SECTION 6 - JLG CONTROL SYSTEMSECTION 6 - JLG CONTROL SYSTEM 3121259 6-73 GLOWPLUG – SHORT TO GROUND 33281 The Ground Module detects a shor t to ground at the Glow Plug out-put

SECTION 6 - JLG CONTROL SYSTEM

6-72 3121259

TELESCOPE OUT VALVE – OPEN CIRCUIT

33186 The Ground Module detects an open circuit at the Telescope Out Valve output.

Tele speed is limited to Creep Check for a good connection at the solenoid and for continuity through this circuit. With the solenoid disconnected, an open circuit voltage of nearly 8.0V exists on the Ground Mod-ule output pin for diagnostic purposes. Inspect wiring for physical damage. Cycle power to clear the fault.

TELESCOPE OUT VALVE – SHORT TO GROUND

33188 The Ground Module detects a short to ground at the Telescope Out Valve output.

Ground Module Telescope Out output is disabled; Tele In speed is limited to Creep.

Inspect wiring for physical damage and check for wire continuity. Check for coil dam-age or shorting condition in connector. Cycle power to clear the fault.

TELESCOPE IN VALVE – OPEN CIRCUIT

33189 The Ground Module detects an open circuit at the Telescope In Valve output.

Tele speed is limited to Creep Check for a good connection at the solenoid and for continuity through this circuit. With the solenoid disconnected, an open circuit voltage of nearly 8.0V exists on the Ground Mod-ule output pin for diagnostic purposes. Inspect wiring for physical damage. Cycle power to clear the fault.

TELESCOPE IN VALVE – SHORT TO GROUND

33190 The Ground Module detects a short to ground at the Telescope In Valve output.

Ground Module Telescope In and Out outputs are disabled.


GLOWPLUG – OPEN CIRCUIT 33279 The Ground Module detects an open circuit at the Glow Plug output. (Kubota)

No response required Check for a good connection at the relay and for continuity through this circuit. With the relay disconnected, an open circuit voltage of nearly 8.0V exists on the Ground Module output pin for diagnostic pur-poses. Inspect wiring for physi-cal damage. Cycle power to clear the fault.

GLOWPLUG – SHORT TO BAT-TERY

33280 The Ground Module detects a short to battery at the Glow Plug out-put. (Kubota)

Ground Module Glow Plug relay output is disabled.

Inspect wiring for physical damage and check for wire continuity. Cycle power to clear the fault.

Table 6-15. Fault Code Troubleshooting Information

Help Message DTC Condition Producing DTCControl System Response or

Machine Condition

Corrective Action/Operational Requirement

for Function Movement and/or to Clear Fault

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3121259 6-73

GLOWPLUG – SHORT TO GROUND

33281 The Ground Module detects a short to ground at the Glow Plug out-put. (Kubota)

Ground Module Glow Plug relay output is disabled.

Inspect wiring for physical damage and check for wire continuity. Check for relay damage or shorting condition in connector. Cycle power to clear the fault.

LIFT – CURRENT FEEDBACK READING TOO LOW

33287 The Ground Module calls for current greater than 250mA, but the actual current is at least 125mA less than the called for current for more than 1 second

The Ground Module suspends Lift Up/Down commands and reverts to Open Loop Current control for Lift; Lift speed is lim-ited to Creep after both Lift Up/Down controls have been returned to neutral and the machine is not Enabled

Part of the commanded current is being divided either prior to the solenoid connection or on the ground return path. Inspect wiring for physical damage and check for wire continuity and a low resistance return path. Cycle power to clear the fault.

SWING LEFT VALVE – OPEN CIRCUIT

33295 The Ground Module detects an open circuit at the Swing Left Valve output.

The Ground Module suspends Swing Left/Right commands and reverts to Open Loop Cur-rent control for Swing; Swing speed is limited to Creep after both Swing Left/Right controls have been returned to neutral and the machine is not Enabled

Check for a good connection at the solenoid and for continuity through this circuit. With the solenoid disconnected, an open circuit voltage of nearly 8.0V exists on the Ground Mod-ule output pin for diagnostic purposes. Inspect wiring for physical damage. Cycle power to clear the fault.

FLOW CONTROL VALVE – OPEN CIRCUIT

33314 The Ground Module detects an open circuit at the Flow Control Valve output.

The Ground Module suspends output commands and reverts to Open Current loop control for Flow Control Valve; Tele In/Out, Jib Up, Rotate Right/Left, and Level Up/Down speed are lim-ited to Creep after controls for those functions have all been simultaneously returned to neutral and the machine is not Enabled.


FLOW CONTROL VALVE – SHORT TO BATTERY

33315 The Ground Module detects a short to battery at the Flow Control Valve output.

Disable Ground Module Flow Control Valve output and open the ground current return path; disallow energization of valves for Tele In/Out, Jib Up (permit-ted if operating in Emergency Descent mode), Level Up/Down, or Rotate Right/Left.




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6-74 3121259

FLOW CONTROL VALVE – SHORT TO GROUND

33316 The Ground Module detects a short to ground at the Flow Control Valve output.

Ground Module Flow Control Valve output is disabled; disal-lows energization of valves for Tele In/Out, Jib Up (permitted if operating in Emergency Descent mode), Level Up/Down, or Rotate Right/Left.


DRIVE FORWARD VALVE – OPEN CIRCUIT

33317 The Ground Module detects an open circuit at the Drive Forward Valve output.

The Ground Module suspends Drive Forward/Reverse com-mands and reverts to Open Cur-rent loop control for Drive; Drive speed is limited to Creep after both Drive Forward/Reverse controls have been returned to neutral and the machine is not Enabled.


DRIVE VALVES – SHORT TO BATTERY

33318 The Ground Module detects a short to battery at either the Drive For-ward or Drive Reverse valve.

Ground Module Drive Forward and Reverse outputs are dis-abled and open the ground cur-rent return path.


DRIVE FORWARD VALVE – SHORT TO GROUND

33319 The Ground Module detects a short to ground at the Drive Forward Valve output.

Ground Module Drive Forward and Reverse outputs are dis-abled.


DRIVE REVERSE VALVE – OPEN CIRCUIT

33320 The Ground Module detects an open circuit at the Drive Reverse Valve output.



DRIVE REVERSE VALVE – SHORT TO GROUND

33322 The Ground Module detects a short to ground at the Drive Reverse Valve output.

Ground Module Drive Forward and Reverse outputs are dis-abled.




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3121259 6-75

DRIVE – CURRENT FEEDBACK READING TOO LOW




LIFT UP VALVE – SHORT TO GROUND

33406 The Ground Module detects a short to ground at the Lift Up Valve out-put.

Lift Up is disabled; Lift Down speed is limited to Creep


DRIVE – LOSS OF CURRENT FEEDBACK

33410 Measured feedback current is less than 225mA while Ground Module output is greater than 40% (Displayed on Analyzer DIAGNOSTICS menu).


Part or all of the commanded current is being diverted from the ground return path. Inspect wiring for physical damage and check for wire continuity and a low resistance return path. Cycle power to clear the fault.

SWING VALVES – SHORT TO BATTERY

33412 The Ground Module detects a short to battery at either the Swing Right or Swing Left valve

Ground Module Swing Left and Right outputs are disabled and open the ground current return path is open circuited.


TOWER LIFT – CURRENT FEED-BACK READING TOO LOW


The Ground Module suspends Tower Lift commands and reverts to Open Current loop control for Tower Lift; Tower Lift speed is limited to Creep after both Tower Lift Up/Down con-trols have been returned to neutral and the machine is not Enabled.


SWING – CURRENT FEEDBACK READING TOO LOW


The Ground Module suspends Swing Left/Right commands and reverts to Open Loop Cur-rent control for Swing; Swing speed is limited to Creep after both Swing Left/Right have been returned to neutral and the machine is not Enabled




Machine Condition



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6-76 3121259

FLOW CONTROL VALVE – CUR-RENT FEEDBACK READING TOO LOW


The Ground Module suspends and reverts to Open Current loop control for Flow Control Valve; Tele In/Out, Jib Up, Rotate Right/Left, and Level Up/Down speed is limited to Creep after controls for those functions have all been simul-taneously returned to neutral and the machine is not Enabled


TOWER LIFT – CURRENT FEED-BACK READING LOST


The Ground Module suspends commands and reverts to Open Current loop control for Tower Lift; Tower Lift speed is limited to Creep after both Lift Up/Down controls have been returned to neutral and the machine is not Enabled.


LIFT – CURRENT FEEDBACK READING LOST


The Ground Module suspends Lift Up/Down commands and reverts to Open Loop Current control for Lift; Lift speed is lim-ited to Creep after both Lift Up/Down controls have been returned to neutral and the machine is not Enabled.


SWING – CURRENT FEEDBACK READING LOST


The Ground Module suspends Swing Left/Right commands and reverts to Open Loop Cur-rent control for Swing; Swing speed is limited to Creep after both Swing Left/Right have been returned to neutral and the machine is not Enabled.


FLOW CONTROL VALVE – CUR-RENT FEEDBACK READING LOST


The Ground Module suspends and reverts to Open Current loop control for Flow Control Valve; Tele In/Out, Jib Up, Rotate Right/Left, and Level Up/Down speed is limited to Creep after controls for those functions have all been simul-taneously returned to neutral and the machine is not Enabled


TRACTION LOCK VALVE – SHORT TO BATTERY

33420 The Ground Module detects a short to battery at the Traction Lock valve output.

If in Max Speed drive mode, the machine switches to Max Torque; Max Speed drive mode is disabled.




Machine Condition



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3121259 6-77

TRACTION LOCK VALVE – OPEN CIRCUIT

33421 The Ground Module detects an open circuit at the Traction Lock valve output.

If in Max Speed drive mode, the machine switches to Max Torque; Max Speed drive mode is disabled.

Check for a good connection at the solenoid and for continuity through this circuit. Inspect wiring for physical dam-age.Cycle power to clear the fault.

TRACTION LOCK VALVE – SHORT TO GROUND

33422 The Ground Module detects a short to ground at the Traction Lock valve output.

Traction Lock valve output is disabled. If in Max Speed drive mode, the machine switches to Max Torque; Max Speed drive mode is disabled.


OSCILLATING AXLE VALVES – SHORT TO BATTERY

33423 The Ground Module detects a short to battery condition on the J1-7 output.

The Ground Module assumes an Above Elevation State and de-energizes the J1-7 Oscillat-ing Axle output.


OSCILLATING AXLE VALVES – SHORT TO GROUND

33424 The Ground Module detects a short to ground condition on the J1-7 output.

The Ground Module to assumes an Above Elevation State and de-energizes J1-7 Oscillating Axle output.

Inspect wiring for physical damage and check for wire continuity. Check for shorting condition in connector. Cycle power to clear the fault.

TOWER LIFT VALVES – SHORT TO BATTERY

33425 The Ground Module detects a short to battery at either the Tower Lift Up or Tower Lift Down valve.

Ground Module Tower Lift Up and Down outputs are disabled and open the ground current return path.


PLATFORM ROTATE LEFT VALVE – OPEN CIRCUIT

349 The Platform Module detects an open circuit at the Platform Rotate Left Valve output and reports it to the Ground Module.

Platform Rotate speed is lim-ited to Creep

Check for a good connection at the solenoid and for continuity through this circuit. Inspect wiring for physical damage. Cycle power to clear the fault.

PLATFORM ROTATE LEFT VALVE – SHORT TO BATTERY

3410 The Platform Module detects a short to battery at the Platform Rotate Left Valve output and reports it to the Ground Module.

Platform Module are disabled for Platform Rotate Right, Rotate Left, and Flow Control Valve outputs are disabled.


PLATFORM ROTATE LEFT VALVE – SHORT TO GROUND

3411 The Platform Module detects a short to ground at the Platform Rotate Left Valve output and reports it to the Ground Module.

Platform Rotate Right and Left outputs are disabled.


PLATFORM ROTATE RIGHT VALVE – OPEN CIRCUIT

3412 The Platform Module detects an open circuit at the Platform Rotate Right Valve output and reports it to the Ground Module.

Platform Rotate speed is lim-ited to Creep




Machine Condition



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6-78 3121259

PLATFORM ROTATE RIGHT VALVE – SHORT TO BATTERY

3413 The Platform Module detects a short to battery at the Platform Rotate Right Valve output and reports it to the Ground Module.

Platform Rotate Right, Rotate Left, and Flow Control Valve outputs.


PLATFORM ROTATE RIGHT VALVE – SHORT TO GROUND

3414 The Platform Module detects a short to ground at the Platform Rotate Right Valve output and reports it to the Ground Module.

Platform Rotate Right and Left outputs are disabled.


JIB LIFT UP VALVE – OPEN CIR-CUIT

3415 The Platform Module detects an open circuit at the Jib Lift Up Valve output and reports it to the Ground Module.

Jib Lift speed is limited to Creep. Check for a good connection at the solenoid and for continuity through this circuit. Inspect wiring for physical damage. Cycle power to clear the fault.

JIB LIFT UP VALVE – SHORT TO BATTERY

3416 The Platform Module detects a short to battery at the Jib Lift Up Valve output and reports it to the Ground Module.

Jib Lift Up and Flow Control Valve outputs are disabled; Jib Lift Down speed is limited to Creep


JIB LIFT UP VALVE – SHORT TO GROUND

3417 The Platform Module detects a short to ground at the Jib Lift Up Valve output and reports it to the Ground Module.

Jib Lift Up output is disabled; Jib Lift Down speed is limited to Creep


JIB LIFT DOWN VALVE – OPEN CIRCUIT

3418 The Platform Module detects an open circuit at the Jib Lift Down Valve output and reports it to the Ground Module.

Jib Lift speed is limited to Creep. Check for a good connection at the solenoid and for continuity through this circuit. Inspect wiring for physical damage. Cycle power to clear the fault.

JIB LIFT DOWN VALVE – SHORT TO BATTERY

3419 The Platform Module detects a short to battery at the Jib Lift Down Valve output and reports it to the Ground Module.

Jib Lift Up and Down outputs are disabled.


JIB LIFT DOWN VALVE – SHORT TO GROUND

3420 The Platform Module detects a short to ground at this output and reports it to the Ground Module.

Jib Lift Up and Down outputs are disabled.




Machine Condition



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3121259 6-79

FUEL SENSOR SHORT TO BAT-TERY

431 Ground Module fuel sensor input (J2-25) detects a voltage higher than 2.50 volts

The Control System shuts down all fuel level indicators in Plat-form and Ground stations.

Disconnect fuel sender and ver-ify resistance readings can range from approximately 30ohms (full) to 240ohms (empty). If not, replace sender. With fuel sender connected, backprobe J2-25 and verify voltage range from approxi-mately 0.5V to 2.3V. Trouble-shoot wiring or connections.

FUEL SENSOR SHORT TO GROUND

432 Ground Module fuel sensor input (J2-25) detects a voltage less than or equal to 0.3 volts

The Control System shuts down all fuel level indicators in Plat-form and Ground stations.

Disconnect fuel sender and ver-ify resistance readings can range from approximately 30ohms (full) to 240ohms (empty). If not okay, replace sender. With fuel sender con-nected, backprobe J2-25 and verify voltage range from approximately 0.5V to 2.3V. Troubleshoot wiring or connec-tions.

OIL PRESSURE SHORT TO BAT-TERY

433 MACHINE SETUP ENGINE = KUBOTA D1105Oil Pressure reads a high value at Startup even though the engine has not been started (occurs for STB or OC – wire off pressure switch)

If MACHINE SETUP ENGINE SHUTDOWN = ENABLED then engine start is not permitted; Low Oil Pressure indicator will be activated

Verify wire is connected to oil pressure switch. With engine off, switch should show low impedance to ground or replace switch. Observe state change on Analyzer under DIAGNOSTICS-->ENGINE-->ENGINE OIL PRESS

COOLANT TEMPERATURE SHORT TO GROUND

435 MACHINE SETUP ENGINE = KUBOTA D1105Ground Module coolant temperature input (J1-14) detects a voltage less than or equal to 0.05 volts

If MACHINE SETUP ENGINE SHUTDOWN = ENABLED then engine will be shutdownHigh Engine Temperature indi-cator will be activated

Disconnect temperature sender and verify resistance reading > 0.15ohms (up to 50kohms is acceptable); then troubleshoot wiring. With sys-tem on, backprobe J1-14 and verify voltage > 1.5V.

ENGINE TROUBLE CODE 437 The engine controller reports a J1939 fault Engine will operate at 1800RPM until power cycle.

Cycle power to clear the fault.

HIGH ENGINE TEMP 438 For a machine configured with a Kubota D1105 engine, the engine has been running more than 10 seconds and the engine coolant tem-perature is greater than 110ºC:

For a machine with electronic engine controls, the ECM transmits an engine coolant high temperature critical fault (SPN:FMI 110:0)

If MACHINE SETUP ENGINE SHUTDOWN = ENABLED then the engine will be shut down and the High Engine Tempera-ture indicator will be lit

Reduce hydraulic loading of machine and inspect radiator for blockage of air flow.

