTB pass
connector pin 3 [ X008.3] and pin 4 [X008.4]? thru - 19 position connector [X043]
No Go to step 8
Step 8 Disconnect the ground Is there 11VDC or more between ground mod- Yes Repair/replace harness between the ground
module J8 connector ule J8 connector pin 3 [X008.3] and pin 4 module J8 connector [X008] and the MTB pass
[X008]. Turn machine on in [X008.4]? thru - 19 position connector [X043]
platform mode No Replace the ground module

DTC 666 - CANBUS FAILURE - ENGINE CONTROLLER


Engine controller CAN communications lost. The ground module is not receiving CAN messages from the engine controller.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the 6613 - CANBUS FAILURE - EXCESSIVE Yes Troubleshoot DTC 6613 - CANBUS FAILURE -
CANBUS ERRORS fault active in the fault log? EXCESSIVE CANBUS ERRORS on Pg. 55 first
No Go to step 2
Step 2 Does the BLAM software version show "??" in Yes See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
ANALYZER  DIAGNOSTICS  VERSIONS 48
 B.L.A. MODULE SOFTWARE:? No Go to step 3

3128411 1200SJP 1350SJP 1-39


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Disconnect the EMR2 ECU Does the voltage between EMR2 ECU equip- Yes Go to step 5
equipment connector ment connector socket 14 [X240.14.soc] and No Go to step 4
[X240]. Turn on the socket 1 [X240.1.soc] measure 12VDC?
machine.
Step 4 Backprobe between any ter- Does the voltage between any terminal of the Yes Repair the YEL/RED 2-1-99 wire between the
minal of the MTB power bus MTB power bus connector [X010] and the MTB power bus connector [X010] and the EMR2
connector [X010] and the ground module J1 connector terminal 8 ECU equipment connector terminal 14 [X240.14]
ground module J1 connec- [X001.8] measure 12VDC? and/or the black wire between of the EMR2 ECU
tor terminal 8 [X001.8]. See equipment connector terminal 1 [X240.1] and the
Backprobing on Pg. 245 for ground module J1 connector terminal 8 [X001.8]
details. No Check the connections, make sure the machine is
turned on, and return to step 3. If the problem per-
sists, replace the ground module
Step 5 Backprobe EMR2 ECU Does the CAN resistance between EMR2 ECU Yes Go to step 6
equipment connector termi- equipment connector terminal 12 [X240.12] No See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
nal 12 [X240.12] and termi- and terminal 13 [X240.13] measure 60? 48
nal 13 [X240.13]
Step 6 Disconnect the EMR2 ECU Is there CAN HI continuity between socket 12 Yes Call Deutz dealer
equipment connector of the EMR2 ECU equipment connector No Go to step 7
[X240] and the BLAM mod- [X240.12.soc] and socket 3 of the BLAM
ule J4 connector [X089]. module J4 connector [X089.3.soc] and CAN
See 6.3 Continuity Measure- LO continuity between socket 13 of the EMR2
ment Over Long Distances ECU equipment connector [X240.13.soc] and
on Pg. 247. socket 4 of the BLAM module J4 connector
[X089.4.soc]?
Step 7 Disconnect the EMR2 ECU Is there CAN HI continuity between socket 12 Yes Replace the valve harness between the BLAM
equipment connector of the EMR2 ECU equipment connector module J4 connector [X089] and the CAN pass
[X240] and the CAN pass [X240.12.soc] and pin A of the CAN pass thru thru for EMR2 - 3 position connector [X268]
thru for EMR2 - 3 position for EMR2 - 3 position connector [X268.A.pin] No Check the RED and BLACK wires between the
connector [X268]. See 6.3 and CAN LO continuity between socket 13 of EMR2 ECU equipment connector [X240.12
Continuity Measurement the EMR2 ECU equipment connector X240.13] and the CAN pass thru for EMR2 - 3
Over Long Distances on Pg. [X240.13.soc] and pin B of the CAN pass thru position connector [X268.A X268.B]
247. for EMR2 - 3 position connector
[X268.B.pin]?

DTC 6610 - CANBUS FAILURE - BLAM


BLAM CAN communications lost. The system cannot communicate with the Boom Length Angle Module (BLAM). This may
be due to wiring problems between the platform and chassis modules. If power is lost to the BLAM, then power will not be
provided to the cylinder load pin and the 6612 - CANBUS FAILURE - CYLINDER LOAD PIN fault will also be active.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check the fault log for other Is CYLINDER LOAD PIN CAN COMMUNICA- Yes Go to step 2
modules having lost com- TIONS LOST fault active? No Go to 5
munication (6-6 codes)
Step 2 Disconnect BLAM J1 Does the voltage between socket 5 [X086.5] Yes Keep BLAM J1 [X086] connector disconnected.
[X086] connector and 4 [X086.4] measure 12 VDC? Go to step 5.
No Go to step 3
Step 3 Disconnect Valve Passthru Does the voltage between Valve Passthru Yes Repair wire(s) between Valve Passthru [X280]
[X280] socket 1 [X280.1.soc] and socket 6 and BLAM J1 [X086]
[X280.6.soc] measure 12 VDC? No Go to step 4

1-40 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 4 Disconnect MTB Power Bus Does the voltage between one of the sockets Yes Repair wire(s) between MTB Power Bus[X010]
[X010] of the MTB Power Bus[X010] and Ground and Valve Passthru socket 1 [X280.1.soc] and/or
Module J8 terminal 3 [X008.3] measure 12 Ground Module J8 terminal 3 [X008.3] and Valve
VDC? Passthru socket 6 [X280.6.soc].
No Repair 2-70 wire between MTB Power bus
[X010] and Power Down Relay [X011].
Step 5 Disconnect BLAM J1 Does the resistance between BLAM J1 socket Yes Keep BLAM J1 [X086] connector disconnected.
[X086] connector 6 [X086.6.soc] and socket 7 [X086.7.soc] Go to step Figure 6
measure 60? -AND- Is there an open circuit No Go to step 11
between socket 6 [X086.6.soc] and shield
[X086.8]. -AND- Is there an open circuit
between socket 7 [X086.7.soc] and shield
[X086.8]?
Step 6 Disconnect BLAM J1 Is there continuity only between the following Yes Ensure BLAM and Ground Module are running
[X086] connector and points? proper version. Replace BLAM
Ground Module J7 [X007] • BLAM J1 socket 6 [X086.6.soc] and No Keep Ground Module J7 [X007] disconnected.
Ground Module J7 socket 13 Go to step 7
[X007.13.soc]
• BLAM J1 socket 7 [X086.7.soc] and
Ground Module J7 socket 24
[X007.24.soc]
• BLAM J1 socket 8 [X086.8.soc] and
Ground Module J7 socket 18
[X007.18.soc]
Step 7 Disconnect CAN 3-Way to Is there continuity only between the following Yes Keep CAN 3-Way to BLAM [X269] disconnected.
BLAM [X269] and Ground points? Go to step 8
Module J7 [X008] • CAN 3-Way to BLAM pin A [X269.A.pin] No Keep BLAM J1 [X086] disconnected.
and Ground Module J7 socket 13 Go to step 10
[X007.13.soc]
• CAN 3-Way to BLAM pin B [X269.B.pin]
and Ground Module J7 socket 24
[X007.24.soc]
• CAN 3-Way to BLAM pin C [X269.C.pin]
and Ground Module J7 socket 18
[X007.18.soc]
Step 8 Disconnect CAN 3-Way to Is there continuity only between the following Yes Go to step 9
BLAM [X269] and CAN points? No Repair wire(s) between CAN 3-Way to BLAM
Passthru for EMR2 [X268] • CAN 3-Way socket A [X269.A.soc] and [X269] and CAN Passthru for EMR2 [X278]
C A N Pa s s t h r u f o r E M R 2 s o c k e t A
[X268.A.soc]
• CAN 3-Way socket B [X269.B.soc] and
C A N Pa s s t h r u f o r E M R 2 s o c k e t B
[X268.B.soc]
• CAN 3-Way socket C [X269.C.soc] and
C A N Pa s s t h r u f o r E M R 2 s o c k e t C
[X268.C.soc]

3128411 1200SJP 1350SJP 1-41


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 9 Disconnect CAN Passthru to Is there continuity only between the following Yes Replace CAN 3-way connected to CAN Passthru
BLAM [X278] and BLAM J1 points? to BLAM [X278]
[X086] • BLAM J1 socket 6 [X086.6.soc] and CAN No Repair failing wire(s) between CAN Passthru to
Passthru to BLAM socket A [X278.A.soc] BLAM [X278] BLAM J1 [X086]
• BLAM J1 socket 7 [X086.7.soc] and CAN
Passthru to BLAM socket B [X278.B.soc]
• BLAM J1 socket 8 [X086.8.soc] and CAN
Passthru to BLAM socket C [X278.C.soc]
Step 10 Disconnect CAN 3way - to Is there continuity only between the following Yes Replace CAN 3-way connected to CAN 3way - to
Ground Module [X014]and points? Ground Module [X014]
Ground Module J7 [X007] • CAN 3-Way to Ground Module pin A No Repair failed wire(s) between CAN 3way - to
[X014.A.pin] and Ground Module J7 Ground Module [X014]and Ground Module J7
socket 13 [X007.13.soc] [X008]
• CAN 3-Way to Ground Module pin B
[X014.B.pin] and Ground Module J7
socket 24 [X007.24.soc]
• CAN 3-Way to Ground Module pin C
[X014.C.pin] and Ground Module J7
socket 18 [X007.18.soc]
Step 11 Disconnect CAN Passthru Does the resistance between CAN Passthru Yes Go to step 14
for EMR2 [X268] for EMR2 socket A [X268.A.soc] and socket B No Go to step 12
[X268.B.soc] measure 120? -AND- Is there
an open circuit between CAN Passthru for
EMR2 socket A [X268.A.soc] and shield
socket C [X268.C.soc]. -AND- Is there an
open circuit between CAN Passthru for EMR2
socket B [X268.B.soc] and shield socket C
[X268.C.soc]?
Step 12 Disconnect CAN 3way - to Does the resistance between CAN 3way - to Yes Go to step 13
Platform [X270] Platform socket A [X270.A.soc] and socket B No Go to step 20
[X270.B.soc] measure 120? -AND- Is there
an open circuit between CAN 3way - to Plat-
form socket A [X270.A.soc] and shield socket
C [X270.C.soc]. -AND- Is there an open circuit
between CAN 3way - to Platform socket B
[X270.B.soc] and shield socket C
[X270.C.soc]?
Step 13 Is the software in the BLAM and Ground Mod- Yes Replace BLAM
ule the proper version? No Load proper software
Step 14 Disconnect CAN Passthru to Does the resistance between CAN Passthru to Yes Repair wire(s) between CAN Passthru to Engine
Engine Harness [X279] Engine Harness socket A [X279.A.soc] and Harness [X279] CAN T-connector and BLAM J1
socket B [X279.B.soc] measure 120? - [X086]
AND- Is there an open circuit between CAN No Go to step 15
Passthru to Engine Harness socket A
[X279.A.soc] and shield socket C
[X279.C.soc]. -AND- Is there an open circuit
between CAN Passthru to Engine Harness
socket B [X279.B.soc] and shield socket C
[X279.C.soc]?

1-42 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 15 Disconnect Swivel Top con- Does the resistance between Swivel Top con- Yes Go to step 18
nector [X083] nector pin 1 [X083.1.pin] and pin 2 No Go to step Figure 16
[X083.2.pin] measure 120? -AND- Is there
an open circuit between Swivel Top connector
pin 1 [X083.1.pin] and pin 3 [X083.3.pin]? -
AND- Is there an open circuit between Swivel
Top connector pin 2 [X083.2.pin] and pin 3
[X083.3.pin]?
Step 16 Disconnect Swivel Chassis Does the resistance between Swivel Chassis Yes Repair failed wire(s) and/or slip rings between
connector [X216] connector pin 1 [X216.1.pin] and pin 2 Swivel Top connector [X083] and Swivel Chassis
[X216.2.pin] measure 120? -AND- Is there connector [X216]
an open circuit between Swivel Chassis con- No Keep Swivel Chassis connector [X216] discon-
nector pin 1 [X216.1.pin] and pin 3 nected.
[X216.3.pin]? -AND- Is there an open circuit Go to step 17.
between Swivel Chassis connector pin 2
[X216.2.pin] and pin 3 [X216.3.pin]?
Step 17 Disconnect Chassis Module Is there continuity only between the following Yes Replace Chassis Module
J1 [X229] and Swivel Chas- points? No Repair failed wire(s) between Chassis Module J1
sis connector [X216] • Chassis Module J1 socket 6 [X229.6.soc] [X229] and Swivel Chassis connector [X216]
and Swivel Chassis connector pin1
[X216.1.pin]
• Chassis Module J1 socket 7 [X229.7.soc]
and Swivel Chassis connector pin 2
[X216.2.pin]
• Chassis Module J1 socket 8 [X229.8.soc]
and Swivel Chassis connector pin 3
[X216.3.pin]
• Chassis Module J1 socket 9 [X229.9.soc]
a nd Ch ass is Module J 1 soc ke t 10
[X229.10.soc]
Step 18 Disconnect Deutz EMR2 Does the resistance between Deutz EMR2 Yes Go to step 19
Chassis CAN connector Chassis CAN connector [X084] pin A No Repair failed wire(s) between Swivel Top con-
[X084] [X084.A.pin] and pin B [X084.B.pin] measure nector [X083] and Deutz EMR2 Chassis CAN
120? -AND- Is there an open circuit between connector [X084]
Deutz EMR2 Chassis CAN connector pin A
[X084.A.pin] and pin C [X084.C.pin]? -AND-
Is there an open circuit between Deutz EMR2
Chassis CAN connector pin B [X084.B.pin]
and pin C [X084.C.pin]?
Step 19 Disconnect EMR2 ECU Does the resistance between EMR2 ECU Yes Repair failed wire(s) between EMR2 ECU Equip-
Equipment Connector Equipment Connector socket 12 ment Connector [X240] and CAN Passthru to
[X240] and CAN Passthru to [X240.12.soc] and socket 13 [X240.13.pin] Engine Harness [X279]
Engine Harness [X279]. measure 120? -AND- Is there an open cir- No Repair failed wire(s) between EMR2 ECU Equip-
cuit between the shield and both EMR2 ECU ment Connector [X240] and Deutz EMR2 Chassis
Equipment Connector socket 12 CAN connector [X084]
[X240.12.soc] and socket 13 [X240.13.pin]?

3128411 1200SJP 1350SJP 1-43


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 20 Disconnect Platform Control Does the resistance between Platform Control Yes Go to step 21
Box Passthru [X160] Box Passthru connector pin 2 [X160.2.pin] No Keep Platform Control Box Passthru [X160] dis-
and pin 3 [X083.3.pin] measure 120? - connected.
AND- Is there an open circuit between Plat- Go to step 22
form Control Box Passthru connector pin 1
[X160.1.pin] and pin 2 [X160.2.pin]? -AND-
Is there an open circuit between Platform Con-
trol Box Passthru connector pin 1
[X160.1.pin] and pin 3 [X160.3.pin]?
Step 21 Disconnect MTB Passthru Does the resistance between MTB Passthru Yes Repair failed wire(s) between MTB Passthru
[X043] connector pin 2 [X043.2.pin] and pin 3 [X043] and CAN 3way - to Platform [X270]
[X043.3.pin] measure 120? -AND- Is there No Repair failed wire(s) between MTB Passthru
an open circuit between MTB Passthru con- [X043] and Platform Control Box Passthru
nector pin 1 [X043.1.pin] and pin 2 [X160]
[X043.2.pin]? -AND- Is there an open circuit
between MTB Passthru connector pin 1
[X043.1.pin] and pin 3 [X043.3.pin]?
Step 22 Disconnect Platform Control Is there continuity only between the following Yes Replace Platform Module
Box Passthru [X160] and points? No Repair failed wire(s) between Platform Control
Platform Module J7 [X169] • Platform Control Box Passthru pin 1 Box Passthru [X160] and Platform Module J7
[X160.1.pin] and Platform Module J7 [X169]
socket 32 [X169.32.soc]
• Platform Control Box Passthru pin 2
[X160.2.pin] and Platform Module J7
socket 30 [X169.30.soc]
• Platform Control Box Passthru pin 3
[X160.3.pin] and Platform Module J7
socket 31 [X169.31.soc]

DTC 6611 - CANBUS FAILURE - CHASSIS MODULE


Chassis CAN communications lost. The system cannot communicate with the chassis module. This may be due to wiring
problems between the chassis and ground module.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check fault log for other Have most modules lost communications? Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE
modules having lost com- CANBUS ERRORS on Pg. 55
munication No Go to step 2
Step 2 Is Chassis Power fuse [X267] blown? Yes Replace with 30A fuse. If it blows again immedi-
(Located by Aux Power Pump.) ately, repair the short to ground on Chassis Power
Relay terminal 30 [X266.30] and/or terminal 87a
[X266.87a]. It it blows again, but only after turn-
ing on the machine, go to step 16
No Go to step 3
Step 3 Disconnect the chassis Is there 11VDC or more between chassis Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE
module J1 connector module J1 connector socket 4 [X229.4.soc] CANBUS ERRORS on Pg. 55 fault step 3
[X229]. Turn on machine and socket 5 [X229.5.soc]? No Keep machine on. Go to step 4
Step 4 Disconnect the chassis Is there zero VDC between chassis module J1 Yes Keep machine on. Go to step 6
module J1 connector connector socket 4 [X229.4.soc] and socket No Go to step 5
[X229]. Turn on machine 5 [X229.5.soc]?

1-44 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 5 Remove any corrosion on Does battery still exhibit low power? Yes Replace battery
battery terminals and battery No Retry normal vehicle operation
cable terminals. Run
machine to recharge bat-
tery.
Step 6 Disconnect Lower Swivel Is there 11VDC or more between of the Lower Yes Inspect/repair/replace harness between the
connector [X216]. Turn on Swivel connector socket 4 [X216.4.soc] and Lower Swivel connector [X216] and the chassis
machine socket 5 [X216.5.soc]? module J1 connector [X229]
No Go to step 7
Step 7 Disconnect Upper Swivel Is there 11VDC or more between of the Upper Yes Repair swivel harness or replace swivel slip rings
connector [X083]. Turn on Swivel connector socket 4 [X083.4.soc] and No Go to step 8
machine socket 5 [X083.5.soc]?
Step 8 Turn on machine Is there 11VDC or more at the Chassis Power Yes Repair/replace harness between the Upper
relay terminal 87 [X266.87]? Swivel connector [X083] and the Chassis Power
relay terminal 87 [X266.87]
No Keep machine on. Go to step 9
Step 9 Disconnect Chassis Power Is there about 12 VDC at the Chassis Power Yes Go to step 11
Relay [X266]. Turn on relay terminal 30.soc [X266.30.soc]? No Go to step 10
machine
Step 10 Remove the Chassis Power Is there about 12 VDC at the Auxiliary Pump Yes Replace fuse or repair/replace harness
Fuse from the holder [X267] solenoid side of the Chassis Power fuse No Repair/replace harness between the Chassis
holder [X267]? Power fuse connector [X267] and the battery
positive [X116] through the Auxiliary Pump Relay
positive terminal [X108].
Step 11 Disconnect Chassis Power Is there about 12 VDC between Chassis Power Yes Replace Chassis Power relay.
Relay [X266]. Turn on relay connector socket 86 [X266.86.soc] and No Go to step 12
machine. socket 85 [X266.85.soc]?
Step 12 Disconnect the Valve Is there about 12 VDC between the Valve Yes Repair/replace harness between the Valve
passthru - 6 pos connector passthru - 6 pos connector socket 3 passthru - 6 pos connector [X280] and the chas-
[X280]. Turn on machine [X280.3.soc] and socket 5 [X280.5.soc]? sis power relay connector [X266].
No Go to step 13
Step 13 Perform this test by back- Is there about 12 VDC between pin 3 of the Yes Go to step 14
probing. See Backprobing Valve passthru - 6 pos connector [X280.3.pin] No Go to step 15
on Pg. 245. and Auxiliary Pump B- terminal?
Step 14 Is there continuity between Chassis Power Yes Repair/replace the YEL/RED 2-70-4 wire
distribution relay socket 85 [X266] and Auxil- between the Valve passthru - 6 pos connector ter-
iary Pump B- terminal [X110]? minal 3 [X280.3] and the 12 Pos Batt Busbar
[X097].
No Repair/replace the Black wire between Chassis
Power distribution relay socket 85[X266.85.soc]
and Auxiliary Pump B- terminal [X110].
Step 15 Do the faults 849 - BOOM ANGLE SENSOR #1 Yes See DTC 849 - BOOM ANGLE SENSOR #1 -
- COMMUNICATIONS FAULT and 8410 - COMMUNICATIONS FAULT on Pg. 75 to trouble-
BOOM ANGLE SENSOR #2 - COMMUNICA- shoot the power supply.
TIONS FAULT both show in the fault log before No Repair/replace harness between the 6 position
a power cycle? BLAM passthru connector [X280] and the 12-pin
V-Batt+ bus connector [X097] and/or the 12-pin
ground bus connector [X098].

3128411 1200SJP 1350SJP 1-45


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 16 Disconnect chassis module Is there a short to ground on socket 5 of chas- Yes Go to step 18
J1 connector [X229] sis module J1 connector [X229.5.soc]? No Leave chassis module disconnected.
Go to step 17
Step 17 Disconnect chassis module Is there a short between the chassis module J1 Yes Replace the chassis module
J1 connector [X229] connector pin 4 [X229.4.pin] and pin 5 No Check the connections at the chassis module J1
[X229.5.pin]? connector [X229]
Step 18 Disconnect Lower Swivel Is there a short between of the Lower Swivel Yes Repair/replace Chassis harness between the
connector [X216] connector pin 4 [X216.4.pin and pin 5 Lower Swivel connector [X216] and chassis
[X216.5.pin]? module J1 connector [X229]
No Go to step 19
Step 19 Disconnect Upper Swivel Is there a short between Upper Swivel connec- Yes Repair Swivel harness or replace Swivel
connector [X083] tor pin 4 [X083.4.pin] and pin 5 [X083.5.pin]? No Go to step 20
Step 20 Disconnect the chassis Is there a short between socket 87 of the Chas- Yes Repair/replace harness between the chassis
power relay connector sis Power Relay connector [X266.87.soc] power relay connector [X266] and the Upper
[X266] and socket 85 of the Chassis Power Relay Swivel connector [X083]
connector [X266.85.soc] or the negative side No Leave the chassis power relay connector discon-
of the battery [X117]? nected. Go to step 21.
Step 21 Disconnect the chassis Is there a short between socket 30 of the Chas- Yes Repair/replace harness between the Chassis
power relay connector sis Power Relay connector [X266.30.soc] Power Relay [X266] and the Chassis Power Fuse
[X266] and socket 85 of the Chassis Power Relay [X267]
connector [X266.85.soc] or the negative side No Replace Chassis Power Relay
of the battery [X117]?

DTC 6612 - CANBUS FAILURE - CYLINDER LOAD PIN


Cylinder load pin CAN communications lost. The system cannot communicate with the cylinder load pin. This may be due to
wiring problems between the cylinder load pin and BLAM module.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the 6613 - CANBUS FAILURE - EXCESSIVE Yes Troubleshoot DTC 6613 - CANBUS FAILURE -
CANBUS ERRORS fault active in the fault log? EXCESSIVE CANBUS ERRORS on Pg. 55 first
No Go to step 2
Step 2 Does the BLAM software version show "??" in Yes See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
ANALYZER  DIAGNOSTICS  VERSIONS 48
 B.L.A. MODULE SOFTWARE:? No Go to step 3
Step 3 Disconnect the load pin con- Does the voltage between the load pin connec- Yes Go to step 5
nector [X062]. Turn on the tor socket A [X062.A.soc] and socket B No Go to step 4
machine [X062.B.soc] measure 12VDC?
Step 4 Backprobe BLAM module J4 Does the voltage between the BLAM module Yes Replace load pin harness
terminal 1 [X089.1] and ter- J4 connector terminal 1 [X089.1] and terminal No Replace the BLAM module
minal 2 [X089.2] 2 [X089.2] measure 12VDC?
Step 5 Backprobe the BLAM mod- Does the CAN resistance between the BLAM Yes Go to step 6
ule J4 connector module J4 connector terminal 3 [X089.3] and No See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
terminal 3 [X089.3], terminal 4 [X089.4] measure 60 and open 48
terminal 4 [X089.4], and circuit between terminal 3 [X089.3] and shield
terminal 5 [X089.5] terminal 5 [X089.5] and open circuit between
terminal 4 [X089.4] and shield terminal 5
[X089.5]?

1-46 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Disconnect the load pin con- Is there CAN HI continuity between socket D of Yes Replace the load pin
nector [X062] and the BLAM the load pin connector [X062.D.soc] and No Replace the load pin harness
module J4 connector socket 3 of the BLAM module J4 connector
[X089]. [X089.3.soc] and CAN LO continuity between
socket E of the load pin connector
[X062.E.soc] and socket 4 of the BLAM mod-
ule J4 connector [X089.4.soc]?

DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS


Excessive CAN bus communication errors. More than 500 bus off or more than 500 bus passive conditions have been
detected by the ground module in the current power cycle. This could be due to faulty bus wiring or termination resistors,
capacitance on the bus, or a module not communicating.

Note Pretest Instructions Test Result Corrective Action


Step 1 Does the CAN resistance between ground Yes Go to step 2
module J7 connector terminal 13 [X007.13] No Go to step 17 to examine the CAN termination
and terminal 24 [X007.24] measure 60 and
open circuit between terminal 13 [X007.13]
and shield [X007.18] and open circuit
between terminal 24 [X007.24] and shield
[X007.18]?
Step 2 Does the platform software version show "??" Yes Go to step 3
in ANALYZER  DIAGNOSTICS  VER- No Go to step 8
SIONS  PLATFORM MODULE SOFT-
WARE:??
Step 3 For help with this type of test Is there CAN HI continuity between terminal 31 Yes Go to step 8
see 6.3 Continuity Measure- of the platform module J7 connector No Go to step 4
ment Over Long Distances [X169.31] and terminal 13 of the ground mod-
on Pg. 247 ule J7 connector [X007.13] and CAN LO conti-
nuity between terminal 30 of the platform
module J7 connector [X169.30] and terminal
24 of the ground module J7 connector
[X007.24]?
Step 4 Is there CAN HI continuity between terminal 3 Yes Check the RED, BLACK, and Shield wires
of the platform control box passthru - 19 posi- between the platform module J7 connector
tion connector [X160.3] and terminal 13 of the [X169] and the platform control box passthru - 19
ground module J7 connector [X007.13] and position connector [X160]
CAN LO continuity between terminal 2 of the No Go to step 5
platform control box passthru - 19 position
connector [X160.2] and terminal 24 of the
ground module J7 connector [X007.24]?
Step 5 Is there CAN HI continuity between terminal 3 Yes Check the RED, BLACK, and Shield wires
of the MTB pass thru - 19 position connector between the MTB pass thru - 19 position connec-
[X043.3] and terminal 13 of the ground mod- tor [X043] and the platform control box passthru -
ule J7 connector [X007.13] and CAN LO conti- 19 position connector [X160].
nuity between terminal 2 of the MTB pass thru No Go to step 6
- 19 position connector [X043.2] and terminal
24 of the ground module J7 connector
[X007.24]?

3128411 1200SJP 1350SJP 1-47


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Is there CAN HI continuity between terminal A Yes Check the RED, BLACK, and Shield wires
of the platform module side of the 3 way CAN between the platform module side of the 3 way
connector in the main terminal box [X270.A] CAN connector in the main terminal box [X270]
and terminal 13 of the ground module J7 con- and the MTB pass thru - 19 position connector
nector [X007.13] and CAN LO continuity [X043]
between terminal B of the platform module No Go to step 7
side of the 3 way CAN connector in the main
terminal box [X270.B] and terminal 24 of the
ground module J7 connector [X007.24]?
Step 7 Is there CAN HI continuity between terminal A Yes Repair/Replace the 3 way CAN connector in the
of the 3 way CAN connector [X014.A] and ter- main terminal box [X014] [X269] [X270]
minal 13 of the ground module J7 connector No Repair/Replace the harness between the 3 way
[X007.13] and CAN LO continuity between CAN connector in the main terminal box [X014]
terminal B of the 3 way CAN connector and the ground module J7 connector [X007]
[X014.B] and terminal 24 of the ground mod-
ule J7 connector [X007.24]?
Step 8 Does the BLAM software version show "??" in Yes Go to step 9
ANALYZER  DIAGNOSTICS  VERSIONS No Go to step 10
 B.L.A. MODULE SOFTWARE:??
Step 9 For help with this type of test Is there CAN HI continuity between terminal 6 Yes Go to step 10
see 6.3 Continuity Measure- of the BLAM module J1 connector [X086.6] No Go to DTC 6610 - CANBUS FAILURE - BLAM on
ment Over Long Distances and terminal 13 of the ground module J7 con- Pg. 48
on Pg. 247 nector [X007.13] and CAN LO continuity
between terminal 7 of the BLAM module J1
connector [X086.7] and terminal 24 of the
ground module J7 connector [X007.24]?
Step 10 Is the CYLINDER LOAD PIN CAN COMMUNI- Yes Go to step 11
CATIONS LOST fault active in the fault log?
No Go to step 13
Step 11 For help with this type of test Is there CAN HI continuity between Load Pin Yes Go to step 13
see 6.3 Continuity Measure- pin 3 [X062.3.pin] and ground module J7 con- No Go to step 12
ment Over Long Distances nector terminal 13 [X007.13]. Also, CAN LO
on Pg. 247. Disconnect continuity between Load Pin pin 4
Load Pin [X062]. [X062.4.pin] and ground module J7 connec-
tor terminal 24 [X007.24]?
Step 12 Is there CAN HI continuity between Load Pin Yes Check BLAM internal CAN lines by looking for
pin [X062.3.pin] and BLAM J4 socket 3 CAN HI continuity between BLAM J4 pin 3
[X089.3.soc]; and CAN LO continuity between [X089.3.pin] and J1 pin 6 [X086.6.pin] and CAN
Load Pin pin 4 [X062.4.pin] and BLAM J4 LO continuity between J4 pin 4 [X089.4.pin] and
socket 4 [X089.4.soc]? J1 pin 7 [X086.7.pin] and shield continuity
between J4 pin 5 [X089.5.pin] and J1 pin 8
[X086.8.pin]. Replace BLAM if bad.
No Check the WHITE, GREEN, and BROWN/BLACK
wires between the Load Pin [X062] and BLAM
J4.
Step 13 Is the 666 - CANBUS FAILURE - ENGINE Yes Go to step 14
CONTROLLER fault active in the fault log?
No Go to step 15

1-48 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 14 For help with this type of test Is there CAN HI continuity between terminal 12 Yes Go to step 15
see 6.3 Continuity Measure- of the engine module connector [X240.12] No Check the RED, BLACK, and shield wires
ment Over Long Distances and terminal 13 of the ground module J7 con- between the engine module connector [X240]
on Pg. 247 nector [X007.13] and CAN LO continuity and the ground module J7 connector [X007]
between terminal 13 of the engine module
connector [X240.13] and terminal 24 of the
ground module J7 connector [X007.24]?
Step 15 Does the Chassis software version show "??" Yes Go to step 16
in ANALYZER  DIAGNOSTICS  VER- No Go to step 17
SIONS  CHASSIS MODULE SOFTWARE:??
Step 16 For help with this type of test Is there CAN HI continuity between terminal 6 Yes Check all CAN connections for moisture and bad
see 6.3 Continuity Measure- of the chassis module J1 connector [X229.6] connections
ment Over Long Distances and terminal 13 of the ground module J7 con- No Check the RED, BLACK, and Shield wires
on Pg. 247 nector [X007.13] and CAN LO continuity between the chassis module J1 connector
between terminal 7 of the chassis module J1 [X229], through the swivel [X083] [X216] and the
connector [X229.7] and terminal 24 of the ground module J7 connector [X007]
ground module J7 connector [X007.24]?
Step 17 Disconnect the platform Does the CAN resistance between platform Yes Go to step 18
module J7 connector module J7 connector pin 31 [X169.31.pin] No Replace the platform module
[X169] and pin 30 [X169.30.pin] measure 120?
Step 18 Disconnect the chassis Does the CAN resistance between of the chas- Yes Leave the chassis module disconnected and go
module J1 connector sis module J1 connector pin 6 [X229.6.pin] to step 19
[X229] and pin 10 [X229.10.pin] measure 120? No Replace the chassis module
Step 19 Disconnect the chassis Does the CAN resistance between chassis Yes Go to step 20
module J1 connector module J1 connector[X229.9.soc] socket 9 No Repair/Replace the Chassis harness or CAN ter-
[X229] and socket 10 [X229.10.soc] measure 0? mination jumper wire between chassis module
J1 connector socket 9 of the [X229.9.soc] and
socket 10 [X229.10.soc]
Step 20 Disconnect the Top Swivel Does the CAN resistance between Top Swivel Yes Go to step 21
connector [X083] connector socket 1 of the [X083.1.soc] and No Go to step 22
socket 2 [X083.2.soc] measure 120?
Step 21 Disconnect the Bottom Does the CAN resistance between Bottom Yes Repair the RED, BLACK, and/or Shield wires
Swivel connector [X216] Swivel connector socket 1 [X216.1.soc] and between the Bottom Swivel connector [X216]
socket 2 [X216.2.soc] measure 120? and the chassis module J1 connector [X229]
No Replace the Swivel
Step 22 Disconnect the BLAM mod- Does the CAN resistance between BLAM Yes Repair the RED, BLACK, and/or Shield wires
ule J1 connector [X086] module J1 connector socket 6 [X086.6.soc] between the Top Swivel connector [X083] and
and socket 7 [X086.7.soc] measure 120? the BLAM module J1 connector [X086]
No Repair the RED, BLACK, and/or Shield wires
between the ground module J7 connector [X007]
and the BLAM module J1 connector [X086]

3128411 1200SJP 1350SJP 1-49


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 6622 - CANBUS FAILURE - TCU MODULE


CAN bus failure - Telematics Communications Unit Module. The TCU cannot comunicate with ground module. Machine
Setup indicates that the Telematics system is installed, but there was no comunication from the gateway module for 30 sec-
onds.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is TCU fuse [X295] blown? Yes Replace fuse. Repeated blowing of fuse requires
repair of wire harness(es) or replacement of TCU.
No Go to step 2
Step 2 Read active DTC’s Is 6613 - CANBUS FAILURE - EXCESSIVE Yes Go to DTC 6613 - CANBUS FAILURE - EXCES-
CANBUS ERRORS or other DTC on a CAN SIVE CANBUS ERRORS on Pg. 55 or the respec-
device that is not an option active? tive DTC on other device first.
No Go to step 3.
Step 3 Read active DTC’s Is 6623 - CANBUS FAILURE - GATEWAY MOD- Yes Go to DTC 6623 - CANBUS FAILURE - GATEWAY
ULE? MODULE on Pg. 59.
No Go to step 4.
Step 4 Disconnect Telematics Is there 12 VDC between Telematics Commu- Yes Keep connector disconnected.
Communications Unit nication Unit connector socket 15 Go to step 5.
[X290]. Turn on machine. [X290.15.soc] and scoket 16 [X290.16.soc]? No Repair wire(s) between Telematics Communica-
tion Unit connector socket 15 [X290.15.soc]and
battery bus connector [X097] -AND- between
socket 16 [X290.16.soc] and ground bus con-
nector [X098].
Step 5 Disconnect Telematics Is there 12 VDC on Telematics Communica- Yes Go to step 7
Communication Unit tion Unit connector socket 23 [X290.23.soc]? No Go to step 6
[X290]. Do not turn on
machine. Ground meter.
See Grounding on Pg. 245
for details.
Step 6 Remove Telematics Com- Is there 12VDC on the contact closest to the Yes Repair RED 1-100-1 wire between fuse holder
munication Unit fuse [X295] MTB EMS? and Telematics Communication Unit
from holder. Do not turn on No Repair wire between fuse holder and battery side
unit. Ground meter. of MTB EMS.
Step 7 Disconnect telematics com- Is there 60 Ohms between telematics com- Yes Go to step8
munication unit connector munication unit connector socket 7 No Keep connector disconnected.
[X290]. [X290.7.soc] and socket 22 [X290.22.soc]? Go to step 10
Step 8 Disconnect gateway mod- Is there 60 Ohms between gateway module Yes Go to step 9
ule gray connecor [X287]. black connector socket ? No Repair wire(s) between Telematics Communica-
tion unit black connector and Gateway CAN 3way
connector X291.
Step 9 Disconnect gateway mod- Gateway module black connector socket 3 Yes Reprogram/replace telematics communication
ule black connector [X288] [X288.3.soc] should have continuity to TCU unit [X290].
and TCU CAN 3way to TCU CAN 3way to TCU pin C [X293.C.pin]? -AND- No Repair wire as needed.
[X293]. Pin C [X293.C.pin] should be open to both pin
A [X293.A.pin] and pin B [X293.B.pin] .
Are measurements correct?
Step 10 Disconnect telematics Is there 120 Ohms between telematics com- Yes Keep TCU CAN 3 way to harness [X294] discon-
communication unit con- munication unit connector socket 7 nected. Go to step 12
nector [X290] and TCU CAN [X290.7.soc] and socket 22 [X290.22.soc]? No Keep telematics communication unit connector
3way to harness [X294]. [X290] disconnected. Go to step 11

1-50 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 11 Disconnect telematics Is there continuity between telematics com- Yes Repair/replace TCU CAN 3 way and/or resistor
communication unit con- munication unit connector socket 7 No Repair/replace wire(s) without continuity.
nector [X290] and TCU CAN [X290.7.soc] to TCU CAN 3 way to TCU
3way to TCU [X293]. socket A [X293.A.soc]?
Step 12 Disconnect TCU CAN 3 way There should be continuity be tween TCU CAN Yes Go to step 13
to harness [X294] and Gate- 3 way to harness connector socket A No Repair bad wire(s)
way CAN 3 way to Harness [X294.A.soc] to Gateway CAN 3 way to Har-
connector [X292]. ness socket A [X292.A.soc] and open to the
other terminals. Check terminals B and C the
same way.
Are measurements correct?
Step 13 Disconnect gateway mod- There should be continuity be tween Gateway Yes Repair/replace Gateway CAN 3 way to Gateway
ule gray [X287] and black CAN 3 way to gateway connector socket A [X291]
[X288] connectors. Also, [X291.A.soc] to gateway module gray con- No Repair bad wire(s)
disconnect Gateway CAN 3 nector socket 8 [X287.8.soc] and open to the
way to Gateway [X291]. other terminals. There should be continuity be
tween Gateway CAN 3 way to Gateway con-
nector socket A [X291.B.soc] to gateway
module gray connector socket 7 [X287.7.soc]
and open to the other terminals. There should
be continuity be tween Gateway CAN 3 way to
Gateway connector socket A [X291.C.soc] to
gateway module black connector socket 3
[X288.3.soc] and open to the other terminals.
Are measurements correct?

DTC 6623 - CANBUS FAILURE - GATEWAY MODULE


CAN bus failure - Gateway Module. Telematics gateway module cannot comunicate with ground module. Machine Setup
indicates Telematics system is installed, but there was no comunication from the gateway module for 30 seconds.

Note Pretest Instructions Test Result Corrective Action


Step 1 Read active faults Is the fault DTC 6613 - CANBUS FAILURE - Yes Go to DTC 6613 - CANBUS FAILURE - EXCES-
EXCESSIVE CANBUS ERRORS or other fault SIVE CANBUS ERRORS on Pg. 55 or the respec-
on a CAN device that is not an option active? tive fault on other device first.
No Go to step 3.
Step 2 Disconnect gateway mod- Is there 12 VDC between socket 12 Yes Keep connector disconnected.
ule gray connector [X287]. [X287.12.soc] and socket 11 [X287.11.soc]? Go to step 3.
Turn on machine. No Repair wire(s) between gateway module gray
connector socket 11 [X287.11.soc] and ground
bus [X098]; and/or between gateway module
gray connector socket 12 [X287.12.soc]and
battery bus connector [X097].
Step 3 Disconnect gateway mod- Is there 60 Ohms between socket 9 Yes Reprogram/replace gateway module
ule gray connector [X287]. [X287.9.soc] and socket 10 [X287.10.soc]? No Go to step 4

3128411 1200SJP 1350SJP 1-51


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 4 Disconnect gateway mod- Is there continuity between gateway module Yes Go to DTC 6610 - CANBUS FAILURE - BLAM on
ule gray connector [X287] gray connector socket 10 [X287.10.soc]and Pg. 48.
and the two connectors on both "A" terminals at the connectors discon- No Repair wire(s) without continuity.
the same harness, T-ed in at nected from the CAN passthru to the Engine
the CAN passthru to Engine harness [X279.A]? -AND- Is there continuity
Hns [X279]. between [X287.9] and both B terminals
[X279.B]? -AND- Is there continuity between
both C terminals [X279.C].

DTC 6629 - TELEMATICS CANBUS LOADING TOO HIGH


The Telematics Gateway Module has detected CAN message traffic levels that are too high. Communications between the
machine and the telematics system are restricted. This DTC will stay active at least until a power cycle.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any other CAN bus DTC’s? Yes Troubleshoot those first.
No Go to Step 2
Step 2 Cycle power. Did DTC clear? Yes Troubleshooting complete
No Call JLG

DTC 681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP


The control system has received a command to disable the machine from the Telematics control center. This condition
remains in effect until the enable command is received from the Telematics control center. Call the control center to send the
enable signal.

DTC 813 - CHASSIS TILT SENSOR NOT CALIBRATED


Chassis tilt sensor not calibrated. Notification that the chassis tilt sensor calibration information has been lost. Machine will
indicate that it is tilted at all times. Perform tilt calibration. See 5.6 Calibrating Tilt Sensor on Pg. 221.

DTC 815 - CHASSIS TILT SENSOR DISAGREEMENT


Chassis tilt sensor disagreement. Reserved for future use. Should not occur on current machine.

Note Pretest Instructions Test Result Corrective Action


Step 1 Go to ANALYZER  Are parameters and configuration set properly Yes Go to Step 2 .
MACHINE SETUP in Machine Setup? No Reprogram/replace ground module
Step 2 Reprogram ground module. Does fault clear? Yes Troubleshooting complete
No Reprogram/replace ground module

DTC 825 - LSS HAS NOT BEEN CALIBRATED


Load sensor not calibrated. The load sense system (LSS) sensors require calibration. See the calibration procedure in the
LSS manual for more details.

DTC 826 - RUNNING AT CREEP - PLATFORM OVERLOADED


Running at creep - platform overloaded. Reported when the platform is overloaded, causing the machine to be in creep
mode. Only displayed when the load sensor machine configuration is set to WARN ONLY.

1-52 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED


Drive & boom prevented - platform overloaded. Only applies to machines configured with platform load sensing. Drive and
boom functions will be prevented while the platform is overloaded.

DTC 828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED


Lift up & telescope out prevented - platform overloaded. Notification that the machine is configured with load system cut-
outs, the platform is overloaded, and lift up or tele out is selected. Lift up and telescope out are prevented while the platform
is overloaded.

DTC 831 - PLATFORM LEVELING OVERRIDE ON


Platform leveling override on. This fault only applies to service access levels. Notification that the user has forced platform
leveling on.

DTC 832 - PLATFORM LEVELING OVERRIDE OFF


Platform leveling override off. This fault only applies to service access levels. Notification that the user has forced platform
leveling off.

DTC 833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED


Platform leveling crackpoint up not calibrated. The control system detected there was no stored calibration data for the plat-
form leveling up valve current crackpoint. This could be due to installing a new ground module that has not yet been cali-
brated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic platform
leveling will be disabled. Platform leveling can still be performed manually, but the PLATFORM LEVELING SYSTEM TIME-
OUT fault will still be enabled. Complete a level up crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217

Note Pretest Instructions Test Result Corrective Action


Step 1 Run a system test Are there any platform leveling sensor faults? Yes Troubleshoot those faults first.
No Go to step 2
Step 2 Complete a level up crackpoint calibration, see Yes Troubleshooting complete
5.5 Calibrating Platform Level on Pg. 217. Did No Go to step 3
it complete successfully?
Step 3 Install a high pressure gauge Activate level up to end of stroke. Does gauge Yes Go to step 4
on port M1 of the platform read or adjust to about 2500 psi? No Keep machine in same condition.
valve. Start engine. Go to step 5.
Step 4 Remove hose from platform Start engine. Activate level down. Does pres- Yes Repair/replace level circuit check valve
valve port L2. - Cap port L2. sure on gauge read about 2500 psi? No Repair/replace level cylinder holding valve.
Install a high pressure gauge
on end of hose.
Step 5 Install a high pressure gauge Activate level down to end of stroke. Does Yes Go to step 8
on port MP of the platform gauge read about 3400psi? No Go to step 6
valve. Start engine.
Step 6 Install a high pressure gauge Activate level down to end of stroke. Does Yes Unclog/repair/replace pressure filter at the plat-
on port MP of the main valve. gauge read about 3400psi? form and/or hose from main valve port P3 to plat-
Start engine. form valve port P.
No Keep machine in same condition.
Go to step 7.

3128411 1200SJP 1350SJP 1-53


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Install a high pressure gauge Activate level down to end of stroke. Adjust Yes Inspect/repair/replace hydraulics between main
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3- valve and platform valve, including filter at plat-
Start engine. 2. Pumps Layout on Pg. 164 for location. Can form valve.
it be adjusted to proper pressure? No Repair/replace function pump and/or high pres-
sure relief
Step 8 Start engine. Do the other platform functions operate? Yes Go to step 10
No Go to step 9
Step 9 Turn off machine. Discon- Does the platform dump solenoid [X135] Yes Clean/repair/replace platform dump valve [X135]
nect platform dump sole- measure about 6.4 ? cartridge.
noid [X135]. No Replace platform dump solenoid [X135]
Step 10 In the platform valve, swap cartridge common Yes Repair/replace cartridge that was originally
to level up solenoid [X136] and level down installed common to level up solenoid [X136] and
solenoid [X135] with the cartridge common to level down solenoid [X135]
rotate right [X138] and rotate left [X139]. Does No Go to step 11
the crackpoint calibrate?
Step 11 Cap platform valve port L2 Operate level up to end of stroke. Adjust pres- Yes Repair/replace platform level cylinder
and its hose. Install a high sure of the platform level down relief for No Repair/replace platform level up relief
pressure gauge in port M2. 2500psi. See Figure 3-3. Platform Valve Lay-
Start engine. out on Pg. 165 for location. Does gauge read
the proper pressure?

DTC 834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED


Platform leveling crackpoint down not calibrated. The control system detected there was no stored calibration data for the
platform leveling down valve current crackpoint. This could be due to installing a new ground module that has not yet been
calibrated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic plat-
form leveling will be disabled. Platform leveling can still be performed manually, but the PLATFORM LEVELING SYSTEM
TIMEOUT fault will still be enabled. Complete a level down crackpoint calibration, see 5.5 Calibrating Platform Level on Pg.
217

Note Pretest Instructions Test Result Corrective Action


Step 1 Run a system test Are there any platform leveling sensor faults? Yes Troubleshoot those faults first.
No Go to step 2
Step 2 Complete a level down crackpoint calibration, Yes Troubleshooting complete
see 5.5 Calibrating Platform Level on Pg. 217. No Go to step 3
Did it complete successfully?
Step 3 Install a high pressure gauge Activate level down to end of stroke. Does Yes Go to step 4
on port M2 of the platform gauge read or adjust to about 1500 psi? No Keep machine in same condition.
valve. Start engine. Go to step Step 5 .
Step 4 Remove hose from platform Start engine. Activate level down. Does pres- Yes Repair/replace level circuit check valve
valve port L1. - Cap port L1. sure on gauge read about 1500 psi? No Repair/replace level cylinder holding valve.
Install a high pressure gauge
on end of hose.
Step 5 Install a high pressure gauge Activate level down to end of stroke. Does Yes Go to step 8
on port MP of the platform gauge read about 3400psi? No Go to step 6
valve. Start engine.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Install a high pressure gauge Activate level down to end of stroke. Does Yes Unclog/repair/replace pressure filter at the plat-
on port MP of the main valve. gauge read about 3400psi? form and/or hose from main valve port P3 to plat-
Start engine. form valve port P.
No Keep machine in same condition.
Go to step 7.
Step 7 Install a high pressure gauge Activate level down to end of stroke. Adjust Yes Inspect/repair/replace hydraulics between main
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3- valve and platform valve, including filter at plat-
start engine. 2. Pumps Layout on Pg. 164 for location. Can form valve.
it be adjusted to proper pressure? No Repair/replace function pump and/or high pres-
sure relief
Step 8 Start engine. Do the other platform functions operate? Yes Go to step 10
No Go to step 9
Step 9 Turn off machine. Discon- Does the platform dump solenoid [X135] Yes Clean/repair/replace platform dump valve [X135]
nect platform dump sole- measure about 6.4 ? cartridge.
noid [X135]. No Replace platform dump solenoid [X135]
Step 10 In the platform valve, swap cartridge common Yes Repair/replace cartridge that was originally
to level up solenoid [X136] and level down installed common to level up solenoid [X136] and
solenoid [X135] with the cartridge common to level down solenoid [X135]
rotate right [X138] and rotate left [X139]. Does No Go to step 11
the crackpoint calibrate?
Step 11 Cap platform valve port L2 Operate level down to end of stroke. Adjust Yes Repair/replace platform level cylinder
and its hose. Install a high pressure of the platform level down relief for No Repair/replace platform level down relief
pressure gauge in port M2. 1500psi. See Figure 3-3. Platform Valve Lay-
Start engine. out on Pg. 165 for location. Does gauge read
the proper pressure?

DTC 837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY


Platform leveling sensor 1 short to battery. The platform module J1 right platform level sensor communication terminal
[X016.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT


Platform leveling sensor 1 short to ground or open circuit. The platform module J1 right platform level sensor communication
terminal [X016.25] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY


Platform leveling sensor 2 short to battery. The platform module J1 left platform level sensor communication terminal
[X016.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT


Platform leveling sensor 2 short to ground or open circuit. The platform module J1 left platform level sensor communication
terminal [X016.26] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE


Platform leveling tilt reference 1 out of range. Platform J7, terminal 11 [X169.11] is reading outside of the expected range of
4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is
present only in software before version P7.0.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Is fault still present? Yes Go to step 2
No Troubleshooting complete
Step 2 Inspect harness and at platform module J7. Is Yes Repair/replace harness
there a wire or short to terminal 11 [X169.11]? No Reprogram/replace platform module

DTC 8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE


Platform leveling tilt reference 2 out of range. Platform J7, terminal 12 [X169.12] is reading outside of the expected range of
4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is
present only in software before version P7.0.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Is fault still present? Yes Go to step 2
No Troubleshooting complete
Step 2 Inspect harness and at platform module J7. Is Yes Repair/replace harness
there a wire or short to terminal 12 [X169.12]? No Reprogram/replace platform module

DTC 8315 - PLATFORM LEVELING SENSOR - DISAGREEMENT


Platform leveling tilt sensors disagree. The platform leveling tilt readings from platform tilt sensor #1 and #2 both appear to
be good, but their measurements are not within 5.0° of each other. This value is programmable. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any other platform leveling faults? Yes Troubleshoot them first
No Go to step 2
Step 2 Are both sensors mounted properly and Yes Go to step 3
securely? No Repair as needed
Step 3 Disconnect platform level Turn on machine. Does the PLATFORM LEV- Yes Go to step 4
sensor #1 (Right) [X150] ELING TILT SENSOR 1 COMMUNICATIONS No Wires to wrong sensor. Swap harness connec-
LOST fault appear? tions and ensure they attach to the correct sen-
sor.
Step 4 Perform 5.5 Calibrating Does it calibrate successfully? -AND- Does Yes Troubleshooting complete
Platform Level on Pg. 217. fault clear? No Replace both platform level sensors, #1 [X148]
(There is also helpful infor- and #2 [X150]
mation in section 5.4 Elec-
tronic Platform Leveling on
Pg. 214.)

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST


Platform leveling tilt sensor 1 communications lost. The control system lost serial communications with platform tilt angle
sensor #1 (right). A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is harness from platform level sensor 1 [X150] Yes Go to step 2
plugged into the platform level passthru 1 No Correct wiring
[X162]? Also, are those connections in good
condition?
Step 2 Check the faults. Is the fault PLATFORM LEVELING TILT SEN- Yes Go to step 9
SOR 2 COMMUNICATIONS LOST active? No Go to step 3
Step 3 Plug platform level sensor 2 Does the PLATFORM LEVELING TILT SEN- Yes Replace original platform level sensor 1 (RIGHT)
(left) [X148] into connector SOR 1 COMMUNICATIONS LOST fault clear? [X150]
for platform level sensor 1 No Go to step 4
(right) [X150]
Step 4 Disconnect platform level Measure voltage between platform level sen- Yes Go to step 5
sensor 1 [X150]. Turn on sor 1 pin1[X150.1.pin] and pin 3 No Go to step 7
machine. [X150.3.pin]. Does it measure about 12VDC?
Step 5 Disconnect platform level Is there continuity between platform level sen- Yes Replace platform level sensor 1 [X150]
sensor 1 [X150] and plat- sor 1 pin 2 [X150.2.pin] and platform module No Go to step 6
form module J1 J1 socket 25 [X165.25.soc]?
Step 6 Disconnect platform level Is there continuity between platform level Yes Repair/replace harness between platform level
passthru 1 [X162] and plat- passthru 1 pin 2 [X162.2.pin] and platform passthru 1 [X162] and platform level sensor 1
form module J1 [X165] module J1 socket 25 [X165.25.soc]? [X150]
No Repair/replace harness between platform level
passthru 1 [X162] and platform module J1
[X165]
Step 7 Disconnect platform module Turn on machine. Measure voltage between Yes Go to step 8
J2 [X166]. Ground meter. platform module J2 pin 32 [X166.32] and No Replace platform module
See Grounding on Pg. 245 ground. Does it measure about 12VDC?
for details.
Step 8 Disconnect platform level Measure voltage between platform level Yes Repair/replace harness between platform level
passthru 1 [X162]. Turn on passthru 1 pin 1 [X162.1.pin] and pin 3 passthru 1 [X162] and platform level sensor 1
machine. [X162.3.pin]. Does it measure about 12VDC? [X150]
No Repair/replace harness between platform level
passthru 1 [X162] and platform module J7
[X169] and/or J1 [X165]
Step 9 Take the following measure- Is there about 12 VDC between platform mod- Yes Go to step 10
ment by backprobing. See ule J2 terminal 32 [X166.32] and platform No Replace platform module
Backprobing on Pg. 245 for module J7 terminal 21 [X169.21]?
details.
Step 10 Turn on machine. Measure voltage between platform level sen- Yes Go to step 12
sor 1 pin 1 [X150.1.pin] and pin 3 No Go to step 11
[X150.3.pin]. Also, between platform level
sensor 2 pin 1 [X148.1.pin] and pin 3
[X148.3.pin]. Do they measure about 12
VDC?

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 11 Turn on machine. Discon- Measure voltage between platform level Yes Repair/replace harness between the platform
nect platform level passthru passthru pin 1 [X162.1.pin] and pin 3 level sensor and platform level passthru connec-
1 [X162] and platform level [X162.3.pin]. Also, measure voltage between tor that did not have the proper voltage.
passthru 2 [X163] platform level passthru 2 pin 1 [X163.1.pin] No Repair/Replace harness between the platform
and pin 3 [X163.3.pin]. Do they measure level passthru connector +1 [X162] and 2
about 12 VDC? [X163] and the platform module connector J1
[X165] that did not have the proper voltage.
Step 12 Disconnect platform level Is there continuity between platform level Yes Go to step 13
passthru 1 [X162] and plat- passthru 1 pin 3 [X162.3.pin] and ground? No Repair/replace harness between platform mod-
form level passthru 2 Also, is there continuity between platform level ule J7 [X169] and the connectors platform level
[X163]. Ground meter. passthru 2 pin 3 [X163.3.pin] and ground? passthru 1 [X162] and platform level passthru 2
[X163].
Step 13 Disconnect platform level Is there continuity between platform level sen- Yes Replace both platform level sensors
sensor 1 [X150] and plat- sor 1 pin 3 [X150.3.pin] and ground. Also, is No Repair/replace harness(es) that did not have con-
form level sensor 2 [X148]. there continuity between platform level sensor tinuity.
Ground meter. 2 pin 3 [X148.3.pin] and ground.

DTC 8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST


Platform leveling tilt sensor 2 communications lost. The control system lost serial communications with platform tilt angle
sensor #2 (Left).

Note Pretest Instructions Test Result Corrective Action


Step 1 Is harness from platform level sensor 2 [X148] Yes Go to step 2
plugged into the platform level passthru 2 No Correct wiring
[X163]? Also, are those connections in good
condition?
Step 2 Check the faults. Is the fault PLATFORM LEVELING TILT SEN- Yes Go to step 9
SOR 1 COMMUNICATIONS LOST active? No Go to step 3
Step 3 Plug platform level sensor 1 Does the PLATFORM LEVELING TILT SEN- Yes Replace original platform level sensor 2 (left)
(right) [X150] into connec- SOR 2 COMMUNICATIONS LOST fault clear? [X148]
tor for platform level sensor No Go to step 4
2 (left) [X148]
Step 4 Disconnect platform level Measure voltage between platform level sen- Yes Go to step 5
sensor 2 (left) [X148]. Turn sor 2 pin1[X148.1.pin] and pin 3 No Go to step 7
on machine. [X148.3.pin]. Does it measure about 12VDC?
Step 5 Disconnect platform level Is there continuity between platform level sen- Yes Replace platform level sensor 2 (left) [X148]
sensor 2 (left) [X148] and sor 1 pin 2 [X148.2.pin] and platform module No Go to step 6
platform module J1 J1 socket 26 [X165.26.soc]?
Step 6 Disconnect platform level Is there continuity between platform level Yes Repair/replace harness between platform level
passthru 2 [X163] and plat- passthru 2 pin 5 [X163.5.pin] and platform passthru 2 [X163] and platform level sensor 2
form module J1 [X165] module J1 socket 26 [X165.26.soc]? (LEFT) [X148]
No Repair/replace harness between platform level
passthru 2 [X163] and platform module J1
[X165]
Step 7 Disconnect platform module Turn on machine. Measure voltage between Yes Go to step 8
J2 [X166]. Ground meter. platform module J2 pin 32 [X166.32] and No Replace platform module
See Grounding on Pg. 245 ground. Does it measure about 12VDC?
for details.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 8 Disconnect platform level Measure voltage between platform level Yes Repair/replace harness between platform level
passthru 1 [X162]. Turn on passthru 1 pin 1 [X162.1.pin] and pin 3 passthru 1 [X162] and platform level sensor 1
machine. [X162.3.pin]. Does it measure about 12VDC? [X150]
No Repair/replace harness between platform level
passthru 1 [X162] and platform module J7
[X169] and/or J1 [X165]
Step 9 Take the following measure- Is there about 12 VDC between platform mod- Yes Go to step 10
ment by backprobing. See ule J2 terminal 32 [X166.32] and platform No Replace platform module
Backprobing on Pg. 245 for module J7 terminal 21 [X169.21]?
details.
Step 10 Turn on machine. Measure voltage between platform level sen- Yes Go to step 12
sor 1 pin 1 [X150.1.pin] and pin 3 No Go to step 11
[X150.3.pin]. -AND- measure voltage
between platform level sensor 2 pin 1
[X148.1.pin] and pin 3 [X148.3.pin]. Do they
measure about 12 VDC?
Step 11 Turn on machine. Discon- Measure voltage between platform level Yes Repair/Replace harness between the platform
nect platform level passthru passthru pin 1 [X162.1.pin] and pin 3 level sensor and platform level passthru connec-
1 [X162] and platform level [X162.3.pin]. -AND- measure voltage tor that did not have the proper voltage.
passthru 2 [X163] between platform level passthru 2 pin 1 No Repair/Replace harness between the platform
[X163.1.pin] and pin 3 [X163.3.pin]. Do they level passthru connector 1 [X162] and 2 [X163]
measure about 12 VDC? and the platform module connector J1 [X165]
that did not have the proper voltage.
Step 12 Disconnect platform level Is there continuity between platform level Yes Go to step 13
passthru 1 [X162] and plat- passthru 1 pin 3 [X162.3.pin] and ground? No Repair/replace harness between platform mod-
form level passthru 2 -AND- Is there continuity between platform ule J7 [X169] and the connectors platform level
[X163]. Ground meter. level passthru 2 pin 3 [X163.3.pin] and passthru 1 [X162] and platform level passthru 2
ground? [X163].
Step 13 Disconnect platform level Is there continuity between platform level sen- Yes Replace both platform level sensors
sensor 1 [X150] and plat- sor 1 pin 3 [X150.3.pin] and ground. No Repair/replace harness(es) that did not have con-
form level sensor 2 [X148]. -AND- Is there continuity between platform tinuity.
Ground meter. level sensor 2 pin 3 [X148.3.pin] and ground.

DTC 8318 - PLATFORM LEVELING SYSTEM TIMEOUT


Platform leveling system time-out. The control system detected the platform tilt angle was not within 5.0° of the setpoint for at
least 2 seconds while out of transport or for at least 15 seconds while in the transport position. These values are program-
able. This fault can happen when driving too fast over abrupt terrain changes because the platform leveling system cannot
respond fast enough. Platform operations will be disabled.

Note Pretest Instructions Test Result Corrective Action


Step 1 Examine active faults Are there any other platform leveling faults? Yes Troubleshoot those first
No Go to step 2
Step 2 Does the fault only occur when driving over Yes Drive slower. If fault still occurs, go to step 3
changing terrain? No Go to step 3
Step 3 Are the mounting blocks for both sensors Yes Go to step 4
properly assembled? -AND- Is the hardware No Repair as needed
tight?

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 4 Disconnect platform level Is the fault PLATFORM LEVELING TILT SEN- Yes Go to step 5
sensor #1 (Right) connec- SOR 1 COMMUNICATIONS LOST now an No Connections are swapped. Make proper harness
tor [X150] active fault? connections to sensors.
Step 5 Does the platform move slowly or not at all Yes Perform platform leveling calibration. See 5.5
when commanded? Calibrating Platform Level on Pg. 217. If this does
not fix problem go to step 6
No Go to step 6
Step 6 Do the other platform functions operate? Yes Go to step 10
No Go to step 7
Step 7 Install a high pressure gauge Activate level down to end of stroke. Does Yes Go to step 9
on port MP of the platform gauge read about 3400psi? No Go to step 8
valve. Start engine.
Step 8 Install a high pressure gauge Activate level down to end of stroke. Adjust Yes Inspect/repair/replace hydraulics between main
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3- valve and platform valve, including filter at plat-
Start engine. 2. Pumps Layout on Pg. 164 for location. Can form valve.
it be adjusted to proper pressure? No Repair/replace function pump and/or high pres-
sure relief
Step 9 Turn off machine. Discon- Does the platform dump solenoid [X135] Yes Clean/repair/replace platform dump valve [X135]
nect platform dump sole- measure about 6.4 ? cartridge.
noid [X135]. No Replace platform dump solenoid [X135]
Step 10 Turn off machine. Discon- Do both solenoids measure 10.1? Yes Go to step 11
nect platform level UP No Replace platform level valve coil [X136] [X137]
[X136] and level DOWN
[X137].
Step 11 Take cartridge from platform Does problem clear or move? Yes Replace cartridge originally in the platform level
level valve [X136] [X137] valve [X136] [X137].
and swap it with the one in No Go to step 12
the jib swing valve [X140]
[X141]
Step 12 Install a high pressure gauge Activate level down to end of stroke. Does Yes Repair/replace 75psi check valve and/or level
on ports M1 and M2 of the pressure measure or adjust to about 1500 cylinder assembly
platform valve. Start engine. psi? Also, activate level up to end of stroke. No Repair/replace relief valve that does not produce
Does pressure measure or adjust to about proper pressure.
2500 psi?

DTC 841 - BOOM ANGLE SENSOR DISAGREEMENT


The control system detected a difference in angle measurements from the Boom Angle Sensors of greater than 2.5 for
longer than 2 seconds.

Note Pretest Instructions Test Result Corrective Action


Step 1 Connect Analyzer. Read Are there another Boom Angle Sensor faults? Yes Troubleshoot those first.
active faults. (Logged faults No Go to step 2
before power cycle.)
Step 2 Put boom in transport posi- Do the readings on the machine approximately Yes Keep ANALYZER connected.
tion. Navigate to ANALYZER agree with the following? Go to step 4
 ACCESS LEVEL 1  • MAIN LIFT 1 ANGLE A/D: -38.7 No Go to step 3
DIAGNOSTICS  ENVE- • MAIN LIFT 2 ANGLE A/D: -38.9
LOPE • MAIN LIFT 1 ANGLE: -1.1
• MAIN LIFT 2 ANGLE: -1.0

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Calibrate boom sensors. Do sensors calibrate successfully? Yes Troubleshooting complete
See 5.9 Calibrating the No Troubleshoot according to calibration fault
Boom Sensors on Pg. 228.
Step 4 Is the fault BOOM ANGLE SENSOR 2# COM- Yes Sensor wires are swapped. Connect harnesses
Turn off vehicle. Disconnect MUNICATIONS FAULT active? to proper sensors.
Boom Angle Sensor 1. Con- No Go to step 5
nect Analyzer. Turn on vehi-
cle.
Step 5 Observe MAIN LIFT 1 ANGLE A/D value while Yes Repeat test several times. If no bad behavior is
Navigate to ANALYZER  slowly raising and lowering boom. The value observed calibrate and go to step.3
ACCESS LEVEL 1  DIAG- should change smoothly and consistently No Replace sensor that exhibits bad behavior.
NOSTICS  ENVELOPE. without jumping or stopping. Does it?
Repeat for sensor MAIN LIFT 2 ANGLE A/D.

DTC 842 - BOOM LENGTH SWITCH FAILED


Boom Length Switch Failed. Both Boom Length (Transport) Limit Switches show same state, when they should be reading
opposite.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is Boom Length Limit Switch [X281] jammed, Yes Repair as needed
obstructed, loose or mounted incorrectly? No Go to step 2
Also, is the switch prevented from properly
contacting the boom?
Step 2 Disconnect Boom Transport Check continuity between Boom Transport Yes Leave Boom Transport Switch Passthru [X017]
Switch Passthru [X017] Switch Passthru socket 1 [X017.1.soc] and disconnected.
both socket 2 [X017.2.soc] and socket 6 Go to step 3
[X017.6.soc]. One measurement should have No Leave Boom Transport Switch Passthru [X017]
continuity and the other should not. Operate disconnected.
the limit switch arm 90 to the opposite Go to step 4
switched position and measure again. These
measurements should be opposite to previous
measurements. Are measurements proper?
Step 3 Disconnect Boom Transport Is there continuity between all of the follow- Yes Replace Ground Module
Switch Passthru [X017] and ing? Boom Transport Switch Passthru pin 1 No Repair/Replace wire that did not have continuity.
Ground Module J7 [X007] [X017.1.pin] to Ground Module J7 pin socket
29 [X007.29.pin];
[X017.2.pin] to [X007.11.soc]; and
[X017.6.pin] to [X007.35.soc]
Step 4 Disconnect Boom Transport Is there continuity between all of the follow- Yes Replace Boom Transport Switch [X281]
Switch Passthru [X017] and ing? Boom Transport Switch Passthru socket No Repair/Replace wire that did not have continuity.
gain access wires inside 1 [X017.1.soc] to both Boom Length Limit
Boom Length Limit Switch Switch terminal 14 [X281.14] and terminal 22
[X281] [X281.22];
[X017.2.soc] to [X281.21]
[X017.6.soc] to [X281.13]

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENT


Boom Length Switch/Sensor Disagreement. The control system did not detect a change in the boom length switch at the
calibrated point. This could be a problem with the Boom Length Sensor or Boom Length Limit Switch, or the boom sensor
calibration.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is Boom Length Limit Switch [X281] jammed, Yes Repair as needed
obstructed, loose or mounted incorrectly? No Go to step 2
Step 2 Is the Boom Length Sensor [X273] jammed, Yes Repair as needed
obstructed, loose, have cable stuck or No Goo to step 3
mounted incorrectly?
Step 3 Is there a Boom Length Sensor or Boom Yes Troubleshoot those first
Check active faults (before Length Limit Switch fault present? No Go to step 4
first power cycle)
Step 4 Calibrate boom sensors. See 5.9 Calibrating Yes Troubleshooting complete
the Boom Sensors on Pg. 228. Does machine No Troubleshoot in accordance with calibration
calibrate without faults? fault.

DTC 844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE


Boom Length Sensor Not Detecting Length Change. The control system has not detected a minimum change in length while
the user commanded telescope. The minimum change is 0.3" over 3 seconds when command is at least 45%. This fault
check is enabled when the boom is greater than 5 inches from the maximum or minimum mechanical length. An EMS cycle
is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Have swing, lift, telescope, and platform func- Yes Go to step 17
tions stopped operating? No Go to step 2
Step 2 Check active faults. (Fault Are there any other Boom Length sensor Yes Troubleshoot those first
log before power cycle.) faults? No Go to step 3
Step 3 Examine the electrical connections at the Yes Clean or replace any bad connections
boom length sensor [X273], Boom Length No Go to step 4
Sensor Passthru [X272] and BLAM module J3
connector [X088]. Are there any loose con-
nections, moisture or corrosion?
Step 4 Is the boom length sensor [X273] properly Yes Go to step 5
mounted to the machine. -AND- Is the sensor No Remount/repair sensor, etc.
cable free to move with boom?
Step 5 Extend boom completely Apply lubricant to wear pad tracks on booms. Yes Troubleshooting complete
Move boom in and out completely. Does fault No Go to step 6
clear?
Step 6 Raise and extend boom. Does boom retract without command? Yes Keep test setup in place.
Plug main valve port 8. Go to step 7
No Go to step 8
Step 7 Raise and extend boom. Does fluid flow from hose previously in port 8? Yes Replace telescope cylinder port block
Plug main valve port 8. No Replace telescope cylinder piston seal
Step 8 Torque boom wire ropes per procedure. See Yes Troubleshooting complete
5.10 Wire Rope Tensioning Procedure on Pg. No Go to step 9
240. Does fault clear?

1-62 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 9 Connect a 5000 psi pres- Adjust the low pressure relief on the function Yes Keep gauge installed. Make note of results.
sure gauge to MP port on the pump until gauge reads 400 psi. See Figure 3- Go to step 10.
main valve manifold 2. Pumps Layout on Pg. 164 for location. Can No Replace function pump compensating valve.
adjustment be made to correct pressure?
Step 10 Connect a 5000 psi pres- While activating main telescope in, adjust the Yes Keep gauge connected. Make note of results.
sure gauge to MP on the high pressure relief on the function pump till Go to step 12
main valve manifold. the gauge reads 3400 psi. See Figure 3-2. No Go to step 17
Remove the solenoid from Pumps Layout on Pg. 164 for location. Can
the main tele proportional adjustment be made to correct pressure?
valve.
Step 11 Remove Main Tele Extend Measure resistances. Do they both measure Yes Replace Main Tele Extend/Retract valve cartridge
[X071] and Main Tele about 5 Ohms? No Replace Main Tele Extend/Retract coil.
Retract [X073] connectors
Step 12 Connect a 5000 psi pres- Activate telescope out. Does pressure read or Yes Make note of results.
sure gauge to M8 on the adjust to 3000 psi? See Figure 3-1. Main Valve Go to step 13
main valve manifold. Cap Layout on Pg. 163 for location of extend pres- No Make note of results.
the hose and port on port 8. sure adjustment. Go to step 13
Step 13 Connect a 5000 psi pres- Activate telescope in. Does pressure read or Yes Make note of results
sure gauge to M7 on the adjust to 3200psi? See Figure 3-1. Main Valve Go to step 14
main valve manifold. Cap Layout on Pg. 163 for location of retract pres- No Make note of results
the hose and port on port 7. sure adjustment. Go to step 14
Step 14 Did ONE of either M7 or M8 fail to adjust to Yes Replace relief that did not adjust to proper pres-
pressure listed above? sure.
No Go to step 15
Step 15 Did both M7 and M8 pressures fail to adjust to Yes Go to step 16
pressures above No Go to step 6
Step 16 Swap Tele proportional Does fault move? Yes Replace cartridge originally in Tele proportional
valve [X072] cartridge with valve [X072]
the Lift proportional [X286] No Go to step 17
cartridge.
Step 17 Disconnect main dump Measure resistance. Is coil resistance about 5 Yes Go to step 18
[X074] Ohms? No Replace main dump coil.
Step 18 On main valve, cap port B Activate telescope in. Does pressure read or Yes Keep test setup in place.
and P2 (to aux pump). Install adjust to 3400 psi with high pressure relief? Go to step 19
5000psi gauge on MP port No Go to step 20
and.
Step 19 Remove cap from port B and Activate telescope in. Does pressure read or Yes Repack/reseal swivel
restore connection. adjust to 3400psi with high pressure relief? No Replace check valve in aux pump.
Step 20 Replace main dump car- Does fault clear? Yes Troubleshooting complete
tridge. No Replace function pump compensating valve.

3128411 1200SJP 1350SJP 1-63


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGH


Boom Length Sensor Out of Range High. The control system reads a boom length greater than 1480.9" for the 1350 or
1294.4" for the 1200. This could be caused by a mechanical problem with the sensor or cable, the sensor ground wire being
broken, or a sensor failure.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the boom length sensor [X273] securely Yes Go to step 2
mounted to the machine and is cable free to No Repair as needed
move?
Step 2 Disconnect boom length Does the boom length sensor connector Yes Repair as needed
sensor [X273] [X273] have moisture, damage or corrosion? No Keep boom length sensor [X273] disconnected.
Go to step 3
Step 3 Turn on machine. Discon- Is there about 5VDC between boom length Yes Go to step 6.
nect boom length sensor sensor socket A [X273.A.soc] and socket B No Keep machine in same state. Go to step 4
[X093] [X273.B.soc]?
Step 4 Turn on machine. Discon- Is there about 5VDC between BLAM J 3 pin 7 Yes Go to step 5
nect BLAM J 3 [X088] [X088.7.pin] and pin 9 [X088.7.pin]? No Replace BLAM
Step 5 Turn on machine. Discon- Is there about 5VDC between Boom Length Yes Repair/replace harness between Boom Length
nect Boom Length Sensor Sensor Passthru pin 1 [X272.1.pin] and pin 2 Sensor [X273] and Boom Length Sensor
Passthru [X272]. [X272.2.pin]? Passthru [X272]
No Repair/replace harness between
BLAM J3 [X088] and
Boom Length Sensor Passthru [X273]
Step 6 Unclip sensor cable from Have second person slowly walk cable out Yes Go to step 7
boom. Observe resistance and back completely. The sensor cable No Replace boom length sensor [X273]
between boom length sen- extends 350 inches (29’ 2"). (Do not allow
sor pin A [X273.A.pin] and cable to retract in an uncontrolled or rapid
pin C [X273.C.pin]. manner. This will break the sensor.) Does
resistance change smoothly and consistently
up to 5000  ± 500  and back?
Step 7 Disconnect boom length Is there a short between the Blue wire in boom Yes Keep boom length sensor [X273] disconnected.
sensor [X273] and BLAM length sensor socket C [X273.C.soc] and red Go to step 8
module J3 connector wire in socket A [X273.A.soc] -OR- between No Leave boom length sensor [X273] and BLAM
[X088]. boom length sensor socket C [X273.C.soc] module J3 [X088] disconnected.
and battery positive [X116]? Go to step 9
Step 8 Disconnect boom length Is there a short between the Blue wire in boom Yes Repair short or replace harness between boom
sensor [X273] and boom length sensor socket C [X273.C.soc] and red length sensor [X273] and boom length sensor
length sensor passthru wire in socket A [X273.A.soc] -OR- between passthru [X272]
[X272] boom length sensor socket C [X273.C.soc] No Repair short or replace harness between boom
and battery positive [X116]? length sensor [X272] and BLAM J3 [X088]
Step 9 Disconnect boom length Is there continuity between boom length sen- Yes Go to step 11
sensor [X273] and BLAM sor socket C [X273.C.soc] and BLAM module No Go to step 10
module J3 connector J3 socket 8 [X088.8.soc]?
[X088]
Step 10 Disconnect boom length Is there continuity between boom length sen- Yes Repair or replace harness between BLAM J3
sensor [X273] and boom sor passthru socket 3 [X272.3.soc] and boom [X088] and boom length sensor [X273]
length sensor passthru length sensor socket C [X273.C.soc]? No Repair/replace harness between boom length
[X272] sensor [X093] and BLAM module J3 connector
[X088].