NO ALTERNATOR OUTPUT 4310 The engine has been running more than 10 seconds and Ground Module system voltage is less than 11.5 volts for 10 seconds

The No Charge indicator will be lit

Ground Module system voltage greater than 11.7 volts



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6-80 3121259

LOW OIL PRESSURE 4311 For a machine configured with a Kubota D1105 engine, the engine has been running more than 10 seconds and the engine oil pressure is LOW (debounce 3s).For a machine with electronic engine controls, the ECM transmits an engine oil low pressure critical fault (SPN:FMI 100:1).

If MACHINE SETUP ENGINE SHUTDOWN = ENABLED then the engine will be shut down and the Low Oil Pressure indi-cator will be lit

Check engine oil level. Cycle power to clear the fault.

THROTTLE ACTUATOR FAILURE 4313 For a machine configured with a Kubota D1105 engine:THROTTLE ACTUATOR – OPEN CIRCUIT (33131) is not activeTHROTTLE ACTUATOR – SHORT TO GROUND (33130) is not activeLOSS OF ENGINE SPEED SENSOR (4322) is not activedesired engine speed is greater than 1800 but actual RPM is less than 1400 (debounce time = 3s) when no fault exists with Proportional Fuel Rack actuator

Disable Ground Module Throt-tle Actuator output and call for full opening (current = 1500mA) to Proportional Fuel Rack Actuator.


WRONG ENGINE SELECTED – ECM DETECTED

4314 Machine is configured with a non-electronic controlled Kubota D1105 engine and the Ground Module detects an electronic engine controller on the CAN bus

No function inhibits required Cycle power to clear the fault.

LOSS OF ENGINE SPEED SEN-SOR

4322 Machine is configured with a Kubota D1105 engine and the engine is running: LOW OIL PRESSURE fault (4311) is not activeOIL PRESSURE SHORT TO BATTERY fault (433) is not active No engine shutdown command existsEngine RPM is read as 0 for 1500ms and Engine oil pressure is not LOW

Ground Module to limit all function speeds to creep, but run at High Engine speed until the oil pressure drops to a low value. Ground Module to dis-able Generator relay output until generator operator switch cycled.

Check proper seating/clear-ance of engine speed sensor installation. Verify continuity of wiring before replacing sen-sor. Fault cleared when Engine RPM greater than 0

SPEED SENSOR READING INVALID SPEED

4323 Machine is configured with a Kubota D1105 engine and the engine RPM reading is greater than 4000

The Ground Module commands High Engine speed and places all functions in Creep.

Verify integrity of wiring, par-ticularly the ground, before replacing sensor. Fault cleared when engine RPM reading < 4000

FUEL ACTUATOR – SHORT TO GROUND

4326 The Ground Module detects a short to ground at the fuel actuator output. (Kubota)

The Ground Module disables the Fuel Actuator output


FUEL ACTUATOR – OPEN CIR-CUIT

4327 The Ground Module detects an open circuit at the fuel actuator out-put. (Kubota)

The Ground Module controls revert to Open Loop and restrict machine speeds to Creep.




Machine Condition



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3121259 6-81

FUEL ACTUATOR – SHORT TO BATTERY

4328 The Ground Module detects a short to battery at the fuel actuator output. (Kubota)

Disable Ground Module Fuel Actuator output and open the ground current return path.


FUEL ACTUATOR - CURRENT FEEDBACK READING TOO LOW


The Ground Module controls revert to Open Loop control and restricts all machine speeds to Creep.


FUEL ACTUATOR – CURRENT FEEDBACK READING LOST

4330 Measured feedback current is less than 225mA while Ground Module output is greater than 40% for a period of 100ms (Displayed on Ana-lyzer DIAGNOSTICS menu).

The Ground Module controls revert to Open Loop and restricts all machine speeds to Creep.


BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN

441 The Ground Module detects that its supply voltage is less than 9 volts Disable all Ground Module valve outputs except those used during Emergency Descent (Tower Lift Down, Lift Down, Jib Up/Down). If MACHINE SETUP H&T LIGHTS = YES or ENGINE = KUBOTA D1105 turn off lights and disable glow plugs.

Perform battery maintenance. Fault cleared when voltage is greater than 9.25 volts

BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN

442 The Ground Module detects that its supply voltage is greater than 16.0 volts.

Disable all Ground Module and Platform outputs until voltage is less than 15.75 volts

Likely cause is poor alternator regulation; check alternator. Cycle power to clear the fault.

LSS BATTERY VOLTAGE TOO HIGH

443 MACHINE SETUP LOAD SYSTEM NOT EQUALThe machine is configured with and Load Sensing System and the Ground Module detects that the LSS reports supply voltage greater than 16.0 volts.

Ground Module to set Platform Load State = Overloaded

LSS reports voltage less than 16.0V

LSS BATTERY VOLTAGE TOO LOW

444 The machine is configured with and Load Sensing System and the Ground Module detects that the LSS reports supply voltage less than 9.0 volts.


LSS reports voltage greater than 9.0V

BATTERY VOLTAGE LOW 445 The Ground Module detects that its supply voltage < 11 volts for 5 seconds while none of the following conditions exist:Engine is not crankingEmergency Descent Mode is not activeGlow Plugs are not energized

No functions are inhibited Voltage is greater than 11.25 volts



Machine Condition



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6-82 3121259

LSS BATTERY VOLTAGE - INI-TIALIZATION ERROR

4479 The shear beam is reporting a Sensor Supply Voltage Initialization Error

The machine will assume the platform is overloaded.

This fault, once annunciated is latched within a given key cycle.

Possible sensor hardware issue.

LSS BATTERY VOLTAGE - NOT CALIBRATED

4480 The shear beam is reporting a Sensor Supply Voltage calibration error.




CANBUS FAILURE – PLAT-FORM MODULE

662 Ground Module does not receive any CAN messages from the Plat-form Module in 250ms

All functions will be deceler-ated to zero and generator will be disabled. If machine equipped with Dual Fuel engine, state of Fuel Selection switch shall be retained until CAN Bus 1 is restored. Reactiva-tion of Footswitch is required to resume operation.

With power off, disconnect the boom cable at the bottom of the Platform box. With a multi-meter, verify that the resistance between the CAN1H and CAN1L pins of the boom cable is approximately 120ohms. Verify the same at the connector entering the bottom of the box. If Okay, connect cable at plat-form and disconnect cable at connection near turntable. Check in the same manner then continue splitting and measur-ing in the manner over remain-der of machine CAN Bus. When a bad reading occurs, check wire continuity on the individ-ual wire.Fault is cleared when CAN mes-sages are received from the Platform Module

CANBUS FAILURE – LOAD SENSING SYSTEM MODULE

663 The control system has lost communication with the load sensing sys-tem load pin.


Ground Module to assume Plat-form Load State = Overloaded

Check wiring to load sensor.



Machine Condition



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3121259 6-83

CANBUS FAILURE – ENGINE CONTROLLER

666 An engine with a CAN engine controller is configured in MACHINE SETUP No CAN messages are received from the engine controller for more than 250ms

Ground Module shall decel all functions, set Target engine RPM = Mid-Engine if Engine State ENGINE STOPPED, and assume Engine Controller reporting mid-Engine; other-wise Engine State = ENGINE STOPPED. If MACHINE SETUP GENERATOR = YES, Genera-tor Relay output to be turned off until re-enabled by opera-tor. Reactivation of Footswitch is required to resume opera-tion.

With power off, disconnect the CAN2 cable going to the engine at the tee near the UGM. With a multimeter, verify that the resistance between theCAN2H and CAN2L pins is approximately 120ohms both in the path to engine and path to UGM. If a bad reading occurs, check wire continuity on indi-vidual wires. CAN messages are received from the engine con-troller. Ground Module shall require re-activation of Foot-switch to enable functions.

CANBUS FAILURE – EXCESSIVE CANBUS ERRORS

6613 More than 22 error frames per second for 4 seconds or more than 500 Buss Off conditions since last power cycle.

No functions are inhibited. Cycle power to clear the fault.

CANBUS FAILURE – TCU MOD-ULE

6622 MACHINE SETUP CLEARSKY = YESNo CAN2 messages are received from the TCU module for more than 30 seconds

No functions are inhibited. CAN messages are received from the TCU module.

REMOTE CONTRACT MANAGE-MENT OVERRIDE – ALL FUNC-TIONS IN CREEP

681 MACHINE SETUP CLEARSKY = YESValue set by ClearSky TCU

Puts the machine into Creep and locks into Transport

Cleared by ClearSky TCU

CHASSIS TILT SENSOR NOT CALIBRATED

813 The tilt sensor has not been calibrated The Ground Module reports a faulted chassis tilt angle of 90 degrees

Calibrate the Tilt sensor to clear the fault

CHASSIS TILT SENSOR OUT OF RANGE

814 Fault CHASSIS TILT SENSOR NOT CALIBRATED (813) is not present and Tilt sensor measurement greater than 19º for 4 seconds. Note: Not to be reported during Tilt Sensor calibration.

No additional action required beyond Tilted requirements specified above. Ground Mod-ule reports 90° angle.

Tilt sensor reads less than 19º.

CHASSIS TILT SENSOR DIS-AGREEMENT

815 The Ground Module detects one of the following conditions:

If a Drive, Steer, or Boom function is active or if the engine is cranking or if the primary raw Tilt Sensor readings greater than ±10 º then: if the two ground board tilt sensors disagree by more than or equal to 3 degrees for either the X axis or the Y axis for longer than 5 seconds then the fault will be logged.

If no Drive, Steer, or Boom functions are active and the engine is not cranking or the primary raw Tilt Sensor readings are less than ±10 º then: if the two ground board tilt sensors disagree by more than or equal to 1 degree for either the X axis or the Y axis for longer than 3 seconds then the fault will be logged.Note: This fault is not reported if DTC 814 is active.

The Ground Module reports a faulted chassis tilt angle of 90 degrees


LSS CELL #1 ERROR 821 MACHINE SETUP LOAD SYSTEM is not set = NOThe Ground Module detects that LSS is reporting error with Cell #1


CAN messages are received from the LSS module.



Machine Condition



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6-84 3121259

LSS READING UNDER WEIGHT 8211 LSS has been calibrated and the UGM has determined that the load sensing system reading is underweight while a period of time while operating drive or boom lift up at speeds greater than creep OR the UGM has determined that the load sensing system reading is less than -1.5 x Gross Platform Weight.

The machine will assume the platform is overloaded.This fault, once annunciated is latched within a given key cycle.

Ensure platform is not resting on the ground or is not leveled at an extreme negative angle.

Re-calibrate the load sensing system if the above items are not a factor.




LSS STRAIN GAUGE 1 - STAG-NANT

8222 The control system has determined that the strain gauge 1 reading in the load sensor is stagnant (not changing).

If the platform is not considered to be overloaded boom functions will be restricted to creep..

If DTC 8223 is active in combination with DTC 8222 the machine will assume the platform is overloaded.



LSS STRAIN GAUGE 2 - STAG-NANT

8223 The control system has determined that the strain gauge 2 reading in the load sensor is stagnant (not changing).

If the platform is not considered to be overloaded boom functions will be restricted to creep.

If DTC 8222 is active in combination with DTC 8223 the machine will assume the platform is overloaded.



LSS STRAIN GAUGE 1 - OUT OF RANGE LOW

8224 The shear beam is reporting an out of range low issue with the strain gauge 1 reading.

If the platform is not overloaded the machine will be placed in to creep.

If DTC 8225 is also active the machine will assume the platform is over-loaded.



LSS STRAIN GAUGE 2 - OUT OF RANGE LOW

8225 The shear beam is reporting an out of range low issue with the strain gauge 2 reading.







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3121259 6-85

LSS STRAIN GAUGE 1 - OUT OF RANGE HIGH

8226 The shear beam is reporting an out of range high issue with the strain gauge 1 reading.





LSS STRAIN GAUGE 2 - OUT OF RANGE HIGH

8227 The shear beam is reporting an out of range high issue with the strain gauge 2 reading.





LSS STRAIN GAUGE 1 - INITIAL-IZATION ERROR

8228 The shear beam is reporting an initialization issue with the strain gauge 1 sensor.





LSS STRAIN GAUGE 2 - INITIAL-IZATION ERROR

8229 The shear beam is reporting an initialization issue with the strain gauge 2 sensor.





LSS STRAIN GAUGE 1 - NOT CAL-IBRATED

8230 The shear beam is reporting a calibration issue with the strain gauge 1 sensor.










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LSS STRAIN GAUGE 2 - NOT CAL-IBRATED

8231 The shear beam is reporting a calibration issue with the strain gauge 2 sensor.





LSS STRAIN GAUGE 1 - SENSOR DEFECT

8232 The shear beam is reporting a sensor defect issue with the strain gauge 1 sensor.





LSS STRAIN GAUGE 2 - SENSOR DEFECT

8233 The shear beam is reporting a sensor defect issue with the strain gauge 2 sensor.





LSS STRAIN GAUGE 1 - NOT INSTALLED

8234 The shear beam is reporting a not installed issue with the strain gauge 1 sensor.





LSS STRAIN GAUGE 2 - NOT INSTALLED

8235 The shear beam is reporting a not installed issue with the strain gauge 2 sensor.





LSS NOT DETECTING CHANGE 8236 The control system has determined that the load sensor reading has not deviated by more than 1lb for 5s while operating drive or boom functions at greater than creep speed.





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LSS STRAIN GAUGE 1 - A/D DEFECT

8237 The shear beam is reporting an internal issue with the strain gauge 1 sensor.





LSS STRAIN GAUGE 2 - A/D DEFECT

8238 The shear beam is reporting an internal issue with the strain gauge 2 sensor.





LSS CELL #4 ERROR 824 MACHINE SETUP LOAD SYSTEM is not set = NOThe Ground Module detects that LSS is reporting error with Cell #4.



LSS HAS NOT BEEN CALI-BRATED

825 The load sensing system is configured but has not been calibrated.



Calibrate the load sensing sys-tem.

RUNNING AT CREEP – PLAT-FORM OVERLOADED

826 Machine Setup LOAD SYSTEM = WARN ONLYThe platform is OverloadedGround mode is active with Emergency Descent mode not active or Platform mode is active

Refer to Table 6-16, Overload Variations for machine response.

Not all of the trigger conditions are met

DRIVE & BOOM PREVENTED – PLATFORM OVERLOADED

827 The Platform is Overloaded and Machine Setup LOAD SYSTEM = CUTOUT PLATFORM, Platform Mode is active, and conditions of Table 6-16, Overload Variations apply.-or-The Platform is Overloaded and Machine Setup LOAD SYSTEM = CUTOUT ALL and conditions of Table 6-16, Overload Variations apply.



LIFT UP & TELE OUT PRE-VENTED – PLATFORM OVER-LOADED

828 MACHINE SETUP LOAD SYSTEM = SPECIAL 1 Platform Mode is activeThe platform is Overloaded



LSS READING UNDER WEIGHT 8211 MACHINE SETUP LOAD SYSTEM NOThe load sensor has been calibrated and Gross Platform Weight <(0.5 * Empty Platform Weight).



FRONT LEFT STEER VALVE – OPEN CIRCUIT

8639 The Ground Module detects an open circuit at the Front Left Steer Valve output.

Steer Left and Right speed are limited to Creep


FRONT LEFT STEER VALVE – SHORT TO BATTERY

8640 The Ground Module detects a short to battery at the Front Left Steer Valve output.

The Ground Module disables the Drive Forward/Reverse and Steer Left/Right outputs.




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FRONT LEFT STEER VALVE – SHORT TO GROUND

8641 The Ground Module detects a short to ground at the Front Left Steer Valve output.

The Ground Module disables the Steer Left and Right out-puts.


FRONT RIGHT STEER VALVE – OPEN CIRCUIT

8642 The Ground Module detects an open circuit at the Front Right Steer Valve output.

Steer Left and Right speed is limited to Creep


FRONT RIGHT STEER VALVE – SHORT TO BATTERY

8643 The Ground Module detects a short to battery at the Front Right Steer Valve output.

The Ground Module disables the Drive Forward/Reverse and Steer Left/Right outputs


FRONT RIGHT STEER VALVE – SHORT TO GROUND

8644 The Ground Module detects a short to ground at the Front Right Steer Valve output.

The Ground Module disables the Steer Left and Right out-puts


OSCILLATING AXLE SWITCH DISAGREEMENT

8669 The Ground Module detects that Oscillating Axle switch #1 and switch #2 are not in agreement. Note: This fault will not to be reported if DTC 23104 BOOM TRANSPORT SWITCH DISAGREEMENT is active.

The Ground Module assumes an Above Elevation State and de-energizes J1-7 Oscillating Axle output.


FUNCTIONS LOCKED OUT 9911

LSS WATCHDOG RESET 991 The Ground Module detects an LSS report of an anomaly that has caused a WatchDog Timer reset.

The Ground Module sets the Platform Load State to Over-loaded


LSS EEPROM ERROR 992 The Ground Module detects an LSS report of an anomaly that exists in the LSS EEPROM



LSS INTERNAL ERROR – PIN EXCITATION

993 The Ground Module detects an LSS report of improper excitation voltage.



LSS INTERNAL ERROR – DRDY MISSING FROM A/D

994 The Ground Module detects an LSS report of an anomaly that exists in the LSS A/D converter operations.



EEPROM FAILURE - CHECK ALL SETTINGS

998 The Ground Module has detected an anomaly in the EEPROM The Ground Module disables all functions and resets the section of EEPROM where the failure occurred back to the defaults.


FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFT-WARE VERSION IMPROPER

9910 The Ground Module software major version number does not match the major version number of the platform software

The platform alarm sounds continuously and, Creep mode is active. If the Platform Mode is active all Drive, Steer, and Boom functions are disabled.

Platform Module needs repro-grammed with correct version of software.

FUNCTION LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER

9911 The Ground Module determines that the LSS software version is not compatible with existing code.



CHASSIS TILT SENSOR NOT GAIN CALIBRATED

9915 The tilt sensor gain calibration values recorded to flash memory dur-ing manufacturing are not present

The Ground Module reports a faulted chassis tilt angle of 90 degrees

Valid values must be present to reset.



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GROUND SENSOR REF VOLT-AGE OUT OF RANGE

9919 The Ground Module has detected reference voltage is out of range (Reference Voltage is between 2.3V and 2.7V).

If MACHINE SETUP Kubota D1105 and ENGINE SHUTDOWN ENABLED, then call for engine shutdown and disable engine start operations; other-wise, no interlocks required.


PLATFORM SENSOR REF VOLT-AGE OUT OF RANGE

9920 The Platform Module detects that its reference voltage is out of range and reports the fault to the Ground Module

If in Platform mode, Lift/Swing and Drive are placed in Creep. All other functions shall oper-ate normally.


GROUND MODULE FAIL-URE:HIGH SIDE DRIVER CUT-OUT FAULTY

9921 The engine is not runningThe engine is not crankingThe Ground Module footswitch input (J7-15) is LOWThe machine is in Platform ModeThe Main Dump output (J2-13) is detected as HIGH via the analog feedback 300ms after it is attempted to be activated during the one time startup test of the Ground Module hardware shutoff circuitry

All Drive/Steer and Boom func-tions except Tower Lift Down, Lift Down, and Jib Lift Down are disabled.


PLATFORM MODULE FAILURE: HWFS CODE 1

9922 The Platform Module detects faulty hardware No response required. Cycle power to clear the fault; if faults remains, replace board.

GROUND MODULE FAILURE: HWFS CODE 1

9923 The Ground Module detects faulty hardware. No response required. Cycle power to clear the fault; if faults remains, replace board.

FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED

9924 The machine is powered up and no model has been selected yet in the MACHINE SETUP menu

Display??? or NO MODEL at Ana-lyzer MACHINE SETUP menu MACHINE SETUP->MODEL NUMBERNo other faults will be reported.All machine functions are dis-abled and the engine is not per-mitted to start.


LSS - FACTORY CALIBRATION ERROR

99285 The load sensor is reporting a factor calibration issue (internal error)




CURRENT FEEDBACK GAINS OUT OF RANGE

9944 One or more of the current feedback gains that are calculated and written to flash memory during manufacturing are detected as being out of range

A gain of 1 is used for the fac-tory gain(s) that was out of range; all functions are placed in Creep mode.


CURRENT FEEDBACK CALI-BRATION CHECKSUM INCOR-RECT

9945 The current feedback gains checksum that is calculated and written to flash memory during manufacturing is detected as being incorrect

All machine and engine func-tions are disabled (i.e., com-mand engine shutdown and do not permit start).




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MACHINE CONFIGURATION OUT OF RANGE – CHECK ALL SETTINGS

9949 The Ground Module has detected an anomaly in stored readings for the Machine Setup configuration.

The Ground Module prompts the operator to correct the issue via Analyzer and disable all functions until stored data in corrupted area is changed.

Cycle Power and change the Machine Setup data.

LSS CORRUPT EEPROM 9977 The Ground Module is advising that the LSS module has detected faulty stored parameters.



FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER

9979 Ground Module detects a disagreement with internal checks on the version of software.

All machine and engine func-tions are disabled (i.e., com-mand engine shutdown and do not permit start)


GROUND MODULE VLOW FET FAILURE

9986 Ground Module has determined a hardware fault exists and is unable to read high-sensing inputs.

All machine and engine func-tions are disabled (i.e., com-mand engine shutdown and do not permit start)


1Annotated DTCs do not flash a numeric code, sound an alarm, and are not stored in annotated DTCs in Logged Help queue (this applies to most DTCs < 0100).



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3121259 6-91

Table 6-16. Overload Variations

BROADCAST ONLY3 WARN ONLY CUTOUT ALLSPECIAL 1

(Access Industries)CUTOUT PLATFORM

Platform

Activate visual overload light at Platform Station


Activate System Distress and Over-load lights at Platform station


Activate System Distress and Overload lights at Platform sta-tion

Activate Platform and Ground Alarm – 5 sec ON, 2 sec OFF



Activate Platform and Ground Alarm – on continuously


Do not report Fault Activate creep mode all functions, energize Creep light, and report Fault

Do not permit Machine Enable (no creep light) and report Fault

Activate creep mode all functions, energize Creep light, and report Fault

Do not permit Machine Enable (no creep light) and report Fault

Disable Telescope Out and Lift Up

Ground

Activate visual overload light (Ground Station)




Activate visual Overload light at Ground Station




Activate Platform and Ground Alarm – on continuously


Do not report Fault Report Fault Report Fault Do not report Fault Do not report fault.

Activate creep mode all functions Do not permit Machine Enable (no creep light)

Overload shall have no effect on function speeds.

Overload shall have no effect on function speeds.

Auxiliary Power/Emergency Descent

Platform operation and annuncia-tion as Platform Mode above


Platform operation and annuncia-tion as Platform Mode above, except do not disable all functions


Platform operation and annunci-ation as Platform Mode above, except do not report Fault or dis-able all functions

Ground operation and annunciation as Ground Mode above, except do not activate creep mode

Ground operation and annunciation as Ground Mode above, except do not activate creep mode

Ground operation and annunciation as Ground Mode above, except do not report Fault or disable all func-tions

Ground operation and annunciation as Ground Mode above

Ground operation and annuncia-tion as Ground Mode above

Faults

No applicable fault When the platform is overloaded, report “RUNNING AT CREEP - PLAT-FORM OVERLOADED.”

When the platform is overloaded, report "DRIVE & BOOM PREVENTED – PLATFORM OVERLOADED."

When the platform is overloaded, report "LIFT UP & TELE OUT PRE-VENTED – PLATFORM OVER-LOADED.”

When the platform is over-loaded, report the "DRIVE & BOOM PREVENTED – PLATFORM OVERLOADED."

Clarifications: 1. The term Report Fault is defined as logging the DTC on the Analyzer fault stack and flashing the System Distress lamp.2. When specified, Ground Alarm energization shall only occur if MACHINE SETUP GROUND ALARM ≠ NO.3. This selection is not Analyzer configurable in MACHINE SETUP LOAD SYSTEM but is shown here for completeness of the response table.Go t

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NOTES:

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SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS

3121259 7-1

SECTION 7. BASIC ELECTRICAL INFORMATION & SCHEMATICS

7.1 GENERALThis section contains basic electrical information and sche-matics to be used for locating and correcting most of the oper-ating problems which may develop. If a problem shoulddevelop which is not presented in this section or which is notcorrected by listed corrective actions, technically qualifiedguidance should be obtained before proceeding with anymaintenance.

NOTE: Some of the procedures/connectors shown in this sectionmay not be applicable to all models.

7.2 MULTIMETER BASICSA wide variety of multimeters or Volt Ohm Meters (VOM) canbe used for troubleshooting your equipment. This sectionshows diagrams of a common, digital VOM configured for sev-eral different circuit measurements. Instructions for your VOMmay vary. Please consult the meter operator’s manual for moreinformation.

Grounding"Grounding the meter" means to take the black lead (which isconnected to the COM (common) or negative port) and touchit to a good path to the negative side of the Voltage source.

BackprobingTo "backprobe" means to take the measurement by accessinga connector’s contact on the same side as the wires, the backof the connector. Readings can be done while maintaining cir-cuit continuity this way. If the connector is the sealed type,great care must be taken to avoid damaging the seal aroundthe wire. It is best to use probes or probe tips specificallydesigned for this technique, especially on sealed connectors.Whenever possible insert probes into the side of the connec-tor such that the test also checks both terminals of the con-nection. It is possible to inspect a connection within a closedconnector by backprobing both sides of a connector terminaland measuring resistance. Do this after giving each wire a gen-tle pull to ensure the wires are still attached to the contact andcontacts are seated in the connector.

Min/MaxUse of the "Min/Max" recording feature of some meters canhelp when taking measurements of intermittent conditionswhile alone. For example, you can read the Voltage applied toa solenoid when it is only operational while a switch, far fromthe solenoid and meter, is held down.

PolarityGetting a negative Voltage or current reading when expectinga 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 correctly.Also check that the lead on the "COM" port goes to the Groundor negative side of the signal and the lead on the other portgoes to the positive side of the signal.

ScaleM = 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 kΩ = 1200 ΩExample: 50 mA = 0.05 A

Voltage Measurement

• If meter is not auto ranging, set it to the correct range(See multimeter’s operation manual)

• Use firm contact with meter leads

Figure 7-1. Voltage Measurement (DC)

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Resistance Measurement

• First test meter and leads by touching leads together.Resistance should read a short circuit (very low resis-tance)

• Circuit power must be turned OFF before testing resis-tance

• Disconnect component from circuit before testing

• If meter is not auto ranging, set it to the correct range(See multimeter’s operation manual)


Continuity Measurement

• Some meters require a separate button press to enableaudible continuity testing

• Circuit power must be turned OFF before testing conti-nuity

• Disconnect component from circuit before testing


• First test meter and leads by touching leads together.Meter should produce an audible alarm, indicatingcontinuity

Figure 7-2. Resistance Measurement

Figure 7-3. Continuity Measurement

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3121259 7-3

Current Measurement

• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correct jacksfor the current range you have selected

• If meter is not auto ranging, set it to the correct range(See multi meter’s operation manual)


7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO ELECTRICAL CONNECTIONS

NOTE: This section is not applicable for battery terminals.

JLG P/N 0100048 DIELECTRIC GREASE (NOVAGARD G661) IS THE ONLY MATE-RIAL APPROVED FOR USE AS A DIELECTRIC GREASE.

NOTE: Do NOT apply dielectric grease to the following connec-tions:

• Main Boom Rotary sensor connections (on Celesco Sensor),

• LSS Modules connections,

• Deutz EMR 2 ECM connection.

Silicone Dielectric Compound must be used on all electricalconnections except for those mentioned above for the follow-ing reasons:

• To prevent oxidation at the mechanical joint between maleand female pins.

• To prevent electrical malfunction caused by low level con-ductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Com-pound to the electrical connectors. This procedure applies toall plug connections not enclosed in a box. Silicone greaseshould not be applied to connectors with external seals.

1. To prevent oxidation, silicone grease must be packedcompletely around male and female pins on the insideof the connector prior to assembly. This is most easilyachieved by using a syringe.

NOTE: Over a period of time, oxidation increases electrical resis-tance at the connection, eventually causing circuit failure.

2. To prevent shorting, silicone grease must be packedaround each wire where they enter the outside of theconnector housing. Also, silicone grease must beapplied at the joint where the male and female connec-tors come together. Any other joints (around strainreliefs, etc.) where water could enter the connectorshould also be sealed.

NOTE: This condition is especially common when machines arepressure washed since the washing solution is much moreconductive than water.

3. Anderson connectors for the battery boxes and batterychargers should have silicone grease applied to the con-tacts only.

NOTE: Curing-type sealants might also be used to prevent short-ing and would be less messy, but would make future pinremoval more difficult.

Figure 7-4. Current Measurement (DC)

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When applied to electrical connections, dielectric grease helpsto prevent corrosion of electrical contacts and improper con-ductivity between contacts from moisture intrusion. Open andsealed connectors benefit from the application of dielectricgrease.

Dielectric grease shall be applied to all electrical connectors atthe time of connection (except those noted under Exclusions).

Installation of Dielectric GreaseBefore following these instructions, refer to excluded connec-tor types (See Exclusions below).

1. Use dielectric grease in a tube for larger connectionpoints or apply with a syringe for small connectors.

2. Apply dielectric grease to the female contact (fill itapproximately ½ full; see example below)

3. Leave a thin layer of dielectric grease on the face of theconnector

4. Assemble the connector system immediately to preventmoisture ingress or dust contamination

5. Pierce one of the unused wire seals prior to assembly ifthe connector system tends to trap air (i.e. AMP Seal)and then install a seal plug.

Deutsch HD, DT, DTM, DRC SeriesThe Deutsch connector system is commonly used for harshenvironment interconnect. Follow the installation instructions.

AMP SealThe AMP Seal connector system is used on the Control ADEPlatform and Ground Modules.

Apply dielectric grease to the male connector. If trapped airprevents the connector from latching, pierce one of theunused wire seals. After assembly, install a seal plug (JLG#4460905) in that location to prevent moisture ingress.

Note that seal plugs may be installed by the wire harness man-ufacturer if an unused wire seal becomes compromised (wireinserted in the wrong cavity during assembly and then cor-rected).

Figure 7-5. Application to Male Connector

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AMP Mate-N-LokThis connector system is widely used inside enclosures forgeneral purpose interconnect. Follow the installation instruc-tions..

DIN ConnectorsThis connector is typically used on hydraulic valves. Follow theinstallation instructions.

Figure 7-6. Use of Seal Plugs

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Exclusions

A limited number of connectors do not benefit from dielectricgrease, or may be permanently damaged by application.Dielectric grease may not be required in properly sealedenclosures.

BRAD HARRISON / PHOENIX CONTACT M12 The connector uses gold contact material to resist corrosionand an o-ring seal for moisture integrity. If dielectric grease ismistakenly applied to this connector system, the low-forcecontacts cannot displace the grease to achieve electrical con-tact. Once contaminated, there is no practical way to removethe dielectric grease (replacement of female contactsrequired). The JLG Load Sensing System and Rotary Angle Sensors are examples of components with the M12 connectorsystem.

ENGINE CONTROL UNIT CONNECTORSThese connectors use back-seals for moisture integrity. How-ever, the low-force contacts cannot displace dielectric greaseand create electrical contact. It is possible to use solvents (i.e.contact cleaner or mineral spirits) for the removal of improp-erly applied dielectric grease. The EMR4 engine control mod-ule from Deutz employs this connector system (for example).

SEALED ENCLOSURESApplication of dielectric grease is not required in properlysealed enclosures. To meet criteria, the enclosure must berated to at least IP66 (dust tight; protected from powerful jetsof water). The enclosure must be fitted with a high quality,continuous gasket and all wiring must pass through cableentrances.

Figure 7-7. Brad-Harrison M12

Figure 7-8. Phoenix Contact M12

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3121259 7-7

MIL-C-5015 SPEC CONNECTORSCrown Connector Inc's recommendation is to not use dielec-tric grease for this series connector. For similar model seriesconnectors, the manufacturer should be contacted for confir-mation before applying dielectric grease. A typical applicationfor this connector is on David Clark Intercom connections inAerial Work Platforms.

MOLEX CMC SERIES CONNECTORSThe CMC connector family is a sealed, high-density connec-tion system using matte-seal technology for CP 0.635 and 1.50mm terminals. To guarantee IP6K7 and IP6K9 sealing, a sealplug option is used. However, the low-force contacts cannotdisplace dielectric grease and create electrical contact. It ispossible to use solvents (i.e. contact cleaner or mineral spirits)for the removal of improperly applied dielectric grease. Theflexbox control modules from JDES employ this connectorsystem (for example).

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7.4 AMP CONNECTOR

Applying Silicone Dielectric Compound to AMP Connectors

Silicone Dielectric Compound must be used on the AMP con-nections for the following reasons:

• To prevent oxidation at the mechanical joint between maleand female pins.

• To prevent electrical malfunction caused by low level con-ductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Com-pound to the electrical connectors.