1-64 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 11 Disconnect boom length Is there continuity between boom length sen- Yes Leave boom length sensor [X273] disconnected.
sensor [X273] and BLAM sor socket B [X273.B.soc] and BLAM module Go to step 13
module J3 connector J3 connector socket 9 [X088.9.soc]? No Go to step 12
[X088]
Step 12 Disconnect boom length Is there continuity between boom length sen- Yes Repair/replace harness between boom length
sensor [X273] and boom sor socket B [X273.B.soc] and boom length sensor passthru [X272] and BLAM J3 [X088]
length sensor sensor passthru socket 2 [X272.2.soc]? No Repair/replace harness between boom length
passthru[X272] sensor [X273] and boom length sensor passthru
[X272]
Step 13 Turn on machine. Discon- Does the fault become inactive -AND- the fault Yes Replace boom length sensor [X273]
nect boom length sensor BOOM LENGTH SENSOR ONE VALUE OUT OF No Reprogram/replace BLAM
[X273] RANGE LOW appear?

DTC 846 - BOOM LENGTH SENSOR - OUT OF RANGE LOW


Boom Length Sensor Out of Range Low. The control system reads a boom length less than 443.0" for the 1350 or 394.9" for
the 1200. This could be caused by a mechanical problem with the sensor or cable, a disconnected or broken sensor cable
clip, the sensor power and/or signal wire being broken, or sensor failure.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the boom length sensor [X273] securely Yes Go to step 2
mounted to the machine, is cable free to move No Repair as needed
and is it connected correctly?
Step 2 Disconnect boom length Does the boom length sensor connector Yes Repair as needed
sensor [X273] [X273] have moisture, damage or corrosion? No Keep boom length sensor [X273] disconnected
and machine on. Go to step 3
Step 3 Disconnect boom length Is there about 5VDC between boom length Yes Leave machine on. Go to step6
sensor [X273]. Turn on sensor socket A [X273.A.soc] and socket B No Go to step 4
machine. [X273.B.soc]?
Step 4 Disconnect BLAM J3 X088]. Is there about 5VDC between BLAM J3 pin 7 Yes Go to step 5
Turn on machine. [X088.7.pin] and pin 9 [X088.9.pin]? No Replace BLAM
Step 5 Disconnect boom length Is there about 5VDC between boom length Yes Repair/replace harness between boom length
sensor passthru [X272]. sensor passthru pin 1 [X272.1.pin] and pin 2 sensor passthru [X272] and boom length sensor
Turn on machine [X272.2.pin]? [X273]
No Repair/replace harness between boom length
sensor passthru [X272] and BLAM J3 [X088]
Step 6 Unclip sensor cable from Have second person slowly walk cable out Yes Go to step 7
boom. Observe resistance and back completely. The sensor cable No Replace boom length sensor [X273]
between boom length sen- extends 350 inches (29’ 2"). (Do not allow
sor pin A [X273.A.pin] and cable to retract in an uncontrolled or rapid
pin C [X273.C.pin]. manner. This will break the sensor.) Does
resistance change smoothly and consistently
up to 5000  ± 500  and back?
Step 7 Disconnect boom length Is there a short between boom length sensor Yes Repair/replace harness between boom length
sensor [X273] and BLAM J3 socket C [X273.C.soc] or BLAM J3 socket 8 sensor socket C [X273.C.soc], BLAM J3 socket
[X088] [X088.8.soc] to battery negative [X117]? 8 [X088.8.soc] and battery negative [X117]
No Leave boom length sensor [X273] and BLAM J3
[X088] disconnected. Go to step 8

3128411 1200SJP 1350SJP 1-65


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 8 Disconnect boom length Is there continuity between boom length sen- Yes Go to step 10
sensor [X273] and BLAM J3 sor socket C [X273.C.soc] and BLAM J3 No Go to step 9
[X088] socket 8 [X088.8.soc]?
Step 9 Disconnect boom length Is there continuity between boom length sen- Yes Repair/replace harness between boom length
sensor [X273] and boom sor socket C [X273.C.soc] and boom length sensor socket C [X273.C.soc], BLAM J3 socket
length sensor passthru sensor passthru socket 3 [X272.3.soc]? 8 [X088.8.soc]
[X272] No Repair/replace harness between boom length
sensor [X273] and boom length sensor passthru
[X272]
Step 10 Disconnect boom length Is there a short between boom length sensor Yes Go to step 11
sensor [X273] and BLAM J3 socket C [X273.C.soc] and socket B No Reprogram/replace BLAM
[X088] [X273.B.soc]?
Step 11 Disconnect boom length Is there a short between boom length sensor Yes Repair/replace harness between boom length
sensor passthru [X272] and socket C [X273.C.soc] and socket B sensor socket C [X273.C.soc] and socket B
boom length sensor [X273] [X273.B.soc]? [X273.B.soc]
No Repair/replace harness between boom length
sensor passthru [X272] and BLAM J3 [X088]

DTC 847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH


Boom Length Sensor Value Out of Range High. The control system detected the boom length sensor input voltage is above
acceptable range.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Ensure all optional power Does fault clear? Yes Leave all optional power sources de-energized.
sources are de-energized, Go to step 3.
including welding and off- No Go to step 4
board power.
Step 3 Ensure all optional power Re-energize one source and re-check faults. Yes Look for shorts in the harness for that system to
sources are de-energized, Does fault re-appear? harness at BLAM J3.
including welding and off- No Go to "Test" box in this step.
board power.
Step 4 Disconnect BLAM J3 Is there between 5.5 V and 4.5 volts measured Yes Go to step 5
[X088]. Turn on machine. between the following points on No Replace BLAM
BLAM J3:
pin 1 [X088.8.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
pin 7 [X088.7.pin] to pin 9 [X088.9.pin];
pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?
Step 5 Disconnect BLAM J3 Is there a short between the battery (+) termi- Yes Troubleshoot BLAM J3 [X088] harness wire with
[X088]. Disconnect battery nal [X116] and any of the following: BLAM J3, short
(+) terminal [X116] socket 1 [X088.1.soc], socket 4 No Reprogram/replace BLAM
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?

1-66 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW


Boom Length Sensor Value Out of Range Low. The control system detected the boom length sensor input voltage is below
acceptable range.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Disconnect BLAM J3 Is there continuity measured between BLAM Yes Go to step 3
[X088] and Boom Length J3 [X088] and Boom Length Sensor [X273] at No Repair Harness
Sensor [X273]. the following locations:
Pin 7 [X088.7.pin] to pin A [X273.A.pin];
Pin 8 [X088.8.pin] to pin C [X273.C.pin];
Pin 9 [X088.9.pin] to pin B [X273.B.pin]?
Step 3 Disconnect BLAM J3 Is there between 4.5 V and 5.5 V measured Yes Go to step 4
[X088]. Turn on machine. between all of the following points on No Replace BLAM
BLAM J3:
pin 1 [X088.1.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
pin 7 [X088.7.pin] to pin 9 [X088.9.pin];
pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?
Step 4 Unclip sensor cable from Have a second person slowly walk the cable Yes Reprogram BLAM and calibrate boom sensors
boom. Observe resistance out and back completely. The sensor extends No Replace Boom Length Sensor
between Boom Length Sen- 350 inches (29'). (Do not allow the cable to
sor pin A [X273.A. pin] and retract in an uncontrolled or rapid manner. This
pin C [X273.C.pin] will break the sensor.) Does the resistance
change smoothly and consistently up to 5000
ohm and back?

DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT


Boom angle sensor #1 communications fault. The control system lost serial communications with #1 angle sensor (Opera-
tor’s right side).

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there loose or damaged connections at the Yes Repair any loose or damaged wires or connec-
#1 boom angle sensor connector [X099]? tors
No Go to step 2
Step 2 Does the fault log show BOOM ANGLE SEN- Yes Go to step 4
SOR #2 COMMUNICATIONS FAULT before a No Go to step 3
power cycle?
Step 3 Turn on machine. Discon- Is there 12VDC on #1 boom angle sensor Yes Leave connector disconnected. Go to step 8.
nect #1 boom angle sensor connector socket 1 [X099.1.soc] and socket No Go to step 4
connector [X099] 3 [X099.3.soc]?
Step 4 Turn on machine. Back- Is there 12VDC between 12-pin V-Batt+ bus Yes Repair/replace 12-pin V-Batt+ bus connector
probe between the 12-pin connector[X097] and 12-pin ground bus con- [X097] and/or 12-pin ground bus connector
ground bus connector nector [X098]? [X098].
[X098] and 12-pin V-Batt+ No Leave machine on. Go to step 5.
bus connector [X097] by the
BLAM. (See 6.2 Multimeter
Basics on Pg. 245 for details
on backprobing.)

3128411 1200SJP 1350SJP 1-67


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 5 Turn on machine. Discon- Is there 12VDC between 6-pin Deutsch pin 2 Yes Go to step 11
nect 6-pin Deutsch connec- [X280.2.pin] and pin 5 [X280.5.pin]? No Leave 6-pin Deutsch connector [X280] dicon-
tor [X280]. nected. Go to step 6.
Step 6 Disconnect 6-pin Deutsch Is there continuity between 6-pin Deutsch Yes Leave 6-pin Deutsch connector [X280] discon-
connector [X280] and connector socket 2 [X280.2.soc] and Power nected. Go to step 7.
Power Down Relay [X011] Down Relay socket 87 [X011.87.soc]? No Repair/Replace harness between 6-pin Deutsch
connector [X280], including the bus connector
itself [X010] and the Power Down Relay [X011]
Step 7 Disconnect 6-pin Deutsch Is there continuity between 6-pin Deutsch Yes Ensure both contacts of the 6-pin Deutsch con-
connector [X280] and connector pin 5 [X280.5.pin] and ground con- nector pin 5 [X280.2.pin] are seated properly in
ground control module J8 trol module J8 socket 3 [X008.3.soc]? the connector bodies and that there is continuity
[X008] between all pins.
No Repair/replace harness and or connectors
between 6-pin Deutsch connector [X280] and
ground control module J3 socket 3 [X008.3]
Step 8 Plug the #2 boom angle Does the BOOM ANGLE SENSOR #2 COM- Yes Replace sensor #1
sensor connector [X100] MUNICATIONS FAULT appear? No Leave the #1 boom angle sensor [X099] discon-
into the #1 sensor and the nected.
boom angle sensor #1 con- Go to step 9
nector [X099] into the #2
sensor. Read faults.
Step 9 Disconnect #1 boom angle Is there continuity between #1 boom angle Yes Go to step 11
sensor connector [X099] sensor pin 2 [X099.2.pin] and BLAM J2 No Leave the #1 boom angle sensor [X099] discon-
and BLAM J2 [X087] socket 8 [X087.8.soc]? nected.
Go to step 10.
Step 10 Disconnect the #1boom Is there continuity between #1 boom angle Yes Repair/replace harness between boom angle
angle sensor [X099] and sensor pin 2 [X099.2.pin] and boom angle sensor 1 pass through [X095] and BLAM J2
boom angle sensor 1 sensor 1 passthru pin 2 [X095.2.pin]? Also, [X087]
passthru [X095] (See Figure are the contacts free from damage and seated No Repair/replace harness between #1 boom angle
2-5. Main Valve Area Con- correctly? sensor pin 2 [X099.2.pin] and #1 boom angle
nectors on Pg. 119 for loca- sensor passthru - 4 position pin 2 [X095.2.pin]
tion).
Step 11 Disconnect the #1 boom Is there 12VDC between the #1 boom angle Yes Leave the connector disconnected and machine
angle sensor passthru - 4 sensor passthru socket 1 [X095.1.soc] and on. Go to step 13.
position [X095]. Turn on the socket 3 [X095.3.soc]? No Go to step 12
machine.
Step 12 Disconnect battery busbar - Is there 12VDC between ANY of the sockets in Yes Repair/replace harness and or connectors
12 pos. [X097] and ground battery busbar [X097] and ANY of the sockets between #1 boom angle sensor passthru [X095]
busbar - 12 pos. [X098] in ground busbar [X098]? This measurement and the 12-pin V-Batt+ bus connector sockets
may also be taken by backprobing the connec- [X097] and/or 12-pin ground bus connector
tor without disconnecting it. (See Backprob- sockets [X098].
ing on Pg. 245.) No Repair/replace harness and or connectors
between battery busbar - 12 pos. [X097] and 6-
pin Deutsch connector socket 2 [X280.2.soc]
and/or the ground busbar - 12 pos. [X098] and 6-
pin Deutsch connector socket 5 [X280.5.soc]

1-68 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 13 Disconnect the #1 boom Is there 12VDC between the #1 boom angle Yes Leave the connector disconnected. Go to step
angle sensor [X099]. Turn sensor harness connector closest to the sen- 14.
on the machine. sor socket 1 [X099.1.soc] and socket 3 No Repair/replace the harness and or connectors
[X099.3.soc]? between the #1 boom angle sensor [X099] and
#1 boom angle sensor passthru [X095]
Step 14 Disconnect the #1 boom Is there continuity between #1 boom angle Yes Reprogram/replace the BLAM
angle sensor [X099] and the sensor socket 2 [X099.2.soc] and the BLAM No Repair/replace harness and/or contacts as
BLAM connector J2 [X087] connector J2 socket 8 [X087.8.soc]? Also, needed
are the contacts free from damage?

DTC 8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT


Boom angle sensor #2 communications fault. The control system lost serial communications with #2 boom angle sensor
(Operator’s left side).

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there loose or damaged connections at the Yes Repair any loose or damaged wires or connec-
#2 boom angle sensor connector [X100]? tors
No Go to step 2
Step 2 Does the fault log show BOOM ANGLE SEN- Yes Go to step 4
SOR #1 COMMUNICATIONS FAULT before a No Go to step 3
power cycle?
Step 3 Turn on machine. Discon- Is there 12VDC on #2 boom angle sensor Yes Leave connector disconnected. Go to step 8.
nect #2 boom angle sensor connector socket 1 [X100.1.soc] and socket No Go to step 4
connector [X100] 3 [X100.3.soc]?
Step 4 Turn on machine. Back- Is there 12VDC between 12-pin V-Batt+ bus Yes Repair/replace 12-pin V-Batt+ bus connector
probe between the 12-pin connector[X097] and 12-pin ground bus con- [X097] and/or 12-pin ground bus connector
ground bus connector nector [X098]? [X098].
[X098] and 12-pin V-Batt+ No Leave machine on. Go to step 5.
bus connector [X097] by the
BLAM. (See Backprobing
on Pg. 245 for details on
backprobing.)
Step 5 Turn on machine. Discon- Is there 12VDC between 6-pin Deutsch pin 2 Yes Go to step 11
nect 6-pin Deutsch connec- [X280.2.pin] and pin 5 [X280.5.pin]? No Leave 6-pin Deutsch connector [X280] dicon-
tor [X280]. nected. Go to step 6.
Step 6 Disconnect 6-pin Deutsch Is there a short between 6-pin Deutsch con- Yes Leave 6-pin Deutsch connector [X280] discon-
connector [X280] and nector pin 2 [X280.2.pin] and Power Down nected.
Power Down Relay [X011] Relay socket 87 [X011.87.soc]? Go to step 7.
No Repair/Replace harness between 6-pin Deutsch
connector [X280], including the bus connector
itself and the Power Down Relay [X011]
Step 7 Disconnect 6-pin Deutsch Is there a short between 6-pin Deutsch con- Yes Ensure both contacts of the 6-pin Deutsch con-
connector [X280] and nector pin 2 [X280.2.pin] and ground control nector terminal 2 [X280.2] are seated properly in
ground control module J8 module J8 socket 3 [X008.3.soc]? the connector bodies and that there is continuity
[X008] between all pins.
No Repair/replace harness and or connectors
between 6-pin Deutsch connector [X280] and
ground control module J3 socket 3 [X008.3]

3128411 1200SJP 1350SJP 1-69


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 8 Plug the #1 boom angle Does the BOOM ANGLE SENSOR #1 COM- Yes Replace sensor #2
sensor connector [X099] MUNICATIONS FAULT appear? No Go to step 9
into the #2 sensor and the
#2 boom angle sensor con-
nector [X100] into the #1
sensor. Read faults.
Step 9 Disconnect #2 boom angle Is there continuity between #2 boom angle Yes Go to step 11
sensor connector [X100] sensor pin 2 [X100.2.pin] and BLAM J2 No Leave the #2 boom angle sensor [X100] discon-
and BLAM J2 [X087] socket 9 [X087.9.soc]? nected. Go to step 10.
Step 10 Disconnect the #2 boom Is there continuity between #2 boom angle Yes Repair/replace harness between #2 angle sen-
angle sensor [X100] and #2 sensor socket 2 [X100.2.soc] and #2 boom sor pass through [X096] and BLAM J2 [X087]
angle sensor passthru angle sensor passthru pin 2 [X096.2.pin]? No Repair/replace harness between #2 boo m angle
[X096] (See Figure 2-5. Also, are the contacts free from damage and sensor socket 2 [X100.2.soc] and #2 boom
Main Valve Area Connectors seated correctly? angle sensor passthru - 4 position pin 2
on Pg. 119 for location). [X096.2.pin]
Step 11 Disconnect the #2 boom Is there 12VDC between the #2 boom angle Yes Leave the connector disconnected and machine
angle sensor passthru - 4 sensor passthru socket 1 [X096.1.soc] and on. Go to step 13
position [X096]. Turn on the socket 3 [X096.3.soc]? No Go to step 12
machine.
Step 12 Disconnect battery busbar - Is there 12VDC ANY of the sockets in battery Yes Repair/replace harness and or connectors
12 pos. [X097] and ground busbar [X097] and ANY of the sockets in between #2 boom angle sensor passthru [X096]
busbar - 12 pos. [X098] ground busbar [X098]? This measurement and the 12-pin V-Batt+ bus connector sockets
may also be taken by backprobing the connec- [X097] and/or 12-pin ground bus connector
tor without disconnecting it. (See Backprob- sockets [X098].
ing on Pg. 245.) No Repair/replace harness and or connectors
between battery busbar - 12 pos. [X097] and 6-
pin Deutsch connector socket 2 [X280.2.soc]
and/or the ground Busbar - 12 pos. [X098] and 6-
pin Deutsch connector socket 5 [X280.5.soc]
Step 13 Disconnect the #2 boom Is there 12VDC between the #2 boom angle Yes Leave the connector disconnected. Go to step 14
angle sensor [X100]. Turn sensor harness connector closest to the sen- No Repair/replace the harness and or connectors
on the machine. sor socket 1 [X100.1.soc] and socket 3 between the #2 boom angle sensor [X100] and
[X100.3.soc]? #2 boom angle sensor passthru [X096].
Step 14 Disconnect the #2 boom Is there continuity between #2 boom angle Yes Reprogram/replace the BLAM
angle sensor [X100] and the sensor socket 2 [X100.2.soc] and the BLAM No Repair/replace harness and/or contacts as
BLAM connector J2 [X087] connector J2 socket 9 [X087.9.soc]? Also, needed
are the contacts free from damage?

DTC 8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE


Angle sensor number 1 invalid angle. Boom angle sensor 1 (right) is reading over +80 degrees or less than -25 degrees.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check fault log for active Is BOOM ANGLE SENSOR #1 COMMUNICA- Yes Troubleshoot that fault first
faults. TIONS FAULT present? No Go to step 2
Step 2 Is sensor mounted correctly and undamaged? Yes Go to step 3
No Repair as needed

1-70 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Disconnect Boom Angle Does BOOM ANGLE SENSOR #2 COMMUNI- Yes Sensor connections between sensor #1 [X099]
Sensor #1 (Right) [X099]. CATIONS FAULT appear? and #2 [X100] are swapped. Restore proper
connections.
No Go to step 4
Step 4 Disconnect Boom Angle Turn on the machine. Is there about 12 VDC Yes Keep sensor disconnected.
Sensor #1 (Right) [X099]. between Boom Angle Sensor #1 socket1 Go to step 6
[X099.1.soc] and socket 3 [X099.2.soc]? No Go to step 5
Step 5 Disconnect Boom Angle Turn on the machine. Is there about 12 VDC Yes Repair/replace harness between Boom Angle
Sensor #1 Passthru [X095] between Boom Angle Sensor #1 Passthru sensor #1 Passthru [X095] and Boom Angle
socket 1 [X095.1.soc] and socket 3 Sensor #1 [X099].
[X095.3.soc]? No Repair/replace harness between Boom angle
Sensor #1 Passthru [X095] and both the Battery
bus Bar [X097X] and Ground Bus Bar [X098]
Step 6 Disconnect Boom Angle Is there continuity between Boom Angle Sen- Yes Go to step 7
Sensor #1 (Right) [X099] sor #1 (Right) socket 2 [X099.2.soc] and No Repair/replace harness between Boom Angle
and Boom Angle Sensor #1 Boom Angle Sensor #1 Passthrough pin 2 Sensor #1 (Right) socket 2 [X099.2.soc] and
Passthrough [X095] [X095.2.pin]? Boom Angle Sensor #1 Passthrough pin 2
[X095.2.pin]
Step 7 Disconnect Boom Angle Is there continuity between Boom Angle Sen- Yes Go to step 8
Sensor #1 Passthru [X095] sor #1 Passthru socket 2 [X095.2.soc] and No Repair /replace harness between Boom Angle
and BLAM J2 [X087] BLAM J2 socket 8 [X087.8.soc]? Sensor #1 Passthru socket 2 [X095.2.soc] and
BLAM J2 socket 8 [X087.8.soc]
Step 8 Put boom in transport posi- Observe value while operating boom lift up Yes Calibrate boom sensors. See 5.9 Calibrating the
tion. Go to ANALYZER  through normal range of operation. Does the Boom Sensors on Pg. 228.
DIAGNOSTICS  ENVE- value change slowly and smoothly starting at No Replace Boom Angle Sensor #1 (Right) [X099]
LOPE  MAIN BOOM A/D about -39 and then increase?
ANGLE #1.

DTC 8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLE


Angle sensor number 2 invalid angle. Boom Angle sensor 2 (left) is reading over +80 degrees or less than -25 degrees.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check fault log for active Is BOOM ANGLE SENSOR #1 COMMUNICA- Yes Troubleshoot that fault first
faults. TIONS FAULT present? No Go to step 2
Step 2 Is sensor mounted correctly and undamaged? Yes Go to step 3
No Repair as needed
Step 3 Disconnect Boom Angle Does BOOM ANGLE SENSOR #1 COMMUNI- Yes Sensor connections between sensor #1 [X099]
Sensor #2 (Left) [X100]. CATIONS FAULT appear? and #2 [X100] are swapped. Restore proper
connections.
No Go to step 4
Step 4 Disconnect Boom Angle Turn on the machine. Is there about 12 VDC Yes Keep sensor disconnected.
Sensor #2 (Left) [X100]. between Boom Angle Sensor #2 socket1 Go to step 6
[X100.1.soc] and socket 3 [X100.2.soc]? No Go to step 5

3128411 1200SJP 1350SJP 1-71


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 5 Disconnect Boom Angle Turn on the machine. Is there about 12 VDC Yes Repair/replace harness between Boom Angle
Sensor #2 Passthru [X096] between Boom Angle Sensor #2 Passthru sensor #2 Passthru [X096] and Boom Angle
socket 1 [X096.1.soc] and socket 3 Sensor #2 [X100].
[X096.3.soc]? No Repair/replace harness between Boom angle
Sensor #2 Passthru [X096] and both the Battery
bus Bar [X097X] and Ground Bus Bar [X098].
Step 6 Disconnect Boom Angle Is there continuity between Boom Angle Sen- Yes Go to step 7
Sensor #2 (Left) [X100] sor #2 (Left) socket 2 [X100.2.soc] and No Repair/replace harness between Boom Angle
and Boom Angle Sensor #2 Boom Angle Sensor #2 Passthrough pin 2 Sensor #2 (Left) socket 2 [X100.2.soc] and
Passthrough [X096] [X096.2.pin]? Boom Angle Sensor #2 Passthrough pin 2
[X096.2.pin]
Step 7 Disconnect Boom Angle Is there continuity between Boom Angle Sen- Yes Go to step 8
Sensor #2 Passthru [X096] sor #2 Passthru socket 2 [X096.2.soc] and No Repair /replace harness between Boom Angle
and BLAM J2 [X087] BLAM J2 socket 9[X087.9.soc]? Sensor #2 Passthru socket 2 [X096.2.soc] and
BLAM J2 socket 9 [X087.9.soc]
Step 8 Put boom in transport posi- Observe value while operating boom lift up Yes Calibrate boom sensors. See 5.9 Calibrating the
tion. Go to ANALYZER  through normal range of operation. Does the Boom Sensors on Pg. 228.
DIAGNOSTICS  ENVE- value change slowly and smoothly starting at No Replace boom Angle Sensor #2 (Left) [X100]
LOPE  MAIN BOOM A/D about -39 and then increase?
ANGLE #2.

DTC 8413 - WRONG TELESCOPE RESPONSE


Wrong telescope response. Boom telescope movement contrary to user command. This could be caused by a hydraulic
problem preventing the boom from telescoping in the direction commanded.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any faults for the Boom Length Sen- Yes Troubleshoot those faults first
sor [X273], Boom Length Limit Switch No Go to step 2
[X281], Main Tele In[X073] or Main Tele Out
[X071]?
Step 2 Raise and extend boom. Operate main boom telescope IN and OUT. Is Yes Go to step 3
the response correct? No Go to step 6
Step 3 Extend boom completely Apply lubricant to wear pad tracks on booms. Yes Troubleshooting complete
Move boom in and out completely. Does fault No Go to step 4
clear?
Step 4 Torque boom wire ropes. See 5.10 Wire Rope Yes Troubleshooting complete
Tensioning Procedure on Pg. 240. Does fault No Go to step 5
clear?
Step 5 Calibrate boom sensors. Does calibration complete successfully? Yes Troubleshooting complete
See 5.9 Calibrating the No Repair according to calibration fault
Boom Sensors on Pg. 228.
Also, calibrate telescope
crack points. See 5.8 Cali-
brating Telescope Crack
point on Pg. 225.
Step 6 Disconnect main tele in Does the fault MAIN OUT OPEN CIRCUIT Yes Harnesses for main tele in [X073] and main tele
[X073] connector appear? out [X071] are swapped. Correct them.
No Go to step 7

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Does the hosing between the main valve - Yes Repair/replace main tele cylinder holding valve
main tele section and main tele cylinder match No Correct hosing as needed
the schematic in Figure 3-12. Hydraulic Sche-
matic - Boom Control - Sheet 1 of 2 on Pg.
174?

DTC 8414 - WRONG LIFT RESPONSE


Wrong lift response. Boom lift movement contrary to user command. This could be caused by a hydraulic problem prevent-
ing the boom from lifting in the direction commanded.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any faults for the Boom Angle Sen- Yes Troubleshoot them first
sors [X099] & [X100], or Main lift UP [X276] No Go to step 2
and Main lift Down [X277]?
Step 2 Raise and extend boom. Operate main boom lift UP and DOWN. Is the Yes Go to step 3
response correct? No Go to step 4
Step 3 Calibrate boom sensors. Do both calibrations complete successfully? Yes Troubleshooting complete
See 5.9 Calibrating the No Repair according to calibration fault
Boom Sensors on Pg. 228.
Also, calibrate lift crack
points. See 5.7 Calibrating
Lift Crack Point on Pg. 222.
Step 4 Does the main lift up solenoid have a tan 3-3 Yes Go to step 5
wire? -AND- Does main lift down solenoid No Harnesses for main lift up [X276] and main lift
have a tan 4-3 wire? down [X277] are swapped. Correct them.
Step 5 Does the hosing between the main valve - Yes Repair/replace main tele cylinder holding valve
main lift valves and main lift cylinder match the No Correct hosing as needed
schematic in Figure 3-12. Hydraulic Sche-
matic - Boom Control - Sheet 1 of 2 on Pg.
174?

DTC 851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE


Moment pin - horizontal force out of range. The control system has detected that the force applied to the horizontal axis of
the moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is
required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Calibrate boom sensors. Does fault still occur? -OR- Does pin fail to cal- Yes Replace moment pin
See 5.9 Calibrating the ibrate? No Troubleshooting complete
Boom Sensors on Pg. 228
for details.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGE


Moment pin - vertical force out of range. The control system has detected that the force applied to the vertical axis of the
moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Calibrate boom sensors. Does fault still occur? -OR- Does pin fail to cal- Yes Replace moment pin
See 5.9 Calibrating the ibrate? No Troubleshooting complete
Boom Sensors on Pg. 228
for details.

DTC 855 - MOMENT PIN - SENSOR FAULT


Moment pin sensor fault. The control system has detected a fault in the moment pin.

Note Pretest Instructions Test Result Corrective Action


Step 1 Calibrate boom sensors. Does fault still occur? Yes Replace moment pin
See 5.9 Calibrating the No Troubleshooting complete
Boom Sensors on Pg. 228
for details.

DTC 857 - NEW MOMENT PIN DETECTED FAULT


New moment pin detected fault. The moment pin detected by the system is different from the one used to calibrate machine.

Note Pretest Instructions Test Result Corrective Action


Step 1 Calibrate boom sensors. Does fault still occur? Yes Replace moment pin
See 5.9 Calibrating the No Troubleshooting complete
Boom Sensors on Pg. 228
for details.

DTC 861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH


DISAGREEMENT
Restricted to transport - Oscillating axle pressure switch disagreement. The control system detected hydraulic pressure at
the oscillating axle lockout pressure switch while the oscillating axle lockout valve solenoid was not being energized or did
not detect pressure while the solenoid was energized. These fault conditions were detected for at least 5 seconds. This fault
is ignored if the engine speed is under 1200 RPM. Only when driving in transport position should the oscillating axle lockout
valve solenoid be energized, closing the oscillating axle lockout pressure switch and unlocking the oscillating axle cylinders.
When out of transport position, drive/steer, main lift up, and main telescope out are prevented. This fault will be active until
an EMS cycle, the engine will be stopped if out of transport and pressure is indicated with this fault, and engine starting will
be prevented while out of transport and pressure is indicated by this switch.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the primary fault, 33173 - RESTRICTED TO Yes Troubleshoot any primary faults first
TRANSPORT - AXLE LOCKOUT VALVE - No Go to step 2
SHORT TO BATTERY OR OPEN CIRCUIT
present in the fault log?
Step 2 With the machine idling, does ANALYZER  Yes Go to step 14
DIAGNOSTICS  SYSTEM  OSCILATING No Go to step 3
AXLE PRES. SW. read CLOSED?

1-74 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 While drive is activated in the transport posi- Yes Go to step 4
tion does ANALYZER  DIAGNOSTICS  No Go to step 5
SYSTEM  OSCILATING AXLE PRES. SW.
read CLOSED?
Step 4 While drive is activated in the elevated position Yes Perform drive calibration. See 5.3 Calibrating
does ANALYZER  DIAGNOSTICS  SYS- Drive on Pg. 210.
TEM  OSCILATING AXLE PRES. SW. read No Check the fault log. Troubleshoot any 3-3 codes
OPEN? in the fault log first
Step 5 Tee in a 1000 psi pressure While drive is activated in the transport posi- Yes Go to step 11
gauge next to the pressure tion does the gauge read above 200 psi? No Go to step 6
switch on the traction con-
trol valve manifold
Step 6 Connect a 1000 psi pres- With the machine idling, can the pressure be Yes Replace the axle lockout valve cartridge
sure gauge to the MP port on adjusted with the adjacent charge relief valve No Go to step 7
the traction control valve so that the gauge reads 500psi?
manifold
Step 7 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes Reassemble, but keep gauge installed. Go to step
four drive hoses at the top of has been warmed up. Does the gauge read 9.
the swivel (ports 3, 4, 5, and about 500psi? No Shut down, and reassemble, but keep gauge
6). Tee a gauge in with the installed. Go to step 8.
hoses at the charge (pres-
sure) filter (on engine side).
Plug open lines.
Step 8 Tee a gauge in with the Start engine and let it idle. Ensure hydraulic oil Yes Repair/replace right side drive pump
hoses at the charge filter. has been warmed up. Does the gauge read No Repair/replace left side drive pump.
Disconnect the front drive about 500psi?
pump charge pressure lines
(ports Fa and Fe). A jumper
hose between the fittings on
the pump is required to pre-
vent pump damage.
Step 9 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes Shut down, and reassemble, but keep gauge
four drive hoses at the bot- has been warmed up. Does the gauge read installed. Go to step 10.
tom of the swivel (ports 3, 4, about 500psi? No Repair seals in swivel.
5, and 6). Tee a gauge in with
the hoses at the charge filter.
Plug open lines.
Step 10 Disconnect hoses to trac- Start engine and let it idle. Ensure hydraulic oil Yes Repair drive motor leakage or replace.
tion valve ports A3, A4, A5, has been warmed up. Does the gauge read No Repair/replace traction valve.
A6, B3, B4, B5, and B6. about 500psi?
Plug/cap open lines and
ports. Tee a gauge in with
the hoses at the charge filter.
Step 11 Does the voltage at the axle lockout pressure Yes Go to step 12
switch connector YEL/RED 2-1-7 wire No Check YEL/RED 2-1-7 wire for breaks between
[X213.1.soc] measure 12VDC? the axle lockout pressure switch [X213] and ter-
minal 1 of the Chassis module J4 connector
[X232.1]
Step 12 While drive is activated in the transport posi- Yes Go to step 13
tion, does the voltage at the axle lockout pres- No Replace the axle lockout pressure switch
sure switch connector ORN/RED 49-107 wire
[X213.3] measure 12VDC?

3128411 1200SJP 1350SJP 1-75


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 13 While drive is activated in the transport posi- Yes Replace the chassis module
tion, does the voltage at terminal 7 of the chas- No Check ORN/RED 49-107 wire for breaks between
sis module J2 connector ORN/RED 49-107 the axle lockout pressure switch [X213] and ter-
wire [X230.7.soc] measure 12VDC? minal 7 of the Chassis module J2 connector
[X230.7]
Step 14 Plumb a 1000 psi pressure With the machine idling, does the gauge read Yes Go to step 15
gauge to the pressure any pressure? No Go to step 16
switch port on the traction
control valve manifold
Step 15 Remove the axle lockout With the machine idling, does the gauge read Yes Replace the axle lockout valve cartridge
valve solenoid from the any pressure? No Go to DTC 33173 - RESTRICTED TO TRANS-
valve. Tee in a 1000 psi PORT - AXLE LOCKOUT VALVE - SHORT TO BAT-
pressure gauge next to the TERY OR OPEN CIRCUIT
pressure switch on the trac-
tion control valve manifold
Step 16 Disconnect the axle lockout With the machine idling, does ANALYZER  Yes Go to step 17
pressure switch DIN con- DIAGNOSTICS  SYSTEM  OSCILATING No Replace the axle lockout pressure switch
nector [X213] AXLE PRES. SW. read CLOSED?
Step 17 Remove socket 7 from the With the machine idling, does ANALYZER  Yes Replace the chassis module
chassis module J2 connec- DIAGNOSTICS  SYSTEM  OSCILATING No Check the ORN/RED 49-107 wire for shorts
tor [X230.7.soc] AXLE PRES. SW. read CLOSED? between the axle lockout pressure switch [X213]
and terminal 7 of the Chassis module J2 connec-
tor [X230.7]

DTC 862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT


Axle extend short to battery or open circuit. The control system detected a short to battery or open circuit on the axle exten-
sion valve output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 863 - AXLE EXTEND VALVE - SHORT TO GROUND


Axle extend short to ground. The control system detected a short to ground on the axle extension valves output [X230.11]
controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PRO-
CEDURE on Pg. 114.

DTC 864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT


Axle retract short to battery or open circuit. The control system detected a short to battery or open circuit on the axle retract
valves output [X230.12] controlling the front axles retract solenoid [X209] and the rear axles retract solenoid [X221]. See
DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 865 - AXLE RETRACT VALVE - SHORT TO GROUND


Axle retract short to ground. The control system detected a short to ground on the axle retract valves output [X230.12] con-
trolling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PROCE-
DURE on Pg. 114.

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.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND


Right front steer right short to ground. The control system detected a short to ground on the chassis module right front steer
right valve output [X233.1]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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 869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND


Right front steer left short to ground. The control system detected a short to ground on the chassis module right front steer
left valve output [X233.2]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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].