1. To prevent oxidation and low level conductivity, siliconedielectric grease must be packed completely aroundmale and female pins on the inside of the connectorafter the mating of the housing to the header. This iseasily achieved by using a syringe to fill the header withsilicone dielectric compound, to a point just above thetop of the male pins inside the header. When assem-bling the housing to the header, it is possible that thehousing will become air locked, thus preventing thehousing latch from engaging.

2. Pierce one of the unused wire seals to allow the trappedair inside the housing to escape.

3. Install a hole plug into this and/or any unused wire sealthat has silicone dielectric compound escaping from it.

AssemblyCheck to be sure the wedge lock is in the open, or as-shipped,position (See Figure 7-9.). Proceed as follows:

1. To insert a contact, push it straight into the appropriatecircuit cavity as far as it will go (See Figure 7-11.).

2. Pull back on the contact wire with a force of 1 or 2 lbs. tobe sure the retention fingers are holding the contact(See Figure 7-11.).

Figure 7-9. Connector Assembly Figure 1

Figure 7-10. AMP Connector

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3121259 7-9

3. After all required contacts have been inserted, thewedge lock must be closed to its locked position.Release the locking latches by squeezing them inward(See Figure 7-12.).

4. Slide the wedge lock into the housing until it is flushwith the housing (See Figure 7-13.).




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Disassembly

5. Insert a 4.8 mm (3/16") wide screwdriver blade betweenthe mating seal and one of the red wedge lock tabs.

6. Pry open the wedge lock to the open position.

7. While rotating the wire back and forth over a half turn(1/4 turn in each direction), gently pull the wire until thecontact is removed.

NOTE: The wedge lock should never be removed from the housingfor insertion or removal of the contacts.

Wedge Lock

The wedge lock has slotted openings in the forward, or matingend. These slots accommodate circuit testing in the field, byusing a flat probe such as a pocket knife. DO NOT use a sharppoint such as an ice pick.

Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

It has been common practice in electrical troubleshooting toprobe wires by piercing the insulation with a sharp point. Thispractice should be discouraged when dealing with theAMPSEAL plug assembly, or any other sealed connector sys-tem. The resulting pinholes in the insulation will allow mois-ture to invade the system by traveling along the wire strands.This nullifies the effectiveness of the connector seals andcould result in system failure.

Figure 7-14. Connector Disassembly

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Figure 7-15. Connector Installation

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7.5 DEUTSCH CONNECTORS

DT/DTP Series Assembly

1. Grasp crimped contact about 25mm behind the contactbarrel.

2. Hold connector with rear grommet facing you.

3. Push contact straight into connector grommet until aclick is felt. A slight tug will confirm that it is properlylocked in place.

4. Once all contacts are in place, insert wedgelock witharrow pointing toward exterior locking mechanism. Thewedgelock will snap into place. Rectangular wedges arenot oriented. Thy may go in either way.

NOTE: The receptacle is shown - use the same procedure for plug.

DT/DTP Series Disassembly

5. Remove wedgelock using needlenose pliers or a hookshaped wire to pull wedge straight out.

6. To remove the contacts, gently pull wire backwards,while at the same time releasing the locking finger bymoving it away from the contact with a screwdriver.

7. Hold the rear seal in place, as removing the contact maydisplace the seal.

Figure 7-16. DT/DTP Contact Installation

A B

C DFigure 7-17. DT/DTP Contact Removal

A B

C

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3121259 7-13

HD30/HDP20 Series Assembly

8. Grasp contact about 25mm behind the contact crimpbarrel.

9. Hold connector with rear grommet facing you.

10. Push contact straight into connector grommet until apositive stop is felt. A slight tug will confirm that it isproperly locked in place.

NOTE: For unused wire cavities, insert sealing plugs for full envi-ronmental sealing

HD30/HDP20 Series Disassembly

11. With rear insert toward you, snap appropriate sizeextractor tool over the wire of contact to be removed.

12. Slide tool along into the insert cavity until it engagescontact and resistance is felt.

13. Pull contact-wire assembly out of connector.

NOTE: Do Not twist or insert tool at an angle.

Figure 7-18. HD/HDP Contact Installation

A B

C

Figure 7-19. HD/HDP Locking Contacts Into Position

Figure 7-20. HD/HDP Contact Removal

A B

C

Figure 7-21. HD/HDP Unlocking Contacts

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7-14 3121259

7.6 TELEMATICS GATEWAYPersonnel using machines equipped with an optional telemat-ics gateway will be able to view the following data throughtheir telematics device:

Telematics-Ready (TCU) Plug

The telematics-ready (TCU) plug is a standard 12-pin Deutschconnector. Pin-out locations are shown below:

JLG LABEL DESCRIPTION UNIT

Engine Speed Actual engine speed. RPM

DEF Tank Level (If Equipped)

Indicates the level of DEF (diesel exhaust fluid) within the DEF tank if the machine is equipped with DEF tank.• 0% = Empty

• 100% = Full

Percentage (%)

JLG Machine Faults:Active / Not-Active

• 00 - No Machine Faults

• 01 - Active Machine Fault

• 10 - Error

• 11 - Not available

Bit

Total Idle Fuel Used Total amount of fuel used during vehicle operation during idle conditions. Liters

Total Idle Hours Total time of engine operation during idle conditions. Seconds

Total Engine Hours Total time of engine operation. Seconds

Total Fuel Used Total amount of fuel used during vehicle operation. Liters

Fuel Rate Amount of fuel consumed by engine per unit of time. Liters/Hour

Fuel Level

Ratio of fuel volume to the total volume of the fuel storage container. When a low fuel limit switch is present, the fuel level will indicate "full" until the switch opens, which will then indicate 10% fuel remaining.

When Fuel Level 2 (SPN 38) is not used, Fuel Level 1 represents the total fuel in all fuel storage containers. When Fuel Level 2 is used, Fuel Level 1 represents the fuel level in the primary or left side fuel storage container.

Percentage (%)

DM1 Engine Faults Shows actual engine fault codes. N/A

DIAGNOSTICS PLUG

TELEMATICS-READY PLUG

GATEWAY MODULE

1234567

89

101112

CAN-LO 2 - CAN-HI 2 -

- BATTERY - GROUND

- IGNITIONGo to Disc

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3121259 7-15

MS1

619-

3M

S161

9-1

MS1

619-

2

X160

9

MS1

620-

1

S161

4 S161

5M

S161

8-2

MS1

620-

3

MS1

620-

2M

S161

8-3

CO

1613

-J2

CO

1613

-J1

X160

6

Figu

re 7

-22.

Tel

emat

ics

Gat

eway

Har

ness

- Sh

eet 1

of 3

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7-16 3121259

X1606 (DIAG)

CONN POS WIRE COLOR WIRE LABEL GAUGE JACKET TO

A BLK 0-1 GND 16 AWG GXL S1615 (2)

B RED 1-0 BAT 16 AWG GXL X1609 (1)

C YEL CANH1 18 AWG GXL MS1618-3 (A)

D GRN CANL1 18 AWG GXL MS1618-3 (B)

H ORN 2-1 IGN 16 AWG GXL S1614 (2)

S1615


1 BLK 0-0 GND 16 AWG GXL X1609 (2)

2 BLK 0-1 GND 16 AWG GXL X1606 (A)

2 BLK 0-2 GND 16 AWG GXL CO1613-J1 (11)

S1614


1 ORN 2-0 IGN 16 AWG GXL X1609 (4)

2 ORN 2-1 IGN 16 AWG GXL X1606 (H)

2 ORN 2-2 IGN 16 AWG GXL CO1613-J1 (12)

CO1613-J2 (GATEWAY 2)


9 GRN CANL2 18 AWG GXL MS1620-3 (B)

10 YEL CANH2 18 AWG GXL MS1620-3 (A)

X TCU1609 ( )


1 RED 1-0 BAT 16 AWG GXL X1606 (B)

2 BLK 0-0 GND 16 AWG GXL S1615 (1)

4 ORN 2-0 IGN 16 AWG GXL S1614 (1)

9 GRN CANL2 18 AWG GXL MS1619-2 (B)


MS1619-3 (CAN-T 2)


A YEL CANH2 18 AWG GXL MS1620-2 (A)

B GRN CANL2 18 AWG GXL MS1620-2 (B)

MS1619-2 (CAN-T 2)


A YEL CANH2 18 AWG GXL X1609 (10)

B GRN CANL2 18 AWG GXL X1609 (9)

CO1613-J1 (GATEWAY 1)


9 GRN CAN1 18 AWG GXL MS1618-2 (B)


11 BLK 0-2 GND 16 AWG GXL S1615 (2)

12 ORN 2-2 IGN 16 AWG GXL S1614 (2)

MS1620-3 (CAN-T 2)


A YEL CANH2 18 AWG GXL CO1613-J2 (10)

B GRN CANL2 18 AWG GXL CO1613-J2 (9)

MS1620-2 (CAN-T 2)


A YEL CANH2 18 AWG GXL MS1619-3 (A)

B GRN CANL2 18 AWG GXL MS1619-3 (B)

MS CAN T1618-2 ( - 1)


A YEL CANH1 18 AWG GXL CO1613-J1 (10)

B GRN CANL1 18 AWG GXL CO1613-J1 (9)

MS1618-3 (CAN-T 1)


A YEL CANH1 18 AWG GXL X1606 (C)

B GRN CANL1 18 AWG GXL X1606 (D)

Figure 7-23. Telematics Gateway Harness - Sheet 2 of 3

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3121259 7-17

FROM TO

WIRE NO. COLOR WIRE GAUGE LENGTH (mm) JACKET REFERENCE PIN REFERENCE PIN

CAN L2 GRN 18 AWG 1151 GXL MS1619-3 B MS1620-2 B

CAN L2 GRN 18 AWG 151 GXL X1609 9 MS1619-2 B

CAN L1 GRN 18 AWG 157 GXL MS1618-2 B CO1613-J1 9

CAN L2 GRN 18 AWG 225 GXL MS1620-3 B CO1613-J2 9

CAN L1 GRN 18 AWG 1076 GXL MS1618-3 B X1606 D

CAN H2 YEL 18 AWG 155 GXL X1609 10 MS1619-2 A

CAN H2 YEL 18 AWG 233 GXL MS1620-3 A CO1613-J2 10

CAN H1 YEL 18 AWG 157 GXL MS1618-2 A CO1613-J1 10

CAN H2 YEL 18 AWG 1150 GXL MS1619-3 A MS1620-2 A

CAN H1 YEL 18 AWG 1079 GXL MS1618-3 A X1606 C

0-0 GND BLK 16 AWG 1006 GXL X1609 2 S1615 1

0-1 GND BLK 16 AWG 1145 GXL X1606 A S1615 2

0-2 GND BLK 16 AWG 223 GXL CO1613-J1 11 S1615 2

1-0 BAT RED 16 AWG 2150 GXL X1609 1 X1606 B

2-0 IGN ORN 16 AWG 939 GXL X1609 4 S1614 1

2-1 IGN ORN 16 AWG 1212 GXL S1614 2 X1606 H

2-2 IGN ORN 16 AWG 287 GXL CO J1613- 1 12 S1614 2

Figure 7-24. Telematics Gateway Harness - Sheet 3 of 3

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7-18 3121259

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3121259 7-19

7.7 ELECTRICAL SCHEMATICS

SHEET 2: PLATFORM BOX

SHEET 3: PLATFORM AND BOOM COMPONENTS

SHEET 4: CHASSIS, TURN-TABLE, AND UGM

SHEET 5: GROUND USER INTERFACE AND TELEMATICS INTERFACE

SHEET 6: ENGINE (KUBOTA) AND GENERATOR

SHEET 7: ENGINE (GM) VENDOR SCHEMATIC

SHEET 8: MIDENGINE HARNESS SCHEMATIC

SHEET 9: CHASSIS LIGHT, PLATFORM LIGHTS SCHEMATIC

SHEET 10: ALERT BEACON OPTION

SHEET 11: PLATFORM BOXCONSOLE BOX HARNESS WITH SKYGUARDCONN AND 1 CELL LSS

HARNESS,GEN 2 PLAT INTERFACE

1001119638-QMAF03010

Figure 7-25. Electrical Schematic - Sheet 1 of 20Go to D

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7-20 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

R

RR

R G

YR

YG

G

G

G

Y

Y

Y

G

Y

G

G

G

PLATFORM MODULE

CO01-J1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J7

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J6

1

2

3

4

5

6

7

8

CO

01-J

2

1 2 34 5 67 89 10 11 121314 1516 1718 19 2021 22 2324 25 26 2728 2930 31 32 33 3435

CO01-J8

12

CO01-J5

1

2

3

4

5

6

7

8

WH

T 2-

10 P

LAT

IGN

12

AW

G

BLK

0-6

PLA

T G

ND

12

AW

G

GENERIC

ENGINE SPEED

SW09

1 32 4 5 6

GENERIC

PLATFORM LEVEL

SW10

1 32 4 5 6

WHT 42-1 MAX SPEED

WH

T 42

-1 M

AX

SPE

ED

WHT 2-17 SWITCH IGNW

HT

2-17

SW

ITC

H IG

NWHT 41-1 MAX TORQUE

WH

T 41

-1 M

AX

TO

RQ

UE

WHT 25-1 PLAT LVL UP

WH

T 25

-1 P

LAT

LVL

UP

WHT 26-1 PLAT LVL DN

WH

T 26

-1 P

LAT

LVL

DN

WH

T 2-

17-1

SW

ITC

H IG

N

WH

T 2-

17-1

SW

ITC

H IG

N

WH

T 2-

17-2

SW

ITC

H IG

N

WH

T 2-

17-2

SW

ITC

H IG

N

WHT 35-1 HORN

WH

T 35

-1 H

OR

N

GEN

ERIC

PLA

TFO

RM

RO

TATE

SW12

1

3

2

4

5

6

WHT 24-1 PLAT ROT RTWHT 24-1 PLAT ROT RT

WHT 40-2 PUMP POT CMD


WHT 0-20 PUMP POT GND


WHT 40-1 PUMP POT REF


WHT 55-1 CREEP MODE

WHT 55-1 CREEP MODE

WHT 2-17-3 SWITCH IGN

WH

T 2-

17-3

SW

ITC

H IG

N

WHT 23-1 PLAT ROT LFT WHT 23-1 PLAT ROT LFT



GEN

ERIC

TOW

ER L

IFT

SW14

1

3

2

4

5

6

GEN

ERIC

JIB

LIF

T

SW15

1

3

2

4

5

6

GEN

ERIC

MA

IN T

ELES

CO

PE

SW16

1

3

2

4

5

6

GEN

ERIC

STA

RT

/ A

UX

PO

WER

SW17

1

3

2

4

5

6

WHT 5-1 TWR LFT UPWHT 5-1 TWR LFT UP

WHT 6-1 TWR LFT DNWHT 6-1 TWR LFT DN



WHT 27-1 JIB UP

WHT 27-1 JIB UP

WHT 28-1 JIB DN

WHT 28-1 JIB DN





WHT 13-1 MAIN TELE IN


WHT 14-1 MAIN TELE OUT




WHT 53-1 AUX POWER

WHT 53-1 AUX POWER

WHT 45-1 START

WHT 45-1 START

GEN

ERIC

FUEL

SEL

ECT

(OPT

ION

AL)

SW18

1

3

2

4

5

6

GEN

ERIC

DR

IVE

OR

IEN

TATI

ON

SW19

1

3

2

4

5

6

WHT 52-1 FUEL SELECT






WHT 34-1 DOS OVERRIDE

WH

T 34

-1 D

OS

OV

ERR

IDE

WH

T 55

-2 C

REE

P M

OD

EW

HT

55-2

CR

EEP

MO

DE

WH

T 31

-3 F

UN

C E

NA

BLE

WH

T 31

-3 F

UN

C E

NA

BLE

WHT 0-21 DISPLAY GND


WH

T 34

-3 D

OS

WH

T 34

-3 D

OS

WH

T 66

-1 S

YS

DIS

TRES

SW

HT

66-1

SY

S D

ISTR

ESS

WH

T 54

-3 G

EN O

NWHT 54-3 GEN ON W

HT

57-1

OV

ERLO

AD

WH

T 57

-1 O

VER

LOA

D

WH

T 56

-1 T

ILTE

DW

HT

56-1

TIL

TED

WH

T 48

-1 G

LOW

PLU

GS

WH

T 48

-1 G

LOW

PLU

GS

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 0-

22 F

UEL

GN

D

WH

T 0-

22 F

UEL

GN

D

WH

T 39

-6 F

ULL

FU

EL L

VL

WH

T 39

-6 F

ULL

FU

EL L

VL

WH

T 39

-7 L

OW

FU

ELW

HT

39-7

LO

W F

UEL

WH

T 2-

18 L

SS P

WR

WH

T 71

-4 G

ND

WH

T 71

-3 T

X

WH

T 71

-2 R

X

WH

T 71

-1 P

WR

PUSH BUTTON

HORN

SW22

4-1

1

SW22

4-2 1

HEA

D/T

AIL

LIG

HT

GEN

ERIC

SW280-11

SW280-2

1

WHT 29-1 HEAD/TAIL LT




GENERIC

GD

20-J

11 2 3 4 5 6

GD

20-J

21 2 3 4 5 6

GD

20-J

31 2 3 4 5 6

GD

20-J

41 2 3 4 5 6

WH

T 2-

22 D

ISP

PWR

PUM

P PO

T

GEN

ERIC

SW13

1

2

3

4

5

6

SHEET 2

Figure 7-26. Electrical Schematic - Sheet 2 of 20

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3121259 7-21

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

R

R

G

Y

G

G

Y

Y

Y

G

Y

G

G

G

PLATFORM MODULE

CO01-J7

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J6

1

2

3

4

5

6

7

8

1 2 34 5 67 810 11 121314 1516 1718 19 2021 22 2324 25 26 2728 2930 31 32 33 3435

CO01-J8

12

CO01-J5

1

2

3

4

5

6

7

8

GEN

ERIC

JLG

ALA

RM

AH02+1

AH02-1

WHT 37-1 PLAT ALARM

WHT 37-1 PLAT ALARM

WHT 0-28 ALARM GND

WHT 0-28 ALARM GND

WHT 2-20 GEN SW IGN

WHT 2-20 GEN SW IGN

WHT 31-1 FOOT PEDAL

WHT 31-1 FOOT PEDAL

WHT 2-19 FTS IGN

WHT 2-19 FTS IGN

LIFT

AN

D S

WIN

G

GEN

ERIC

WHT

ORN/YEL

BLU/YEL

RED

BRN

GRN

ELEC

TRO

NIC

JO

YST

ICK

GEN

ERIC

LEFT

RIGHTWHT/YEL

WHT/RED

WHT/GRN

RED

BLK

BLU

BRN

BLK

BLU

WHT 23-3 PLAT ROT LFT


WHT 24-3 PLAT ROT RT


WHT 27-3 JIB UP

WHT 27-3 JIB UP

WHT 28-3 JIB DOWN

WHT 28-3 JIB DOWN

WHT 0-26 VLV GND

WHT 0-26 VLV GND

WHT 2-10 PLAT IGN 12 AWG

WH

T 2-

10 P

LAT

IGN

12

AW

G

BLK

0-6

PLA

T G

ND

12

AW

G

BLK 0-6 PLAT GND 12 AWG

WHT 2-12 GND MODE

WHT 2-12 GND MODE

WHT 2-8 PLAT EMS

WHT 2-8 PLAT EMS

WHT 0-27 LSS GND

WH

T 34

-1 D

OS

OV

ERR

IDE

WH

T 31

-3 F

UN

C E

NA

BLE

WH

T 31

-3 F

UN

C E

NA

BLE



WH

T 34

-3 D

OS

WH

T 34

-3 D

OS

WH

T 66

-1 S

YS

DIS

TRES

SW

HT

66-1

SY

S D

ISTR

ESS

WH

T 54

-3 G

EN O

NWHT 54-3 GEN ON W

HT

57-1

OV

ERLO

AD

WH

T 57

-1 O

VER

LOA

D

WH

T 56

-1 T

ILTE

DW

HT

56-1

TIL

TED

WH

T 48

-1 G

LOW

PLU

GS

WH

T 48

-1 G

LOW

PLU

GS

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 0-

22 F

UEL

GN

D

WH

T 39

-6 F

ULL

FU

EL L

VL

GENERIC

EMERGENCY

EMS

SW21-1A

1A

SW21-2A

2A

SW21-1B

1B

SW21-2B

2B

WHT 2-6 PLAT MODE

WHT 2-6 PLAT MODE

WHT 2-4 PLAT MODE

WHT 2-4 PLAT MODE

WHT 2-11 STROBE

WHT 2-11 STROBE

WHT 2-7 PLAT EMS

WHT 2-7 PLAT EMS

WH

T 39

-7 L

OW

FU

ELW

HT

39-7

LO

W F

UEL

WHT 54-1 GEN ON

WHT 54-1 GEN ON

WH

T 2-

18 L

SS P

WR

WH

T 71

-4 G

ND

WH

T 71

-4 G

ND

WH

T 71

-3 T

X

WH

T 71

-3 T

X

WH

T 71

-2 R

X

WH

T 71

-2 R

X

WH

T 71

-1 P

WR

WH

T 71

-1 P

WR

GRNGRNSheet_3-[1,F]

RED TP CAN CABLE

RED TP CAN CABLE

BLK TP CAN CABLE

BLK TP CAN CABLE

SHLD TP CAN CABLE

SHLD TP CAN CABLE

RED TP CAN CABLE -

BLK TP CAN CABLE -

SHLD TP CAN CABLE

GENERIC

AUX POWER

MS220+1

MS220-1

RED 1-7 B+ 12AWGRED 1-7 B+ 12AWG

RED 0-7 GND 12AWGRED 0-7 GND 12AWG

X1

TO SHEET 3X1

12

11

10

9

8

7

6

5

4

3

2

1

13

14

15

X2

TO SHEET 3X2

1

2

3

4

5

6

7

8

9

10

11

12

X3

TO SHEET 3

BOOM CABLEX3

LSS MODULESINGLE CELL(OPTIONAL)

12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

T7 1

T8 1

X4

TO ANALYZER PORT

IN BASE OF PLATFORM BOX

1 2 3 4

3 x 4 Buss Bar

GENERIC

MS2

69 1 2 3 4 5 6 7 89 1011 12

GENERIC

2 3 4 5 6

GD

20-J

31 2 3 4 5 6

GD

20-J

41 2 3 4 5 6

WHT 0-44 DISP GND

WHT 0-44 DISP GND

WH

T 2-

22 D

ISP

PWR

WHT 2-22 DISP PWR

CO99 1

2

3

4

5

S435 WHT 2-18-1 LSS PWRS436

WHT 0-27-1 LSS GND

WHT 2-18-2 LSS PWR

BLU 2-27-2 LSS GND

BLK CAN HI

GRY CAN LO

MAF02790

1001119638-QSHEET 2


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7-22 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

GENERIC

GENERATOR (OPTIONAL)

SW42

1 32 4 5 6

4 CELL LSS MODULE (OPTIONAL)

CO

44-J

21 2 3 4 5 6 7 8 9 10 11 12

CO

44-J

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

BLU

/OR

N 5

2-4

BLU/ORN 52-4

TELE OUT

GENERIC

V59

1 2

LEVEL DOWN

GENERIC

V61

1 2

LEVEL UP

GENERIC

V62

1 2

BLU/ORN 52-3

BLU

/OR

N 5

2-3

BLK

BLK

WHT

WH

T

WH

T 2-

18 L

SS P

WR

WHT 2-18 LSS PWR

WHT 0-27 LSS GNDW

HT

0-27

LSS

GN

D

S65

TELE IN

GENERIC

V60

1 2

LOCATED MID BOOM

JOINT BETWEEN

GRNG

RN

Sheet_2-[7,D]

LIMIT SWITCHSW151

BOOM ANGLE SWITCH #1

13

21

22

14

LIMIT SWITCHSW152

BOOM ANGLE SWITCH #2

13

21

22

14

UPPER AND

LOWER BOOMS

RED 12AWG

BLK 18AWG

RED 18AWG

BLU 18AWG

ORN 18AWG

YEL 18AWG

BRN 18AWG

BLU/BLK 18AWG

BLK/WHT 12AWG

ORN 12AWG

YEL/BLK 18AWG

RED/BLK 18AWG

ORN/BLK 18AWG

SHLD

BLK 12AWG

RED 12AWG

BLK 12AWG

BLK 18AWG

RED 18AWG

BLU 18AWG

ORN 18AWG

YEL 18AWG

BRN 18AWG

BLU/BLK 18AWG

BOOM CABLE

PLATFORM BOX

BLK/WHT 12AWG

ORN 12AWG

YEL/BLK 18AWG

RED/BLK 18AWG

ORN/BLK 18AWG

SHLD

X1

X1INSIDE PLATFORM BOX

12

11

10

9

8

7

6

5

4

3

2

1

13

14

15

X3

TO SHEET 2

X3

12

16

1

2

3

5

4

6

7

8

11

14

TO SHEET 2

17

19

18

10

15

9

13

X5 12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

X6 1

2

3

4

5

6

X17 1

2

3

4

5

6

7

8

9

10

11

12

X5 12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

TOWER LIFT DOWN

GENERIC

V71

1 2

LIFT DOWN

GENERIC

V76

1 2

LIMIT SWITCHSW242

TOWER ELEV

13

21

22

14

T2 1

T3 1

T4

TO SHEET 21

T5 1

T6 1

ORN/BLK

BRN/BLK

X2

X2

INSIDE PLATFORM BOX

1

2

3

4

5

6

7

8

9

10

11

12

WH

T C

AB

LE 2

WHT CABLE 2

BLK

CA

BLE

2

BLK CABLE 2

BLK

/RED

CA

BLE

4

BLK/RED CABLE 4

BR

N/B

LK C

AB

LE 4

BRN/BLK CABLE 4

BLU

/BLK

CA

BLE

3

BLU/BLK CABLE 3

OR

N/B

LK

YEL

/BLK

CA

BLE

3

YEL/BLK CABLE 3

OR

N/B

LK

BLK

/RED

CA

BLE

3

BLK/RED CABLE 3

OR

N/B

LK

BLU

/RED

CA

BLE

3

BLU/RED CABLE 3

OR

N/B

LK

ORN/BLK CABLE 3

ORN/BLK CABLE 4

ORN/BLK CABLE 4

YEL/BLK CABLE 4

YEL/BLK CABLE 4

WHT CABLE 1

WHT CABLE 1

BLK CABLE 1

BLK CABLE 1

GENERIC

FOOT SWITCH

SW43

1 2 3

SHLD

TP

CA

N C

AB

LE

SHLD TP CAN CABLE

T3911

T3921

T3931

T3941

T3951

BLK

- TP

CA

N C

AB

LE

BLK - TP CAN CABLE

RED

- TP

CA

N C

AB

LE

RED - TP CAN CABLE

BLU/BLK CABLE 4

BLU/BLK CABLE 4

BLU/RED CABLE 4

BLU/RED CABLE 4

X411 1

2

3

4

5

6

X411A 1

2

3

4

5

6

BLU/BLK

YEL/BLK

BLK/RED

SHEET 3


Go to Disc

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om to

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parts


3121259 7-23

MAF02800

1001119638-Q

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

4 CELL LSS MODULE (OPTIONAL)

CO

44-J

21 2 3 4 5 6 7 8 9 10 11 12

CO

44-J

13 4 5 6 7 8 9 10 11 12

PLAT ROT LEFT

GENERIC

V55

1 2

PLAT ROT RIGHT

GENERIC

V56

1 2

JIB UP

GENERIC

V57

1 2

JIB DOWN

GENERIC

V58

1 2

S64

LOCATED END OF BOOM

JOINT BETWEEN

UPPER AND

LOWER BOOMS

RED 12AWG

BLK 18AWG

RED 18AWG

BLU 18AWG

ORN 18AWG

YEL 18AWG

BRN 18AWG

BLU/BLK 18AWG X7

BLK/WHT 12AWG

ORN 12AWG

YEL/BLK 18AWG

RED/BLK 18AWG

ORN/BLK 18AWG

SHLD

BLK 12AWG

X5 12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

X7

TO SHEET 4BOOM CABLE

12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

X6

TO SHEET 4X6

1

2

3

4

5

6

X17

TO SHEET 4

X17

1

2

3

4

5

6

7

8

9

10

11

12

T2 1

T3 1

T4 1

T5 1

T6 1

ORN/BLK

BRN/BLK

BR

N/B

LK

BLK/REDB

LK/R

ED

BLK

/RED

BLK

/RED

BLK

/RED

WHT CABLE 2

BLK CABLE 2

BLK/RED CABLE 4

BRN/BLK CABLE 4

BLU/BLK CABLE 3

YEL/BLK CABLE 3

BLK/RED CABLE 3

BLU/RED CABLE 3

ORN/BLK CABLE 3

ORN/BLK CABLE 4

ORN/BLK CABLE 4

YEL/BLK CABLE 4

YEL/BLK CABLE 4

WHT CABLE 1

WHT CABLE 1

BLK CABLE 1

BLK CABLE 1

SHLD

TP

CA

N C

AB

LE

BLK

- TP

CA

N C

AB

LE

RED

- TP

CA

N C

AB

LE

BLU/BLK CABLE 4

BLU/BLK CABLE 4

BLU/RED CABLE 4

BLU/RED CABLE 4

X411 1

2

3

4

5

6

X411A 1

2

3

4

5

6

BLU

/BLK

BLU/BLK

OR

N/B

LK

YEL

/BLK

YEL/BLK

BLK/RED

SHEET 3


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arts


7-24 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

GROUND MODULE

TO SHEET 5

TO SHEET 8

TO S

HEE

T 8

WH

T 0-

43

CO66-J4

CO66-J11

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO66-J2

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO

66-J

4

123 49 101112 1314 15 1620 2122 2324 252627 28 29 31 32 3334 35

CO

66-J

31 2 3 4 5 6 7 8 9 10 11 12 13 14

CO66-J8

1 2 3 4

WHT 39-1 FUEL LVL

WHT 39-1 FUEL LVL

WHT 0-14 FUEL GND

WHT 0-14 FUEL GND

MA

IN D

UM

P

GEN

ERIC V70

1

2

WHT 6-3 TWR LIFT DN

WHT 6-3 TWR LIFT DN

FLO

W C

ON

TRO

L

GEN

ERIC V72

1

2

SWIN

G R

IGH

T

GEN

ERIC V73

1

2

SWIN

G L

EFT

GEN

ERIC V74

1

2

LIFT

UP

GEN

ERIC V75

1

2

WHT 4-3 LIFT DN

WHT 4-3 LIFT DN

WHT 3-3 LIFT UP

WHT 3-3 LIFT UP

WHT 21-3 SWG LFT

WHT 21-3 SWG LFT

WHT 22-3 SWG RT

WHT 22-3 SWG RT

WHT 50-2 FLOW VLV

WHT 50-2 FLOW VLV

WHT 50-1 MAIN DUMP

WHT 50-1 MAIN DUMP

WHT 0-13-6 MAIN DUMP GND

WHT 0-13-6 MAIN DUMP GND

WHT 0-13-11 LIFT VLV RTN

S77

WH

T 0-

13-3

LIF

T V

LV R

TN

WHT 0-13-10 LIFT VLV RTN

WHT 0-13-9 SWG VLV RTN S78

WH

T 0-

13-2

SW

G V

LV R

TN

WHT 0-13-8 SWG VLV RTN

WHT 0-13-7 FLOW VLV RTN

WH

T 0-

13-7

FLO

W V

LV R

TN

WHT 0-13-5 TWR VLV RTN

TOW

ER L

IFT

UP

GEN

ERIC V79

1

2WHT 5-3 TWR LIFT UP

WHT 5-3 TWR LIFT UP

STEE

R L

EFT

GEN

ERIC V80

1

2

STEE

R R

IGH

T

GEN

ERIC V81

1

2

DR

IVE

REV

ERSE

GEN

ERIC V82

1

2

DR

IVE

FOR

WA

RD

GEN

ERIC V83

1

2

WHT 9-2 STEER LFT

WHT 9-2 STEER LFT

WHT 10-2 STEER RT

WHT 10-2 STEER RT

WHT 47-3 DRV VLV RTN S86

WH

T 47

-1 D

RV

VLV

RTN

WHT 0-12-1 STR VLV GND S87

WHT 0-12 STR VLV GND

WHT 8-2 DRV REVERSE

WH

T 8-

2 D

RV

REV

ERSE

WHT 7-2 DRV FORWARD

WH

T 7-

2 D

RV

FO

RW

AR

D





WHT 13-3 TELE IN

WHT 13-3 TELE IN

WHT 14-3 TELE OUT

WHT 14-3 TELE OUT

WHT 0-10 MID VLV GND

WHT 0-10 MID VLV GND

BLK

0-5

SY

S G

ND

10A

WG

WH

T 0-

9 G

ND

WH

T 2-

10 P

LAT

IGN

12A

WG

BLK

0-6

PLA

T G

ND

12A

WG

WH

T 2-

9 IG

N 1

2AW

G

WHT 47-2 DRV VLV RTN

WHT 0-12-2 STR VLV GND

S138

WH

T 0-

13-1

TW

R V

LV R

TN

WHT 0-13-4 TWR VLV RTN

WH

T 0-

18 V

LV G

ND

X17

TO SHEET 3X17

1

2

3

4

5

6

7

8

9

10

11

12

TO ESTOP 1A2

X16

6

IGN BUS

123456

X16

7

GND BUS

TO S

HEE

T 6

WH

T 0-

33

TO S

HEE

T 5

WH

T 2-

23

123456789101112

STEE

R D

UM

P

GEN

ERIC V240

1

2WHT 0-13-12 STEER DUMP GND

WHT 0-13-12 STEER DUMP GND

WHT 50-3 STEER DUMP

WHT 50-3 STEER DUMPX

308

TO SHEET 8X308

12345678

WH

T 49

-1 C

RIB

BIN

GW

HT

49-1

CR

IBB

ING

WHT 51-1 NITE BRITE

WH

T 51

-1 N

ITE

BR

ITE

WH

T 2-

21 IG

N 1

6AW

G

Sheet_8-[4,F]