Note Pretest Instructions Test Result Corrective Action


Step 1 Connect analyzer and read Does fault log shows other steer STB or OC Yes Go to step 2
fault log faults. No Go to step 4
Step 2 Disconnect chassis module Check for an open between chassis module J1 Yes Leave negative battery terminal disconnected. Go
J1 [X230] and battery nega- [X229] socket 4 [X229.4.soc] and the nega- to step 8
tive terminal [X117] tive battery terminal No Go to step 3
Step 3 Is there a bad connection at chassis module J5 Yes Re-connect connector
connector [X233] or the left front steer right No Go to step 4
solenoid connector [X207]?
Step 4 Disconnect the left front Is the solenoid resistance about 4.9 ? Yes Go to step 5
steer right solenoid connec- No Replace solenoid
tor [X207]. Measure the
solenoid resistance.
Step 5 Disconnect the left front Are all contacts good and is there continuity Yes Leave solenoid connector and chassis module J5
steer right solenoid connec- between left front steer right solenoid connec- disconnected. Go to step 6
tor [X207] and chassis tor [X207] YELLOW wire and Chassis module No Repair/Replace harness
module J5 [X233]. J5 socket 4 [X233.4.soc]?
Step 6 Disconnect positive battery Is there a short between left front steer right Yes Repair/Replace harness
terminal [X116], left front solenoid [X207] YELLOW 9-1 wire and posi- No Go to step 7
steer right solenoid [X207] tive battery terminal [X116]?
and chassis module J5
[X233].
Step 7 Check black ground wire Are there loose, bent, broken or corroded Yes Repair/Replace harness
between terminal 5 of the wires or contacts or moisture in the connec- No Repair/Replace connector as needed.
bottom swivel connector tors?
[X216.5.soc] and the left
front steer right solenoid
connector [X207]
Step 8 Disconnect Upper Swivel Is there an open between socket 5 Yes Leave negative battery terminal disconnected. Go
connector [X083] and nega- [X083.5.soc] and battery negative terminal to step 10
tive battery terminal [X117]. [X117]? No Leave negative battery terminal disconnected. Go
to step 9

3128411 1200SJP 1350SJP 1-77


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 9 Disconnect negative battery Is there an open between negative battery ter- Yes Replace swivel
terminal [X117] and Lower minal [X117] and Lower Swivel connector pin No Repair/replace harness to Chassis module.
Swivel connector [X216]. 5 [X216.5.pin]?
Step 10 Disconnect negative battery Is there an open between Auxiliary Power Yes Repair/replace harness between Auxiliary Power
terminal [X117] Pump negative terminal and the negative bat- Pump negative terminal and negative battery ter-
tery terminal [X117]. minal.
No Repair/replace harness between Upper Swivel
connector and Auxiliary Power Pump negative
connector.

DTC 8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND


Left front steer right short to ground. The control system detected a short to ground on the chassis module left front steer
right valve output [X233.3].

Note Pretest Instructions Test Result Corrective Action


Step 1 Disconnect the left front Is the solenoid about 4.9 ? Yes Leave the left front steer right solenoid connector
steer right solenoid connec- [X207] disconnected. Go to step
tor [X207] No Replace solenoid
Step 2 Disconnect the left front Is there a short between the left front steer right Yes Repair/Replace harness
steer right solenoid connec- solenoid connector [X207] YELLOW 10-1 No Check for loose, bent or corroded contacts or
tor [X207], the chassis wire and the Lower Swivel connector socket 5 moisture in the connectors. Repair/Replace con-
module J5 connector and [X216.5.soc]? nector as needed.
the and the Lower Swivel
connector [X216].

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].

Note Pretest Instructions Test Result Corrective Action


Step 1 Connect analyzer and read Does fault log shows other steer STB or OC Yes Go to step 2
fault log faults. No Go to step 4
Step 2 Disconnect chassis module Check for an open between chassis module J1 Yes Leave negative battery terminal disconnected. Go
J1 [X230] and battery nega- [X229] socket 4 [X229.4.soc] and the nega- to step 8
tive terminal [X117] tive battery terminal No Go to step 3
Step 3 Is there a bad connection at chassis module J5 Yes Re-connect connector
connector [X233] or the left front steer left No Go to step 4
solenoid connector [X210]?
Step 4 Disconnect the left front Is the solenoid resistance about 4.9 ? Yes Go to step 5
steer left solenoid connector No Replace solenoid
[X210]. Measure the sole-
noid resistance.
Step 5 Disconnect the left front Are all contacts good and is there continuity Yes Leave solenoid connector and chassis module J5
steer left solenoid connector between left front steer left solenoid connector disconnected. Go to step 6
[X210] and chassis module yellow wire and Chassis module J5 socket 4 No Repair/Replace harness
J5 [X233]. [X233.4.soc]?

1-78 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Disconnect positive battery Is there a short between left front steer left Yes Repair/Replace harness
terminal [X116], left front solenoid [X210] YELLOW 9-1 wire and posi- No Go to step 7
steer left solenoid [X210] tive battery terminal [X116]?
and chassis module J5
[X233].
Step 7 Check black ground wire Are there loose, bent, broken or corroded Yes Repair/Replace harness
between terminal 5 of the wires or contacts or moisture in the connec- No Repair/Replace connector as needed.
bottom (chassis) swivel tors?
connector [X216.5.soc] and
the left front steer left sole-
noid connector [X210]
Step 8 Disconnect Upper Swivel Is there an open between socket 5 Yes Leave negative battery terminal disconnected. Go
connector [X083] and nega- [X083.5.soc] and battery negative terminal to step 10
tive battery terminal [X117]. [X117]? No Leave negative battery terminal disconnected. Go
to step 9
Step 9 Disconnect negative battery Is there an open between negative battery ter- Yes Replace swivel
terminal [X117] and Lower minal [X117] and Lower Swivel connector pin No Repair/replace harness to Chassis module.
Swivel connector [X216]. 5 [X216.5.pin]?
Step 10 Disconnect negative battery Is there an open between Auxiliary Power Yes Repair/replace harness between Auxiliary Power
terminal [X117] Pump negative terminal and the negative bat- Pump negative terminal and negative battery ter-
tery terminal [X117]. minal.
No Repair/replace harness between Upper Swivel
connector and Auxiliary Power Pump negative
connector.

DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND


Left front steer left short to ground. The control system detected a short to ground on the chassis module left front steer left
valve output [X233.4].

Note Pretest Instructions Test Result Corrective Action


Step 1 Disconnect the left front Is the solenoid about 4.9 ? Yes Leave the left front steer left solenoid [X210]dis-
steer left solenoid connector connected. Go to step 2
[X210]. No Replace the solenoid
Step 2 Disconnect chassis module Is there a short between YELLOW 9-1 on the Yes Repair/Replace harness
connector J5 [X233] left left front steer left solenoid connector [X210] No Check for loose, bent or corroded contacts or
front steer left solenoid con- and the Lower Swivel connector socket 5 moisture in the connectors. Repair/Replace con-
nector [X210] and the Lower [X216.5.soc]? nector as needed.
Swivel connector [X216]

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 8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND


Right rear steer right short to ground. The control system detected a short to ground on the chassis module right rear steer
right valve output [233.5]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

3128411 1200SJP 1350SJP 1-79


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

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 8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND


Right rear steer left short to ground. The control system detected a short to ground on the chassis module right rear steer left
valve output [233.6]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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 8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND


Left rear steer right short to ground. The control system detected a short to ground on the chassis module left rear steer right
valve output [X233.7]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

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 8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUND


Left rear steer left short to ground. The control system detected a short to ground on the chassis module left rear steer left
valve output [X233.8]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8622 - FRONT RIGHT STEER SENSOR - DECOUPLED


Front right wheel steering sensor decoupled. The control system detected the front right steer angle sensor value was below
the mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or
the sensor may be faulty.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check faults Is the fault FRONT RIGHT WHEEL BLOCKED Yes Troubleshoot that first
present? No Go to step 2
Step 2 Disconnect front right steer Do the connectors have any loose, damaged, Yes Repair as needed
sensor [X200] corroded contacts or moisture inside? No Go to step 3
Step 3 Is the front right wheel sensor [X200] in tact Yes Go to step 4
and properly installed? This includes checking No Reinstall and recheck
that the sensor pin will turn the sensor and the
sensor is properly tensioned.
Step 4 Extend axles. Go to ANA- Monitor value while operating steering. Steer Yes Repair/replace sensor and mounting as needed
LYZER  DIAGNOSTICS  fully to the left, then fully to the right. Does the No Go to step 5
DRIVE R FRONT WHEEL displayed angle ever climb above ±42.11?
ANGL -OR- Does the value pause, jump or act errati-
cally?
Step 5 Swap front right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the front right wheel.
sor [X200] with a sensor a wheel sensor fault? No Go to step 6
that doesn’t have a fault.

1-80 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 7
Step 7 Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X200] right wheel sensor socket A [X200.A.soc] and Go to step 8.
socket C [X200.C.soc]? No Go to step 10
Step 8 Disconnect front right wheel Is there continuity between front left wheel Yes Reprogram/replace ground module
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis No Keep front right wheel sensor [X200] discon-
module J3 [X231] module J3 socket 2 [X231.2.soc]? nected.
Go to step 9
Step 9 Disconnect front right wheel Is there continuity between front right wheel Yes Repair harness between front right steer passthru
sensor [X200] and front sensor socket B [X200.B.soc] and front right socket 2 [X201.2.soc] and chassis module J3
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]? socket 2 [X231.2.soc]
[X201] No Repair/replace harness between front right wheel
sensor socket B [X200.B.soc] and front right
steer passthru pin 2 [X201.2.pin]
Step 10 Disconnect front right steer Is there 5VDC between front right steer Yes Repair/replace harness between front right steer
passthru - 4 pos. [X201]. passthru socket 1 [X201.1.soc] and socket 3 passthru [X201] and front right wheel sensor
Turn on machine. [X201.3.soc]? [X200]
No Go to step 11
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front right steer
J3. Turn on machine. 1 [X231.1.pin] and pin 3 [X231.3.pin]? passthru [X201] and chassis module J3 [X231]
No Replace chassis module

DTC 8623 - FRONT LEFT STEER SENSOR - DECOUPLED


Front left wheel steering sensor not sensing movement. The control system detected the front left steer angle sensor value
was below the mechanical minimum angle while the steer sensor is attached to the wheel. The mechanical limitations on the
maximum steering angle depend on the axle extension. When fully retracted, the steering will be mechanically limited to
about 25°. As the axle is extended, the mechanical limit will increase to about 45°, however the control system will maintain a
25° limit until the axle is fully extended, when the control system allows the full 45° of steering. The sensor may be mounted
improperly or the sensor may be faulty.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check faults Is the fault FRONT LEFT WHEEL BLOCKED Yes Troubleshoot that first
present? No 2
Step 2 Disconnect front left steer Do the connectors have any loose, damaged, Yes Repair as needed
sensor [X203] corroded contacts or moisture inside? No Go to step 3
Step 3 Is the front left wheel sensor X203] in tact and Yes Go to step 4
properly installed? This includes checking that No Reinstall and recheck
the sensor pin will turn the sensor and the sen-
sor is properly tensioned.
Step 4 Extend axles. Go to ANA- Monitor value while operating steering. Steer Yes Repair/replace sensor and mounting as needed
LYZER  DIAGNOSTICS  fully to the left, then fully to the right. Does the No Go to step 5
DRIVE  L FRONT WHEEL displayed angle ever climb above ±42.11?
ANGL -OR- Does the value pause, jump or act errati-
cally?
Step 5 Swap front left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the front left wheel.
[X203] with a sensor that a wheel sensor fault? No Go to step 6
doesn’t have a fault.

3128411 1200SJP 1350SJP 1-81


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 7
Step 7 Disconnect front left wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X203] left wheel sensor socket A [X203.A.soc] and Go to step 8.
socket C [X203.C.soc]? No Go to step 10
Step 8 Disconnect front left wheel Is there continuity between front left wheel Yes Reprogram/replace ground module
sensor [X203] and chassis sensor socket B [X203.B.soc] and chassis No Keep front left wheel sensor [X203] discon-
module J3 [X231] module J3 socket 5 [X231.5.soc]? nected.
Go to step 9
Step 9 Disconnect front left wheel Is there continuity between front left wheel Yes Repair harness between front left steer passthru
sensor [X203] and front left sensor socket B [X203.B.soc] and front left socket 2 [X202.2.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X202.2.pin]? socket 5 [X231.5.soc]
[X202] No Repair/replace harness between front left wheel
sensor socket B [X203.B.soc] and front left steer
passthru pin 2 [X202.2.pin]
Step 10 Disconnect front left steer Is there 5VDC between front left steer passthru Yes Repair/replace harness between front left steer
passthru - 4 pos. [X202]. socket 1 [X202.1.soc] and socket 3 passthru [X202] and front left wheel sensor
Turn on machine. [X202.3.soc]? [X203]
No Go to step 11
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front left steer
J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231]
No Replace chassis module

DTC 8624 - REAR RIGHT STEER SENSOR - DECOUPLED


Rear right wheel sensor decoupled. The control system detected the rear right steer angle sensor value was below the
mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the
sensor may be faulty.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check faults Is the fault REAR RIGHT WHEEL BLOCKED Yes Troubleshoot that first
present? No 2
Step 2 Disconnect rear right steer Do the connectors have any loose, damaged, Yes Repair as needed
sensor [X239] corroded contacts or moisture inside? No Go to step 3
Step 3 Is the rear right wheel sensor [X239] in tact Yes Go to step 4
and properly installed? This includes checking No Reinstall and recheck
that the sensor pin will turn the sensor and the
sensor is properly tensioned.
Step 4 Extend axles. Go to ANA- Monitor value while operating steering. Steer Yes Repair/replace sensor and mounting as needed
LYZER  DIAGNOSTICS  fully to the left, then fully to the right. Does the No Go to step 5
DRIVE  R REAR WHEEL displayed angle ever climb above ±42.11?
ANGL -OR- Does the value pause, jump or act errati-
cally?
Step 5 Swap rear right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the rear right wheel.
sor [X239] with a sensor a wheel sensor fault? No Go to step 6
that doesn’t have a fault.
Step 6 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 7

1-82 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect rear right wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X239] right wheel sensor socket A [X239.A.soc] and Go to step 8.
socket C [X239.C.soc]? No Go to step 10
Step 8 Disconnect rear right wheel Is there continuity between rear right wheel Yes Reprogram/replace ground module
sensor [X239] and chassis sensor socket B [X239.B.soc] and chassis No Keep rear right wheel sensor [X239] discon-
module J3 [X231] module J3 socket 8 [X231.8.soc]? nected.
Go to step 9
Step 9 Disconnect rear right wheel Is there continuity between rear right wheel Yes Repair harness between rear right steer passthru
sensor [X239] and rear right sensor socket B [X239.B.soc] and rear right socket 2 [X236.2.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X236.2.pin]? socket 8 [X231.8.soc]
[X236] No Repair/replace harness between rear right wheel
sensor socket B [X239.B.soc] and rear right steer
passthru pin 2 [X236.2.pin]
Step 10 Disconnect rear left steer Is there 5VDC between rear right steer Yes Repair/replace harness between rear left steer
passthru - 4 pos. [X237]. passthru socket 1 [X236.1.soc] and socket 3 passthru [X237] and rear left wheel sensor
Turn on machine. [X236.3.soc]? [X238]
No Go to step 11
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear right steer
J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X236] and chassis module J3 [X231]
No Replace chassis module

DTC 8625 - REAR LEFT STEER SENSOR - DECOUPLED


Rear left wheel sensor decoupled. The control system detected the rear left steer angle sensor value was below the mechan-
ical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the sensor
may be faulty.

Note Pretest Instructions Test Result Corrective Action


Step 1 Check faults Is the fault REAR LEFT WHEEL BLOCKED Yes Troubleshoot that first
present? No 2
Step 2 Disconnect rear left steer Do the connectors have any loose, damaged, Yes Repair as needed
sensor [X238] corroded contacts or moisture inside? No Go to step 3
Step 3 Is the rear left wheel sensor [X238] in tact and Yes Go to step 4
properly installed? This includes checking that No Reinstall and recheck
the sensor pin will turn the sensor and the sen-
sor is properly tensioned.
Step 4 Extend axles. Go to ANA- Monitor value while operating steering. Steer Yes Repair/replace sensor and mounting as needed
LYZER  DIAGNOSTICS  fully to the left, then fully to the right. Does the No Go to step 5
DRIVE  L REAR WHEEL displayed angle ever climb above ±42.11?
ANGL -OR- Does the value pause, jump or act errati-
cally?
Step 5 Swap rear left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the rear left wheel.
[X238] with a sensor that a wheel sensor fault? No Go to step 6
doesn’t have a fault.
Step 6 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 7

3128411 1200SJP 1350SJP 1-83


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect rear left wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X238] left wheel sensor socket A [X238.A.soc] and Go to step 8.
socket C [X238.C.soc]? No Go to step 10
Step 8 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Reprogram/replace ground module
sensor [X238] and chassis sor socket B [X238.B.soc] and chassis mod- No Keep rear left wheel sensor [X238] disconnected.
module J3 [X231] ule J3 socket 11 [X231.11.soc]? Go to step 9
Step 9 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Repair harness between rear left steer passthru
sensor [X238] and rear left sor socket B [X238.B.soc] and rear left steer socket 2 [X238.2.soc] and chassis module J3
steer passthru - 4 pos. passthru pin 2 [X237.2.pin]? socket 11 [X231.11.soc]
[X237] No Repair/replace harness between rear left wheel
sensor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]
Step 10 Disconnect rear left steer Is there 5VDC between rear left steer passthru Yes Repair/replace harness between rear left steer
passthru - 4 pos. [X237]. socket 1 [X237.1.soc] and socket 3 passthru [X237] and rear left wheel sensor
Turn on machine. [X237.3.soc]? [X238]
No Go to step 11
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear left steer
J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X237] and chassis module J3 [X231]
No Replace chassis module

DTC 8626 - FRONT LEFT STEER SENSOR - NOT RESPONDING


Front left wheel steering sensor not sensing movement. The control system is unable to steer the front left wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front left steer angle sen-
sor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front left wheel kept from moving? Yes Free the wheel from any obstructions
No Go to step 2
Step 2 Check the fault log for primary faults, LT FNT Yes If a primary fault is found, troubleshoot it before
STEER LT STB OR OC, LT FNT STEER LT STG, this fault
LT FNT STEER RT STB OR OC, LT FNT STEER No Go to step 3
RT STG, or any steering angle sensor fault
Step 3 Note that glow plug’s large When engine coolant temperature is below Yes Examine the battery condition and contacts
power draw can aggravate 140°F (60°C), air temperature is below 59°F within the Chassis power distribution wiring.
existing problems with (15°C), and battery voltage is less than 11VDC Repair/replace as needed.
power distribution wiring before starting, does fault mainly occur within No Go to step 4
and low battery power. Fre- 30 seconds after starting engine?
quent starting can drain bat-
tery when preheating.
Step 4 Watch the angle sensor Steer completely left, pause, then completely Yes ESC out of calibrate mode. Cycle E-stop switch to
value on ANALYZER  right, pause. Does the value continuously and clear failed calibration message.
ACCESS LEVEL 1  CALI- smoothly change while steering? Go to step 5
BRATIONS  STEER  No Repair/Replace the sensor and calibrate.
CALIBRATE? Press Enter to
view raw value FRONT LT
STEER VALUE = XX. Do not
press Enter.
Step 5 If the wheel will not steer in either direction, Yes Repair/Replace the valve
check the steer valve for a stuck spool. No Go to step 6

1-84 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Are there any bent, damaged, or seized steer- Yes Repair/Replace the component
ing components? No Go to step 7
Step 7 Ensure proper pressure with Install a 3000 psi gauge or higher on Front Yes Troubleshooting complete
ANALYZER  ACCESS Steer Axle valve port MS1 and MS2 Adjust No Do not remove gauges.
LEVEL 1  CALIBRATIONS steer pressures on Front Steer/Axle valve. Go to step 8
 STEER  FRONT LT Adjust relief next to port to 2600 psi ± 10% on
STEER VALUE = XX. gauge on port MS1. Adjust relief next to port to
2000 psi ± 10% on port MS2. ESC out of cali-
brate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Step 8 Install a low pressure gauge Is condition clear? Yes Troubleshooting complete
(1000 psi) on main manifold No Do not remove gauges.
MP1 and adjust to 450 psi ± Go to step 9
10% on load sense
Step 9 Swap valve section with the Does condition follow valve section to other Yes Repair/replace valve section
one on the other side of side of machine? No Repair/replace front left steer cylinder and/or
machine. hoses.

DTC 8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDING


Front right wheel steering sensor not sensing movement. The control system is unable to steer the front right wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front right steer angle
sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front right wheel kept from moving? Yes Free the wheel from any obstructions
No Go to step 2
Step 2 Check the fault log for primary faults, RT FNT Yes If a primary fault is found, troubleshoot it before
STEER LT STB OR OC, RT FNT STEER LT STG, this fault
RT FNT STEER RT STB OR OC, RT FNT STEER No Go to step 3
RT STG, or any sensor value too high or too
low
Step 3 Note that glow plug’s large When engine coolant temperature is below Yes Examine the battery condition and contacts
power draw can aggravate 140°F (60°C), air temperature is below 59°F within the Chassis power distribution wiring.
existing problems with (15°C), and battery voltage is less than 11VDC Repair/replace as needed.
power distribution wiring before starting, does fault mainly occur within No Go to step 4
and low battery power. Fre- 30 seconds after starting engine?
quent starting can drain bat-
tery when preheating.
Step 4 Watch the angle sensor Steer completely left, pause, then completely Yes ESC out of calibrate mode. Cycle E-stop switch to
value on ANALYZER  right, pause. Does the value continuously and clear failed calibration message. Go to step 5
ACCESS LEVEL 1  CALI- smoothly change while steering? No Repair/Replace the sensor and calibrate.
BRATIONS  STEER 
CALIBRATE? Press Enter
then right arrow to view
FRONT RT STEER VALUE =
XX Do not press Enter.
Step 5 If the wheel will not steer in either direction, Yes Repair/Replace the valve
check the steer valve for a stuck spool. No Go to step 6

3128411 1200SJP 1350SJP 1-85


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Are there any bent, damaged, or seized steer- Yes Repair/Replace the component
ing components? No Go to step 7
Step 7 Ensure proper pressure with Install a 3000 psi gauge or higher on Front Yes Troubleshooting complete
ANALYZER  ACCESS Steer Axle valve port MS3 and MS4 Adjust No Do not remove gauges. Go to step 8
LEVEL 1  CALIBRATIONS steer pressures on Front Steer/Axle valve.
 STEER  FRONT RT Adjust proper cartridge for 2600 psi ± 10% on
STEER VALUE = XX. gauge on port MS3. Adjust proper cartridge for
2000 psi ± 10% on port MS4. ESC out of cali-
brate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Step 8 Install a low pressure gauge Is condition clear? Yes Troubleshooting complete
(1000 psi) on main manifold No Do not remove gauges. Go to step 9
MP1 and adjust to 450 psi ±
10% on load sense
Step 9 Swap valve section with the Does condition follow valve section to other Yes Repair/replace valve section
one on the other side of side of machine? No Repair/replace front left steer cylinder and/or
machine. hoses.

DTC 8628 - REAR LEFT STEER SENSOR - NOT RESPONDING


Rear left wheel steering sensor not sensing movement. The control system is unable to steer the rear left wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear left steer angle sen-
sor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the rear left wheel kept from moving? Yes Free the wheel from any obstructions
No Go to step 2
Step 2 Check the fault log for primary faults, LT REAR Yes If a primary fault is found, troubleshoot it before
STEER LT STB OR OC, LT REAR STEER LT this fault
STG, LT REAR STEER RT STB OR OC, LT No Go to step 3
REAR STEER RT STG, or any steer angle sen-
sor fault
Step 3 Note that glow plug’s large When engine coolant temperature is below Yes Examine the battery condition and contacts
power draw can aggravate 140°F (60°C), air temperature is below 59°F within the Chassis power distribution wiring.
existing problems with (15°C), and battery voltage is less than 11VDC Repair/replace as needed.
power distribution wiring before starting, does fault mainly occur within No Go to step 4
and low battery power. Fre- 30 seconds after starting engine?
quent starting can drain bat-
tery when preheating.
Step 4 Watch the angle sensor Steer completely left, pause, then completely Yes ESC out of calibrate mode. Cycle E-stop switch to
value on ANALYZER  right, pause. Does the value continuously and clear failed calibration message.
ACCESS LEVEL 1  CALI- smoothly change while steering? Go to step 5
BRATIONS  STEER  No Repair/Replace the sensor and calibrate.
CALIBRATE? Press Enter to
view raw value REAR LT
STEER VALUE = XX Do not
press Enter.
Step 5 If the wheel will not steer in either direction, Yes Repair/Replace the valve
check the steer valve for a stuck spool. No Go to step 6

1-86 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Are there any bent, damaged, or seized steer- Yes Repair/Replace the component
ing components? No Go to step 7
Step 7 Ensure proper pressure with Install a 3000 psi gauge or higher on Rear Yes Troubleshooting complete
ANALYZER  ACCESS Steer Axle valve port MS1 and MS2 Adjust No Do not remove gauges.
LEVEL 1  CALIBRATIONS steer pressures on Rear Steer/Axle valve. Go to step 8
 STEER  REAR LT Adjust relief next to port to 2600 psi ± 10% on
STEER VALUE = XX. gauge on port MS1. Adjust relief next to port to
2000 psi ± 10% on port MS2. ESC out of cali-
brate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Step 8 Install a low pressure gauge Is condition clear? Yes Troubleshooting complete
(1000 psi) on main manifold No Do not remove gauges.
MP1 and adjust to 450 psi ± Go to step 9
10% on load sense
Step 9 Swap valve section with the Does condition follow valve section to other Yes Repair/replace valve section
one on the other side of side of machine? No Repair/replace rear left steer cylinder and/or
machine. hoses.

DTC 8629 - REAR RIGHT STEER SENSOR - NOT RESPONDING


Rear right wheel steering sensor not sensing movement. The control system is unable to steer the rear right wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear right steer angle sen-
sor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the right rear wheel kept from moving? Yes Free the wheel from any obstructions
No Go to step 2
Step 2 Check the fault log for primary faults, RT REAR Yes If a primary fault is found, troubleshoot it before
STEER LT STB OR OC, RT REAR STEER LT this fault
STG, RT REAR STEER RT STB OR OC, RT No Go to step 3
REAR STEER RT STG, or any steer angle sen-
sor fault
Step 3 Note that glow plug’s large When engine coolant temperature is below Yes Examine the battery condition and contacts
power draw can aggravate 140°F (60°C), air temperature is below 59°F within the Chassis power distribution wiring.
existing problems with (15°C), and battery voltage is less than 11VDC Repair/replace as needed.
power distribution wiring before starting, does fault mainly occur within No Go to step 4
and low battery power. Fre- 30 seconds after starting engine?
quent starting can drain bat-
tery when preheating.
Step 4 Watch the angle sensor Steer completely left, pause, then completely Yes ESC out of calibrate mode. Cycle E-stop switch to
value on ANALYZER  right, pause. Does the value continuously and clear failed calibration message.
ACCESS LEVEL 1  CALI- smoothly change while steering? Go to step 5
BRATIONS  STEER  No Repair/Replace the sensor and calibrate.
CALIBRATE? Press Enter to
view raw value REAR RT
STEER VALUE = XX Do not
press Enter.
Step 5 If the wheel will not steer in either direction, Yes Repair/Replace the valve
check the steer valve for a stuck spool. No Go to step 6

3128411 1200SJP 1350SJP 1-87


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Are there any bent, damaged, or seized steer- Yes Repair/Replace the component
ing components? No Go to step 7
Step 7 Ensure proper pressure with Install a 3000 psi gauge or higher on Rear Yes Troubleshooting complete
ANALYZER  ACCESS Steer Axle valve port MS1 and MS2 Adjust No Do not remove gauges.
LEVEL 1  CALIBRATIONS steer pressures on Rear Steer/Axle valve. Go to step 8
 STEER  REAR RT Adjust relief next to port to 2600 psi ± 10% on
STEER VALUE = XX. gauge on port MS1. Adjust relief next to port to
2000 psi ± 10% on port MS2. ESC out of cali-
brate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Step 8 Install a low pressure gauge Is condition clear? Yes Troubleshooting complete
(1000 psi) on main manifold No Do not remove gauges.
MP1 and adjust to 450 psi ± Go to step 9
10% on load sense
Step 9 Swap valve section with the Does condition follow valve section to other Yes Repair/replace valve section
one on the other side of side of machine? No Repair/replace front left steer cylinder and/or
machine. hoses.

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.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front right steer angle sensor [X200] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to R FRONT
DRIVE  R FRONT WHEEL WHEEL ANGL analyzer screen. Steer to right
ANGL. about two seconds while monitoring the value.
Repeat checks. Repeat process for entire
swing of wheel. Did the value, while steering,
pause, jump or act erratically? -OR- Was the
left front wheel angle more than 2° difference
from other wheels?
Step 3 Swap front right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the front right wheel.
sor [X200] with a sensor a wheel sensor out of range low fault? No Go to step 4
that doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X200] right wheel sensor socket A [X200.A.soc] and Go to step 6.
socket C [X200.C.soc]? No Go to step 8
Step 6 Disconnect front right wheel Is there continuity between front right wheel Yes Reprogram/replace ground module
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis No Keep front right wheel sensor [X200] discon-
module J3 [X231] module J3 socket 2 [X231.2.soc]? nected.
Go to step 7

1-88 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect front right wheel Is there continuity between front right wheel Yes Repair harness between front right steer passthru
sensor [X200] and front sensor socket B [X200.B.soc] and front right socket 2 [X201.2.soc] and chassis module J3
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]? socket 2 [X231.2.soc]
[X201] No Repair/replace harness between front right wheel
sensor socket B [X200.B.soc] and front left steer
passthru pin 2 [X201.2.pin]
Step 8 Disconnect front right steer Is there 5VDC between front right steer Yes Repair/replace harness between front right steer
passthru - 4 pos. [X201]. passthru socket 1 [X201.1.soc] and socket 3 passthru [X201] and front right wheel sensor
Turn on machine. [X202.3.soc]? [X200]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front right steer
J3. Turn on machine. 1 [X231.1.pin] and pin 3 [X231.3.pin]? passthru [X201] and chassis module J3 [X231]
No Replace chassis module

DTC 8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERY


Front right wheel sensor short to battery. The control system detected the front right steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front right steer angle sensor [X200] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to R FRONT
DRIVE  R FRONT WHEEL WHEEL ANGL analyzer screen. Steer to right
ANGL. about two seconds while monitoring the value.
Repeat checks. Repeat process for entire
swing of wheel. Did the value, while steering,
pause, jump or act erratically? -OR- Was the
right front wheel angle more than 2° difference
from other wheels?
Step 3 Swap front right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the front right wheel.
sor [X200] with a sensor a wheel sensor out of range high fault? No Go to step 4
that doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X200] right wheel sensor socket A [X200.A.soc] and Go to step 6.
socket C [X200.C.soc]? No Go to step 8
Step 6 Disconnect front right wheel Is there continuity between front right wheel Yes Reprogram/replace ground module
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis No Keep front right wheel sensor [X200] discon-
module J3 [X231] module J3 socket 2 [X231.2.soc]? nected.
Go to step 7

3128411 1200SJP 1350SJP 1-89


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect front right wheel Is there continuity between front right wheel Yes Repair harness between front right steer passthru
sensor [X200] and front sensor socket B [X200.B.soc] and front right socket 2 [X202.2.soc] and chassis module J3
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]? socket 2 [X231.2.soc]
[X201] No Repair/replace harness between front right wheel
sensor socket B [X200.B.soc] and front right
steer passthru pin 2 [X201.2.pin]
Step 8 Disconnect front right steer Is there 5VDC between front right steer Yes Repair/replace harness between front right steer
passthru - 4 pos. [X201]. passthru socket 1 [X201.1.soc] and socket 3 passthru [X201] and front right wheel sensor
Turn on machine. [X201.3.soc]? [X201]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front right steer
J3. Turn on machine. 1 [X231.1.pin] and pin 3 [X231.3.pin]? passthru [X201] and chassis module J3 [X231]
No Replace chassis module

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.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front left steer angle sensor [X203] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to L FRONT
DRIVE  L FRONT WHEEL WHEEL ANGL analyzer screen. Steer to right
ANGL. about two seconds while monitoring the value.
Repeat checks. Repeat process for entire
swing of wheel. Did the value, while steering,
pause, jump or act erratically? -OR- Was the
left front wheel angle more than 2° difference
from other wheels?
Step 3 Swap front left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the front left wheel.
[X203] with a sensor that a wheel sensor out of range low fault? No Go to step 4
doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect front left wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X203] left wheel sensor socket A [X203.A.soc] and Go to step 6.
socket C [X203.C.soc]? No Go to step 8
Step 6 Disconnect front left wheel Is there continuity between front left wheel Yes Reprogram/replace ground module
sensor [X203] and chassis sensor socket B [X203.B.soc] and chassis No Keep front left wheel sensor [X203] discon-
module J3 [X231] module J3 socket 5 [X231.5.soc]? nected.
Go to step 7

1-90 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect front left wheel Is there continuity between front left wheel Yes Repair harness between front left steer passthru
sensor [X203] and front left sensor socket B [X203.B.soc] and front left socket 2 [X202.2.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X202.2.pin]? socket 5 [X231.5.soc]
[X202] No Repair/replace harness between front left wheel
sensor socket B [X203.B.soc] and front left steer
passthru pin 2 [X202.2.pin]
Step 8 Disconnect front left steer Is there 5VDC between front left steer passthru Yes Repair/replace harness between front left steer
passthru - 4 pos. [X202]. socket 1 [X202.1.soc] and socket 3 passthru [X202] and front left wheel sensor
Turn on machine. [X202.3.soc]? [X203]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front left steer
J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231]
No Replace chassis module

DTC 8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERY


Front left wheel sensor shorted to battery. The control system detected the front left steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the front left steer angle sensor [X203] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to L FRONT
DRIVE  L FRONT WHEEL WHEEL ANGL analyzer screen. Steer to right
ANGL. about two seconds while monitoring the value.
Repeat checks. Repeat process for entire
swing of wheel. Did the value, while steering,
pause, jump or act erratically? -OR- Was the
left front wheel angle more than 2° difference
from other wheels?
Step 3 Swap front left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the front left wheel.
[X203] with a sensor that a wheel sensor out of range high fault? No Go to step 4
doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect front left wheel Turn on machine. Is there 5VDC between front Yes Keep sensor disconnected.
sensor [X203] left wheel sensor socket A [X203.A.soc] and Go to step 6.
socket C [X203.C.soc]? No Go to step 8
Step 6 Disconnect front left wheel Is there continuity between front left wheel Yes Reprogram/replace ground module
sensor [X203] and chassis sensor socket B [X203.B.soc] and chassis No Keep front left wheel sensor [X203] discon-
module J3 [X231] module J3 socket 5 [X231.5.soc]? nected.
Go to step 7

3128411 1200SJP 1350SJP 1-91


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect front left wheel Is there continuity between front left wheel Yes Repair harness between front left steer passthru
sensor [X203] and front left sensor socket B [X203.B.soc] and front left socket 2 [X202.2.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X202.2.pin]? socket 5 [X231.5.soc]
[X202] No Repair/replace harness between front left wheel
sensor socket B [X203.B.soc] and front left steer
passthru pin 2 [X202.2.pin]
Step 8 Disconnect front left steer Is there 5VDC between front left steer passthru Yes Repair/replace harness between front left steer
passthru - 4 pos. [X202]. socket 1 [X202.1.soc] and socket 3 passthru [X202] and front left wheel sensor
Turn on machine. [X202.3.soc]? [X203]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between front left steer
J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231]
No Replace chassis module

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.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the rear right steer angle sensor [X239] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to R REAR WHEEL
DRIVE  R REAR WHEEL ANGL analyzer screen. Steer to right about two
ANGL. seconds while monitoring the value. Repeat
checks. Repeat process for entire swing of
wheel. Did the value, while steering, pause,
jump or act erratically? -OR- Was the left front
wheel angle more than 2° difference from
other wheels?
Step 3 Swap rear right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the rear right wheel.
sor [X239] with a sensor a wheel sensor out of range low fault? No Go to step 4
that doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect rear right wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X239] right wheel sensor socket A [X239.A.soc] and Go to step 6.
socket C [X239.C.soc]? No Go to step 8
Step 6 Disconnect rear right wheel Is there continuity between rear right wheel Yes Reprogram/replace ground module
sensor [X239] and chassis sensor socket B [X239.B.soc] and chassis No Keep rear right wheel sensor [X239] discon-
module J3 [X231] module J3 socket 8 [X231.8.soc]? nected.
Go to step 7

1-92 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect rear right wheel Is there continuity between rear right wheel Yes Repair harness between rear right steer passthru
sensor [X239] and rear right sensor socket B [X239.B.soc] and rear right socket 2 [X2.236.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X236.2.pin]? socket 8 [X231.8.soc]
[X236] No Repair/replace harness between rear right wheel
sensor socket B [X239.B.soc] and rear right steer
passthru pin 2 [X236.2.pin]
Step 8 Disconnect rear right steer Is there 5VDC between rear right steer Yes Repair/replace harness between rear right steer
passthru - 4 pos. [X236]. passthru socket 1 [X236.1.soc] and socket 3 passthru [X236] and rear right wheel sensor
Turn on machine. [X236.3.soc]? [X239]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear right steer
J3. Turn on machine. 7 [X231.10.pin] and pin 9 [X231.9.pin]? passthru [X236] and chassis module J3 [X231]
No Replace chassis module

DTC 8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERY


Rear right wheel sensor short to battery. The control system detected the rear right steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the rear right steer angle sensor [X239] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to R REAR WHEEL
DRIVE  R REAR WHEEL ANGL analyzer screen. Steer to right about two
ANGL. seconds while monitoring the value. Repeat
checks. Repeat process for entire swing of
wheel. Did the value, while steering, pause,
jump or act erratically? -OR- Was the right rear
wheel angle more than 2° difference from
other wheels?
Step 3 Swap rear right wheel sen- Check faults. Does the new location now have Yes Replace sensor originally at the rear right wheel.
sor [X239] with a sensor a wheel sensor out of range high fault? No Go to step 4
that doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect rear right wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X239] right wheel sensor socket A [X239.A.soc] and Go to step 6.
socket C [X239.C.soc]? No Go to step 8
Step 6 Disconnect rear right wheel Is there continuity between rear right wheel Yes Reprogram/replace ground module
sensor [X239] and chassis sensor socket B [X239.B.soc] and chassis No Keep rear right wheel sensor [X239] discon-
module J3 [X231] module J3 socket 8 [X231.8.soc]? nected.
Go to step 7

3128411 1200SJP 1350SJP 1-93


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 7 Disconnect rear right wheel Is there continuity between rear right wheel Yes Repair harness between rear right steer passthru
sensor [X239] and rear left sensor socket B [X239.B.soc] and rear right socket 2 [X236.2.soc] and chassis module J3
steer passthru - 4 pos. steer passthru pin 2 [X236.2.pin]? socket 8 [X231.8.soc]
[X236] No Repair/replace harness between rear right wheel
sensor socket B [X239.B.soc] and rear right steer
passthru pin 2 [X236.2.pin]
Step 8 Disconnect rear right steer Is there 5VDC between rear right steer Yes Repair/replace harness between rear right steer
passthru - 4 pos. [X236]. passthru socket 1 [X237.1.soc] and socket 3 passthru [X236] and rear right wheel sensor
Turn on machine. [X236.3.soc]? [X239]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear right steer
J3. Turn on machine. 7 [X231.7.pin] and pin 9 [X231.9.pin]? passthru [X236] and chassis module J3 [X231]
No Replace chassis module

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.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the rear left steer angle sensor [X238] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to L REAR WHEEL
DRIVE  L REAR WHEEL ANGL analyzer screen. Steer to right about two
ANGL. seconds while monitoring the value. Repeat
checks. Repeat process for entire swing of
wheel. Did the value, while steering, pause,
jump or act erratically? -OR- Was the left front
wheel angle more than 2° difference from
other wheels?
Step 3 Swap rear left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the front left wheel.
[X238] with a sensor that a wheel sensor out of range low fault? No Go to step 4
doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect rear left wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X238] left wheel sensor socket A [X238.A.soc] and Go to step 6.
socket C [X238.C.soc]? No Go to step 8
Step 6 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Reprogram/replace ground module
sensor [X238] and chassis sor socket B [X238.B.soc] and chassis mod- No Keep rear left wheel sensor [X238] disconnected.
module J3 [X231] ule J3 socket 11 [X231.11.soc]? Go to step 7
Step 7 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Repair harness between rear left steer passthru
sensor [X238] and rear left sor socket B [X238.B.soc] and rear left steer socket 2 [X2.237.soc] and chassis module J3
steer passthru - 4 pos. passthru pin 2 [X237.2.pin]? socket 11 [X231.11.soc]
[X237] No Repair/replace harness between rear left wheel
sensor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]

1-94 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 8 Disconnect rear left steer Is there 5VDC between rear left steer passthru Yes Repair/replace harness between rear left steer
passthru - 4 pos. [X237]. socket 1 [X237.1.soc] and socket 3 passthru [X237] and rear left wheel sensor
Turn on machine. [X237.3.soc]? [X237]
No Go to step 9
Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear left steer
J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X237] and chassis module J3 [X231]
No Replace chassis module

DTC 8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERY


Rear left wheel sensor short to battery. The control system detected the rear left steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.

Note Pretest Instructions Test Result Corrective Action


Step 1 Is the rear left steer angle sensor [X238] Yes Go to step 2
installed and connected properly? No Repair as needed
Step 2 Extend axles. Enable crab Observe angle while operating steering. Steer Yes Go to step 3
steering mode. Go to ANA- fully to the left. Check all wheel angles. They No Go to step 5
LYZER  DIAGNOSTICS  should be within 2 °. Return to L REAR WHEEL
DRIVE  L REAR WHEEL ANGL analyzer screen. Steer to right about two
ANGL. seconds while monitoring the value. Repeat
checks. Repeat process for entire swing of
wheel. Did the value, while steering, pause,
jump or act erratically? -OR- Was the left rear
wheel angle more than 2° difference from
other wheels?
Step 3 Swap rear left wheel sensor Check faults. Does the new location now have Yes Replace sensor originally at the rear left wheel.
[X238] with a sensor that a wheel sensor out of range high fault? No Go to step 4
doesn’t have a fault.
Step 4 Calibrate steering. Does fault clear? Yes Troubleshooting complete
No Go to step 5
Step 5 Disconnect rear left wheel Turn on machine. Is there 5VDC between rear Yes Keep sensor disconnected.
sensor [X238] left wheel sensor socket A [X238.A.soc] and Go to step 6.
socket C [X238.C.soc]? No Go to step 8
Step 6 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Reprogram/replace ground module
sensor [X238] and chassis sor socket B [X238.B.soc] and chassis mod- No Keep rear left wheel sensor [X238] disconnected.
module J3 [X231] ule J3 socket 11 [X231.11.soc]? Go to step 7
Step 7 Disconnect rear left wheel Is there continuity between rear left wheel sen- Yes Repair harness between rear left steer passthru
sensor [X238] and rear left sor socket B [X238.B.soc] and rear left steer socket 2 [X237.2.soc] and chassis module J3
steer passthru - 4 pos. passthru pin 2 [X237.2.pin]? socket 11 [X231.11.soc]
[X237] No Repair/replace harness between rear left wheel
sensor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]
Step 8 Disconnect rear left steer Is there 5VDC between rear left steer passthru Yes Repair/replace harness between rear left steer
passthru - 4 pos. [X237]. socket 1 [X237.1.soc] and socket 3 passthru [X237] and rear left wheel sensor
Turn on machine. [X237.3.soc]? [X238]
No Go to step 9

3128411 1200SJP 1350SJP 1-95


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes Repair/Replace harness between rear left steer
J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X237] and chassis module J3 [X231]
No Replace chassis module

DTC 8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT


Engine shutdown - axle lockout valve fault. The control system detected a short to battery or open circuit on the axle lockout
valve and detects pressure on the pressure switch and the boom is out of transport position. Engine starting will be pre-
vented while this fault is active. Use auxiliary power to lower the boom to transport. See DTC 33173 - RESTRICTED TO
TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 30.

DTC 998 - EEPROM FAILURE - CHECK ALL SETTINGS


EEPROM failure - check all settings. A critical failure occurred with the EEPROM. Personalities, machine configuration digits,
etc. may be reset to default values and should be checked. A power cycle is required. This can occur if new software that
adds a personality or other configurations, is downloaded to the machine.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Reprogram/replace ground module

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 9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIRED


Platform module software update required. The platform module software is a different major version than the ground mod-
ule. Load new platform module software.

DTC 9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATED


Chassis tilt sensor not gain calibrated. Chassis tilt sensor calibration information has been lost. Machine will indicate that it is
tilted at all times. This calibration data is programmed into the ground module during its manufacture, not in the field.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Replace ground module

DTC 9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGE


Chassis tilt sensor gain out of range. Chassis tilt sensor calibration information has been corrupted. This calibration data is
programmed into the ground module during its manufacture, not in the field.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Replace ground module

1-96 1200SJP 1350SJP 3128411


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST


High resolution analog to digital failure-interrupt lost. This fault should only occur with software versions prior to 7.0. There is
an internal problem with the platform module.

DTC 9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMIT


High resolution analog to digital failure - reinit limit. This fault should only occur with software versions prior to 7.0. There is
an internal problem with the platform module.

DTC 9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGE


Ground sensor reference voltage out of range. The ground module 7VDC reference voltage is out of acceptable range. This
reference voltage is unused at this time. Possible causes of this fault include bad supply circuit in the module, or wires mis-
takenly connected to the following pins on ground module J7 [X007]: J7-5, J7-16, J7-26, or J7-27.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any wires present in any of the fol- Yes Make note of other faults then remove one wire. If
lowing terminals: ground module J7 terminal 5 any new faults appear or faults go away, use that
[X007.5], terminal 16 [X007.16], terminal 26 information to find proper place for the wire.
[X007.26], or terminal 27 [X007.27]? Repeat until all wires are placed correctly.
No Go to step 2
Step 2 Use backprobing for follow- Is there 6.6VDC - 7.5VDC at the following ter- Yes Reprogram/replace the ground module
ing measurement. See minals: ground module J7 terminal 5 No Replace the ground module
Backprobing on Pg. 245 for [X007.5], terminal 16 [X007.16], terminal 26
details. [X007.26], or terminal 27 [X007.27]?

DTC 9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGE


Platform sensor reference voltage out of range. The platform module 7VDC reference voltage is out of acceptable range.
This supply is used for the lift, swing, drive and pump controls.

Note Pretest Instructions Test Result Corrective Action


Step 1 Disconnect platform module Is there about 2.5k between platform mod- Yes Keep connector disconnected.
J5 [X167] ule J5 socket 1 [X167.1.soc] and J5 socket 7 Go to step 2.
[X167.7.soc]? No Repair/replace Lift & Swing joystick assembly
and/or wiring
Step 2 Disconnect platform module Is there 6.6V - 7.5V between platform module Yes Keep J5 [X167] disconnected.
J5 [X167] and J6 [X168] J5 pin 1 [X167.1.pin] and J5 pin 7 Go to step 3.
and hyd speed pot passthru [X167.7.pin]? No Go to step 12
- 6 pos [X199]. Turn on
machine.
Step 3 Disconnect platform module Is there a short between platform module J5 Yes Repair/replace harness affecting Lift & Swing
J5 [X167]. Ground multime- socket 1 [X167.1.soc] and ground? joystick wiring.
ter. See Grounding on Pg. No Go to step 4
245 for details.
Step 4 Disconnect platform module Turn on machine. Is there about 12 VDC Yes Short to battery. Repair/replace harness affecting
J5 [X167]. Ground multime- between platform module J5 socket 1 the Lift & Swing joystick wiring.
ter. See Grounding on Pg. [X167.1.soc] and ground? No Go to step 5
245 for details.
Step 5 Disconnect platform module Is there about 5k between platform module Yes Go to step 6
J6 [X168] J6 socket 1 [X168.1.soc] and J6 socket 7 No Repair/replace Drive joystick and/or wiring
[X168.7.soc]?

3128411 1200SJP 1350SJP 1-97


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Disconnect platform module Is there a short between platform module J6 Yes Short to ground. Repair/replace harness affecting
J6 [X168]. Ground multime- socket 1 [X168.1.soc] and ground? Drive joystick assembly.
ter. See Grounding on Pg. No Go to step 7
245 for details.
Step 7 Disconnect platform module Turn on machine. Is there about 12 VDC Yes Short to battery. Repair/replace harness affecting
J6 [X168]. Ground multime- between platform module J6 socket 1 Drive joystick wiring.
ter. See Grounding on Pg. [X168.1.soc] and ground? No Go to step 8
245 for details.
Step 8 Disconnect hyd speed pot Measure resistance between hyd speed pot Yes Repair/replace hyd speed pot passthru [X199]
passthru - 6 pos. [X199] passthru socket 4 [X199.4.soc] and socket 5 and or Speed Controller [X192]
[X199.5.soc]. Is there a short or open? No Keep hyd speed pot passthru [X199] discon-
nected.
Go to step 9
Step 9 Disconnect hyd speed pot Measure resistance from hyd speed pot Yes Keep hyd speed pot passthru [X199] discon-
passthru - 6 pos. [X199]. passthru pin 4 [X199.4.pin] and pin 5 nected.
[X199.5.pin]. Is there a short? Go to step 10
No Keep hyd speed pot passthru [X199] discon-
nected.
Go to step 11
Step 10 Disconnect hyd speed pot Measure resistance from platform module J1 Yes Repair/replace harness between hyd speed pot
passthru [X199] and plat- socket 13 [X165.13.soc] and socket 34 passthru [X199] pin 4 [X199.4.pin] and pin 6
form module J1 [X165]. [X165.34.soc]. Is there a short? [X199.6.pin] and platform module J1 [X 165]
socket 13 [X165.13.soc] and socket 34
[X165.34.soc]
No Short inside module. Replace platform module
Step 11 Disconnect hyd speed pot Measure resistance between hyd speed pot Yes Repair/replace Speed Controller [X192]
passthru [X199] passthru socket 3 [X199.3.soc] and socket 4 No Keep hyd speed pot passthru [X199] discon-
[X199.4.soc]. Is there a short? nected.
Go to step 12
Step 12 Disconnect hyd speed pot Measure resistance between hyd speed pot Yes Keep hyd speed pot passthru [X199] discon-
passthru [X199] passthru pin 3[X199.3.pin] and pin 4 nected.
[X199.4.pin]. Is there a short? Go to step 13.
No Reprogram/replace platform module
Step 13 Disconnect hyd speed pot Measure resistance between hyd speed pot Yes Repair/replace harness between hyd speed pot
passthru [X199] and plat- passthru pin 3[X199.3.pin] and pin 4 passthru pin 3[X199.3.pin] and pin 4
form module J1 [X165] [X199.4.pin]. Is there a short? [X199.4.pin]
No Short inside module. Replace platform module.

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 9922 - PLATFORM MODULE FAILURE - HWFS CODE 1


Platform module failure: hardware fail-safe code 1. Platform module V(low) FET has failed. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Replace platform module

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 9923 - GROUND MODULE FAILURE - HWFS CODE 1


Ground module failure: hardware fail-safe code 1. The ground module V(low) FET has failed. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Replace 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 9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIRED


Ground module constant data update required. The ground module has old constant data that is not compatible with the
current ground module software. The ground module constant data must be updated to a newer version. A power cycle is
required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Reprogram/replace ground module

DTC 9928 - ENVELOPE CONTROL DISABLED


Envelope control disabled. The user has forced envelope control off with the analyzer from access level 0. This can happen
if calibration procedure is not followed properly.

Note Pretest Instructions Test Result Corrective Action


Step 1 Calibrate boom sensors. Did fault clear? Yes Troubleshooting complete
See 5.9 Calibrating the No Reprogram/replace ground module
Boom Sensors on Pg. 228
for details.

DTC 9929 - MOMENT CONTROL DISABLED


Moment control disabled. The user has forced envelope control off with the analyzer from access level 0.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault still occur? Yes Go to step 2
No Troubleshooting complete
Step 2 Calibrate boom sensors. Does fault still occur? Yes Replace ground module
See 5.9 Calibrating the No Troubleshooting complete
Boom Sensors on Pg. 228
for details.

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 9930 - STEER SENSORS NOT CALIBRATED


Steer sensors not calibrated. The steering sensors require calibration. This fault can happen if calibration is incorrect or a
new chassis module has been installed and steering calibration is not done. See 5.2 Calibrating Steer on Pg. 208 for instruc-
tions 5.2 Calibrating Steer on Pg. 208.

DTC 9931 - BOOM SENSORS NOT CALIBRATED


Boom sensors not calibrated. The Boom sensors require calibration. See 5.1 Calibration Instructions on Pg. 207, Table 5-2.
Calibrations Listed by Service Action on Pg. 207 and 5.9 Calibrating the Boom Sensors on Pg. 228 for more details. The
machine will be in electrical retrieval mode until in transport position. Then, controlled angle, auto main lift, and main lift up
will be disabled.

Note Pretest Instructions Test Result Corrective Action


Step 1 Read active faults Are there any boom sensor faults? Yes Troubleshoot those faults first
No Go to step 2
Step 2 Perform boom sensor cali- Does machine calibrate successfully? Yes Troubleshooting complete
bration. No Troubleshoot in accordance with calibration fault

DTC 9932 - LIFT CRACKPOINTS NOT CALIBRATED


Lift crackpoints not calibrated. The lift valves require a calibration that has not yet been performed. See 5.7 Calibrating Lift
Crack Point on Pg. 222 for instructions.

DTC 9933 - TELESCOPE CRACKPOINTS NOT CALIBRATED


The telescope valves require a calibration that has not yet been performed. See 5.8 Calibrating Telescope Crack point on Pg. 225 for
instructions.

DTC 9934 - DRIVE CRACKPOINTS NOT CALIBRATED


Drive crackpoints not calibrated. The drive valves require a calibration that has not been performed.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are there any Drive faults? Yes Troubleshoot those first
No Go to step 2
Step 2 Perform dive calibration. Did calibration complete successfully? Yes Troubleshooting complete
See 5.3 Calibrating Drive on No Go to step 3
Pg. 210.
Step 3 Were there any calibration faults? Yes Troubleshoot all calibration faults
No Go to step 4
Step 4 Tee in a 1000 psi pressure While drive is activated in the transport posi- Yes Replace the ground module
gauge next to the pressure tion does the gauge read about 500 psi? No Go to step 5
switch on the traction con-
trol valve manifold
Step 5 Connect a 1000 psi pres- With the machine idling, can the pressure be Yes Replace the axle lockout valve cartridge
sure gauge to the MP port on adjusted with the adjacent charge relief valve No Go to step 6
the traction control valve so that the gauge reads 500psi?
manifold

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 6 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes Reassemble, but keep gauge installed.
four drive hoses at the top of has been warmed up. Does the gauge read Go to step 8.
the swivel (ports 3, 4, 5, and about 500psi? No Shut down, and reassemble, but keep gauge
6). Tee in a gauge with the installed.
hoses at the charge (pres- Go to step 7.
sure) filter (on engine side).
Plug open lines.
Step 7 Tee in a gauge with the Start engine and let it idle. Ensure hydraulic oil Yes Repair/replace right side drive pump
hoses at the charge filter. has been warmed up. Does the gauge read No Repair/replace left side drive pump.
Disconnect the front drive about 500psi?
pump charge pressure lines
(ports Fa and Fe). A jumper
hose between the fittings on
the pump is required to pre-
vent pump damage.
Step 8 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes Shut down, and reassemble, but keep gauge
four drive hoses at the bot- has been warmed up. Does the gauge read installed.
tom of the swivel (ports 3, 4, about 500psi? Go to step 9.
5, and 6). Tee in a gauge with No Repair seals in swivel.
the hoses at the charge filter.
Plug open lines.
Step 9 Disconnect hoses to trac- Start engine and let it idle. Ensure hydraulic oil Yes Repair drive motor leakage or replace drive
tion valve ports A3, A4, A5, has been warmed up. Does the gauge read motor.
A6, B3, B4, B5, and B6. about 500psi? No Repair/replace traction valve.
Plug/cap open lines and
ports. Tee a gauge in with
the hoses at the charge filter.

DTC 9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGH


BLAM sensor supply out of range high. BLAM sensor power supply voltage for the boom angle sensors is above the
expected range. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Ensure all optional power Does fault clear? Yes Leave all optional power sources de-energized.
sources are de-energized, Go to step 3.
including welding and off- No Go to step 4
board power.
Step 3 Ensure all optional power Re-energize one source and re-check faults. Yes Look for shorts in the harness for that system to
sources are de-energized, Does fault re-appear? harness at BLAM J3.
including welding and off- No Go to "Test" box in this step.
board power.
Step 4 Disconnect BLAM J3 Is there between 5.5 V and 4.5 volts measured Yes Go to step 5
[X088]. Turn on machine. between the following points on No Replace BLAM
BLAM J3?
pin 1 [X088.8.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin]

3128411 1200SJP 1350SJP 1-101


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 5 Disconnect BLAM J3 Is there a short between the battery (+) termi- Yes Troubleshoot BLAM J3 [X088] harness wire with
[X088]. Disconnect battery nal [X116] and any of the following: BLAM J3, short
(+) terminal [X116] socket 1 [X088.1.soc], socket 4 No Reprogram/replace BLAM
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?

DTC 9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOW


BLAM sensor supply out of range low. BLAM sensor power supply voltage for the boom angle sensors is below the expected
range. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Disconnect BLAM J3 Is there between 5.5 V and 4.5 volts measured Yes Go to step 3
[X088]. Turn on machine. between the following points on No Replace BLAM
BLAM J3?
pin 1 [X088.8.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
Step 3 Disconnect BLAM J3 Is there a short between the battery ( - ) termi- Yes Troubleshoot BLAM J3 [X088] harness wire with
[X088]. Disconnect battery nal [X117] and any of the following: chassis short
( - ) terminal [X117] module J3, socket 1 [X088.1.soc], socket 4 No Reprogram/replace BLAM
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?

DTC 9937 - LENGTH SENSOR REF VOLTAGE HIGH


Length sensor reference voltage high. Supply voltage for the boom length sensors is above 5.5VDC. A power cycle is
required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Did fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Disconnect all on-board and Did fault clear? Yes Isolate system by turing on each optional power
off-board optional power system individually and checking fault. Then look
systems such as 110VAC for shorts between length sensor harness and
and welders to keep them faulty system harness.
from energizing No Go to step 3
Step 3 Disconnect BLAM J3 Is there between 5.5 VDC and 4.5 VDC mea- Yes Go to step 4
[X088]. Turn on machine. sured between all of the following points on No Replace BLAM
BLAM J3:
pin 1 [X088.1.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
pin 7 [X088.7.pin] to pin 9 [X088.9.pin];
pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?
Step 4 Disconnect BLAM J3 Is there a short between the battery (+) termi- Yes Troubleshoot BLAM J3 [X088] harness wire(s)
[X088] and battery + termi- nal [X116] and any of the following: BLAM J3 with short
nal [X116]. socket 1 [X088.1.soc], socket 4 No Reprogram/replace BLAM
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 9938 - LENGTH SENSOR REF VOLTAGE LOW


Length sensor reference voltage low. Supply voltage for the boom length sensors is below 4.5VDC. A power cycle is
required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Did fault clear? Yes Troubleshooting complete
No Go to step 3
Step 2 Disconnect BLAM J3 Is there between 5.5 VDC and 4.5 VDC mea- Yes Go to step 4
[X088]. Turn on machine. sured between the following points on No Replace BLAM
BLAM J3:
pin 1 [X088.1.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
pin 7 [X088.7.pin] to pin 9 [X088.9.pin];
pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?
Step 3 Disconnect BLAM J3 Is there a short between ground and any of the Yes Troubleshoot BLAM J3 [X088] harness wire(s)
[X088]. Ground meter. See following: BLAM J3 socket 1 [X088.1.soc], with short
Grounding on Pg. 245 for socket 4 [X088.4.soc], socket 7 No Reprogram/replace BLAM
details. [X088.7.soc], or socket 10 [X088.10.soc]?

DTC 9939 - BLAM HIGH RES A/D FAILURE


BLAM high resolution analog to digital converter failure. A BLAM internal circuit to measure sensor output had a failure. A
power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power. Check faults. Does fault continue to occur after cycling Yes Replace BLAM
power? No Troubleshooting complete

DTC 9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH


Chassis sensor supply out of range high. The supply voltage for steer angle sensors is above the expected range. A power
cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Ensure all optional power Does fault clear? Yes Leave all optional power sources de-energized.
sources are de-energized, Go to step 3.
including welding and off- No Go to step 4
board power.
Step 3 Ensure all optional power Re-energize one source and re-check faults. Yes Look for shorts in the harness for the system just
sources are de-energized, Does fault re-appear? energized to harness at chassis module J3.
including welding and off- No Go to "Test" box in this step. Repeat until source
board power. of fault is found.
Step 4 Disconnect chassis module Is there between 5.5 V and 4.5 volts measured Yes Go to step 5
J3 [X231]. Turn on machine. between all of the following points on No Replace chassis module
chassis module J3:
pin 1 [X231.1.pin] to pin 3 [X231.3.pin];
pin 4 [X231.4.pin] to pin 6 [X231.6.pin];
pin 7 [X231.7.pin] to pin 9 [X231.9.pin];
pin 10 [X231.10.pin] to pin 12 [X231.12.pin]?

3128411 1200SJP 1350SJP 1-103


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 5 Disconnect chassis module Is there a short between the battery (+) termi- Yes Troubleshoot chassis module J3 [X231] harness
J3 [X231]. Disconnect bat- nal [X116] and any of the following: chassis wire with short
tery (+) terminal [X116] module J3, socket 1 [X231.1.soc], socket 4 No Reprogram/replace chassis module
[X231.4.soc], socket 7 [X231.7.soc], or
socket 10 [X231.10.soc]?

DTC 9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOW


Chassis sensor supply out of range low. The supply voltage for chassis steer angle sensors is below the expected range. A
power cycle is required.

Note Pretest Instructions Test Result Corrective Action


Step 1 Cycle power Does fault clear? Yes Troubleshooting complete
No Go to step 2
Step 2 Disconnect chassis module Is there between 5.5 V and 4.5 volts measured Yes Go to step 3
J3 [X231]. Turn on machine. between the following points on No Replace chassis module
chassis module J3:
pin 1 [X231.1.pin] to pin 3 [X231.3.pin];
pin 4 [X231.4.pin] to pin 6 [X231.6.pin];
pin 7 [X231.7.pin] to pin 9 [X231.9.pin];
pin 10 [X231.10.pin] to pin 12 [X231.12.pin]?
Step 3 Disconnect chassis module Is there a short between the battery(-) terminal Yes Troubleshoot chassis module J3 [X231] harness
J3 [X231]. Disconnect bat- [X117] and any of the following: chassis mod- wire with short
tery - terminal [X117] ule J3, socket 1 [X231.1.soc], socket 4 No Reprogram/replace chassis module
[X231.4.soc], socket 7 [X231.7.soc], or
socket 10 [X231.10.soc]?

DTC 9944 - CURRENT FEEDBACK GAINS OUT OF RANGE


Current feedback gains out of range. Reserved for future use. Should not occur on current machine..

Note Pretest Instructions Test Result Corrective Action


Step 1 Go to ANALYZER  Are parameters set properly in Machine Yes Go to step 2
MACHINE SETUP Setup? No Reprogram/replace ground module
Step 2 Reprogram ground module. Does fault clear? Yes Troubleshooting complete
No Reprogram/replace ground module

DTC 9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT


Current feedback calibration checksum incorrect. Reserved for future use. Should not occur on current machine..

Note Pretest Instructions Test Result Corrective Action


Step 1 Go to ANALYZER  Are parameters and configuration set properly Yes Go to step 2
MACHINE SETUP in Machine Setup? No Reprogram/replace ground module
Step 2 Reprogram ground module. Does fault clear? Yes Troubleshooting complete
No Reprogram/replace ground module

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

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...

Note Pretest Instructions Test Result Corrective Action


Step 1 Is machine fitted with telematics equipment? Yes Go to step 2.
No Go to ANALYZER  MACHINE SETUP.
Set TELEMATICS to NO.
Step 2 Go to ANALYZER  Is model is correct? Yes Reprogram ground module with proper software.
MACHINE SETUP. No Set correct model.

DTC 33XX - COMMON STB OR OC PROCEDURE


Common short to battery or open circuit procedure. A module input or output pin has been shorted to battery or the circuit
has an open in it. All driver faults are detected in a similar manner. Open circuit faults are detected when the analog feedback
reads too high and the output is commanded off. Short to battery is detected when the analog feedback reads Vbat and the
output is commanded off. See the fault description for the component or module pin identification. Frequently, this is due to
a failed component shorting to battery voltage. This procedure applies to a number of faults, so it leaves the determination of
specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine
schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For
example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some
components are effectively a separate module, such as the main boom angle sensors. When opening any electrical connec-
tion, inspect the connectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several exam-
ples are given starting at DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg.
86.

Note Pretest Instructions Test Result Corrective Action


Step 1 Are other STB/OC faults in the fault log? Yes Check for an open at a point in circuit common to
this fault and the others.
No Go to step 2
Step 2 Find component on sche- Is the component good? Check the compo- Pass Go to step 3
matic and on the machine. nent resistance. Resistances of coils are given Fail Repair as needed
in Section 2. Electrical Reference on Pg. 109.
Other loads or sensors should be neither short
nor open. Some values are given on the sche-
matics. For details on what some switch posi-
tions mean see Table 2-1. Limit Switch States
on Pg. 109. Also, inspect the connector for
pins that are damaged, loose pushed out, etc.
Step 3 Find component power con- Is the component power good? Turn on Pass Go to step 4
tacts. machine and check the harness connector Fail Follow power connections back to source check-
contacts for power. Not all components are ing for power or continuity. Typically, the failure
powered by 12VDC. isn’t too close to the battery ground terminal
because then so many things wouldn’t work, this
fault would not be detected. Repair as needed

3128411 1200SJP 1350SJP 1-105


SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 4 Is the signal wire good? Check the signal wire Pass Go to step 5
between the component and the signal input/ Fail Repair as needed
output on the module. Signal lists start with
section 2.2 BLAM Module Connector Pinouts
on Pg. 152. The information is also on the
schematics. There should only be continuity
between the component and the proper pin on
the module in accordance with the schematic.
There should not be shorts between the wire
and battery + or - terminals, etc. Isolate har-
ness sections that may have a problem by dis-
connecting connectors as needed. Be sure to
check for pins that are damaged, loose or
pushed out of the connector, etc.
Step 5 Are the other wires good? Check wire from the Pass Recheck measurements or try troubleshooting a
component in question ground connection to different fault. If the component and wiring are
the nearest major component. It should have good, reprogram/replace the associated module.
continuity to the module, swivel or bus con- Fail Repair as needed
nector in accordance with the schematic.

DTC 33XX - COMMON STG PROCEDURE


Common short to ground procedure. A module input or output pin has been shorted to ground. All driver faults are detected
in a similar manner. Short to ground is detected when the analog feedback reads low and the output is commanded on. See
the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting
ground. This procedure applies to a number of faults so it leaves the determination of specific troubleshooting steps to the
technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power
for a particular component does not necessarily come directly from the battery. For example, the platform module power and
ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate
module, such as the main boom angle sensors and PVG valves. When opening any electrical connection, inspect the con-
nectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several examples are given start-
ing at DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND on Pg. 87.

Note Pretest Instructions Test Result Corrective Action


Step 1 Find component on sche- Is the component good? Check the compo- Pass Go to step 3
matic and on the machine. nent resistance. Resistances of coils are given Fail Repair as needed
in Section 2. Electrical Reference on Pg. 109.
Other loads or sensors should be neither short
nor open. Also, inspect the connector for pins
that are damaged, loose or pushed out, etc.
Step 2 Find component power con- Is the component power good? Turn on Pass Go to step 4
tacts. machine and check the harness connector Fail Follow power connections back to source check-
contacts for power. Not all components are ing for power or continuity. Typically, the failure
powered by 12VDC. isn’t too close to the battery ground terminal
because then so many things wouldn’t work, this
fault would not be detected. Repair as needed

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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

Note Pretest Instructions Test Result Corrective Action


Step 3 Is the signal wire good? Check the signal wire Pass Go to step 4
between the component and the signal input/ Fail Repair as needed
output on the module. Signal lists start with
section 2.2 BLAM Module Connector Pinouts
on Pg. 152. The information is also on the
schematics. There should only be continuity
between the component and the proper pin on
the module in accordance with the schematic.
There should not be shorts between the wire
and battery + or - terminals, etc. Isolate har-
ness sections that may have a problem by dis-
connecting connectors as needed. Be sure to
include checking for pins that are damaged,
loose or pushed out of the connector.
Step 4 Are the other wires good? If it does not go to Pass Recheck measurements or try troubleshooting a
ground, check other wire from the component different fault. If the component and wiring are
in question connection to the nearest major good, reprogram/replace the associated module.
component. It should have continuity to the Fail Repair as needed
module, swivel, bus or other connector in
accordance with the schematic.

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SECTION 2 - ELECTRICAL REFERENCE

SECTION 2. ELECTRICAL REFERENCE


Limit Switch States

Table 2-1. Limit Switch States


Normally Open or
Connector Switch Reference State
Closed
X146 Jib Stow NC Open = Stowed (Jib > 70° Right)
X147 Jib Center NC Open = Jib Centered ±5°
X204 RF Axle Extension NC Closed = Extended
X205 LF Axle Extension NC Closed = Extended
X213 Osc Axle Lockout Pressure NO Closed = Pressure > 200psi
X216 Drive Orientation NO Open = Normal Orientation
X225 LR Axle Extension NC Closed = Extended
X226 RR Axle Extension NC Closed = Extended
X281 Transport Limit Switch NC & NO NC (White to Black) = Closed -AND- NO (White to Red) = Open
= Transport position
X282 Broken Cable Proximity Switch NO Closed (Black to Blue = 12 V) = Cable in tact

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SECTION 2 - ELECTRICAL REFERENCE

Color Key

Figure 2-1. Color Key

3128463 1200SJP 1350SJP 2-111


SECTION 2 - ELECTRICAL REFERENCE

Platform Area Solenoids

Table 2-2. Platform Area Solenoids


Nominal Resistance
Connector Function
(Ohms)
X135 Platform Dump 6.4
X136 Level Up 10.1
X137 Level Down 10.1
X138 Rotate Right 10.1
X139 Rotate Left 10.1
X140 Jig Swing Right 10.1
X141 Jib Swing Left 10.1
X142 Jib Up 10.1
X143 Jib Down 10.1

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SECTION 2 - ELECTRICAL REFERENCE

Platform Area Connectors

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

1. Power/Emergency Stop 12. Soft Touch Indicator


1705744 A
2. Engine Start / Aux Power 13. Platform Rotate
3. Capacity Select 14. Jib Stow Override
J1 J4 4. Drive Orientation Override 15. Function Speed Control
5. Drive/Steer 16. Main Lift / Swing
J2 J3 6. Main Boom Telescope 17. Drive Speed / Torque Select
1702565 A
7. Lights 18. Steer Select
8. Jib Lift 19. Platform Level Override
9. Soft Touch Override 20. Axle Extend / Retract
1705745 B

10. Jib Swing 21. Horn


11. Tower Boom Lift (1250 Only) 22. Indicator Panel
23. Boom Control Select

1705171 A 1702938 1705170 A

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

PLATFORM CONTROL AREA


Figure 2-2. Platform Area Connectors

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SECTION 2 - ELECTRICAL REFERENCE

Boom Area Connectors

LOAD SENSING PIN


PLATFORM LEVEL BOOM LENGTH (VIEW ROTATED. CONNECTOR
X281
SENSOR LEFT LIMIT SWITCH ON VALVE SIDE.)

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

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2-116 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Engine Area Connectors

X241
X240

X103
X084

X113

STARTER
7500W
GENERATOR

X120 RIGHT DRIVE FWD


X118 RIGHT DRIVE REV
X121 LEFT DRIVE FWD
X119 LEFT DRIVE REV THESE VIEWS SHOWN FOR CLARITY

X250
X251

ENGINE SIDE AREA


Figure 2-4. Engine Area Connectors

3128463 1200SJP 1350SJP 2-117


SECTION 2 - ELECTRICAL REFERENCE

Main Valve Area Solenoids

Table 2-3. Main Valve Area Solenoids


Nominal Resistance
Connector Function
(Ohms)
X069 Swing Right 5.2
X070 Swing left 5.2
X071 Main Tele Extend 4.7
X072 Tele Proportional 4.7
X073 Tele Retract 4.7
X074 Main Dump 7.2
X274 Aux Lift Down Select 5.0
X275 Aux Lift Down 5.0
X276 Lift Up 5.0
X277 Lift Down 5.0
X286 Lift Flow Control 5.0

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SECTION 2 - ELECTRICAL REFERENCE

Main Valve Area Connectors

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

X278 CAN to BLAM

VIEW ROTATED X268 CAN to MTB MAIN LIFT SWING


FOR CLARITY DOWN LEFT
X277 MAIN X070
MAIN TELE MAIN TELE LIFT UP
EXTEND SWING
RETRACT X276 RIGHT
X071 X073 MAIN
X279 CAN to Engine X069 DUMP
LIFT DOWN
X074
X088
J3 X086
AUXILIARY

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

MAIN VALVE AREA


Figure 2-5. Main Valve Area Connectors

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SECTION 2 - ELECTRICAL REFERENCE

Ground Control Connectors

X017
X008 X007
X001
X271
X010

X043

X002 X004

X003
X012
X011

X024

X025

X023

X022
X021
X029

X026

X020
X028
X030

X014 CAN to Ground Module X018

X270 CAN to Platform GROUND CONTROL BOX AREA


X269 CAN to BLAM
Figure 2-6. Ground Control Connectors

3128463 1200SJP 1350SJP 2-121


SECTION 2 - ELECTRICAL REFERENCE

Chassis Area Solenoids

Table 2-4. Chassis Area Solenoids


Nominal Resistance
Connector Function
(Ohms)
X206 Front Axles Extend 4.9
X207 Front Left Steer Right 4.9
X208 Front Right Steer Right 4.9
X209 Front Axles Retract 4.9
X210 Front Left Steer Left 4.9
X211 Front Right Steer Left 4.9
X212 Axle Lockout Solenoid 6.2
X214 2 Speed Solenoid 6.2
X215 Brake Release Solenoid 6.3
X219 Rear Right Steer Left 4.9
X220 Rear Left Steer left 4.9
X221 Rear Axles Retract 4.9
X222 Rear Right Steer Right 4.9
X223 Rear Left Steer Right 4.9
X224 Rear Axles Extend 4.9

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SECTION 2 - ELECTRICAL REFERENCE

Chassis Area Connectors

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

VALVES TURNED FOR CLARITY

CHASSIS AREA
Figure 2-7. Chassis Area Connectors

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SECTION 2 - ELECTRICAL REFERENCE

Ground, Engine and BLAM Schematic

DRAWING NUMBER REV.


8 7 6 5 4 3 2 1 1870214 B

14 GA. FUSE LINK


18 BLACK (12) X030 MTB
B1 EMS
13 YEL/RED 2-5 2
YEL/RED 2-4 (12)
4 X029 X027 STARTER
10 YEL/RED 2-2 (12) 1 MOTOR DEUTZ ENGINE
YEL/RED 2-1 (12)
3 RED 1-2(10) SOL.
YEL/RED 2-30 B2
H 30 AMP H
YEL/RED 2-30-4 STARTER
X113 MOTOR
YEL/RED 2-1-1(12)

4 YEL/RED 2-3-1 BLACK (16)


RECTIFER B+
87a 87
YEL/RED 2-4-1 IGN. ON
9 COOLANT X124 2 FUSIBLE
85 86 RELAY 8 GRD(TempAll)
STATOR

48-12(12)
WHT/YEL
7 30 TEMPERATURE 1 1 LINK
X012 9 ADC7(TEMP3)
5 13 SPEED 2 X125
ENGINE 2
X112

EMR2 ENGINE CONTROL TO ENGINE


SPEED X122
87 sol.