Sheet_8-[2,E]

FUEL SENSOR

GENERIC

SN241

1

2

WH

T 2-

9-1

IGN

16A

WG

GEN

ERIC

ALA

RM

AH216 1

2

3

WHT 36-2 GND ALARM

WHT 36-2 GND ALARM

WHT 0-15-1 GND ALARM GND

WHT 36-1 GND ALARM B+

WH

T 36

-1 G

ND

ALA

RM

B+

WH

T 0-

35 G

ND

16A

WG

BLK

102

-1 C

NFG

1 G

ND

BLK 102-1 CNFG1 GNDSheet_5-[1,G]

CO

66-J

3 11

WH

ITE

NO

ISE

ALA

RM

AH217

1

2

S425

WHT 0-15 GND ALARM GND

WHT 77-1 WHT NOISE

WHT 77-1 WHT NOISE

WHT 0-15-2 GND NOISE

PRES

S R

ELEA

SE

LOW

FLO

W V434 1

2WHT 0-13-13 LOW FLOW VLV RTN

WHT 0-13-13 LOW FLOW VLV RTN

WHT 1-99 LOW FLOW VLV

WHT 1-99 LOW FLOW VLV

SHEET 4


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arts


3121259 7-25

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

LIMIT SWITCH

LIMIT SWITCH

GROUND MODULE

TO SHEET 5

TO S

HEE

T 8

WH

T 0

-43

CO66-J4

CO66-J7

1

23

456

78

9

10

11

12

13

14

15

1617

18

19

20212223

24

252627

2829

3031

32

33

34

35

CO66-J12

12345678

CO

66

-J4 123 4 567 89 1

0

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO

66

-J3 1 2 3 4 5 6 7 8 9 1

01

11

21

31

4

CO66-J8

1 2 3 4

WH

T 0

-13

-3 L

IFT

VLV

RTN

WH

T 0

-13

-2 S

WG

VLV

RTN

WH

T 0

-13

-7 F

LOW

VLV

RTN

WH

T 4

7-1

DR

V V

LV R

TNW

HT

8-2

DR

V R

EVER

SEW

HT

7-2

DR

V F

OR

WA

RD

BLK

0-5

SY

S G

ND

10

AW

G

BLK 0-5 SYS GND 10AWGBLK 0-7 GND 12AWG

BLK 0-7 GND 12AWG

WHT 0-9 GND

WH

T 0

-9 G

ND

WHT 2-10 PLAT IGN 12AWG

WH

T 2

-10

PLA

T IG

N 1

2A

WG

BLK 0-6 PLAT GND 12AWG

BLK

0-6

PLA

T G

ND

12

AW

G

WHT 2-8-1 PLAT EMSWHT 31-2 FOOT PEDAL WHT 31-2 FOOT PEDAL

WHT 2-12 GND MODE WHT 2-12 GND MODE

WHT 0-8 GND

WH

T 0

-8 G

ND

ADVANCED DIAGNOSTIC

WHT 63-4 BOOM ELEV SW


WHT 73-1-1 OSC AXLE #1


WHT 63-3-2 BOOM ELEV SW

WHT 72-2 CAN TERM JUMPER

WHT 72-2 CAN TERM JUMPER

IGN

ITIO

N R

ELA

YG

ENER

IC

RL98

1

23

4

5

WHT 2-2 GND EMS 12AWG

WHT 2-2 GND EMS 12AWGWHT 2-9 IGN 12AWG

WH

T 2

-9 IG

N 1

2A

WG

WHT 2-5 GND MODEWHT 2-4 PLAT MODE

WHT 2-4 PLAT MODEWHT 2-6 PLAT MODE

WHT 2-6 PLAT MODE

RED 1-4-1 B+ 12AWG

S100 WHT 2-5-1 GND MODE

WH

T 2

-5-3

GN

D M

OD

E

S101 WHT 2-8 PLAT EMS

S102

WHT 2-5-4 SYS ON

WH

T 2

-8-2

PLA

T EM

S

S103

WH

T 2

-8-4

PLA

T EM

S

WHT 2-8-3 PLAT EMS

STROBEGENERIC

LB104

12

WH

T 0

-13

-1 T

WR

VLV

RTN

RED

1-9

B+

RED 1-9-1 B+

S143

WH

T 0

-18

VLV

GN

D

WH

T 0

-18

VLV

GN

D

WH

T 2

-16

-1 IG

N

WH

T 2

-16

IGN

S145

WHT 73-2 OSC AXLE #2


S146



S147


N/A SEE NOTE 5

WHT 74-1 TRANSPORT SW


RED 1-4-2 B+ 12AWG

OSC AXLE #2

SW225

N.O.

LOCATED ON CAM1

23

4

OSC AXLE #1

SW226

N.C.

LOCATED IN VOID1

23

4

T10

TO GND (STARTER)1

T14 1

T15 TO ESTOP 1A2 1

T16

1

T19

TO B+ (STARTER)1

X7

TO SHEET 3

BOOM CABLEX7

12161235467811141719181015913

X6

TO SHEET 3X6

123456

X8

JHGFE D CBA

X22

TO SHEET 5X22

1234

X23

TO SHEET 5X23

1234

X1

66

IGN BUS

12345

X1

67

GND BUS

TO S

HEE

T 6

WH

T 0

-33

TO S

HEE

T 5

WH

T 2

-23

12345678910

11

12

X1

73

A B C X1

75

TO S

HEE

T 8

X1

75

A B C

X1

74

ABC


GENERICFUSE HOLDER

5A

FC2

52

1 2

GENERICFUSE HOLDER

5A

FC2

53

1 2

BLK_CAN SHLD_CAN

RED

2_C

AN

B

LK2

_CA

N

SHLD

2_C

AN




X3

08

TO SHEET 8X308

12345678

WH

T 4

9-1

CR

IBB

ING

WH

T 4

9-1

CR

IBB

ING

WH

T 5

1-1

NIT

E B

RIT

E

WH

T 2

-21

IGN

16

AW

G

WHT 63-3 BOOM ELEV SWSheet_8-[2,E]

WHT 82-2 SPEED VCC

WHT 82-2 SPEED VCCSheet_8-[2,E]

WHT 0-17 IGN GND

WHT 0-17 IGN GND

WH

T 2

-9-1

IGN

16

AW

G

OSC

AX

LE #

2P

RIM

AR

Y

V96

12

OSC

AX

LE #

1SE

CO

ND

AR

Y

V97

12

WHT 0-18-1 VLV GNDWHT 73-2-2 OSC AXLE #1

WHT 0-18-2 VLV GNDWHT 73-1-2 OSC AXLE #2

WHT 2-11 STROBE

WHT 2-11 STROBE

RED CANH

BLK CANL SHLD CANSHD

RED 1-7 B+

RED_CAN

WH

T 3

6-1

GN

D A

LAR

M B

+

N/A SEE NOTE 5

S34

9


S351




S352


IP2

18

IP2

19

30AIP233

15AIP315

WH

T 0

-35

GN

D 1

6A

WG

MS422-1ABC

MS422-2ABC

MS422-3ABC

RED CANH BLK CANL

SHIELD CANSHD

RED CANL

RED CANL

Sheet_5-[7,G]

BLK CANH

BLK CANH

Sheet_5-[7,G]

BLK

10

2-1

CN

FG1

GN

D

BLK 102-1 CNFG1 GNDSheet_5-[1,G]

CO

66

-J3

1

1

CO66-J7 25

WHT 104 MSSO SWWHT 104 MSSO SWSheet_5-[1,G]

WHT 72-1 JUMPERWHT 72-1 JUMPER

BLK 100-4 MDI GND

BLK 100-4 MDI GND

Sheet_5-[7,G]

WHT 77-1 WHT NOISE

WHT 0-15-2 GND NOISE

SHIELD CANSHD

SHIELD CANSHD Sheet_5-[7,G]

S429

RED 1-9-3 B+

RED

1-9

-2 B

+Sh

eet_

5-[

6,B

]

MAF02810

1001119638-QSHEET 4


Go to D

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arts


7-26 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

GENERIC

PLATFORM LEVEL

SW10

5 1 32 4 5 6

GENERIC

PLATFORM ROTATE

SW10

6 1 32 4 5 6

GENERIC

JIB LIFT

SW10

7 1 32 4 5 6

GENERIC

TELESCOPE

SW10

8 1 32 4 5 6

GEN

ERIC

LIFT

SW109

1

3

2

4

5

6

GEN

ERIC

TOW

ER L

IFT

SW110

1

3

2

4

5

6

GEN

ERIC

SWIN

G

SW111

1

3

2

4

5

6

GEN

ERIC

STA

RT

/ A

UX

PO

WER

SW112

1

3

2

4

5

6

BA

TTER

Y C

HA

RG

ING

GEN

ERIC

LB113

1

2

LOW

FU

EL

GEN

ERIC

LB114

1

2

GLO

W P

LUG

S

GEN

ERIC

LB115

1

2

LOW

OIL

PR

ESSU

RE

GEN

ERIC

LB116

1

2

HI C

OO

LAN

T TE

MP

GEN

ERIC

LB117

1

2SY

S FA

ULT

GEN

ERIC

LB118

1

2

OV

ERLO

AD

GEN

ERIC

LB119

1

2


WH

T 26

-2 P

LAT

LVL

DN

WH

T 25

-2 P

LAT

LVL

UP


WH

T 23

-2 P

LAT

RO

T LF

T



WH

T 24

-2 P

LAT

RO

T R

T

WH

T 27

-2 J

IB U

P

WHT 27-2 JIB UP

WHT 28-2 JIB DOWN

WH

T 28

-2 J

IB D

OW

N

WH

T 14

-2 T

ELE

OU

T

WHT 14-2 TELE OUT

WHT 13-2 TELE IN

WH

T 13

-2 T

ELE

IN

WHT 3-2 LIFT UP

WHT 3-2 LIFT UP

WHT 4-2 LIFT DN

WHT 4-2 LIFT DN

WHT 5-2 TWR LIFT UP

WHT 5-2 TWR LIFT UP

WHT 6-2 TWR LIFT DN

WHT 6-2 TWR LIFT DN

WHT 22-2 SWING RT

WHT 22-2 SWING RT

WHT 21-2 SWING LFT

WHT 21-2 SWING LFT

WHT 53-2 AUX / ENABLE


WHT 2-14 SWITCH IGN

WHT 2-14 SWITCH IGN

CO66-J4

WHT 45-2 START

WHT 45-2 START








WH

T 2-

14-4

SW

ITC

H IG

N

WH

T 2-

14-5

SW

ITC

H IG

N

WH

T 2-

14-5

SW

ITC

H IG

N

WH

T 2-

14-7

SW

ITC

H IG

N

WH

T 2-

14-7

SW

ITC

H IG

N

WH

T 2-

14-8

SW

ITC

H IG

N

WH

T 2-

14-8

SW

ITC

H IG

N

WHT 46-3 ALT WHT 46-3 ALT

WHT 0-17 LAMP GND WHT 0-17 LAMP GND

WHT 39-7 LOW FUEL

WHT 39-7 LOW FUEL

WHT 48-2 GLOW PLUGS

WHT 48-2 GLOW PLUGS

WHT 65-1 LOW OIL PR

WHT 65-1 LOW OIL PR

WHT 65-2 HI TEMP

WHT 65-2 HI TEMP

WHT 66-2 SYS FAULT

WHT 66-2 SYS FAULT

WHT 57-2 OVERLOAD

WHT 57-2 OVERLOAD

WHT 0-17-1 LAMP GND

WHT 0-17-1 LAMP GND

WHT 0-17-2 LAMP GND

WHT 0-17-2 LAMP GND

WHT 0-17-3 LAMP GND

WHT 0-17-3 LAMP GND

WHT 0-17-4 LAMP GND

WHT 0-17-4 LAMP GND

WHT 0-17-5 LAMP GND

WHT 0-17-5 LAMP GND

WHT 0-17-6 LAMP GND

WHT 0-17-6 LAMP GND

WHT 0-17-7 LAMP GND

WHT 0-17-7 LAMP GND

CO66-J4

TO SHEET 4

5

17

6

18

19

8

9

20

30

7

23

33

10

21

35

34

16

25

4

32

24

22

15

11

1

27

26

31

13

3

29

28

2

14

12

CR

IBB

ING

GEN

ERIC

LB251

1

2

WHT 58-2 CRIBBING

WHT 58-2 CRIBBING

BLU 100-3 MDI PWR

MSSO

GENERIC

(CE ONLY)

SW42

6-1 1

SW42

6-2 1

Sheet_4-[5,A]BLK 102-1 CNFG1 GND

S424

BLK

102

-2 C

NFG

1 G

ND

BLK 102 CNFG1 GNDSheet_8-[3,H]

WH

T 10

4 M

SSO

SW

WHT 104 MSSO SWSheet_4-[8,E]

HO

UR

MET

ER

GEN

ERIC

GD121+

1

GD121-1

WHT 32 HOUR METER

WHT 32 HOUR METER (SEE NOTE 1)

NOTES:

1. FOR CE MACHINES ONLY (EQUIPPED WITH EN280). FOR NON CE MACHINES, CONNECT WIRE WHT 32 TO X427 PIN 3.

2. FOR CE MACHINES ONLY (EQUIPPED WITH EN280). FOR NON CE MACHINES, CONNECT WIRE WHT 0-17-8 TO X427 PIN 2.

WHT 0-17-8 LAMP GND

WHT 0-17-8 LAMP GND (SEE NOTE 2)

WHT 0-17-9 LAMP GND

WHT 32-1 HOURMETER

SHEET 5


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3121259 7-27

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

GENERIC

TELESCOPE

SW10

8 1 32 4 5 6

GEN

ERIC

LIFT

SW109

1

3

2

4

5

6

GEN

ERIC

TOW

ER L

IFT

SW110

1

3

2

4

5

6

GEN

ERIC

SWIN

G

SW111

1

3

2

4

5

6

GEN

ERIC

STA

RT

/ A

UX

PO

WER

SW112

1

3

2

4

5

6

BA

TTER

Y C

HA

RG

ING

GEN

ERIC

LB113

1

2

LOW

FU

EL

GEN

ERIC

LB114

1

2

GLO

W P

LUG

S

GEN

ERIC

LB115

1

2

LOW

OIL

PR

ESSU

RE

GEN

ERIC

LB116

1

2

HI C

OO

LAN

T TE

MP

GEN

ERIC

LB117

1

2

SYS

FAU

LT

GEN

ERIC

LB118

1

2

OV

ERLO

AD

GEN

ERIC

LB119

1

2

WH

T 14

-2 T

ELE

OU

T

WH

T 13

-2 T

ELE

IN

WHT 3-2 LIFT UP

WHT 4-2 LIFT DN

WHT 5-2 TWR LIFT UP

WHT 6-2 TWR LIFT DN

WHT 22-2 SWING RT

WHT 21-2 SWING LFT


WHT 2-14 SWITCH IGN

WHT 45-2 START








WH

T 2-

14-4

SW

ITC

H IG

N

WH

T 2-

14-5

SW

ITC

H IG

N

WHT 46-3 ALT

WHT 0-17 LAMP GND

WHT 39-7 LOW FUEL

WHT 48-2 GLOW PLUGS

WHT 65-1 LOW OIL PR

WHT 65-2 HI TEMP

WHT 66-2 SYS FAULT

WHT 57-2 OVERLOAD

WHT 0-17-1 LAMP GND

WHT 0-17-1 LAMP GND

WHT 0-17-2 LAMP GND

WHT 0-17-2 LAMP GND

WHT 0-17-3 LAMP GND

WHT 0-17-3 LAMP GND

WHT 0-17-4 LAMP GND

WHT 0-17-4 LAMP GND

WHT 0-17-5 LAMP GND

WHT 0-17-5 LAMP GND

WHT 0-17-6 LAMP GND

WHT 0-17-6 LAMP GND

WHT 0-17-7 LAMP GND

WHT 0-17-7 LAMP GND

KEY SWITCH

GENERIC

SW123-11

SW123-B1

SW123-31

SW123-2

1

SW123-B11

SW123-41



WHT 2-5 GND MODE

WHT 2-5 GND MODE

WHT 2-6 PLAT MODE

WHT 2-6 PLAT MODE





RED 1-4-1 B+ 12AWG

RED 1-4-1 B+ 12AWG

RED 1-4-2 B+ 12AWG

RED 1-4-2 B+ 12AWG

X22

TO SHEET 4X22

1

2

3

4

X23

TO SHEET 4X23

1

2

3

4

GENERIC

EMERGENCY

STOP SWITCH

2B AND 2B2 ARE TERMINATED

AT THE SAME LOCATION

SW238-1A

1A

SW238-2A

2A

SW238-1B

1B

SW238-2B

2B

SW238-2B2

2B2

CR

IBB

ING

GEN

ERIC

LB251

1

2

WHT 58-2 CRIBBING

GEN

ERIC

CR

IBB

ING

EN

AB

LE (O

PTIO

N)