BRN/WHT 47-8
87a CAMSHAFT 1 12 GRD (SPEED) 10
POWER DOWN IN HEAD GLOW PLUG

RED 1-1(10)
86

WHT/YEL 48-13 (8)


85
RELAY X011 YEL/RED 2-1-3 (12) ALTERNATOR
30 1 23 GRD (ACD2) 11
NOTE: ENGINE WILL ONLY
12
BLACK 2 HAVE INTAKE HEATERS OR REGULATOR
CHARGE 4 ADC5(TEMP1)

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

MTB TO EMR2 ENGINE CONTROL


IN 17 YEL/RED 2-6-2 WHT/YEL 48-10 (10)
X021 MAIN TELE 1 22 +5Vref(ADC4) sol.
OUT BROWN 14-2 30 2 BLU/ORN 52-2 HORN OUTPUT
ENGINE OIL
RIGHT GRAY 24-2 18 2 21 ADC4
X024 ROTATE PRESSURE
LEFT GRAY 23-2 6 X257 INTAKE HEATERS
3 RED/WHT 50-2-1 3 20 X111
GND (ADC4)

RED 1-1 (12)


PINK 25-2 17
LEVEL UP 7 PINK 26-3-1
X025 14 ActorOut
DOWN PINK 26-2 1
5
5 PINK 25-3-1
START SWITCH WHT/YEL 48-1 4 2 15 ActorOut
X026 13 RED/WHT 50-1 MAIN DUMP X074
AUX POWER/ENABLE BRN/ORN 53-2 16 EMR
X004 1 17 RackMeasCom
ACTUATOR 3
UP BLUE 27-2 19
X022 JIB 9 BROWN 55-10 TELE. FLOW CONTROL X072
DOWN BLUE 28-2 8 J4 (BLUE) 4 19 RackMeasSignal
33 X126
UP TAN 3-2 23
X020 MAIN LIFT 4 BROWN 13-3 IN X073 5 18 RackMeasRef
DOWN TAN 4-2 33 MAIN TELE.
X002 16 BROWN 14-3 OUT X071

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

YEL/RED 2-70 (14)


RIGHT WHITE 58-2 19 UP
X023 JIB SWING 11 TAN 3-3 MAIN LIFT X276
F LEFT WHITE 60-2 20 F

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)

BRN/WHT 47-8 RED (18)


ENGINE LOW
X035 30 YEL/RED 2-1-98 A
OIL PRESSURE BRN/WHT 47-5-1 29
X063
ENGINE HIGH HEAD/TAIL X242
X034 BRN/WHT 47-6-1 28 27 BLU/ORN 52-10 J3 GREEN X088 BOOM LENGTH ANGLE MODULE
TEMPERATURE ALARM LIGHTS

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)

15 3 YEL/RED 2-70-4 (14) YEL/RED 2-82 1 ORANGE 1 RED


YEL/RED 2-40-10 23 #2 LEFT SIDE BOOM
9 ORN/RED 49-112 2 2 WHITE

BATTERY CABLE (1 GA.)


22 BLU/ORN 52-5 YELLOW ANGLE SENSOR
31
BLACK 3 BLACK 3 BLACK
10 16 SERIAL OUTPUT
BRN/BLK 4 BRN/BLK
BROKEN CABLE BLACK 4 ORN/RED 49-88 12 7
12
PROX. SWITCH 4 1 BROWN 5 YEL/RED 2-61 32
25 YEL/RED 2-81 1 RED #1 RIGHT SIDE BOOM
X282 16 X098
RED 1
23 GND -
C 3 8 ORN/RED 49-111 2 2 WHITE ANGLE SENSOR C
BLUE
BLUE BLACK

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

Figure 2-8. Ground, Engine and BLAM Electrical Schematic

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2-126 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Pleatform Schematic

DRAWING NUMBER REV.


8 7 6 5 4 3 2 1 1870214 B
X144

ORN/RED 49-10 14 ORN/RED 49-12 2 JIB STOW LIMIT SWITCH X146

YEL/RED 2-11-1 1 BROWN(18)


7
TO MTB
YEL/RED 2-11 13 YEL/RED 2-11 9 RED/BLK
1 JIB INLINE LIMIT SWITCH X147
YEL/RED 2-11-2
5 BLUE(18)

ORN/RED 49-12 21 ORN/RED 49-11 2


H H
X145

YEL/RED 2-12-1 PLATFORM WORK LIGHTS

YEL/RED 2-12-2 X153


8 BLACK (12) 8
ORN/RED 49-80 RED
ORN/RED 49-63 BLACK 18 BLK/WHT (12) 18

V REF. X162 X150 BASKET LEVEL SENSOR #1


25 17

26 7 1 RED 1 RED RED


19 2 BLUE 2 WHITE MOUNTED ON RIGHT BLACK
STROBE LIGHT
IN BROWN 13-1 5 21 ORN/RED 49-68 3 BLACK 3 BLACK SIDE OF BOOM X154
X178 MAIN TELE OUT BROWN 14-1 6 BRAIDED SHIELD BRN/BLK (18)
GRAY 24-1 BLU/ORN 52-11 15 YEL/BLK(18) 15 BLU/ORN 52-11 1 MTB
RIGHT 7
X188 ROTATE SELECT
LEFT
G GRAY 23-1 8
2 SWITCH
G
PINK 25-1 9 4 X163 BASKET LEVEL SENSOR #2
UP X148
X195 LEVEL
DOWN 10 X057
PINK 26-1
4 ORANGE 1 RED
11 35
X180 UP BLUE 27-1 20 AMP C.B.
JIB 5 YELLOW 2 WHITE MOUNTED ON LEFT
DOWN BLUE 28-1 34
12
33 6 3 BLACK SIDE OF BOOM
ORN/RED 49-81 BLACK
X199 33
Ref.V BRAIDED SHIELD BRN/BLK (18)
PUMP 4 RED/WHT 55-30 34
X192 19
POTENTIOMETER WIPER 6 35
RED/WHT 55-31
13
10 WHITE(10)
GND 5 BLACK
11 PINK 26-3-1 BLACK(10)
CREEP 3 2 ORN/RED 49-11 32
12 PINK 25-3-1 GREEN(10)
YEL/RED 2-10 18
13
1 RED/WHT 50-2-1
14
X135 PLATFORM
2 RED/WHT 50-2-3 5 RED/WHT 50-2-3 PLATFORM DUMP
EMS X179
3 15 PINK 25-3-2 UP X136
PINK 25-3-3 7 PINK 25-3-3
LEVEL YEL/RED
4 X165 13 ORN/BLK(18) 13
DOWN X137 2-5
YELLOW 55-16 16 16 PINK 26-3-2 PINK 26-3-3 6 PINK 26-3-3
CRAB STEER
F X196
COORDINATED STEER YEL/RED F
YELLOW 55-17 17 5 GRAY 23-3 8 LEFT X138 10 ORN(12) 10
J1 GRAY 23-3 2-2(12)
ROTATE
500# 15 YEL/RED 2-37 20 (WHITE) 6 GRAY 24-3 9 RIGHT X139
GRAY 24-3
21 X169
X175 CAPACITY RED/YEL 54-1 25 BLUE 27-3 10 UP X142 YEL/RED
1000#
BLUE 27-3
JIB 2-3(16)
22 26 BLUE 28-3 11 BLUE 28-3 DOWN X143
X285 BOOM CONTROL SELECT ORN/RED 49-120
EXT YEL/WHT 43-1 23 J7 27 WHITE 60-3 19 WHITE 60-3 RIGHT
X140
X194 AXLE SET (BLACK)
YEL/WHT 44-1 24 JIB SWING
RET 28 WHITE 59-3 WHITE 59-3
20 LEFT X141

29 BLACK 12 BLACK

START SWITCH WHT/YEL 48-1 14 2 PTF EMS


X177
AUX POWER 15 31 CAN HI RED (18) 3 RED (18) 3
BRN/ORN 53-1
30 CAN LO BLACK (18) 2 BLACK (18) 2
ENGINE SPEED WHT/YEL 48-5 28
X198
TWO SPEED 27 32 CAN SHIELD 1 SHIELD 1
ORN 55-46
EMS PTF TO MTB output YEL/RED 2-3-1 4
X193 31 3 ORN (18) 4
HORN BLU/ORN 52-1
1 GND MODE YEL/RED 2-30-1
X184 SOFT TOUCH OVERIDE ORN/RED 49-40 29

E X181 HEAD/TAIL LIGHTS BLU/ORN 52-12 30 8 ORN/RED 49-70 7 BLACK FOOTSWITCH E


YEL/RED 2-16-2 8 WHITE GREEN 6 YELLOW (18) 6

19 ORN/RED 49-4 X152


ALARM X172
20 BLACK
18 ORN/RED 49-69 3

9 BLU/ORN 52-4 1 BLU/ORN 52-4 GENERATOR


32 22 X155

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

BOOM CONTROL SYSTEM 1 ORN/RED 49-1000 19

AXLE SET 2 WHT/YEL 39-1 14


J3
DRIVE ORIENTATION 3 ORANGE 55-51 30
X182
453KG/1000# CAPACITY 4 RED/YEL 54-3-1 RED/YEL 54-3 13

BROKEN CABLE 5 ORN/RED 49-101 10


SWING
SYSTEM DISTRESS 6 BRN/WHT 47-12 8
C 5K C
8

AUTO LEVEL SYSTEM 1 BRN/WHT 47-10 20 6

GENERATOR ON BLU/ORN 52-4-1 5 X197


2 15 X167
1
OVERLOAD J4
3 ORN/RED 49-100 11
J5 4
226KG/500# CAPACITY X183 4 RED/YEL 54-2 12 (WHITE)
2
TILT 5 ORN/RED 49-3 6 LIFT
12= 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
X160
GLOW PLUG 6 WHT/YEL 48-6 17 3 5K
12= 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOXX161
7
12
= 19 POSITION DEUTSCH CONNECTOR TO MAIN TERMINAL/GROUND BOXX043

= TERMINAL STRIP IN PLATFORM BOX


BLU/ORN 52-3 33

31 8 = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.) X164


LEFT
X173 5 STEER
X168 6 RIGHT
1 ANALYZER POWER RED 11 ORN/RED 49-92 26 X176
B 2 ANALYZER RECEIVE J6 4 B
GREEN 10 ORN/RED 49-91 28
(BLACK) 2
3 ANALYZER TRANSMIT WHITE 9 ORN/RED 49-90 29
1
4 ANALYZER GROUND BLACK/SHIELD 8 ORN/RED 49-89 27 DRIVE
3

X171 14 YEL/RED 2-36 7


LEFT WHITE 59-1 2
X185 JIB SWING YEL/RED 2-10-14 34
RIGHT
WHITE 60-1 1
ORANGE 55-50 4
X174 DRIVE ORIENTATION OVERIDE YEL/RED 2-16 3

YEL/RED 2-16-1

X189 JIB STOW V BAT.


WHITE 59-60 5

YEL/RED 2-16-2 8

A 6 YEL/RED 2-16-3 A

SOFT TOUCH LIMIT SWITCHS BLACK ORN/RED 49-67 4 BLACK WHITE


WHITE 5

8 7 6 5 4 3 2 1

Figure 2-9. Platform Electrical Schematic

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SECTION 2 - ELECTRICAL REFERENCE

Chassis Electric Schematic

DRAWING NUMBER REV.


8 7 6 5 4 3 2 1 1870214 B

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

4 ORN/RED 49-104 ORN/RED 6

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

11 YEL/WHT 39-2-43-1 YEL/WHT 43-1 REAR AXLE EXTEND X224

E 12 YEL/WHT 40-2-44-1 YEL/WHT 44-1 REAR AXLE RETRACT X221


E

YEL/WHT 40-2 FRONT AXLE RETRACT X209

X200

1 RED 1 RED A
X201
RIGHT FRONT
2 WHT 2 BLUE B
STEER SENSOR

3 BLK 3 BLK C

D BLK BRN/BLK 4 BRN/BLK X203 D

1 YEL 10-2 RIGHT FRONT STEER RIGHT X208 4 RED 1 RED A

J3 GREEN
X202
LEFT FRONT

YEL/RED 2-1-1 (14GA)


2 YEL 9-2 RIGHT FRONT STEER LEFT X211 5 WHT 2 BLUE B
STEER SENSOR

3 YEL 10-1 LEFT FRONT STEER RIGHT X207 6 BLK 3 BLK C

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 BRN/BLK 4 BRN/BLK


RED

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

Figure 2-10. Chassis Electrical Schematic

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SECTION 2 - ELECTRICAL REFERENCE

Electrical Wiring Sheet 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

X180 ENGINE X123


X124
J1
X182 X150 X244 SPEED OIL
X183 X166 X243 TEMP PRESSURE
SENSOR SWITCH SWITCH
J5 J6

X184 FOOTSWITCH
X185 X125 X245 X122
J2

X168 LIFT TO CHASSIS


X167 X152 BOOM CYLINDER X083 POWER RELAY
J8

X187 ANGLE PIVOT


X188 X170 X153 PLATFORM SENSOR ALTERNATOR PIN
X154 #1 (RIGHT)
X189 WORK LIGHTS X084
X190 X171 BOOM
X191 LENGTH ANALYZER
X099 SENSOR CONNECTION
X192 X155 GENERATOR
SWITCH X091 SWIVEL
X193 X273
X199 X172
TRANSPORT X062
X194 LIMIT B.L.A.M.
X195 SWITCH MODULE
X196 X164 X281 BOOM
BROKEN ANGLE X087 X090
CABLE SENSOR J2
PROXIMITY #2 (LEFT) X089 J5
X197 X282 SWITCH
X198 J4 X088
X086 X276
X100 J1 J3
X272 X069
PLATFORM STROBE X074
CONTROL DIAGNOSTIC LIGHT X096 X071
BOX X173 ANALYZER
X274
X040 X035
GROUND X034 X036 X271 X013 X007 X278 X279
X033 X039 X269 X275
CONTROL X010 X008 X014 X095
BOX X038 X001
X032 CHASSIS X070
X031 X057 X267 X266 POWER
X037 DISTRIBUTION X098 X280 X268
RELAY X097 X072 MAIN
J8

X073 CONTROL
X024 VALVE
J1

HEADLIGHTS X063 X278


X023 X277
J7

X025 X283 X064


X101 HORN X107
X027 X103 X102 X106
J3 J2

X021 ALARM X110


X026 X104 X105
J4

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)

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SECTION 2 - ELECTRICAL REFERENCE

Electrical Wiring Sheet 2

STEER STEER
ANGLE ANGLE
SENSOR SENSOR

X200 X239

AXLE X226 AXLE


AXLE LIMIT LIMIT AXLE
POWER SWITCH SWITCH POWER
TRACK X204 TRACK

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

X209 X210 X211 X213 X215 X222 X223 X224


AXLE AXLE
POWER POWER
TRACK TRACK
X225
AXLE
LIMIT
SWITCH
AXLE
LIMIT
SWITCH
X205 BATTERY CABLE CONNECTIONS
X110
X116
X117 X108
+
AUX PUMP X238
X203

STARTER X113
STEER START RELAY AUX STEER
ANGLE POWER ANGLE
SENSOR RELAY SENSOR

X112
Figure 2-12. Electrical Wiring (Sheet 2 of 2)

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Telematics System

GATEWAY
MODULE

X289 GATEWAY MODULE TELEMATICS TELEMATICS


DIAGNOSTIC COMMUNICATION
CONNECTOR UNIT
X287 (GRAY) X287 (BLACK) X289 X290

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

Figure 2-13. Telematics System

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SECTION 2 - ELECTRICAL REFERENCE

2.1 CONNECTOR INDEX


Table 2-5. Connector Index
Connector Description End1 End2 Schematic Drawings
X001 Ground J1, White/Natural - 35 Position AMP352P (Neu- -- 2-8. (6D) 2-6.
tral)
X002 Ground J2, Gray - 35 Position AMP354P (Gray) -- 2-8. (6F) 2-6.
X004 Ground J4, Blue - 35 Position AMP355P (Blue) -- 2-8. (7F) 2-6.
X007 Ground J7, Black - 35 Position AMP351P -- 2-8. (7C) 2-6.
(Black)
X008 Ground J8 - 4 Position MMF04P -- 2-8. (7E) 2-6.
X009 MTB Ground Bus - 12 Position DT12BP --
X010 MTB Power Bus - 6 Position DT06AP -- 2-8. (5E) 2-6.
X011 Power Down Relay -- -- 2-8. (5G) 2-6.
X012 Ignition On Relay -- -- 2-8. (4H) 2-6.
X013 Ground Analyzer - 4 Position AMP04R AMP04P 2-8. (5D)
X014 CAN 3way - to Ground Module, Green DT03P032BP -- 2-8. (7B) 2-6.
(Blue)
X015 RS232 passthru DT08AP DT08AR
X016 Ground Panel Relay -- --
X017 Boom Transport Switch Pass thru AMP06P AMP06R 2-8. (7C) 2-6.
X018 Ground Swing Switch E06P -- 2-8. (7F) 2-6.
X019 Ground Tower Lift Switch E06P --
X020 Ground Main Lift Switch E06P -- 2-8. (7F) 2-6.
X021 Ground Main Tele Switch E06P -- 2-8. (7G) 2-6.
X022 Ground Jib Lift Switch E06P -- 2-8. (7F) 2-6.
X023 Ground Jib Swing Switch E06P -- 2-8. (7F) 2-6.
X024 Ground Rotate Switch E06P -- 2-8. (7G) 2-6.
X025 Ground Level Switch E06P -- 2-8. (7G) 2-6.
X026 Ground Start Switch E06P -- 2-8. (7G) 2-6.
X027 Fuseholder with Cover -- -- 2-8. (4H)
X028 Ground Hourmeter -- -- 2-8. (7F) 2-6.
X029 Ground EMS Switch -- -- 2-8. (4H) 2-6.
X030 Ground Key Switch -- -- 2-8. (5H) 2-6.
X031 500 Capacity Light PACKARD2LR -- 2-8. (7E)
X032 Axle Lock Light PACKARD2LR -- 2-8. (7E)
X033 Glow Plugs Light PACKARD2LR -- 2-8. (7E)
X034 High Engine Temperature Light PACKARD2LR -- 2-8. (7E)
X035 Oil Pressure Light PACKARD2LR -- 2-8. (7F)
X036 Battery Voltage Light PACKARD2LR -- 2-8. (7E)
X037 1000 Capacity Light PACKARD2LR -- 2-8. (7E)
X038 Platform Overload (Euro) Light PACKARD2LR -- 2-8. (7E)
X039 Envelope Light (BCS) PACKARD2LR -- 2-8. (7E)
X040 Test Light PACKARD2LR -- 2-8. (7E)
X042 MTB pass thru - 21 Position DHD21R DHD21P
X043 MTB pass thru - 19 Position DHD19R DHD19P 2-8. (8) 2-6.
2-9. (1)
X044 Turntable pass thru - 21 Position DHD21R DHD21P
X045 Turntable pass thru - 19 Position DHD19R DHD19P
X046 Dual Capacity Switch Passthru - 3 Position DT03P DT03R

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X047 Main Boom Transport Switch Passthru - 3 Position DT03R DT03P
X048 Main Rotary Angle Sensor Right - 5 Position PHEONIX5P --
X049 Main Rotary Angle Sensor Left - 5 Position PHEONIX5P --
X050 Boom Sensor Passthru - 19 Position DHD19R DHD19P
X051 Main Boom Angle Switch DTM04P --
X052 Dual Capacity Switch #1 -- --
X053 Dual Capacity Switch #2 -- --
X054 Main Boom Transport Switch #1 -- --
X055 Main Boom Transport Switch #2 -- --
X056 Tower Boom Transport Switch -- --
X057 Strobe Light AMP02R -- 2-9. (1G)
X058 BLAM passthru - 12 Position DT12AR DT12AP
X059 RS232 Backup passthru DT03R --
X060 Load Pin Pass Thru - 8 Position (Gray) DT08AR DT08AP
X061 Filter Module -- --
X062 Load Pin panel - 6 Position ANL06P -- 2-8. (2C) 2-3.
X063 Alarm Connector AMP02P -- 2-8. (6E)
X064 Fuel Level Sensor - 2 Position PACKARD2P --
X065 Main Lift PVG - 4 Position (Black) AMPPVG4P --
(Black)
X066 Tower Lift PVG - 4 Position (Black) AMPPVG4P --
(Black)
X067 Tower Tele PVG - 4 Position (Black) AMPPVG4P --
(Black)
X068 PVG Enable Solenoid DIN43650P --
X069 Swing Right Solenoid DIN43650P -- 2-8. (6F)
X070 Swing Left Solenoid DIN43650P -- 2-8. (6F)
X071 Main Tele Extend Solenoid DIN43650P -- 2-8. (6F)
X072 Main Tele Proportional Solenoid DIN43650P -- 2-8. (6F)
X073 Main Tele Retract Solenoid DIN43650P -- 2-8. (6F)
X074 Main Dump Solenoid DIN43650P -- 2-8. (6G)
X075 Tower Lift Pilot Solenoid DIN43650P --
X076 Tower Tele Pilot Solenoid DIN43650P --
X077 Main Lift Pilot Solenoid DIN43650P --
X078 Hyd Oil Temp Switch - 2 Position DT02P --
X079 Pressure Switch DIN43650P --
X080 Tower Lift Enable Solenoid DIN43650P --
X081 Tower Tele Enable Solenoid DIN43650P --
X082 Main Lift Enable Solenoid DIN43650P --
X083 Swivel - 12 Position (Black) DT12BP -- 2-8. (5B) 2-5.,2-7.
2-10. (5H)
X084 Deutz EMR2 Chassis CAN - 3 Position DT03R DT03P 2-8. (4E) 2-4.
X086 BLAM J1 - 12 Position (Gray) DT12AP -- 2-8. (4D) 2-5.
X087 BLAM J2 - 12 Position (Black) DT12BP -- 2-8. (3C) 2-5.
X088 BLAM J3 - 12 Position DT12CP -- 2-8. (4E) 2-5.
X089 BLAM J4 - 8 Position DT08AP -- 2-8. (3C) 2-5.
X090 BLAM J5 - 12 Position (Green) DT12DP -- 2-8. (3E) 2-5.

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X091 Blam Analyzer - 4 Position AMP04R -- 2-8. (2D) 2-5.
X092 Tower Lift Cyl Angle Sensor - 3 Position DT03P DT03R
X093 Boom Length Sensor 1(Top) - 3 Position DT03P DT03R
X094 Tower Boom Length Sensor 2 (Bottom) - 3 Position DT03P DT03R
X095 Boom Angle Sensor1 Passthrough - 4 Position (Gray) DT04R DT04P 2-8. (2C) 2-5.
X096 Boom Angle Sensor2 Passthrough - 4 Position (Gray) DT04P DT04R 2-8. (2C) 2-5.
X097 12 Pos Batt Busbar DT12BP -- 2-8. (3C) 2-5.
X098 12 Pos Ground Busbar DT12BP -- 2-8. (3C) 2-5.
X099 Boom Angle Sensor #1 (Right) DTM03P DTM03R 2-8. (2C) 2-3.
X100 Boom Angle Sensor #2 (Left) DTM03P DTM03R 2-8. (2C) 2-3.
X101 Lights Relay -- -- 2-8. (6E)
X102 Headlight -- -- 2-5.
X103 Headlight -- -- 2-4.
X104 Taillight -- -- 2-3.
X105 Taillight -- -- 2-3.
X106 BLAM Pump Passthru DT06R -- 2-8. (2E) 2-5.
X107 Horn -- -- 2-5.
X108 Aux Power Relay -- -- 2-8. (2B)
X109 Power Relay Fuse -- -- 2-8. (4B)
X110 Aux Pump -- -- 2-8. (2B) 2-5.
X111 Glow Plug Relay -- -- 2-8. (2G)
X112 Start Relay -- -- 2-8. (2G)
X113 Starter -- -- 2-8. (2H) 2-4.
X116 Battery Positive -- -- 2-8. (1B) 2-5.
X117 Battery Negative -- -- 2-8. (1B) 2-5.
X118 Right Side Drive Reverse Solenoid DIN43650P -- 2-8. (2E) 2-4.
X119 Left Side Drive Reverse Solenoid DIN43650P -- 2-8. (2E) 2-4.
X120 Right Side Drive Forward Solenoid DIN43650P -- 2-8. (2E) 2-4.
X121 Left Side Drive Forward Solenoid DIN43650P -- 2-8. (2D) 2-4.
X122 Engine Speed Sensor - 2 Position AMPJT826008P -- 2-8. (4H)
X123 Engine Oil Pressure Switch -- --
X124 Engine Coolant Temp Switch -- -- 2-8. (4H)
X125 Engine Alternator -- -- 2-8. (1H)
X126 Engine Throttle Actuator DIN43650P -- 2-8. (4F)
X127 Generator Relay -- -- 2-8. (5B)
X128 Generator Connector -- --
X129 Generator Control Box -- --
X130 Generator Extension -- --
X131 Generator Extension -- --
X132 Generator Outlet -- --
X133 Generator -- --
X134 Worklight passthru - 3 Position PACKARD3P PACKARD3R
X135 Platform Dump Solenoid DIN43650P -- 2-9. (4F) 2-2.
X136 Platform Level Up Solenoid DIN43650P -- 2-9. (4F) 2-2.
X137 Platform Level Down Solenoid DIN43650P -- 2-9. (4F) 2-2.
X138 Platform Rotate Right Solenoid DIN43650P -- 2-9. (4F) 2-2.
X139 Platform Rotate Left Solenoid DIN43650P -- 2-9. (4F) 2-2.

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X140 Platform Jib Swing Right DIN43650P -- 2-9. (4F) 2-2.
X141 Platform Jib Swing Left DIN43650P -- 2-9. (4F) 2-2.
X142 Platform Jib Up DIN43650P -- 2-9. (4F) 2-2.
X143 Platform Jib Down DIN43650P -- 2-9. (4F) 2-2.
X144 Jib Stow Pass Thru - 2 Position DT02R -- 2-9. (5H)
X145 Jib Limit Switch Pass Thru - 2 Position DT02P -- 2-9. (5H)
X146 Jib Stow Switch -- -- 2-9. (4H) 2-3.
X147 Jib Position Switch -- -- 2-9. (4H) 2-3.
X148 Platform Level Sensor 2 (Left) DTM03R DTM03P 2-9. (4G) 2-3.
X150 Platform Level Sensor 1 (Right) DTM03R DTM03P 2-9. (4G) 2-3.
X152 Footswitch -- -- 2-9. (3E) 2-2.
X153 Platform Worklight -- -- 2-9. (2H) 2-2.
X154 Platform Worklight -- -- 2-9. (2G) 2-2.
X155 Generator Switch -- -- 2-9. (5E) 2-2.
X156 Floodlights passthru - 3 Position PACKARD3P PACKARD3R
X157 Platform Floodlights component -- --
X158 Floodlight passthru - 2 Position AMP02P AMP02R
X159 Floodlight passthru - 2 Position AMP02P AMP02R
X160 Platform Control Box Passthrough - HD34-24-19-PE DHD19R DHD19P 2-9. (2)
X161 Platform Valve passthru - Deutsch 21 Pin DHD1821R DHD1821P 2-9. (5F)
X162 Platform Level Passthru #1 PHEONIX7P -- 2-9. (5G)
X163 Platform Level Passthru #2 PHEONIX7P -- 2-9. (5G)
X164 Platform passthru - Amp 15 Position AMP15R AMP15P 2-9. (A7,A6,
E5,5D,3E,7F)
X165 Platform J1 Connector - 35 Position (Natural) AMP352P (Neu- -- 2-9. (7F)
tral)
X166 Platform J2 Connector - 35 Position (Blue) AMP355P (Blue) -- 2-9. (7D)
X167 Platform J5 Connector, Male - 8 Position AMP08NP -- 2-9. (6C)
X168 Platform J6 Connector, Female - 8 Position AMP08BP -- 2-9. (6B)
X169 Platform J7 Connector - 35 Position (Black) AMP351P -- 2-9. (6F)
(Black)
X170 Platform J8 Connector, Male - 2 Position MMF02P -- 2-9. (6D)
X171 Platform Diagnostics Connector AMP04R -- 2-9. (8B)
X172 Platform Alarm MMF02P -- 2-9. (5E)
X173 Platform Analyzer Pass Thru AMP15R AMP15P 2-9. (7B)
X174 Drive Orientation Override Switch - 6 Position E06P -- 2-9. (7A) 2-2.
X175 Platform Capacity Select Switch - 6 Position E06P -- 2-9. (7F) 2-2.
X176 Controller Harness/Circuit Board Assembly (Drive and Steer) -- -- 2-9. (6B) 2-2.
X177 Platform Engine Start/ Aux Power Switch - 6 Position E06P -- 2-9. (7E) 2-2.
X178 Platform Boom Telescope Switch - 6 Position E06P -- 2-9. (7G) 2-2.
X179 Platform EMS Switch -- -- 2-9. (2F) 2-2.
X180 Platform Jib Lift Switch - 6 Position E06P -- 2-9. (7G) 2-2.
X181 Platform Lights Switch -- -- 2-9. (7E) 2-2.
X182 Platform LED J4 - 6 Position AMP06P -- 2-9. (8C) 2-2.
X183 Platform LED J3 - 6 Position AMP06P -- 2-9. (8C) 2-2.
X184 Platform Soft Touch Override Switch -- -- 2-9. (7E) 2-2.
X185 Platform Jib Swing Switch - 6 Position E06P -- 2-9. (7B) 2-2.

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X186 Platform Tower Boom Lift Switch - 6 Position E06P -- 2-2.
X187 Platform Soft Touch Indicator -- -- 2-9. (7D) 2-2.
X188 Platform Rotate Switch - 6 Position E06P -- 2-9. (7G) 2-2.
X189 Platform Jib Stow Override -- -- 2-9. (7A) 2-2.
X190 Platform LED J1 - 6 Position AMP06P -- 2-9. (D8) 2-2.
X191 Platform LED J2 - 6 Position AMP06P -- 2-9. (D8) 2-2.
X192 Speed Control Harness -- -- 2-9. (7G) 2-2.
X193 Platform Horn Switch -- -- 2-9. (7E) 2-2.
X194 Platform Axle Extent/Retract Switch - 6 Position E06P -- 2-9. (7F) 2-2.
X195 Platform Level Override Switch - 6 Position E06P -- 2-9. (7G) 2-2.
X196 Platform Steer Select Switch - 6 Position E06P -- 2-9. (7F) 2-2.
X197 Controller Harness Assembly (Lift and Swing) -- -- 2-9. (5C) 2-2.
X198 Platform Drive Speed / Torque Select Switch - 6 Position E06P -- 2-9. (7E) 2-2.
X199 Hyd Speed Pot passthru - 6 Position AMP06P -- 2-9. (7G)
X200 Front Right Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2D) 2-7.
X201 Front Right Steer Passthrough Connector, Gray - 4 Position DT04P DT04R 2-10. (2D)
X202 Front Left Steer Passthrough Connector, Gray - 4 Position DT04P DT04R 2-10. (2D)
X203 Front Left Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2D) 2-7.
X204 Front Right Axle Limit Switch -- -- 2-10. (6G) 2-7.
X205 Front Left Axle Limit Switch -- -- 2-10. (7G) 2-7.
X206 Front Axles Extend Solenoid DIN43650P -- 2-10. (7E) 2-7.
X207 Left Front Steer Right Solenoid DIN43650P -- 2-10. (7D) 2-7.
X208 Right Front Steer Right Solenoid DIN43650P -- 2-10. (7D) 2-7.
X209 Front Axles Retract Solenoid DIN43650P -- 2-10. (7E) 2-7.
X210 Left Front Steer Left Solenoid DIN43650P -- 2-10. (7C) 2-7.
X211 Right Front Steer Left Solenoid DIN43650P -- 2-10. (7D) 2-7.
X212 Axle Lockout Solenoid DIN43650P -- 2-10. (4G) 2-7.
X213 Axle Lockout Pressure Switch DIN43650P -- 2-10. (2G) 2-7.
X214 2spd Solenoid DIN43650P -- 2-10. (4F) 2-7.
X215 Brake Release Solenoid DIN43650P -- 2-10. (4F) 2-7.
X216 Swivel Chassis Connector - 12 Position DT12BR DT12BP 2-10. (5G) 2-7.
X219 Right Rear Steer Left Solenoid DIN43650P -- 2-10. (7C) 2-7.
X220 Left Rear Steer Left Solenoid DIN43650P -- 2-10. (7C) 2-7.
X221 Rear Axles Retract Solenoid DIN43650P -- 2-10. (7E) 2-7.
X222 Right Rear Steer Right Solenoid DIN43650P -- 2-10. (7C) 2-7.
X223 Left Rear Steer Right Solenoid DIN43650P -- 2-10. (7C) 2-7.
X224 Rear Axles Extend Solenoid DIN43650P -- 2-10. (7E) 2-7.
X225 Left Rear Axle Limit Switch -- -- 2-10. (7F) 2-7.
X226 Right Rear Axle Limit Switch -- -- 2-10. (6F) 2-7.
X227 Ground Bus - 6 Position DT06AP -- 2-10. (3F)
X228 Deleted in Newer revisions - 2 Position DT02P --
X229 Chassis Module J1 Connector, Gray - 12 Position DT12AP -- 2-10. (5B) 2-7.
X230 Chassis Module J2 Connector, Black - 12 Position DT12BP -- 2-10. (8G) 2-7.
X231 Chassis Module J3 Connector, Green - 12 Position DT12CP -- 2-7.
X232 Chassis Module J4 Connector, Gray - 8 Position DT08AP -- 2-10. (1G) 2-7.
X233 Chassis Moduel J5 Connector, Brown - 12 Position DT12DP -- 2-10. (8D) 2-7.
X235 Chassis Module Diagnostics Connector AMP04R -- 2-10. (7A) 2-7.

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X236 Rear Right Steer Passthrough Connector, Gray - 4 Position DT04P DT04R 2-10. (2C)
X237 Rear Left Steer Passthrough Connector, Gray - 4 Position DT04P -- 2-10. (2C)
X238 Rear Left Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2C) 2-7.
X239 Rear Right Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2C) 2-4.
X240 EMR2 ECU Equipment Connector AMP25RP -- 2-8. (3G) 2-4.
X241 EMR2 ECU Engine Connector AMP25LP -- 2-8. (3G) 2-4.
X242 EMR2 Engine Diagnostics Connector ITTC12P -- 2-8. (2F)
X243 EMR2 Capped 12 position Plug DEUTZ12ENGR --
X244 EMR2 16 position sensor passthru DEUTZ16P DEUTZ16R
X245 EMR2 12 position passthru DEUTZ12R DEUTZ12P
X246 Skypower Relay -- -- 2-8. (5A)
X247 Skypower Relay -- -- 2-8. (5A)
X248 Skypower Control Box -- -- 2-8. (5A)
X249 Skypower Control Box -- --
X250 Skypower Generator -- -- 2-4.
X251 Skypower Generator -- -- 2-4.
X252 Skypower Distribution Box -- --
X253 Skypower Outlet -- --
X254 Skypower Outlet -- --
X255 Skypower Outlet -- --
X256 EMR2 charge air pressure - 4 position DEUTZE -- 2-8. (4G)
X257 EMR2 engine oil pressure -- -- 2-8. (4G)
X258 EMR2 air filter pressure switch DEUTZG --
X259 Main Lift PVG unused (Gray) AMPPVG4GP --
(Gray)
X260 Tower Lift PVG unused (Gray) AMPPVG4GP --
(Gray)
X261 Tower Tele PVG unused (Gray) AMPPVG4GP --
(Gray)
X262 Load Pin CAN Pass thru - 3 position DT03P DT03R
X263 Chassis Power - 2 position DT02P DT02R
X264 Generator Platform Box Pass Thru -- --
X265 Generator Platform Box Pass Thru -- --
X266 Chassis Power Relay BOSCH05P -- 2-8. (4B)
X267 Chassis Power Fuse -- -- 2-8. (4B)
X268 CAN pass thru for EMR2 - 3 position DT03P DT03R 2-8. (5D) 2-5.
X269 CAN 3way - to BLAM, Blue DT03P032BP -- 2-8. (7B) 2-6.
(Blue)
X270 CAN 3way - to Platform, Blue DT03P032BP -- 2-8. (8B) 2-6.
(Blue)
X271 MTB Ground Bus - 6 Position DT06AP -- 2-8. (6C) 2-6.
X272 Boom Length Sensor Passthru DT06R DT06AP 2-8. (3E) 2-5.
X273 Boom Length Sensor DT03P DT03R 2-8. (3E) 2-3.
X274 Lift Down Auxiliary Select DIN43650P -- 2-8. (6F) 2-5.
X275 Lift Down Auxiliary DIN43650P -- 2-8. (6F) 2-5.
X276 Main Lift Up DIN43650P -- 2-8. (6F) 2-5.
X277 Main Lift Down DIN43650P -- 2-8. (6F) 2-5.

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Table 2-5. Connector Index


Connector Description End1 End2 Schematic Drawings
X278 CAN passthru to BLAM - 3 position (Green) DT03P032BP -- 2-8. (4D)
(Blue)
X279 CAN passthru to Engine Hns - 3 position (Green) DT03P032GP -- 2-8. (5D)
(Green)
X280 Valve passthru DT06AP DT06R 2-8. (5D,5C) 2-5.
X281 Transport Limit Switch -- -- 2-8. (8C) 2-3.
X282 Broken Cable Proximity Switch -- -- 2-8. (8C) 2-3.
X283 Boom Control System Test Switch -- -- 2-8. (8D)
X284 Boom Control System Test Switch -- -- 2-8. (8D)
X285 Boom Control Select E06P -- 2-9. (7F) 2-2.
X286 Main Lift Flow Control DIN43650P -- 2-8. (6F) 2-5.
X287 Gateway Module (Gray) DTM12AP -- 2-13. 2-13.
X288 Gateway Module (Black) DTM12BP -- 2-13. 2-13.
X289 Telematics Diagnostic Connector DHD1939R -- 2-13. 2-13.
X290 Telematics Communication Unit (TCU) AMP23P -- 2-13. 2-13.
X291 Gateway CAN 3-way to Gateway DT03P032OP -- 2-13. 2-13.
(Orange)
X292 Gateway CAN 3-way to Harness DT03P032OP -- 2-13. 2-13.
(Orange)
X293 TCU CAN 3-way to TCU DT03P032OP -- 2-13. 2-13.
(Orange)
X294 TCU CAN 3-way to Harness DT03P032OP -- 2-13. 2-13.
(Orange)
X295 TCU Fuse -- -- 2-13. 2-13.
X296 Telematics Diagnostic Connetor Fuse -- -- 2-13. 2-13.

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SECTION 2 - ELECTRICAL REFERENCE

2.2 BLAM MODULE CONNECTOR PINOUTS


Table 2-6. X086 (J1) BLAM Module Pinout Table 2-9. X089 (J4) BLAM Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
1 Not Used -- -- 1 V Bat Battery Vbatt
2 Not Used -- -- 2 Ground Ground 0VDC
3 Not Used -- -- 3 CAN HI Input/Output Comm
4 Ground Ground 0VDC 4 CAN LO Input/Output Comm
5 V Bat Battery Vbatt 5 CAN Shield Ground 0VDC
6 CAN HI Input/Output Comm 6 Not Used -- --
7 CAN LO Input/Output Comm 7 Not Used -- --
8 CAN Shield Ground 0VDC 8 Not Used -- --
9 CAN Termination Connection Input/Output Comm
Table 2-10. X090 (J5) BLAM Module Pinout
10 CAN Termination Connection Input/Output Comm
Pin Function Type Range (V)
11 Not Used -- --
1 Left Drive Pump Forward Output PWM
12 Not Used -- --
2 Left Drive Pump Reverse Output PWM
Table 2-7. X087 (J2) BLAM Module Pinout 3 Oscillating Axles Output PWM
Pin Function Type Range (V) 4 Not Used -- --
1 Not Used Input -- 5 Not Used -- --
2 Not Used Input -- 6 Not Used -- --
3 -- -- -- 7 Not Used -- --
4 Not Used -- -- 8 Not Used -- --
5 Not Used -- -- 9 Analyzer Power Other Voltage Vbatt
6 Not Used -- -- 10 RS232 Receive Input/Output Comm
7 Not Used -- -- 11 RS232 Transmit Input/Output Comm
8 Boom Angle 1 (Right) Input/Output Comm 12 Ground Ground 0VDC
9 Boom Angle 2 (Left) Input/Output Comm
10 Not Used -- --
11 Right Drive Pump Forward Output PWM
12 Right Drive Pump Reverse Output PWM

Table 2-8. X088 (J3) BLAM Module Pinout


Pin Function Type Range (V)
1 Reference Voltage Other Voltage 5VDC
2 Reference Voltage From J3-1 Analog Input 5VDC
3 Not Used -- --
4 Not Used -- --
5 Not Used -- --
6 Not Used -- --
7 Reference Voltage Other Voltage 5VDC
8 Boom Length Sensor Analog Input 5VDC
9 Ground Ground 0VDC
10 Not Used -- --
11 Not Used -- --
12 Not Used -- --

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SECTION 2 - ELECTRICAL REFERENCE

2.3 CHASSIS MODULE CONNECTOR PINOUTS


Table 2-11. X229 (J1) Chassis Module Pinout Table 2-14. X232 (J4) Chassis Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
1 Not Used -- -- 1 Axle Lockout Pressure Switch Vbatt Vbatt
2 Not Used -- -- Power
3 Not Used -- -- 2 Axle Lockout Solenoid Ground 0VDC
4 Main Ground Ground 0VDC 3 Not Used -- --
5 Main Ignition Vbatt Vbatt 4 Not Used -- --
6 CAN HI Input/Output Comm 5 Not Used -- --
7 CAN LOW Input/Output Comm 6 Not Used -- --
8 CAN Shield Input/Output 0VDC 7 Not Used -- --
9 CAN Terminator (Connected to Input/Output Comm 8 Not Used -- --
J1-10)
Table 2-15. X233 (J5) Chassis Module Pinout
10 CAN Terminator (Connected to Input/Output Comm
J1-9) Pin Function Type Range (V)
11 Ignition Vbatt Vbatt 1 Right Front Steer Right Solenoid Output Vbatt
12 Not used -- -- 2 Right Front Steer Left Solenoid Outupt Vbatt
3 Left Front Steer Right Solenoid Output Vbatt
Table 2-12. X230 (J2) Chassis Module Pinout 4 Left Front Steer Left Solenoid Output Vbatt
Pin Function Type Range (V) 5 Right Rear Steer Right Solenoid Output Vbatt
1 Not Used -- -- 6 Right Rear Steer Left Solenoid Output Vbatt
2 Not Used -- -- 7 Left Rear Steer Right Solenoid Output Vbatt
3 Ground Ground 0VDC 8 Left Rear Steer Left Solenoid Output Vbatt
4 Front Axle Extend Limit Switches Input Vbatt 9 Analyzer Power Vbatt Vbatt
5 Rear Axle Extend Limit Switches Input Vbatt 10 Analyzer RS-232 Receive Input Comm
6 Drive Orientation Switch Input Vbatt 11 Analyzer RS-232 Transmit Output Comm
7 Axle Lockout Pressure Switch Input Vbatt 12 Analyzer Ground Ground 0VDC
8 Not Used -- --
9 Not Used -- --
10 Not Used -- --
11 Axle Extend Output Vbatt
12 Axle Retract Output Vbatt

Table 2-13. X231 (J3) Chassis Module Pinout


Pin Function Type Range (V)
1 Reference Voltage Other Voltage 5VDC
2 Front Right Steer Angle Sensor Analog Input 0 - 5VDC
3 Ground Ground 0VDC
4 Reference Voltage Other Voltage 5VDC
5 Front Left Steer Angle Sensor Analog Input 0 - 5VDC
6 Ground Ground 0VDC
7 Reference Voltage Other Voltage 5VDC
8 Rear Right Steer Angle Sensor Analog Input 0 - 5VDC
9 Ground Ground 0VDC
10 Reference Voltage Other Voltage 5VDC
11 Rear Left Steer Angle Sensor Analog Input 0 - 5VDC
12 Ground Ground 0VDC

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SECTION 2 - ELECTRICAL REFERENCE

2.4 GROUND MODULE CONNECTOR PINOUTS


Table 2-16. X001 (J1) Ground Module Pinout Table 2-17. X002 (J2) Ground Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
1 Not Used -- -- 9 Main Telescope Flow Control Output PWM
2 Not Used -- -- 10 Lift Down Auxiliary Select Output Vbatt
3 Not Used -- -- 11 Main Lift Up Output PWM
4 Not Used -- -- 12 Lift Down Auxiliary Output Vbatt
5 Ground Ground 0VDC 13 Main Dump Output Vbatt
6 Not Used -- -- 14 Ground Ground 0VDC
7 Not Used Output -- 15 Not Used -- --
8 Ground Ground 0VDC 16 Main Telescope Out Output Vbatt
9 Not Used -- -- 17 Ground Ground Vbatt
10 Ignition On Relay Output Vbatt 18 Not Used -- --
11 Start Solenoid (Diesel Only) Output Vbatt 19 Lift Flow Control Output PWM
12 Glow Plug (Diesel Only Option) Output Vbatt 20 Not Used -- --
13 Auxiliary Power Output Vbatt 21 Not Used -- --
14 Not Used -- -- 22 Main Lift Down Output Vbatt
15 Not Used -- -- 23 Not Used -- --
16 Not Used -- -- 24 Not Used -- --
17 Not Used -- -- 25 Fuel Sensor Input Vbatt
18 Not Used -- -- 26 Head/Tail Light Output Vbatt
19 Ground Ground 0VDC 27 Alarm Output Vbatt
20 Two Speed Output Vbatt 28 Not Used -- --
21 Not Used -- -- 29 Ground Ground 0VDC
22 Generator/Welder (Option) Output Vbatt 30 Ground Ground 0VDC
23 Parking Brake Output Vbatt 31 Not Used -- --
24 Constant Battery Battery Vbatt 32 Not Used -- --
25 Not Used -- -- 33 Not Used -- --
26 Not Used -- -- 34 Swing Left Output PWM
27 Not Used -- -- 35 Swing Right Output PWM
28 Analyzer Power Other Voltage 9.5VDC
Table 2-18. X004 (J4) Ground Module Pinout
29 Analyzer RS-232 Receive Input Comm
Pin Function Type Range (V)
30 Analyzer RS-232 Transmit Output Comm
1 Axles Set Lamp Output Vbatt
31 Analyzer Ground Ground 0VDC
2 500# Capacity Lamp Output Vbatt
32 Not Used -- --
3 Boom Control System Lamp Output Vbatt
33 Not Used -- --
4 Start Switch Input Vbatt
34 Not Used -- --
5 Basket Level Down Switch Input Vbatt
35 Not Used -- --
6 Basket Rotate Left Switch Input Vbatt
Table 2-17. X002 (J2) Ground Module Pinout 7 Upper Telescope In Switch Input Vbatt
Pin Function Type Range (V) 8 Jib Down Switch Input Vbatt
1 Not Used -- -- 9 Jib Left Switch Input Vbatt
2 Horn Output Vbatt 10 Not Used -- --
3 Platform Control Valve Output Vbatt 11 Not Used -- --
4 Main Telescope In Output Vbatt 12 Hour Meter Output Vbatt
5 Basket Level Up Override Output Vbatt 13 Moment Control Test Lamp Output Vbatt
6 Ground Ground 0VDC 14 Platform Overload Lamp Output Vbatt
7 Basket Level Down Override Output Vbatt 15 Glow Plugs Output Vbatt
8 Not Used -- -- 16 Auxiliary Power / Enable Input Vbatt

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SECTION 2 - ELECTRICAL REFERENCE

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 2-19. X007 (J7) Ground Module Pinout


Pin Function Type Range (V)
1 Platform EMS Input Vbatt
2 Platform Mode Input Vbatt
3 Ground Mode Input Vbatt
4 Not Used -- --
5 Not Used -- --
6 Not Used -- --
7 Not Used -- --
8 Not Used -- --
9 Not Used -- --
10 Not Used -- --
11 Boom Length Limit Closed Input Vbatt
12 Broken Cable Prox Switch Input Vbatt
13 CAN Hi Input/Output Comm
14 Ground Mode Out to Platform Input Vbatt
15 Footswitch Engage Input Vbatt
16 Not Used -- --
17 Not Used -- --
18 CAN Shield Ground 0VDC
19 Ground Ground 0VDC
20 Not Used -- --
21 Boom Control System Test Input Vbatt
Switch
22 Not Used -- --
23 Ground Control Enable Input Vbatt
24 CAN Lo Input/Output Comm

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SECTION 2 - ELECTRICAL REFERENCE

2.5 PLATFORM MODULE CONNECTOR PINOUTS


Table 2-21. X165 (J1) Platform Module Pinout Table 2-22. X166 (J2) Platform Module Pinout
Pin Function Type Range (V) Pin Function Type Range (V)
1 Not Used -- -- 6 Tilt Lamp Output Vbatt
2 Not Used -- -- 7 Enable Lamp Output Vbatt
3 Not Used -- -- 8 System Distress/Fault Lamp Output Vbatt
4 Not Used -- -- 9 Creep Lamp Output Vbatt
5 Main Telescope In Switch Input Vbatt 10 Broken Cable Lamp Output Vbatt
6 Main Telescope Out Switch Input Vbatt 11 Overload Lamp Output Vbatt
7 Basket Rotate Right Switch Input Vbatt 12 500# Capacity Lamp Output Vbatt
8 Basket Rotate Left Switch Input Vbatt 13 1000# Capacity Lamp Output Vbatt
9 Basket Level Up Switch Input Vbatt 14 Axle Set Lamp Output Vbatt
10 Basket Level Down Switch Input Vbatt 15 Generator On Lamp Output Vbatt
11 Jib Up Switch Input Vbatt 16 Soft Touch Lamp Output Vbatt
12 Jib Down Switch Input Vbatt 17 Glow Plug Lamp Output Vbatt
13 Pump Potentiometer Return Ground 0VDC 18 Lamp Return Ground 0VDC
14 Start Switch Input Vbatt 19 Boom Control System Warning Output Vbatt
15 Auxiliary Switch Input Vbatt Lamp
16 Crab Steer Select Switch Input Vbatt 20 Auto Leveling System Lamp Output Vbatt
17 Coordinated Steer Select Switch Input Vbatt 21 Not Used -- --
18 Switch Input Battery Output Vbatt 22 Fuel 1/4 Full Lamp Output Vbatt
19 Inline Limit Switch Input Vbatt 23 Fuel 3/4 Full Lamp Output Vbatt
20 LSS Platform Overload Input Vbatt 24 Fuel 1/2 Full Lamp Output Vbatt
21 500/1000 # Capacity Select Input Vbatt 25 Fuel Lamp Return Output Vbatt
Switch 26 Analyzer PWR Vbatt Vbatt
22 Boom Control Select Switch Input Vbatt 27 Analyzer Ground Ground 0VDC
23 Axle Extend Switch Input Vbatt 28 Analyzer RS232 Receive Input/Output Comm
24 Axle Retract Switch Input Vbatt 29 Analyzer RS232 Transmit Input/Output Comm
25 Serial Tilt Sensor Input 1 Input/Output Comm 30 Drive Orientation Lamp Output Vbatt
26 Serial Tilt Sensor input 2 Input/Output Comm 31 Not Used -- --
27 Two Speed Switch Input Vbatt 32 Battery Vbatt Vbatt
28 Engine Speed Switch Input Vbatt 33 Battery Vbatt Vbatt
29 Soft Touch Override Switch Input Vbatt 34 Switch Input Battery Vbatt Vbatt
30 Head/Tail Light Switch Input Vbatt 35 Fuel Full Lamp Output Vbatt
31 Horn Switch Input Vbatt
Table 2-23. X167 (J5) Platform Module Pinout
32 Creep Switch Input Vbatt
Pin Function Type Range (V)
33 Not Used -- --
1 Swing & Lift Joystick Supply Vref 7VDC
34 Pump Potentiometer Ref. Volt- Other Voltage 7VDC
age 2 Lift Center Tap Input 7VDC
35 Pump Potentiometer Input 7 VDC 3 Lift Signal Input 7VDC
4 Swing Signal Input 7VDC
Table 2-22. X166 (J2) Platform Module Pinout 5 Swing Center Tap Input 7VDC
Pin Function Type Range (V) 6 Not Used -- --
1 Jib Right Switch Input Vbatt 7 Ground Ground 0VDC
2 Jib Left Switch Input Vbatt 8 Not Used -- --
3 Switch Input Battery Vbatt Vbatt
4 Drive Orientation Override Input Vbatt
Switch
5 Basket Stow Switch Input Vbatt

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SECTION 2 - ELECTRICAL REFERENCE

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 -- --

Table 2-25. X169 (J7) Platform Module Pinout


Pin Function Type Range (V)
1 GND Mode Switch Input Vbatt
2 Platform EMS Switch Input Vbatt
3 Platform EMS to GND Module Input Vbatt
4 Not Used -- --
5 Rotate Left Coil Output PWM
6 Rotate Right Coil Output PWM
7 Not Used -- --
8 Footswitch Disengage Input Vbatt
9 Generator On Input Vbatt
10 Not used -- --
11 Not Used -- --
12 Not Used -- --
13 Not Used -- --
14 Not Used -- --
15 Basket Level Up Coil Output PWM
16 Basket Level Down Coil Output PWM
17 Jib Block Limit Switch Input Vbatt
18 Soft Touch Limit Switch Input Vbatt
19 Platform Alarm Output Vbatt
20 Platform Alarm Return Ground 0VDC
21 Primary Tilt Sensor Ground Ground 0VDC
22 Not used -- --
23 Not used -- --
24 Not used -- --
25 Jib Up Coil Output PWM
26 Jib Down Coil Output PWM
27 Jib Right Coil Output PWM
28 Jib Left Coil Output PWM
29 Digital Output Return Ground 0VDC
30 CAN LO Input/Output Comm
31 CAN HI Input/Output Comm
32 CAN Shield Ground 0VDC
33 Secondary Tilt Sensor Ground Ground 0VDC
34 Not Used -- --
35 Not Used -- --

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SECTION 2 - ELECTRICAL REFERENCE

2.6 CONNECTOR LOADING DIAGRAMS


Table 2-27. Connector Loading Diagrams
ID Description Diagram
AMP02P Amp 2 position plug

AMP02R Amp 2 position recepta-


cle
2
1

AMPJT82600 Amp 2 position plug


8P
1 2

AMP04P Amp 4 position plug

4
3
2
1

AMP04R Amp 4 position recepta-


cle

4
3

AMP06P Amp 6 position plug


32 1

654
AMP06R Amp 6 position recepta-
cle 1 2 3

45 6

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
AMP08BP Amp 8 position black
plug

AMP08NP Amp 8 position natural


plug

1 3

6 8

AMP15P Amp 15 position plug


2

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

AMP25RP Amp Rectangular 25


position plug with key for 14 15 16 17 18 19 20 21 22 23 24 25
right
1 2 3 4 5 6 7 8 9 10 11 12 13

AMPPVG4P Amp PVG Valve 4 posi-


(Black) tion plug
AMPPVG4GP 4
(Gray) 3
2
1

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SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
AMP14P Ampseal 14 position

1 5

10 AMP 14

Socket Rear Insert

AMP23P Ampseal 23 position

1 8

16 23

Socket Rear Insert


AMP351P Ampseal 35 position
(Black)
AMP352P
(Neutral) 1 12

AMP354P
(Gray)
AMP355P
(Blue) 24 AMP 35

Socket Rear Insert


AN350P Anderson Power Con-
nector

ANL06P Amphenol 6 Position


Sealed Plug

2-152 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
BOSCH05P Bosch Relay Sealed Plug

DEUTZ12ENG Deutz Supplied 12 posi-


R tion receptacle 2 3

1 4

9 12

10 11

DEUTZ12P Deutz Supplied 12 posi-


tion plug 3 2

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

3128463 1200SJP 1350SJP 2-153


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DEUTZ16R Deutz Supplied 16 posi-
tion receptacle 3 2

4 1
8 5
12 9
16 13

15 14
DEUTZE Deutz Supplied 4 posi-
tion charge air pressure
sensor Plug

DEUTZG Deutz Supplied 2 posi-


tion air filter pressure
switch Receptacle

DIN43650P Din 43650 4 position


plug 3

1 2

DHD1939R Deutsch 9 position HD


series J1939. Recepta-
cle

2-154 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DHD14P Deutsch 14 position HD
series alum. Plug

Rear View
DHD14R Deutsch 14 position HD
series alum. Receptacle

Rear View
DHD19P Deutsch 19 position HD
series alum. Plug

DHD19R Deutsch 19 position HD


series alum. Receptacle

DHD1821P Deutsch 21 position HD


series alum. Plug

3128463 1200SJP 1350SJP 2-155


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DHD1821R Deutsch 21 position HD
series alum. Receptacle

DHD21P Deutsch 21 position HD


series alum. Plug

DHD21R Deutsch 21 position HD


series alum. Receptacle

DHTP31R Deutsch HDP 31 posi-


(receptacle) tion
DHTP31P 31 20
30
(plug) 19
8 21
9
18 2 10
29
7 3 22
17 1 11
28 6 4 23
16 5 12
15 13
27 14 25
26 24

Socket Rear Insert

DT02P Deutsch 2 position DT


series plug
1 2

DT02R Deutsch 2 position DT


series receptacle
2 1

2-156 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DT03P Deutsch 3 position DT
series plug
B A

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

DT04R Deutsch 4 position DT


series receptacle

DT06AP Deutsch 6 position DT


series plug

DT06EP032R Deutsch 6 position bus


receptacle

DT06R Deutsch 6 position DT


series receptacle

3128463 1200SJP 1350SJP 2-157


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DT08AP Deutsch 8 position DT
series plug with A keys

DT08AR Deutsch 8 position DT


series receptacle with A
keys

DT12AP Deutsch 12 position DT


series plug with A keys
12 1
11 2
10 3
9 4
8 5
7 6

DT12AR Deutsch 12 position DT


series receptacle with A
keys 7 6
8 5
9 4
10 3
11 2
12 1

DT12BP Deutsch 12 position DT


series plug with B keys
12 1
11 2
10 3
9 4
8 5
7 6

DT12BR Deutsch 12 position DT


series receptacle with B
7
keys 8
6
5
9 4
10 3
11 2
12 1

2-158 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DT12CP Deutsch 12 position DT
series plug with C keys
12 1
11 2
10 3
9 4
8 5
7 6

DT12DP Deutsch 12 position DT


series plug with D keys
12 1
11 2
10 3
9 4
8 5
7 6

DT12PBR Deutsch 12 position bus


receptacle
7 6
8 5
9 4
10 3
11 2
12 1

DTM03P Deutsch 3 position DTM


series mini 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

DTM04R Deutsch 4 position DTM


series mini receptacle
1 4
2 3

DTM12AP Deutsch 12 position DT


7 8 9 10 11 12
series mini plug with A
key

6 5 4 3 2 1

3128463 1200SJP 1350SJP 2-159


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
DTM12BP Deutsch 12 position DT
7 8 9 10 11 12
series mini plug with B
key

6 5 4 3 2 1

DTP02P Deutsch 2 position DTP


series plug

1 2

DTP02R Deutsch 2 position DTP


series receptacle

2 1

E06P Eaton Toggle Switch

1 4
2 5
3 6

ITTC12P ITT Cannon 12 position


plug

MMF02P Molex 2 position plug 2 1

MMF04P Molex 4 position plug

4
3
2
1

2-160 1200SJP 1350SJP 3128463


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
MMF08P Molex Mini Fit 8 position
plug

Rear View
MMF10P Molex Mini Fit 10 posi-
tion plug

6
7
8
9
10
1
2
3
4
5

MMF12P Molex Mini Fit 12 posi-


tion plug

7 8 9 10 11 12

1 2 3 4 5 6

MMF24P Molex Mini Fit 24 posi-


tion plug

13
14
15
16
17
1 18
2 19
3 20
4 21
5 22
6 23
7 24
8
9
10
11
12

PHEONIX5P Pheonix 5 position M-12


Plug

3128463 1200SJP 1350SJP 2-161


SECTION 2 - ELECTRICAL REFERENCE

Table 2-27. Connector Loading Diagrams


ID Description Diagram
PHEONIX7P Pheonix 7 position M-12
Plug

PACKARD2LR Packard Light Recepta-


cle

PACKARD2P Packard 2 position plug

A B

PACKARD3P Packard 3 position


receptacle

PACKARD3R Packard 3 position


receptacle

C BA

SUM02N Sumitomo 2 position


natural

1 2
SUM06N Sumitomo 6 position
natural
4 1

5 2

6 3

2-162 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

SECTION 3. HYDRAULIC REFERENCE

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

Figure 3-1. Main Valve Layout

3128463 1200SJP 1350SJP 3-163


SECTION 3 - HYDRAULIC REFERENCE

PUMPS

VIEW ROTATED RIGHT SIDE DRIVE PUMP

LEFT SIDE DRIVE PUMP

FUNCTION PUMP

LOW PRESS
RELIEF ADJ.

HIGH PRESS
RELIEF ADJ.

Figure 3-2. Pumps Layout

3-164 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

Platform Valve Layout

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

Figure 3-3. Platform Valve Layout

3128463 1200SJP 1350SJP 3-165


SECTION 3 - HYDRAULIC REFERENCE

Pump Circuit Schematic

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

"OPTION" SWIVEL PORT


T - #1 #1 - T OIL COOLER #6

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

Figure 3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2

3-166 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

SWIVEL PORT "P1" "LS"


#4 SHT. #1 SHT. #1

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

SWIVEL PORT SWIVEL PORT SWIVEL PORT


#7 #1 #3

RESERVOIR

"T3" 2792771 C
SHT. #1

Figure 3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2

3128463 1200SJP 1350SJP 3-167


SECTION 3 - HYDRAULIC REFERENCE

Platform Control Schematic

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

1500 PSI (1200SJP-1350SJP)

2500 PSI (1200SJP-1350SJP)


2

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

Figure 3-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2

3-168 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

JIB SWING ROTATOR JIB CYLINDER

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

0.3 GPM 2.0 GPM

1 1

PLATFORM CONTROL
1200SJP,1350SJP,1250AJP
2792771 C

Figure 3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2

3128463 1200SJP 1350SJP 3-169


SECTION 3 - HYDRAULIC REFERENCE

Axle Steer Control Schematic

T P

LEFT 2 SWIVEL PORT


#1
2000 PSI
RIGHT SIDE

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

AXLE EXTENSION CYLINDERS STEERING CYLINDERS


BORE: 3.50" 9.62 SQ. IN. BORE: 4.00" 12.56 SQ. IN.
ROD: 2.00" 3.14 SQ. IN. ROD: 1.75" 2.40 SQ. IN.
ANNULUS: 6.48 SQ. IN. ANNULUS: 10.16 SQ. IN.
CYL. AREA RATIO: 1.48:1 CYL. AREA RATIO: 1.23:1
STROKE: 27.125" STROKE: 9.25"

Figure 3-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2

3-170 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

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

3128463 1200SJP 1350SJP 3-171


SECTION 3 - HYDRAULIC REFERENCE

Traction Control Schematic

SEE SHT #4 AXLE


STEER CONTROL

SWIVEL PORT SWIVEL PORT


#2 #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

SWIVEL PORT SWIVEL PORT SWIVEL PORT


#4 #5 #6

2792771 C
TRACTION CONTROL
Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2

3-172 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

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

ANNULUS: 16.49 SQ. IN.


CYL AREA RATIO: 6.25:1
STROKE: 5.00"
SET AT 500 PSI

A B

2.74 CU. IN. MAX


1.0 CU. IN. MIN G1
L
2

L1 G
Br
A6

B6

A2 D
PLANETARY GEAR

88.2 : 1 RATIO
REDUCTION

OSC. AXLE L.O. CYL.


SWIVEL PORT SWIVEL PORT
RIGHT

#3 #1 SWIVEL PORT
#7

TRACTION CONTROL 2792771 C


Figure 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2

3128463 1200SJP 1350SJP 3-173


SECTION 3 - HYDRAULIC REFERENCE

Boom Control Schematic

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

GENERATOR RETURN OIL 1


SWIVEL PORT
T1
2 1 W
"X"
FROM
#2 "LS" PORT OF
2 SHT.#2
MAIN VALVE LS 2
1 2

LS1 3

TO "X" PORT OF
FUNCTION PUMP
SHT.#2 P

A
"OPTION"
TO RESERVOIR
G GENERATOR CONTROL
L B

Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2

3-174 1200SJP 1350SJP 3128463


SECTION 3 - HYDRAULIC REFERENCE

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

2750PSI 3200PSI 3000PSI

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

Figure 3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2

3128463 1200SJP 1350SJP 3-175


SECTION 3 - HYDRAULIC REFERENCE

This Page Left Blank Intentionally

3-176 1200SJP 1350SJP 3128463


SECTION 4 - JLG ANALYZER

SECTION 4. JLG ANALYZER

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.

NOTE: The cable has a four pin connector at each end of


the cable; the cable cannot be connected back-
wards.

2. Power up the Control System by turning the key to


the platform or ground position and pulling both
emergency stop buttons on.

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.

The top level menus are as follows:

HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)

If you press ENTER, at the HELP: PRESS ENTER display,


and a fault is present, the analyzer display will scroll the
fault across the screen. If there was no fault detected, the
display will read: HELP: EVERYTHING OK. If powered up
Figure 4-2. Platform Analyzer Connection Point at the ground station, the display will read: GROUND OK.

3128463 1200SJP 1350SJP 4-177


SECTION 4 - JLG ANALYZER

If ENTER is pressed again, the display moves to the fol-


lowing display:

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.

4-178 1200SJP 1350SJP 3128463


SECTION 4 - JLG ANALYZER

Figure 4-3. Analyzer Flow Chart

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.

3128463 1200SJP 1350SJP 4-179


FROM:

4-180
ACCESS LEVEL 1

MENU: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:


PERSONALITIES DRIVE STEER MAIN LIFT SWING TOWER LIFT MAIN TELESCOPE TOWER TELESCOPE
DRIVE: STEER: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
TO:
ACCEL X.XS MAX SPEED X% ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS ACCEL X.XS
MACHINE SETUP
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
DECEL X.XS DECEL X.XS DECEL X.XS DECEL MEDIUM DECEL X.XS DECEL X.XS
DRIVE: MAIN LIFT: SWING: TOWER LIFT: MAIN TELESCOPE: TOWER TELESCOPE:
MIN FORWARD X% MIN UP X% MIN LEFT X% MIN UP X% MIN IN X% MIN IN X%

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%

DRIVE: MAIN LIFT: SWING:


ELEV. MAX X% MAX DOWN X% MAX RIGHT X%
DRIVE: MAIN LIFT: SWING:
CREEP MAX X% CREEP DOWN X% CREEP RIGHT X%

available depending upon machine configuration.


PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES: PERSONALITIES:
PLATFORM LEVEL PLATFORM ROTATE JIB LIFT JIB SWING GROUND MODE GEN SET/WELDER

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

available depending upon machine configuration.


CHASSIS TILT: SOFT TOUCH:
TILT: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: FUNCTION CUTOUT:
5 DEGREES 1=5 DEG
NO NO MOTION ENABLED NO NO NO
CHASSIS TILT: SOFT
TILT: TOUCH: GEN SET/WELDER: GEN SET CUTOUT: H & T LIGHTS: LOAD SYSTEM: FUNCTION CUTOUT:
4 DEGREES 2=4 DEG
YES BELT DRIVE MOTION CUTOUT YES WARN ONLY BOOM CUTOUT
CHASSIS TILT: TILT: GEN SET/WELDER: LOAD SYSTEM: FUNCTION CUTOUT:
3 DEGREES 3=3 DEG HYDRAULIC DRIVE CUTOUT PLATFORM DRIVE CUTOUT
CHASSIS TILT: TILT: LOAD SYSTEM: FUNCTION CUTOUT:
4 DEGREES + CUT 4=4 DEG PLUS CUT CUTOUT ALL DRIVE CUT E&T

1200SJP 1350SJP
CHASSIS TILT: TILT: LOAD SYSTEM:
3 DEGREES + CUT 5=3 DEG PLUS CUT SPECIAL 1

GROUND ALARM: OSCILLATING TEMP DISPLAY:


NO AXLE: YES CELSIUS
GROUND ALARM: OSCILLATING TEMP DISPLAY:
DRIVE AXLE: NO FAHRENHEIT
GROUND ALARM:
DESCENT
GROUND ALARM:
MOTION

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

MENU: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:


CALIBRATIONS STEER DRIVE BOOM VALVES LEVEL UP CRKPT LEVEL DOWN CRKPT MAIN LIFT CRKPT MAIN TELE CRKPT

CALIBRATE CALIBRATE CALIBRATE CALIBRATE LEVEL CALIBRATE LEVEL CALIBRATE MAIN CALIBRATE MAIN
STEER? DRIVE? BOOM VALVES? UP CRACKPOINT? DOWN CRACKPOINT? LIFT CRACKPOINT? TELE CRACKPOINT?

available depending upon machine configuration.


CALIBRATIONS: CALIBRATIONS: CALIBRATIONS: CALIBRATIONS:
TILT SENSOR BOOM SENSORS DEUTZ SETUP: NONE AVAILABLE
POSITION 1: POSITION 1: DEUTZ SETUP:
CHECK SYSTEM? CHECK SYSTEM? SETUP 1

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

JOYSTICK DRIVE: JOYSTICK LIFT: START SEQUENCE: GROUND MODULE


TO:
FORWARD XXX% MAIN UP XXX% NOT ACTIVE BATTERY: XX.XV
SYSTEM TEST
JOYSTICK STEER: JOYSTICK SWING: BATTERY VOLTAGE: PLATFORM MODULE HORN
LEFT XXX% LEFT XXX% XX.XV BATTERY: XX.XV SWITCH: OPEN

DRIVE OUTPUT: LIFT OUTPUT: COOLANT AMBIENT SOFT TOUCH LIMIT


FORWARD XXX% MAIN UP XXX% TEMPERATURE:XXXC TEMPERATURE:XXXC SWITCH: OPEN

STEER OUTPUT: SWING OUTPUT: ENGINE OIL PLATFORM SELECT SOFT TOUCH
LEFT XXX% LEFT XXX% PRESSURE:XXXXPSI KEYSWITCH:CLOSED OVERRIDE: OPEN

STEER TYPE: PLATFORM LEVEL: AMBIENT GROUND SELECT GENSET/WELDER


NORMAL UP XXX% TEMPERATURE:XXXC KEYSWITCH: OPEN SWITCH: OPEN

BRAKES STATUS: PLATFORM ROTATE: FUEL LEVEL STATION CONTROL: LIGHTS


LOCKED LEFT XXX% SENSOR: OK GROUND SWITCH: OPEN

CREEP MAIN TELESCOPE: STARTER FOOTSWITCH INPUT PLATFORM TILT1


SWITCH: CLOSED IN XXX% CRANK TIME: XX S GROUND: OPEN ANGLE: XX.X DEG

CREEP MODE: TOWER TELESCOPE: ENGINE SPEED FOOTSWITCH INPUT PLATFORM TILT2

available depending upon machine configuration.


OFF IN XXX% ACTUAL: XXXX RPM PLATFORM: CLOSED ANGLE: XX.X DEG

2-SPEED TOWER LIFT: ENGINE SPEED TRANSPORT MODE: PLATFORM TILT1


SWITCH: CLOSED UP XXX% TARGET: XXXX RPM OUT OF TRANSPORT RAW: XXXX

2-SPEED VALVE JIB LIFT: CABLE BREAK PLATFORM TILT2


OUTPUT: OFF UP XXX% SWITCH: CLOSED RAW: XXXX

1200SJP 1350SJP
HIGH ENGINE JIB SWING: CREEP OSCILATING AXLE
SWITCH: OPEN LEFT XXX% SWITCH: CLOSED PRES. SW.: OPEN

DRIVE MODE: PLATFORM CONTROL CREEP MODE: HYDRAULIC OIL


MID ENGINE VALVE: OFF OFF TEMP. SW.: OPEN

L FRONT WHEEL FUNCTION SPEED: CHASSIS TILT: HYDRAULIC OIL:


ANGLE: XX.X PUMP POT XXX% XX.X DEGREES WARM UP NOT DONE

R FRONT WHEEL CREEP CHASSIS TILT MAIN LIFT PILOT


ANGLE: XX.X SWITCH: CLOSED X-AXIS: X.X PRES. SW.: OPEN

L REAR WHEEL CREEP MODE: CHASSIS TILT


ANGLE: XX.X OFF Y-AXIS: X.X

R REAR WHEEL AUXILIARY POWER


ANGLE: XX.X SWITCH: 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

available depending upon machine configuration.


TOWER ANGLE 2
MAIN LIFT ANGLE TOWER LENGTH 2 HIGH CAL: XXX.X LOAD PIN MOMENT
SWITCH NC: OPEN A/D: XXXXX CAL POINT: XXXXX
TOWER CYLINDER
MAIN LIFT ANGLE TOWER ANGLE 1 LOW CAL: XXXXXX LOAD PIN ERROR
SWITCH NO:CLOSED A/D: XX.X FLAGS: 0X0000
TOWER CYLINDER
MAIN LIFT ANGLE TOWER ANGLE 2 HIGH CAL: XXXXXX LOAD PIN X-AXIS
STATUS:TRANSPORT A/D: XX.X VALUE: XXX
MAIN ANGLE 1
TOWER CYLINDER LOAD PIN Y-AXIS

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

available depending upon machine configuration.


VALUE: XX.XXX CAL: XXXXX CAL: XXXXX MAX TEMP XXC S/N: XXXXXX
LOAD PIN ERROR R FRONT STEER YELLOW WITNESS DATALOG: CHASSIS MODULE
FLAGS: 0X0000 CAL: XXXXX MARK CAL: X MIN TEMP XXC SOFTWARE: P7.X
SKY WELDER L REAR STEER LENGTH SWITCH DATALOG: B.L.A. MODULE
INSTALLED: NO CAL: XXXXX CAL: XXXXX MAX VOLTS XX.XV SOFTWARE: P7.X
SKY CUTTER R REAR STEER DATALOG: CYLINDER PIN
INSTALLED: NO CAL: XXXXX RENTAL XH XM SOFTWARE: RX.XX
SKY GLAZIER MAIN LIFT UP DATALOG: CYLINDER PIN

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.

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SECTION 4 - JLG ANALYZER

4.4 ADJUSTING PARAMETERS USING THE 4.5 MACHINE SETUP


HAND HELD ANALYZER When a machine digit item is selected, press the UP or
Once you have gained access to level 1, and a personality DOWN arrow keys to adjust its value, for example:
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:

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.

NOTE: Refer to Table 4-2. Machine Personality Settings and


Speeds on Pg. 202 in this manual for the recom-
mended factory settings.

NOTE: Password 33271 will give you access to level 1,


which will permit you to change all machine person-
ality settings.

There is a setting that JLG strongly recommends that you


do not change. This setting is so noted below:

ELEVATION CUTBACK

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER-


FORMANCE OF YOUR MACHINE.

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SECTION 4 - JLG ANALYZER

Table 4-1. Machine Configuration Programming Information

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

MODEL NUMBER: 1 1200S 1


1
2 1250A

3 1350S

ENVELOPE HEIGHT: 1 1350S: 135' MAX 5


2
2 1350S: 125' MAX

3 1350S: 120' MAX

4 1350S: 110' MAX

5 1200S: 120' MAX

6 1200S: 110' MAX

7 1250A: 125' MAX

8 1250A: 100' MAX

9 1250A: 80' MAX

NOTE: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial
default setting.

MARKET: 0 ANSI USA 0


3
1 ANSI EXPORT

2 CSA

3 CE

4 AUSTRALIA

5 JAPAN

ENGINE: 1 DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1) 3


4
2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)

3 DEUTZ ECM: Engine Control Module

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SECTION 4 - JLG ANALYZER

Table 4-1. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

GLOW PLUG: 0 NO GLOW PLUGS: No glow plugs installed. 2


5
1 AIR INTAKE: Glow plugs installed in the air intake on the manifold.

2 IN-CYLINDER: Glow plugs installed in each cylinder.

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.

1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine


start is NOT permitted until pre-glow is finished.

ENGINE SHUTDOWN: 0 DISABLED: No engine shutdown. 1


7
1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C
or the oil pressure is less than 8 PSI.

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.

SOFT TOUCH: 0 NO: No soft touch system installed. 0


9
1 YES: Soft touch system installed.

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SECTION 4 - JLG ANALYZER

Table 4-1. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

GEN SET/WELDER: 0 NO: No generator installed. 1


10
1 BELT DRIVE: Belt driven setup.

2 HYDRAULIC DRIVE: Hydraulic driven setup.

GEN SET CUTOUT: 0 MOTION ENABLED: Motion enabled when generator is ON. 0
11*
1 MOTION CUTOUT: Motion cutout in platform mode only.