SW327

1

3

2

4

5

6

T331 TO SHEET 8 X308 POS 1 1

T330 TO SHEET 4 X166 POS 4 1

WHT 49-1 CRIBBING WHT 49-1 CRIBBING

WHT 2-23 CRIBBING PWR

WHT 2-23 CRIBBING PWR

X428 1

2

3

4

5

6

NC

RED CANL RED CANL Sheet_4-[8,H]

BLK CANH BLK CANH Sheet_4-[8,H]

BLU 100-3 MDI PWR

WHT 2-4 PLAT MODE

WHT 2-4 PLAT MODE

BLK 100-4 MDI GNDBLK 100-4 MDI GNDSheet_4-[8,F]

SHIELD CANSHD SHIELD CANSHD Sheet_4-[8,H]

HO

UR

MET

ER

GEN

ERIC

GD121+

1

GD121-1

X427 1

2

3

4

RED 1-9-2 B+Sheet_4-[6,C]

WHT 32 HOUR METER (SEE NOTE 1)

WHT 0-17-8 LAMP GND

WHT 0-17-8 LAMP GND (SEE NOTE 2)

WHT 0-17-9 LAMP GND

WHT 0-17-9 LAMP GND

WHT 32-1 HOURMETERWHT 32-1 HOURMETER

WHT 2-6-1 PLAT MODE

WHT 2-6-1 PLAT MODE

MAF02820

1001119638-QSHEET 5


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7-28 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

M

FIVE PIN RELAY

GENERIC

STARTER

RL3

0

30 8587a

87 86

FIVE PIN RELAY

GENERIC

GLOW PLUGS

RL3

1

30 8587a

87 86

WH

T 45

-4 S

TAR

T 12

AW

G

WH

T 45

-4 S

TAR

T 12

AW

G

WH

T 0-

46-1

GN

D

KUBOTA ENGINE HARNESS

GENERATOR HARNESS

T170

B+

1 X17

0

1T1

70-

1

SENSOR, SPEED

SN22

7 1 2 3

GLOW PLUGS

ENGINE

EC22

8 1

STARTER

ENGINE

FIVE PIN RELAY

GENERIC

FULL SPEED RELAY

RL2

55 30 8587

a

87 86

GENERIC

FUSE HOLDER

40A

FC25

8 1 2

S259

WH

T 0-

41 G

ND

14A

WG

WH

T 0-

46-2

GN

D

WH

T 0-

46-3

GN

D

S261

S262

WH

T 86

-1 F

ULL

TH

RO

TTLE

14A

WG

WH

T 46

-1 A

LT E

XC

ITE

16A

WG

GENERIC

FUSE HOLDER

30A

FC26

7 1 2

S268

RED 1-10 B+ 10AWG

WH

T 84

-2 G

LOW

PLU

GS

12A

WG

WH

T 84

-2 G

LOW

PLU

GS

12A

WG

RED

1-1

0-1

B+

12A

WG

RED

1-1

0-2

B+

12A

WG

RED

1-1

0-5

B+

12A

WG

RED

1-1

0-6

B+

12A

WG

RED

1-1

0-6

B+

12A

WG

RED

1-1

0-3

B+

12A

WG

RED

1-1

0-4

B+

12A

WG

WH

T 83

-1 O

IL P

RES

SUR

E

WH

T 82

-2 S

PEED

VC

C

WH

T 82

-1 S

PEED

SN

WH

T 0-

42 S

N G

ND

WH

T 81

-1 C

OO

LAN

T TE

MP

WH

T 0-

41-5

GN

D

WH

T 1-

4 B

+ 1

0AW

G

WH

T 45

-5 S

TAR

T

WH

T 85

-1 F

ULL

TH

RO

TTLE

WH

T 84

-1 G

LOW

PLU

GS

14 GA FUSIBLE LINK

14 G

A F

USI

BLE

LIN

K

GENERICTEMP SENSOR

SN26

2 1 2

PRESSURE SWITCH

GENERIC

SW13

4 1

ALTERNATOR

LAMP IGN B+

GENERIC

X26

6 12 T2

66B

+1

S357

S358

GD

359+

1 GD

359-

1

WH

T 54

-2-2

IGN

BLK

0-3

3-2

GN

D

GENERATOR CONTROL BOX

WHT 0-46 GNDS260

X421

TO GENERATOR

1

2

3

4

5

6

X416

A

B

C

D

E

F

X417 A

B

C

X418

TO SHEET 8X35

A

B

WHT 54-2-1 IGN WHT 54-2 IGN

X419

TO SHEET 4 GND BUS POS 5 1BLK 0-33-1 GND

BLK 0-33 GND

WHT

BLK

SHEET 6


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3121259 7-29

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

FIVE PIN RELAY

GENERIC

GLOW PLUGS

RL3

1

30 8587a

87 86

X16

TO SHEET 8

X16

A

B

C

D

E

F

G

H

J

K

L

M

N

P

R

S

SENSOR, SPEED

SN22

7 1 2 3

GLOW PLUGS

ENGINE

EC22

8 1

WH

T 0-

46-3

GN

D

S261

WH

T 86

-1 F

ULL

TH

RO

TTLE

14A

WG

WHT 46-1 ALT EXCITE 16AWG

WH

T 84

-2 G

LOW

PLU

GS

12A

WG

WH

T 84

-2 G

LOW

PLU

GS

12A

WG

RED

1-1

0-4

B+

12A

WG

WHT 83-1 OIL PRESSURE

WH

T 83

-1 O

IL P

RES

SUR

E

WH

T 82

-2 S

PEED

VC

C

WHT 82-2 SPEED VCC

WHT 82-1 SPEED SN

WH

T 82

-1 S

PEED

SN

WH

T 0-

42 S

N G

ND

WHT 0-42 SN GND

WH

T 81

-1 C

OO

LAN

T TE

MP

WHT 81-1 COOLANT TEMP

WH

T 0-

41-5

GN

D

WH

T 80

-1 T

HR

OTT

LE A

CT

WHT 80-1 THROTTLE ACT

WH

T 0-

43 T

HR

OTT

LE R

TN

WHT 0-43 THROTTLE RTN

WH

T 0-

41-6

GN

D 1

4AW

G

WHT 45-5 START

WHT 85-1 FULL THROTTLE

WHT 84-1 GLOW PLUGS

WH

T 84

-1 G

LOW

PLU

GS

GENERICTEMP SENSOR

SN26

2 1 2

THROTTLE ACTUATOR

GENERIC

EC40

1 2

PRESSURE SWITCH

GENERIC

SW13

4 1

S357

S358

GD

359+

1 GD

359-

1

WH

T 54

-2-2

IGN

BLK

0-3

3-2

GN

D

GENERATOR HOUR METER (OPTION)

GENERATOR CONTROL BOX

X40

6 ABC

X40

7 ABC

RED CAN HI

RED

CA

N H

I

BLK CAN LO

BLK

CA

N L

O

WHT 0-46 GND

WHT 0-46 GNDS260

FULL THROTTLE

GENERIC

EC25

6-1

EC25

6+1

X416

A

B

C

D

E

F

X417 A

B

C

WHT 54-2 IGN

BLK 0-33 GND

WHT

BLK

MAF02830

1001119638-QSHEET 6


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7-30 3121259

4321

G

H

E

F

C

D

A

B

1 2 3 4

MOLEX 56 WAY34576-0703 - 56 CIRCUIT POL G VERSION "0" CONNECTOR33467-0005 - 0.64MM 18/20 AWG GOLD PLATED TERMINAL34575-0003 - 56 WAY WIRE DRESS COVER34586-0001 - 0.64MM CAVITY PLUG

PED_12162279 CONNECTORPED_12124075 TERMINAL


1/4" SPADE(FEMALE)


AMP_1-967616-1 CONNECTORAMP_965906-5 TERMINALAMP_967067-1 SEAL

F4ZB-14A464-MA CONNF3VB-14474-AA TERM

E93B-14A468-DA SPACER







GM ENGINE HARNESS

ECM

SHEET 7


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3121259 7-31

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

1/4" SPADE(FEMALE)

PED_12160825 CONNECTORPED_12177150 TERM (GOLD)PED_12160826 LOCKPED_12089678 SEAL

PED_12052641 CONNECTORPED_12048074 TERMINALPED_12052634 LOCKPED_12048086 SEAL

PED_12103784 CONNECTORPED_12124580 TERM FEMALE (14/16 AWG)PED_12089188 TERM FEMALE (18/20 AWG)PED_12015323 SEAL



PED_15326868 CONNECTORPED_15326269 TERMINALPED_12191153 SEALPED_15305171 CAVITY PLUGPED_15358639 CLIP

PED_15326840 CONNECTORPED_15326269 TERMINALPED_12191153 SEALPED_15305171 CAVITY PLUGPED_15358639 CLIPPED_15317363 LOCK

CAP CONNECTOR 2 WITH MATING CONNECTORPED_15326835, CAVITY PLUGS PED_15305171AND TPA PED_15418415

PED_12052848 CONNECTORPED_12056198 CAVITY PLUGPED_12052850 LOCK

PED_12124107 CONNECTORPED_15324973 SEALPED_12059168 CAVITY PLUGPED_12045773 TERMINALPED_12052850 TPAPED_12020833 CPA

EPC_1F1T-14A624-AA-004 TERMGTS_0330-930009 TERM (18-20)GTS_0330_940001 TERM (14-16)EPC_E6DB-14A468-DA LOCKEPC_F5AB-14A666-AA CAP1/4" SPADE

(FEMALE)

DJF7031A-6.3-20 CONN

AMP_1-967616-1 CONNECTORAMP_965906-5 TERMINALAMP_967067-1 SEAL



CONNECTOR 1

CONNECTOR 2

TO SHEET 8

TO SHEET 8

X16

X40

MAF02840

1001119638-QSHEET 7


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7-32 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

M

GENERIC

12V BATTERY

BT2

09+

1BT2

09-

1

FUEL PUMP

GENERIC

EC21

0-1 EC

210+

1

WHT 70-4 GND WHT 70-4 GND

WHT 70-3 TXWHT 70-3 TX

WHT 70-2 RX WHT 70-2 RX

WHT 70-1 PWRWHT 70-1 PWR

WH

T 65

-4 F

UEL

PU

MP

WHT 65-4 FUEL PUMP

WHT 0-40 FP GND

WH

T 0-

40 F

P G

ND

WHT 54-2 GEN ON

WHT 54-2 GEN ON

TO SHEET 4

X35

WHT 45-3 START

WHT 45-3 START

RED 1-1 B+ 1/0AWG

RED

1-1

B+

1/0

AW

G

BRAKE

GENERIC

V21

2

1 2

BYPASS

GENERIC

V21

3

1 2

WHT 0-11 VLV GND

S214

WH

T 0-

11-2

VLV

GN

D

WH

T 44

-1 B

RA

KE

WHT 44-1 BRAKE

WHT 43-1 BYPASS

WH

T 43

-1 B

YPA

SS



WHT 0-42 SN GND

WHT 0-42 SN GND

WHT 82-1 SPEED SN

WHT 82-1 SPEED SN



WHT 84-1 GLOW PLUGS

WHT 84-1 GLOW PLUGS WHT 80-1 THROTTLE ACT




CO66-J1

CO66-J1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

X175

TO SHEET 4X175 A

B

C

T34 TO STARTER B+ 1

T36 TO STARTER GND 1

X35

TO SHEET 6A

B

X14

ANALYZER PORT1

2

3

4

X16 A

B

C

D

E

F

G

H

J

K

L

M

N

P

R

S

NC

T162 TO SHEET 4 - J3 POS 2 1

RED - TP CAN CABLE

RED - TP CAN CABLE

BLK - TP CAN CABLE

BLK - TP CAN CABLE

SHLD

SHLD

BLK 1-0 GND 1/0AWG

BLK

1-0

GN

D 1

/0A

WG



X40 A

B

C

D

E

F

G

H

WHT 2-21 IGN 16AWGSheet_4-[3,H]


WHT 63-3 BOOM ELEV SWSheet_4-[6,C]

WHT 82-2 SPEED VCC

WHT 82-2 SPEED VCC

Sheet_4-[8,B]

WH

T 0-

11-1

VLV

GN

D

X308

TO SHEET 4X308

1

2

3

4

5

6

7

8

WHT 7-2 DRV FORWARD

WHT 7-2 DRV FORWARD

WHT 8-2 DRV REVERSE

WHT 8-2 DRV REVERSE

TO SHEET 5 WHT 49-1 CRIBBING

TO SHEET 9 WHT 51-1 NITE BRITE



WHT 0-46 GND

WHT 0-46 GND

BLK 102 CNFG1 GND

Shee

t_5-

[1,G

]

CO66-J1 33

SHEET 8


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3121259 7-33

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

M

FUEL PUMP

GENERIC

EC21

0-1 EC

210+

1

WHT 70-4 GND

WHT 70-3 TX

WHT 70-2 RX

WHT 70-1 PWR

WH

T 65

-4 F

UEL

PU

MP

WHT 65-4 FUEL PUMP

WHT 0-40 FP GND

WH

T 0-

40 F

P G

ND

WHT 45-3 START


WHT 0-42 SN GND

WHT 82-1 SPEED SN


WHT 84-1 GLOW PLUGS



X14

ANALYZER PORT1

2

3

4

X16

TO KUBOTA (SHEET 6, X16) / GM (SHEET 7, CONNECTOR 1) ENGINE HARNESS

TO GM (SHEET 7, CONNECTOR 2) ENGINE HARNESS

A

B

C

D

E

F

G

H

J

K

L

M

N

P

R

S

NC

RED - TP CAN CABLE

BLK - TP CAN CABLE

SHLD


X40 A

B

C

D

E

F

G

H

WHT 2-21 IGN 16AWGSheet_4-[3,H]

WHT 82-2 SPEED VCC

T362 TO ESTOP 1B2 1

T363 TO KEYSWITCH POS 1

TO KEYSWITCH POS 3

1

T364 1

S366 TO WHT 0-17 IGN GND SIDE

TO WHT 0-17 IGN GND, IGN RELAY SIDE S367

WIRE WHT 0-17 IGN GND MUST BE CUT NEAR IGN RELAY

SECURITY LOCK (OPTION)

S368 TO LOCK - RED

S369 TO LOCK - BLUE

S370 TO LOCK - ORANGE

S371 TO LOCK - BLACK

S372 TO LOCK - ORANGE

RED 1-11 B+ 16AWG RED 1-11 B+ 16AWG

S373 IP374

IP375

WHT 87-1-1 LOCK 16AWG


WHT 87-1 LOCK 16AWG

S376 WHT 87-2-2 LOCK 16AWG


WHT 87-2 LOCK 16AWG

WHT 87-3 LOCK 16AWG WHT 87-3 LOCK 16AWG


WHT 0-46 GND

MAF02850

1001119638-QSHEET 8


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7-34 3121259

A

B

C

D

E

F

G

H

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

T376 TO SHEET 8, X308 POS 2 1

WH

T 51

-2-1

LIG

HT

16A

WG

WHT 0-45-2 GND 16AWG

WH

T 51

-2-4

LIG

HT

16A

WG

WH

T 0-

45-5

GN

D 1

6AW

G

WH

T 51

-2-2

LIG

HT

16A

WG

WH

T 51

-2-3

LIG

HT

16A

WG

WH

T 0-

45-3

GN

D 1

6AW

GW

HT

0-45

-4 G

ND

16A

WG

S385

S386

CH

ASS

IS L

IGH

TS

GEN

ERIC

RL387

1

2

3

4

5

WHT 51-2 LIGHT 12AWG WHT 51-2 LIGHT 12AWG

WHT 51-1 NITE BRITE

WHT 51-1 NITE BRITE

T388 TO STARTER B+ 1

T389 TO STARTER GND 1

WHT 0-45 GND 12AWGWHT 0-45 GND 12AWGS3

90

14 GA FUSIBLE LINK

RED 1-12 B+ 12AWG

WHT 0-45-1 GND

WHT 0-45-1 GND

LEFT FRONT

GENERIC

LB39

0 12

LEFT REAR

GENERIC

LB39

1 12

RIGHT FRONT

GENERIC

LB39

2

12

RIGHT REAR

GENERIC

LB39

3

12

CHASSIS LIGHT (OPTION)