* Only visible if Gen Set / Welder Menu selection is not 0.

H & T LIGHTS: 0 NO: No head and tail lights installed. 0


12
1 YES: Head and tail lights installed.

LOAD SYSTEM: 0 NO: No load sensor installed. 0


13*
1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2
sec OFF).

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).

* Only visible under certain market selections.

* Certain market selections will limit load system options or alter default setting.

4-190 1200SJP 1350SJP 3128463


SECTION 4 - JLG ANALYZER

Table 4-1. Machine Configuration Programming Information

Default
Configuration Digit Number Description
Number

FUNCTION CUTOUT: 0 NO: No drive cutout. 0


14*
1 BOOM CUTOUT: Boom function cutout while driving above elevation.

2 DRIVE CUTOUT: Drive cutout above elevation.

3 DRIVE CUT E&T: Drive cutout above elevation and tilted.

* Only visible under certain market selections.

* Certain market selections will limit function cutout options or alter default setting.

GROUND ALARM: 0 NO: No ground alarm installed. 0


15*
1 DRIVE: Travel alarm sounds when the drive function is active (Option).

2 DESCENT: Descent alarm sounds when lift down is active (Option).

3 MOTION: Motion alarm sounds when any function is active (Option).

* Certain market selections will alter default setting.

OSCILLATING AXLE: 0 NO: No oscillating axle system installed. 1


16
1 YES: Oscillating axle system installed.

TEMPERATURE: 0 CELSIUS: Celsius unit selection. 1


17*
1 FAHRENHEIT: Fahrenheit unit selection.

* Certain market selections will alter default setting.

4150364-15

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SECTION 4 - JLG ANALYZER

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

HEAD & TAIL LIGHTS


ENGINE SHUTDOWN

GEN SET / WELDER


ENVELOPE HEIGHT

GEN SET CUTOUT


MODEL NUMBER

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

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SECTION 4 - JLG ANALYZER

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

HEAD & TAIL LIGHTS


ENGINE SHUTDOWN

GEN SET / WELDER


ENVELOPE HEIGHT

GEN SET CUTOUT


MODEL NUMBER

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

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SECTION 4 - JLG ANALYZER

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).

Table 4-2. Machine Personality Settings and Speeds

TIME RANGE (SEC)


(SEE 4.6 Machine
SUBMENU DEFAULT Orientation When
PARAMETER
(DISPLAYED ON VALUES Setting Speeds
(DISPLAYED ON ANALYZER DESCRIPTION RANGE
ANALYZER 1ST WHEN SETTING
2ND LINE)
LINE) SPEEDS)
1200 1350 1200S 1350S
DRIVE:
ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3 1.3
MIN FORWARD XX% Displays/adjusts minimum forward 0 to 35% 1 1
drive speed
MAX FORWARD XXX% Displays/adjusts maximum forward 0 to 100% 100 100 36-38 36-38
drive speed
MIN REVERSE XX% Displays/adjusts minimum reverse 0 to 35% 1 1
drive speed
MAX REVERSE XXX% Displays/adjusts maximum reverse 0 to 100% 100 100 36-38 36-38
drive speed
ELEV. MAX XX% Displays/adjusts maximum drive 0 to 50% 25 25 93-104 93-104
speed
NOTE: used when elevation cutout
switches are limiting maximum speed
CREEP MAX XX% Displays/adjusts maximum drive 0 to 50% 35 35 79-87 79-87
speed
NOTE: used when creep switch on
pump pot is active
STEER:
MAX SPEED XXX% Displays/adjusts maximum steer 0 to 100% 100 100
speed.

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Table 4-2. Machine Personality Settings and Speeds

TIME RANGE (SEC)


(SEE 4.6 Machine
SUBMENU DEFAULT Orientation When
PARAMETER
(DISPLAYED ON VALUES Setting Speeds
(DISPLAYED ON ANALYZER DESCRIPTION RANGE
ANALYZER 1ST WHEN SETTING
2ND LINE)
LINE) SPEEDS)
1200 1350 1200S 1350S
MAIN LIFT:
ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 1.0
DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN UP XX% Displays/adjusts minimum main lift 0 to 60% 20 20
up speed
MAX UP XX% Displays/adjusts maximum main lift 0 to 100% 50 50 75-100 75-100
up speed
MIN DOWN XX% Displays/adjusts minimum main lift 0 to 60% 10 10
down speed
MAX DOWN XXX% Displays/adjusts maximum main lift 0 to 100% 50 50 85-110 85-110
down speed
CREEP UP XX% Displays/adjusts maximum main lift 0 to 65% 50 50
up speed
NOTE: used when creep switch on
pump pot is active
CREEP DOWN XX% Displays/adjusts maximum main lift 0 to 75% 45 45
down speed
NOTE: used when creep switch on
pump pot is active
SWING:
ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0
DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.5
MIN LEFT XX% Displays/adjusts minimum swing left 0 to 50% 40 40
speed
MAX LEFT XXX% Displays/adjusts maximum swing left 0 to 100% 65 65 115-125 115-125
speed
MIN RIGHT XX% Displays/adjusts minimum swing 0 to 50% 40 40
right speed
MAX RIGHT XXX% Displays/adjusts maximum swing 0 to 100% 65 65 115-125 115-125
right speed
CREEP LEFT XX% Displays/adjusts maximum swing left 0 to 65% 50 50
speed
NOTE: used when creep switch on
pump pot is active
CREEP RIGHT XX% Displays/adjusts maximum swing 0 to 65% 50 50
right speed
NOTE: used when creep switch on
pump pot is active

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Table 4-2. Machine Personality Settings and Speeds

TIME RANGE (SEC)


(SEE 4.6 Machine
SUBMENU DEFAULT Orientation When
PARAMETER
(DISPLAYED ON VALUES Setting Speeds
(DISPLAYED ON ANALYZER DESCRIPTION RANGE
ANALYZER 1ST WHEN SETTING
2ND LINE)
LINE) SPEEDS)
1200 1350 1200S 1350S
MAIN TELESCOPE:
ACCEL X.Xs Displays/adjusts main telescope 0.1 to 5.0 sec 1.5 1.5
acceleration
DECEL X.Xs Displays/adjusts main telescope 0.1 to 3.0 sec 1.0 1.0
deceleration
MIN IN XX% Displays/adjusts minimum main tele- 0 to 65% 15 15
scope in speed. Same as Creep speed
MAX IN XXX% Displays/adjusts maximum main tele- 0 to 100% 65 65 58-68 65-75
scope in speed
MIN OUT XX% Displays/adjusts minimum main tele- 0 to 65% 15 15
scope out speed. Same as Creep
speed
MAX OUT XXX% Displays/adjusts maximum main tele- 0 to 100% 60 60 45-55 50-60
scope out speed
BASKET LEVEL:
ACCEL X.Xs Displays/adjusts basket level acceler- 0.1 to 5.0 sec 1.5 1.5
ation
DECEL X.Xs Displays/adjusts basket level deceler- 0.1 to 3.0 sec 0.5 0.5
ation
MIN UP XX% Displays/adjusts minimum basket 0 to 65% 40 40
level up speed. Same as Creep speed
MAX UP XXX% Displays/adjusts maximum basket 0 to 100% 70 70
level up speed
MIN DOWN XX% Displays/adjusts minimum basket 0 to 65% 40 40
level down speed. Same as Creep
speed
MAX DOWN XXX% Displays/adjusts maximum basket 0 to 100% 70 70
level down speed
BASKET ROTATE:
ACCEL X.Xs Displays/adjusts basket rotate accel- 0.1 to 5.0 sec 1.0 1.0
eration
DECEL X.Xs Displays/adjusts basket rotate decel- 0.1 to 3.0 sec 0.5 0.5
eration
MIN LEFT XX% Displays/adjusts minimum basket 0 to 100% 60 60
rotate left speed. Same as Creep
speed
MAX LEFT XXX% Displays/adjusts maximum basket 0 to 100% 60 60 24-30 24-30
rotate left speed (180) (180)
MIN RIGHT XX% Displays/adjusts minimum basket 0 to 100% 60 60
rotate right speed. Same as Creep
speed
MAX RIGHT XXX% Displays/adjusts maximum basket 0 to 100% 60 60 24-30 24-30
rotate right speed (180) (180)

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Table 4-2. Machine Personality Settings and Speeds

TIME RANGE (SEC)


(SEE 4.6 Machine
SUBMENU DEFAULT Orientation When
PARAMETER
(DISPLAYED ON VALUES Setting Speeds
(DISPLAYED ON ANALYZER DESCRIPTION RANGE
ANALYZER 1ST WHEN SETTING
2ND LINE)
LINE) SPEEDS)
1200 1350 1200S 1350S
JIB LIFT:
ACCEL X.Xs 0.1 to 5.0 sec 1.5 1.5
DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 1.0
MIN UP XX% Displays/adjusts minimum jib up 0 to 65% 40 40
speed. Same as Creep speed
MAX UP XXX% Displays/adjusts maximum jib up 0 to 100% 65 65 30-36 30-36
speed
MIN DOWN XX% Displays/adjusts minimum jib down 0 to 65% 40 40
speed. Same as Creep speed
MAX DOWN XXX% Displays/adjusts maximum jib down 0 to 100% 60 60 30-36 30-36
speed
JIB SWING:
ACCEL X.Xs Displays/adjusts jib swing accelera- 0.1 to 5.0 sec 1.5 1.5
tion
DECEL X.Xs Displays/adjusts jib swing decelera- 0.1 to 3.0 sec 0.5 0.5
tion
MIN LEFT XX% Displays/adjusts minimum jib left 0 to 65% 40 40
speed. Same as Creep speed
MAX LEFT XXX% Displays/adjusts maximum jib left 0 to 100% 70 70 60-68 60-68
speed (180) (180)
MIN RIGHT XX% Displays/adjusts minimum jib right 0 to 65% 40 40
speed. Same as Creep speed
MAX RIGHT XXX% Displays/adjusts maximum jib right 0 to 100% 70 70 60-68 60-68
speed (180) (180)

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SECTION 4 - JLG ANALYZER

Table 4-2. Machine Personality Settings and Speeds

TIME RANGE (SEC)


(SEE 4.6 Machine
SUBMENU DEFAULT Orientation When
PARAMETER
(DISPLAYED ON VALUES Setting Speeds
(DISPLAYED ON ANALYZER DESCRIPTION RANGE
ANALYZER 1ST WHEN SETTING
2ND LINE)
LINE) SPEEDS)
1200 1350 1200S 1350S
GROUND MODE:
U. LIFT UP XXX% Displays/adjusts fixed main lift up 0 to 100% 60 60
speed
U. LIFT DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 60
SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60 60
BASKET LVL XXX% Displays/adjusts fixed basket level 0 to 100% 75 75
speed
BASKET ROT XXX% Displays/adjusts fixed basket rotate 0 to 100% 75 75
speed
MAIN TELE XXX% Displays/adjusts fixed main telescope 0 to 100% 60 60
speed
TOWER TELE XXX% Displays/adjusts fixed tower tele- 0 to 100% 100 100
scope speed
Not displayed if TOWER TELE=NO

T. LIFT UP XXX% Displays/adjusts fixed tower lift up 0 to 100% 100 100


speed
Not displayed if TOWER LIFT=NO
T. LIFT DN XXX% Displays/adjusts fixed tower lift down 0 to 100% 100 100
speed
Not displayed if TOWER LIFT=NO
JIB (U/D) XXX% Displays/adjusts jib lift speed 0 to 100% 60 60
Not displayed if JIB = 0
JIB (L/R) XXX% Displays/adjusts jib swing speed 0 to 100% 70 70
Displayed if JIB = 2
GEN SET/WELDER:
ENGINE XXXX RPM Control generator/welder RPM. Not 1200-2800 1800 1800
displayed if GEN SET/WELDER = 0
NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine perfor-
mance.
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).
4150453-D

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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.

Drive Reverse (Max): Test should be done on a smooth


level surface. High Speed - Low Torque setting, drive 200
ft. (61 m) front wheels to front wheels. Timed after
machine has obtained maximum speed.

Drive Forward (Creep Max): Test should be done on a


smooth level surface. High Torque - Low Speed setting,
platform speed knob at full creep.

Drive Reverse (Creep Max): Test should be done on a


smooth level surface. High Torque - Low Speed setting,
platform speed knob at full creep.

Drive Forward (Elevated Max - Boom Beyond Trans-


port): Test should be done on a smooth level surface.
High speed - Low Torque setting, platform speed knob out
of creep, Lift boom above transport, drive forward 50 ft.
(15.2 m).

Drive Reverse (Elevated Max - Boom Beyond Trans-


port): Test should be done on a smooth level surface.
High speed - Low Torque setting, platform speed knob out
of creep, Lift boom above transport, drive forward 50 ft.
(15.2 m).

Platform Rotate: Platform level and completely rotated


one direction. Rotate the opposite direction, Record Time.
Rotate the other direction, Record Time.

Articulating Jib: Platform level and centered with the


boom. Start with the Jib down. Jib Up, Record Time. Jib
Down, Record Time.

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SECTION 4 - JLG ANALYZER

2. Plug the analyzer into the connector at the base of 4. The analyzer screen should read:
the platform control box.

3. Pull out the Emergency Stop switch and Start the


engine.

5. Use the arrow button to reach SYSTEM TEST. Hit


Enter. The analyzer will prompt you asking if you
want to activate the system test; hit Enter again to
activate.
6. Follow the flow path in Figure 4-10. System Test
Flow Chart - Platform Tests on Pg. 209 and go
through the component tests. Hit the ESC key dur-
ing any part of the test to return to the main menu
without completing all tests or wait until all tests are
complete. During the TEST ALL INPUTS sequence,
the analyzer allows control switches to be operated
and shows if they are closed (CL) or open (OP).

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Figure 4-10. System Test Flow Chart - Platform Tests

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SECTION 4 - JLG ANALYZER

Test from the Ground Station 4. The analyzer screen should read:

1. Position the Platform/Ground select switch to the


Ground position.

2. Plug the analyzer into the connector inside the


Ground control box.

5. Use the arrow button to reach SYSTEM TEST. Hit


Enter. The analyzer will prompt you asking if you
want to activate the system test; hit Enter again to
activate.
6. Follow the flow path in Figure 4-11. System Test
Flow Chart - Ground Station Tests on Pg. 211 and
go through the component tests. Hit the ESC key
during any part of the test to return to the main menu
without completing all tests or wait until all tests are
complete. During the TEST ALL INPUTS sequence,
the analyzer allows control switches to be operated
and shows if they are closed (CL) or open (OP).

3. Pull out the Emergency Stop switch. and Start the


engine.

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Figure 4-11. System Test Flow Chart - Ground Station Tests

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SECTION 4 - JLG ANALYZER

Table 4-3. System Test Messages

Message Displayed on Message Displayed on


Description
Analyzer Analyzer
RUNNING Initial display when system test is run; certain “critical” checks are made. Prob-
lems that can be reported include below messages.
ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.
BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from
the platform and ground modules. The system test cannot run in ground mode
unless data is being received from the platform module.
CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed
encoder.
BAD GROUND MODULE An internal problem was detected in the ground module.
HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt
sensor.
HOT ENGINE The engine temperature exceeds 100C. This is only a warning.
BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other
problems are also detected, the controller may need replacing.
SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings
at switch on. Check and, if necessary correct, all personality settings.
OPEN FSW In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW In platform mode, the footswitch must be closed when this message is dis-
played; the footswitch MUST BE KEPT CLOSED during the valve & contactor
tests.
BAD FSW The two footswitch signals are not changing together, probably because one is
open-circuit. One footswitch signal (“FSW1”) is routed to the power module,
the other (“FSW2”) is routed to the platform module. Check footswitch and wir-
ing.
TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and
de-energized; checks are made for open- and short- circuit valve coils.
NOTE: In platform mode, the footswitch must be closed.
NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope
valves are not tested if TOWER TELE=NO. Jib valves are not tested if JIB = NO.
Extendable axle valves are not tested if EXT AXLES=NO. Four wheel steer valves
are not tested if 4WS=NO.
NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.
Problems that can be reported include below messages.
CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning cor-
rectly. Check valve wiring. Check ground alarm & hour meter wiring.
XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-cir-
cuited. Check valve wiring.
XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit.
Check valve wiring.

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Table 4-3. System Test Messages

Message Displayed on Message Displayed on


Description
Analyzer Analyzer
CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it
is in its “normal” position; function switches should be open, cutout switches
should be closed, joysticks should be in neutral.
In platform mode any non-neutral platform switch or joystick is reported; any
active cutouts are reported.
In ground mode any non-neutral ground switches is reported; any active cut-
outs are reported.
NOTE: Switches, which are not in use (due to the settings of machine digits), are
not checked.
NOTE: The pump pot is checked only for a wire-off condition; it can be at any
demand from creep to maximum.
Problems that can be reported include below messages.
CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.
CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.
TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a
prompt asks for confirmation that the lamp is lit.
ENTER must be pressed or clicked to continue the test.
NOTE: Lamps, which are not in use (due to the settings of machine digits), are
not checked.
NOTE: Platform Lamps are only tested in platform mode.
NOTE: The GM overload lamp and 500# capacity lamp are not tested.
NOTE: Head and tail lamps are tested in both platform and ground mode if
enabled by a machine digit.
TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a
prompt asks for confirmation that the alarm is sounding.
ENTER must be pressed or clicked to continue the test.
NOTE: The platform alarm and the horn are only tested in platform mode.
NOTE: The ground alarm is not tested if GROUND ALARM = NO.
TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the
system test ends. If ENTER is pressed or clicked, each operator input is
prompted for in turn.
In platform mode every platform switch and joystick is tested.
In ground mode every ground switch is tested.
NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope
switches are not tested if TOWER TELE=NO. Jib switches are not tested if JIB =
NO. Extendable axle switches are not tested if EXT AXLES=NO. Four wheel steer
switches are not tested if 4WS=NO.
NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.
Prompts displayed during the operator input test below messages.
CLOSE XXXXXXX The named switch should be closed.
OPEN XXXXXXX The named switch should be opened.
XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.
XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.
PUMP POT TO MAX The pump pot should be turned to maximum.
PUMP POT TO MIN The pump pot should be turned to minimum.
MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there
could be a short between two inputs.
TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have
been noted and should now be rectified. Press ESC/CANCEL to return to the
RUN SYSTEM TEST Analyzer menu.

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This Page Left Blank Intentionally

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SECTION 5 - CALIBRATIONS

SECTION 5. CALIBRATIONS

5.1 CALIBRATION INSTRUCTIONS Table 5-2. Calibrations Listed by Service Action

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

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SECTION 5 - CALIBRATIONS

1. Position the Platform/Ground select switch to the


5.2 CALIBRATING STEER Platform position.
When calibrating steering, each individual wheel must be
calibrated in order to make the tire and wheel parallel with
the frame. Two methods to help ensure proper calibration
are the use of a carpenter’s square to square the spindle
to the axle or aligning the two wheels on one side using a
stretched string.

2. Plug the analyzer into the connector at the base of


the platform control box.

3. Pull out the Emergency Stop switch and Start the


engine.

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SECTION 5 - CALIBRATIONS

4. The analyzer screen should read: 8. Use the arrow keys to reach Steer. The screen will
read:

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter. 9. Hit Enter. The screen will read:
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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SECTION 5 - CALIBRATIONS

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.

15. Left Rear Steer Calibration will be followed by Right


Forward Steer Calibration which will be followed by
Right Rear Steer Calibration.

16. After completing all the Steer Calibrations, hit ESC


twice to go back to CALIBRATIONS.

5.3 CALIBRATING DRIVE


1. Position the Platform/Ground select switch to the
Platform position.

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.

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SECTION 5 - CALIBRATIONS

2. Plug the analyzer into the connector at the base of 4. The analyzer screen should read:
the platform control box.

3. Pull out the Emergency Stop switch and Start the


engine.

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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SECTION 5 - CALIBRATIONS

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:

12. Activate the Drive Joystick forward full stroke until


the machine just begins to move, then leave off the
joystick immediately. The display will read CRK PT =
and show the numeric crack point value.

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SECTION 5 - CALIBRATIONS

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.

14. Hit Enter. The screen will read:

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SECTION 5 - CALIBRATIONS

b. The Electronic Leveling System Fault Lamp shall


5.4 ELECTRONIC PLATFORM LEVELING flash (to indicate that the leveling function has
been lost).
Platform Leveling Fault Warning c. The platform alarm will sound.
If a fault occurs in the platform leveling system the follow- d. A system fault will be logged.
ing will occur:
e. All function speeds (lift, swing, telescope and
1. Automatic platform leveling will stop (except when drive) will be placed in creep mode (except
there is a fault in only one sensor automatic leveling when the platform is in the transport position).
will remain active as the control system will use the
2. In the case of a short to battery on one of the plat-
other sensor to control leveling)
form leveling valves, the valve cannot be turned off
2. The level fault lamp will flash and the following will occur:
3. The audible alarm will sound a. The platform dump valve will be turned off to
prevent unintended tilting of the platform.
4. All functions will default to creep speed if the plat-
form is out of the transport position. b. All interactions with platform leveling shall
cease.
To reset the fault the emergency stop switch should be
c. The Electronic Leveling System Fault Lamp shall
recycled.
flash (to indicate that the leveling function has
been lost).
d. The platform alarm will sound.
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE
GROUND POSITION, SWITCH THE MACHINE OFF AND CONTACT e. A system fault will be logged.
A QUALIFIED SERVICE REPRESENTATIVE TO INVESTIGATE THE f. All function speeds (lift, swing, telescope and
FAULT. drive) will be placed in creep mode (except
when the platform is in the transport position)
Fault Response 3. In the case of a short to battery on the platform
ERROR RESPONSE dump valve, the valve cannot be turned off. The con-
trollability of the platform leveling function will be
If basket level varies from the current setpoint by ± 5.5° for
impaired and the following will occur:
more than 1.5 seconds when the platform is not in the
transport position, the following events will occur: a. All interactions with platform leveling shall
cease.
1. The platform dump valve will be disabled (level,
rotate and jib functions disabled). b. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has
2. The level system fault lamp will flash (to indicate that been lost).
the leveling function has been lost).
c. The platform alarm will sound.
3. The platform alarm will sound. d. A system fault will be logged.
4. A system fault will be logged. e. All function speeds (lift, swing, telescope and
drive) will be placed in creep mode (except
5. All function speeds (lift, swing, telescope and drive)
when the platform is in the transport position).
will be placed in creep mode (except when the plat-
form is in the transport position see below). Lift, swing, drive and telescope will continue to operate

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.

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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.

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SECTION 5 - CALIBRATIONS

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.

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SECTION 5 - CALIBRATIONS

4. The analyzer screen should read:


5.5 CALIBRATING PLATFORM LEVEL
STEP 1: SETTING THE PLATFORM VALVE
MINIMUMS
1. Position the Platform/Ground select switch to the
Ground position.

2. Plug the analyzer into the connector inside the


Ground control box. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the arrow button to reach PERSONALITIES
adjust the following personalities. Refer to Table 4-2.
Machine Personality Settings and Speeds on page
202 for proper setting values.

Basket Level Up Min


Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.

3. Pull out the Emergency Stop switch and start the


engine.

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SECTION 5 - CALIBRATIONS

STEP 2: CALIBRATING THE PLATFORM LEVEL 5. The analyzer screen should read:

SENSORS
1. Position the Platform/Ground select switch to the
Ground position.

2. Plug the analyzer into the connector inside the


Ground control box.

6. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
7. Enter the Access Code, 33271.
8. Use the arrow button to reach CALIBRATIONS menu
and hit ENTER.
9. Use right arrow go to PLAT. LEVELING screen.
10. Hit ENTER. The screen should read:

3. Pull out the Emergency Stop switch and start the


engine.
4. Manually level the platform with the switch on the
Main Terminal Box.

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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.

STEP 3: BLEEDING THE PLATFORM VALVES


1. Position the Platform/Ground select switch to the
Ground position.

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


2. Plug the analyzer into the connector inside the Enter.
Ground control box.
6. Enter the Access Code, 33271.
7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND
MODE menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following
personalities to 100%.

Basket Rotate
Basket Level
Jib U/D (if configured)

Start up the machine and exercise each above plat-


form function (from the ground) eight (8) to ten (10)
times for 5 seconds in each direction.
11. Return the personality settings back to the values as
3. Pull out the Emergency Stop switch and start the
shown in Table 4-2. Machine Personality Settings
engine.
and Speeds on page 202.
12. Recycle EMS.

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SECTION 5 - CALIBRATIONS

STEP 4: CALIBRATING THE PLATFORM LEVEL 4. The analyzer screen should read:

UP AND DOWN VALVE CRACKPOINTS


1. Position the Platform/Ground select switch to the
Ground position.

2. Plug the analyzer into the connector inside the


Ground control box.

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
6. Enter the Access Code, 33271.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER
again.
10. You will hear engine go to 1800 rpm.
11. Using UP ARROW, increase the value until you see
the basket up movement.
12. Hit ENTER again. CAL. COMPLETE message
should appear
3. Pull out the Emergency Stop switch and start the 13. Engine should again return to idle.
engine.
14. Hit ESC should return to BASKET U CRKPT screen.
15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”
screen. Hit ENTER.
16. CALIBRATE? prompt should appear. Hit ENTER
again.
17. 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 and cycle power to the machine.

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5.6 CALIBRATING TILT SENSOR 3. Plug the analyzer into the connector inside the
Ground control box.

A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE


TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.

DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL


SURFACE.

1. Use the following procedure to calibrate the tilt sen-


sor.

Before the tilt sensor can be calibrated, the following


conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
4. Pull out the Emergency Stop switch and start the
d. Turntable centered.
engine.
e. Boom fully retracted.
5. The analyzer screen should read:
f. Boom angle is less than 45°.
g. Machine on firm, level ground.
2. Position the Platform/Ground select switch to the
Ground position.

6. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
7. Enter the Access Code, 33271.
8. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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SECTION 5 - CALIBRATIONS

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.

2. Plug the analyzer into the connector at the base of


the platform control box.
10. Press ENTER.

11. When prompted, swing turntable 180° to opposite


end of chassis.

12. Press ENTER. The screen should read:

13. Upon completing swing calibration, swing turntable


180° back to the stowed position.

14. Hit ESC twice to go back to CALIBRATIONS.

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SECTION 5 - CALIBRATIONS

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:

4. The analyzer screen should read:

9. Hit enter. The screen will read:

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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SECTION 5 - CALIBRATIONS

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:

11. Hit Enter again. The screen will read:


14. Hit Enter. The screen will read:

12. Activate the Lift Up function by fully stroking the joy-


stick until the boom starts to move, then leave off 15. Repeat steps 10 thru 12 for the Lift Down function.
immediately. The display will read CRK PT = and
16. After completing all the Tele Calibrations, hit ESC
show the numeric crack point value.
twice to go back to CALIBRATIONS.

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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.

4. The analyzer screen should read:

2. Plug the analyzer into the connector at the base of


the platform control box.

5. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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SECTION 5 - CALIBRATIONS

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:

11. Hit enter again. The screen will read:


9. Hit Enter. 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.

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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:

16. Repeat steps 10 thru 12 for the Tele In function.


14. Hit Enter. The screen will read:
17. After completing all the Tele Calibrations, hit ESC
twice to go back to CALIBRATIONS.

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SECTION 5 - CALIBRATIONS

3. Plug the analyzer into the connector inside the


5.9 CALIBRATING THE BOOM SENSORS Ground control box.

DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS


NORMAL FOR THE REAR WHEEL TO LIFT FROM THE GROUND
APPROXIMATELY 1 INCH (2.5 CM). IF THE WHEEL RAISES
APPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10 CM] OR
MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER
OPERATION OR THE NEED FOR BLEEDING, THEN PROCEED
WITH THE BOOM SENSOR CALIBRATION PROCEDURE.
Use the following step-by-step procedure to calibrate the
boom sensors.

1. Before the boom sensors can be calibrated, the fol-


lowing conditions must be met:
a. Steering, telescope crack points, and tilt previ-
ously calibrated
b. Axles Extended 4. Pull out the Emergency Stop switch and start the
c. Wheels Straight engine.
d. Platform Unloaded 5. The analyzer screen should read:
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)

Figure 5-1. Boom Sensor Calibration Position 1

2. Position the Platform/Ground select switch to the


Ground position.

6. Use the arrow button to reach ACCESS LEVEL 2. Hit


Enter.
7. Enter the Access Code, 33271.
8. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.

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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:

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SECTION 5 - CALIBRATIONS

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:

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SECTION 5 - CALIBRATIONS

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:

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SECTION 5 - CALIBRATIONS

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:

24. Lift up to stop (full stroke of cylinder) for Calibration


22. Use the up/down arrows to select yes if the acces- Position 2. When the machine is in that position, hit
sory is installed, no if it is not installed and hit Enter. Enter.
The screen will read:

Figure 5-2. Boom Sensor Calibration Position 2

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SECTION 5 - CALIBRATIONS

The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:

Swing 180 degrees (centered over opposite end of chas-


sis) for Calibration Position 3. When Position 3 calibrating is complete the screen will
read:

Figure 5-3. Boom Sensor Calibration Position 3

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SECTION 5 - CALIBRATIONS

25. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:

26. Swing the machine back 180 degrees (centered


over original end of chassis) for Calibration Position When Position 4 calibrating is complete, the screen will
4. read:

Figure 5-4. Boom Sensor Calibration Position 4

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SECTION 5 - CALIBRATIONS

27. Press Enter. The screen will read: When the machine is in the proper position, hit Enter. The
screen will read:

Telescope out to stop (boom must be fully extended) for


Calibration Position 5. 28. Retract to stop (boom must be fully retracted) for
Calibration Position 6.

Figure 5-6. Boom Sensor Calibration Position 6


Figure 5-5. Boom Sensor Calibration Position 5

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SECTION 5 - CALIBRATIONS

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:

Figure 5-7. Boom Sensor Calibration Position 7

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Press Enter. The screen read: When the machine is in the proper position, hit Enter. The
screen will read:

30. Lift until the function stops (controller will stop at 5


degrees above horizontal) for Calibration Position 8. Press Enter. The screen will read:

Figure 5-8. Boom Sensor Calibration Position 8

31. Telescope to the yellow witness mark (controller will


be close - operator must position the pointer to cen-

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SECTION 5 - CALIBRATIONS

ter line on decal within 0.25" [6 mm]) for Calibration When Position 9 calibrating is complete, the screen will
Position 9. read:

Figure 5-9. Boom Sensor Calibration Position 9

When the boom is in the proper position, hit Enter. The


screen will read: Press Enter. The screen will read:

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SECTION 5 - CALIBRATIONS

32. Telescope in to green witness mark (controller will Press Enter. The screen will read:
find the position - operator must visually verify the
position).

Figure 5-10. Boom Sensor Calibration Position 10

When the boom is in the proper position, the screen will


read:

33. After completing all the Boom Sensors Calibrations,


hit ESC twice to go back to Calibrations.

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SECTION 5 - CALIBRATIONS

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.

NOTE: The inner mid section is positioned by the hydraulic


cylinder. No adjustments will be made to this section.
The wire ropes within the assembly control the
movement of the outer mid and fly boom sections.

If it is necessary to reposition the outer mid and fly boom


sections to achieve the measurements in Figure 5-11.,
Wire Rope Tensioning Figure A, sound technician judg-
ment should be used to compare the thread adjustment
(that is left on the wire rope fittings) to the position of the
boom sections. The sections can be repositioned slightly
to achieve a more even adjustment at the wire rope fittings
when comparing the extend and retract systems.

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

NOTE: Boom shown in fully retracted position.

Figure 5-11. Wire Rope Tensioning Figure A

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SECTION 5 - CALIBRATIONS

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.

5. Retract boom 2 to 3 feet (0.6 to 0.9 m) from exten-


sion point reached in Step #2.

7. Using tool P/N 4120040, torque fly extend adjuster


nuts to 10 ft.lb. (14 Nm), alternating between the four
ropes until all maintain the required torque.

8. Fully retract the boom assembly and verify the


exposed boom section dimensions meet the dimen-
sion tolerances shown in Figure 5-11., Wire Rope
Tensioning Figure A.

9. Reinstall nylon collar locknuts to fly extend wire rope


fittings. Torque locknuts to 10 ft.lb. (14 Nm).

10. Reinstall lock plates to remaining adjuster nuts.

11. Install all covers and check for proper function of


boom assembly.

DO NOT REPEAT STEPS #2 THROUGH #7 MULTIPLE TIMES TO


VERIFY ROPE TENSION. VERIFICATION OF THE ROPE TENSION
SHOULD BE DETERMINED BY PROPER FUNCTION OF THE BOOM
ASSEMBLY.

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SECTION 5 - CALIBRATIONS

BOOM SECTION REPOSITIONING EXAMPLE:


If the outer mid boom section is still extended outside of
the tolerance as shown in Figure 5-11., Wire Rope Ten-
sioning Figure A while the boom assembly is fully
retracted, it will be necessary to loosen the outer mid
extend wire rope fittings. After loosening the outer mid
extend wire rope fittings, extend the boom assembly 5 to 6
feet (1.5 to 1.8 m) from the fully retracted position and
repeat the tensioning steps for the outer mid retract ropes.
Steps #5 & #6 should then be repeated. Once those
steps are complete, fully retract the boom assembly and
verify that the exposed boom section dimensions meet
the dimension tolerances of Figure 5-11., Wire Rope Ten-
sioning Figure A.
This same method can be applied to repositioning the fly
boom section by substituting the correct steps for the fly
boom wire ropes. This is also applicable if either of the
sections is positioned too far in, in the retracted position.
The technician should begin the repositioning procedure
with the boom partially extended, slightly loosen the
retract wire ropes, and partially retract the boom.

NOTE: Ensure that the boom is not fully retracted.

At this point, the correct steps should be followed to ten-


sion the extend wire ropes for that section. Once those
steps are complete, the steps required to tension the
retract wire ropes should then be performed.

NOTE: Any repositioning of the outer mid boom section will


also effect the position of the fly boom section, as the
outer mid is used to control the movement of the fly.
The best practice is to correctly position the outer
mid boom before repositioning the fly boom.

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SECTION 5 - CALIBRATIONS

1. 2" Socket
2. 3/4” Socket
3. Retaining Bolt

Figure 5-12. Wire Rope Adjustment Tools

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SECTION 5 - CALIBRATIONS

This Page Left Blank Intentionally

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SECTION 6 - GENERAL ELECTRICAL INFORMATION

SECTION 6. GENERAL ELECTRICAL INFORMATION

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.

6.2 MULTIMETER BASICS


A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter
with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows dia-
grams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary.
Please consult the meter operator’s manual for more information.

Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch
it to a good 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)

k = kilo = 1,000 * (Displayed Number)

m = milli = (Displayed Number) / 1,000

μ = micro = (Displayed Number) / 1,000,000

Example: 1.2 k = 1200 

Example: 50 mA = 0.05 A

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Voltage Measurement Resistance Measurement

Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement

• 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

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Continuity Measurement Current Measurement

Figure 6-3. Continuity Measurement Figure 6-4. Current Measurement (DC)

• 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

6.3 CONTINUITY MEASUREMENT OVER LONG DISTANCES


When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.

Requirements:
• Harness with at least three separate wires including the wire under test.

• These wires must be able to be isolated from other wires, etc.

• Jumper or method to connect contacts on one side of harness.

• Meter that can measure resistance or continuity.

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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.

3. On one side, jumper from contact of wire #1 and wire #2.


4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this
test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measure-
ment. If still no continuity, repair wires or consult schematic for other wires to use for test.

5. Jumper from wire under test to wire #1.


6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.

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.

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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.

Switch Wiring - Low Side, High Side


When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can mea-
sure the voltage at both power terminals with respect to battery ground. The difference between those two measure-
ments is the voltage applied to the load.

6.5 WORKING WITH AMP CONNECTORS


Applying Silicone Dielectric Compound To Amp Connectors
Silicone Dielectric Compound must be used on the AMP connections for the following reasons:

• 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

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SECTION 6 - GENERAL ELECTRICAL INFORMATION

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.

Figure 6-5. AMP Connector

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:

Figure 6-6. Connector Assembly (1 of 4)

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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)).

Figure 6-7. Connector Assembly (2 of 4)

Figure 6-8. Connector Assembly (3 of 4)

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SECTION 6 - GENERAL ELECTRICAL INFORMATION

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.

2. Pry open the wedge lock to the open position.

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.

Figure 6-10. Connector Disassembly

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.

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Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

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.

Figure 6-11. Connector Installation

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SECTION 6 - GENERAL ELECTRICAL INFORMATION

6.6 WORKING WITH DEUTSCH CONNECTORS


DT/DTP Series Assembly

Figure 6-12. DT/DTP Contact Installation

1. Grasp crimped contact about 25mm behind the contact barrel.

2. Hold connector with rear grommet facing you.

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.

DT/DTP Series Disassembly

Figure 6-13. DT/DTP Contact Removal

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.

HD30/HDP20 Series Assembly

Figure 6-14. HD/HDP Contact Installation

1. Grasp contact about 25mm behind the contact crimp barrel.

2. Hold connector with rear grommet facing you.

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SECTION 6 - GENERAL ELECTRICAL INFORMATION

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.

Figure 6-15. HD/HDP Locking Contacts Into Position

NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing

HD30/HDP20 Series Disassembly

Figure 6-16. HD/HDP Contact Removal


1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages contact and resistance is felt.
3. Pull contact-wire assembly out of connector.

Figure 6-17. HD/HDP Unlocking Contacts

NOTE: Do Not twist or insert tool at an angle.

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This Page Left Blank Intentionally

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Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417

JLG Worldwide Locations


JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester
Australia M24 2GP - England +33 (0) 5 53 88 31 70
+55 19 3295 0407
+61 2 65 811111 +44 (0) 161 654 1000 +33 (0) 5 53 88 31 79
+55 19 3295 1025
+61 2 65 810122 +44 (0) 161 654 1001

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

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UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
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+48 (0) 914 320 245 Scotland 08755 Castellbisbal, Barcelona Sweden
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+44 (0) 141 781 6700
+34 93 772 4700 +46 (0) 850 659 534
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+34 93 771 1762

www.jlg.com

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