J8

TO SHEET 2CO01-J8 1

2

J8_1 CO01-J8TO SHEET 2

1

2BLK 12AWG BLK 12AWG

YEL/RED 12AWG YEL/RED 12AWG

BLK 16AWG

BLK

16A

WG

BLK 16AWG

BLK

16A

WG

IP39

5

3A

IP39

6

3A

SEE NOTE 3

SEE

NO

TE 3

SEE

NO

TE 3

SEE NOTE 3

FLOOD_1

1

2

FLOOD_2 1

2

YEL/RED 16AWG

BLK 16AWGS399

BLK 16AWG S400 YEL/RED 16AWG

YEL/RED 16AWG

YEL/RED 16AWG

GEN

ERIC

PLA

TFO

RM

FLO

OD

LIG

HTS

SWITCH

1

3

2

4

5

6

S402

S401

B

LK 1

6AW

GB

LK 1

6AW

G

WH

T 16

AW

G

LIG

HTS

1 2 3 4

LIG

HTS

_1

1 2 3 4

PLATFORM LIGHTS (OPTION)

PLUG HARNESS BETWEEN PLATFORM BOARD AND EXISTING HARNESS

MAF02780

1001119638-QSHEET 9


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3121259 7-35

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7-36 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

X437

BEACON MODULE

1

2

3

4

5

6

7

8

9

10

11

12X

438

BEA

CO

N M

OD

ULE

123456789

101112

X43

9

1 23 45 6 7 89

1011 12

X44

0

TO E

ND

DIA

G C

ON

N (O

RIG

INA

L)

ABCDEFGHJ X44

1

TO E

ND

DIA

G C

ON

N (N

EW)

ABCDEFGHJ

X442 1

2

X44

3

CA

N T

ERM

INA

TOR

ABC

S444

S445

S446

RED - BEACON PWR

RED - BEACON PWR

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

RED

- C

AN

HIG

H

BLK - GND

BLK - GND

BLK

- G

ND

BLK - GND

BLK

- G

ND

WHT - IGN

WH

T - I

GN

WH

T - I

GN

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

BLK

- C

AN

LO

W

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

WH

T - C

AN

SH

IELD

RED

- B

ATT

ERY

RED

- B

ATT

ERY

ALERT BEACON OPTIONHARNESS P/N 1001142736

SHEET 10


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3121259 7-37

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

IP114

18 OHM

RELAY #1

PLTFM SNSR

RL5

03

30 8587a

87 86

WH

T P1

WHT P1

WH

T P9

-1

WH

T P3

WHT P3

RELAY #2

PLTFM SNSR

RL5

02

3085 87a

8786

WH

T P5

-1

WH

T P9

-2

WH

T P4

-1

WHT P2

PLTFM SNSR

X50

0 1 2 3 4

WH

T P6

WHT P6

WH

T P1

0

WH

T P4

WH

T P5

X5B 1

2

3

4

5

6

HARNESS,GEN 2 PLAT INTERFACE

TO SHEET 11X5A

S192

S191

WH

T P5

-2

WH

T P4

-2

MAF02860

1001119638-QSHEET 10


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7-38 3121259

54321

G

H

E

F

C

D

A

B

1 2 3 4 5

R

RR

R G

YR

YG

G

G

G

Y

Y

Y

G

Y

G

G

G

PLATFORM MODULE

CO01-J1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J7

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J6

1

2

3

4

5

6

7

8

CO

01-J

2

1 2 34 5 67 89 10 11 121314 1516 1718 19 2021 22 2324 25 26 2728 2930 31 32 33 3435

CO01-J8

12

CO01-J5

1

2

3

4

5

6

7

8

WH

T 2-

10 P

LAT

IGN

12

AW

G

WH

T 0-

6 PL

AT

GN

D 1

2 A

WG

GENERIC

ENGINE SPEED

SW09

1 32 4 5 6

GENERIC

PLATFORM LEVEL

SW10

1 32 4 5 6

WHT 42-1 MAX SPEED

WH

T 42

-1 M

AX

SPE

ED

WHT 2-17 SWITCH IGN

WH

T 2-

17 S

WIT

CH

IGN

WHT 41-1 MAX TORQUEW

HT

41-1

MA

X T

OR

QU

E


WH

T 25

-1 P

LAT

LVL

UP


WH

T 26

-1 P

LAT

LVL

DN

WH

T 2-

17-1

SW

ITC

H IG

N

WH

T 2-

17-1

SW

ITC

H IG

N

WH

T 2-

17-2

SW

ITC

H IG

N

WH

T 2-

17-2

SW

ITC

H IG

N

WHT 35-1 HORN

WH

T 35

-1 H

OR

N

GEN

ERIC

PLA

TFO

RM

RO

TATE

SW12

1

3

2

4

5

6

WHT 24-1 PLAT ROT RTWHT 24-1 PLAT ROT RT







WHT 55-1 CREEP MODE

WHT 55-1 CREEP MODE


WH

T 2-

17-3

SW

ITC

H IG

N

WHT 23-1 PLAT ROT LFT WHT 23-1 PLAT ROT LFT



GEN

ERIC

TOW

ER L

IFT

SW14

1

3

2

4

5

6

GEN

ERIC

JIB

LIF

T

SW15

1

3

2

4

5

6

GEN

ERIC

MA

IN T

ELES

CO

PE

SW16

1

3

2

4

5

6

GEN

ERIC

STA

RT

/ A

UX

PO

WER

SW17

1

3

2

4

5

6

WHT 5-1 TWR LFT UPWHT 5-1 TWR LFT UP

WHT 6-1 TWR LFT DNWHT 6-1 TWR LFT DN



WHT 27-1 JIB UP

WHT 27-1 JIB UP

WHT 28-1 JIB DN

WHT 28-1 JIB DN











WHT 53-1 AUX POWER

WHT 53-1 AUX POWER

WHT 45-1 START

WHT 45-1 START

GEN

ERIC

FUEL

SEL

ECT

(OPT

ION

AL)

SW18

1

3

2

4

5

6

GEN

ERIC

DR

IVE

OR

IEN

TATI

ON

SW19

1

3

2

4

5

6







WHT 34-1 DOS OVERRIDE

WH

T 34

-1 D

OS

OV

ERR

IDE

WH

T 55

-2 C

REE

P M

OD

EW

HT

55-2

CR

EEP

MO

DE

WH

T 31

-3 F

UN

C E

NA

BLE

WH

T 31

-3 F

UN

C E

NA

BLE



WH

T 34

-3 D

OS

WH

T 34

-3 D

OS

WH

T 66

-1 S

YS

DIS

TRES

SW

HT

66-1

SY

S D

ISTR

ESS

WH

T 54

-3 G

EN O

NWHT 54-3 GEN ON W

HT

57-1

OV

ERLO

AD

WH

T 57

-1 O

VER

LOA

D

WH

T 56

-1 T

ILTE

DW

HT

56-1

TIL

TED

WH

T 48

-1 G

LOW

PLU

GS

WH

T 48

-1 G

LOW

PLU

GS

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 0-

22 F

UEL

GN

D

WH

T 0-

22 F

UEL

GN

D

WH

T 39

-6 F

ULL

FU

EL L

VL

WH

T 39

-6 F

ULL

FU

EL L

VL

WH

T 39

-7 L

OW

FU

ELW

HT

39-7

LO

W F

UEL

WH

T 2-

18 L

SS P

WR

WH

T 71

-4 G

ND

WH

T 71

-3 T

X

WH

T 71

-2 R

X

WH

T 71

-1 P

WR

PUSH BUTTON

HORN

SW22

4-1

1

SW22

4-2 1

HEA

D/T

AIL

LIG

HT

GEN

ERIC

SW280-11

SW280-2

1





GENERIC

GD

20-J

11 2 3 4 5 6

GD

20-J

21 2 3 4 5 6

GD

20-J

31 2 3 4 5 6

GD

20-J

41 2 3 4 5 6

WH

T 2-

22 D

ISP

PWR

PUM

P PO

T

GEN

ERIC

SW13

1

2

3

4

5

6

GEN

ERIC

SOFT

TOU

CH

OV

ERR

IDE

SW429

1

3

2

4

5

6

SOFT

TOU

CH

IND

ICA

TOR

GEN

ERIC

LB427+

1

LB427-

1



WHT P15 SOFTTOUCH

WHT P15 SOFTTOUCH

WHT 0-45 IND GND

WHT P14 IND SIG

WH

T P1

4 IN

D S

IG

WHT J1-23 SKYG INPUT 2

WHT J1-20 SOFTT OUT

WH

T J2

-31

SOFT

T PW

R

SHEET 11


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3121259 7-39

A

B

C

D

E

F

G

H

87654

4 5 6 7 8

R

R

G

Y

G

G

Y

Y

Y

G

Y

G

G

G

PLATFORM MODULE

CO01-J7

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

CO01-J6

1

2

3

4

5

6

7

8

CO

01-J

2

1 2 34 5 67 89 10 11 121314 1516 1718 19 2021 22 2324 25 26 2728 2930 31 32 33 3435

CO01-J8

12

CO01-J5

1

2

3

4

5

6

7

8

WHT 37-1 PLAT ALARM

WHT 37-1 PLAT ALARM

WHT 0-28-1 ALARM GND

WHT 2-20 GEN SW IGN

WHT 2-20 GEN SW IGN

WHT 31-1 FOOT PEDAL

WHT 31-1 FOOT PEDAL

WHT 2-19 FTS IGN

WHT 2-19 FTS IGN

WHT

ORN/YEL

BLU/YEL

RED

BRN

GRN

WHT/YEL

WHT/RED

WHT/GRN

RED

BLK

BLU

BRN

BLK

BLU





WHT 27-3 JIB UP

WHT 27-3 JIB UP

WHT 28-3 JIB DOWN

WHT 28-3 JIB DOWN

WHT 0-26 VLV GND

WHT 0-26 VLV GND

WHT 2-10 PLAT IGN 12 AWG

WH

T 2-

10 P

LAT

IGN

12

AW

G

WH

T 0-

6 PL

AT

GN

D 1

2 A

WG

WHT 0-6 PLAT GND 12 AWG

WHT 2-12 GND MODE

WHT 2-12 GND MODE

WHT 2-8 PLAT EMS

WHT 2-8 PLAT EMS

WHT 0-27 LSS GND

WH

T 34

-1 D

OS

OV

ERR

IDE

WH

T 55

-2 C

REE

P M

OD

EW

HT

55-2

CR

EEP

MO

DE

WH

T 31

-3 F

UN

C E

NA

BLE

WH

T 31

-3 F

UN

C E

NA

BLE



WH

T 34

-3 D

OS

WH

T 34

-3 D

OS

WH

T 66

-1 S

YS

DIS

TRES

SW

HT

66-1

SY

S D

ISTR

ESS

WH

T 54

-3 G

EN O

NWHT 54-3 GEN ON W

HT

57-1

OV

ERLO

AD

WH

T 57

-1 O

VER

LOA

D

WH

T 56

-1 T

ILTE

DW

HT

56-1

TIL

TED

WH

T 48

-1 G

LOW

PLU

GS

WH

T 48

-1 G

LOW

PLU

GS

WH

T 39

-3 1

/4 F

UEL

LV

L

WH

T 39

-4 1

/2 F

UEL

LV

L

WH

T 39

-5 3

/4 F

UEL

LV

L

WH

T 0-

22 F

UEL

GN

D

WH

T 39

-6 F

ULL

FU

EL L

VL

WH

T 39

-7 L

OW

FU

ELW

HT

39-7

LO

W F

UEL

WHT 54-1 GEN ON

WHT 54-1 GEN ON

WH

T 2-

18 L

SS P

WR

WH

T 71

-4 G

ND

WH

T 71

-4 G

ND

WH

T 71

-3 T

X

WH

T 71

-3 T

X

WH

T 71

-2 R

X

WH

T 71

-2 R

X

WH

T 71

-1 P

WR

WH

T 71

-1 P

WR

RED TP CAN CABLE 1

BLK TP CAN CABLE 1

SHLD TP CAN CABLE 1

GENERIC

GD

20-J

21 2 3 4 5 6

GD

20-J

31 2 3 4 5 6

GD

20-J

41 2 3 4 5 6

WHT 0-44 DISP GND

WHT 0-44 DISP GND

WH

T 2-

22 D

ISP

PWR

WHT 2-22 DISP PWR

ELEC

TRO

NIC

JO

YST

ICK

GEN

ERIC

LEFT

RIGHT

LIFT

AN

D S

WIN

G

GEN

ERIC

X4

TO ANALYZER PORT

IN BASE OF PLATFORM BOX

1 2 3 4

X3

TO SHEET 3

BOOM CABLEX3

12

16

1

2

3

5

4

6

7

8

11

14

17

19

18

10

15

9

13

GENERIC

EMERGENCY

EMS

SW21-1A

1A

SW21-2A

2A

SW21-1B

1B

SW21-2B

2B

WHT 2-6 PLAT MODE

WHT 2-6 PLAT MODE

WHT 2-4 PLAT MODE

WHT 2-4 PLAT MODE

WHT 2-11 STROBE

WHT 2-11 STROBE

GENERIC

AUX POWER

MS220+1

MS220-1

RED 1-7 B+ 12AWG

RED 0-7 GND 12AWG

WHT 2-7 PLAT EMS

WHT 2-7 PLAT EMS

3 x 4 Buss Bar

CAN CHANNEL #2

MS2

69 1 2 3 4 5 6 7 89 1011 12

CO99

LSS MODULESINGLE CELL(OPTIONAL)

1

2

3

4

5

WHT 2-18-2 LSS PWR

BLU 0-27-2 LSS GND

BLK CAN HI

GRY CAN LO

RED TP CAN CABLE 2

BLK TP CAN CABLE 2

SHLD TP CAN CABLE 2

RED TP CAN CABLE 2

BLK TP CAN CABLE 2

SHLD TP CAN CABLE 2

WHT 0-27-1 LSS GND

WHT 2-18-1 LSS PWR

S103

S102

X2

TO SHEET 3X2

1

2

3

4

5

6

7

8

9

10

11

12

T7 1

T8 1

X1

TO SHEET 3X1

TO SHEET 10X5B

12

11

10

9

8

7

6

5

4

3

2

1

13

14

15

GEN

ERIC

JLG

ALA

RM

AH02+1

AH02-1

3 x 4 Buss Bar

CAN CHANNEL #1

MS5

09

1 2 3 4 5 6 7 89

1011 12

WH

T P1

4 IN

D S

IG

X1002 A

B

C

X1001

RED TP CAN CABLE 2

BLK TP CAN CABLE 2SHLD TP CAN CABLE 2

S101

WHT 0-28 ALARM GND

X5A 1

2

3

4

5

6

WHT J7-7-1 SKYG IGN PWRS104

WHT J7-7 SKYG IGN PWR

WHT J7-7-2 SOFTT SENSE

WHT J7-24 SKYG GND

WHT J7-24 SKYG GND




WHT J1-20-1 SOFTT OUT

S105

WHT J1-20-2 SOFTT OUT

WHT J2-31 SOFTT PWR

WH

T J2

-31

SOFT

T PW

R

MAF02870

1001119638-QSHEET 11


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7-40 3121259

MASTER CYLINDERBARREL: 3.0" (75mm)ROD: 1.3" (32mm)STROKE: 11.5" (293mm)

AA

A A

RT MOTOR

RT MOTOR

BB

B B

REAR BRAKES

LF MOTOR

LF MOTOR

REAR AXLE

FRONT AXLE

V1 V2

DISPLACEMENT:

PLATFORM ROTATOR7.9IN (129.5)

P1 P2

SLAVE CYLINDERBARREL: 3.0" (75mm)ROD: 1.3" (32mm)STROKE: 12.24"(311mm)

V1 V2

TELESCOPE CYLINDERBARREL: 2.0" (50mm)ROD: 1.3" (32mm)STROKE: 38.5" (978mm)

OSCILLATING AXLE CYLINDERSBARREL: 2.75" (69.85mm)STROKE: 2.75" (69.85mm)

STEER CYLINDERBARREL: 2.5" (65mm)ROD: 1.75"(45mm)STROKE: 5.5" (139mm)

JIB ROTATE

FLY BOOM VALVE T

P

J2

MP

J1 R2 R1 V1 V2 M1 L1 L2 M2

P1

T1T2

P2 TELESCOPE PLATFORM LEVEL

UPRIGHT VALVE

Front Brakes

Traction lock

2 39

19 21 20 22 10 11

6

7

23

V1

V2

ORF

MAIN LIFT CYLINDERBARREL: 3.5" (90mm)

ROD: 1.96" (50mm)STROKE: 26.29" (668mm)

X

PP

V V

ROD:

JIB CYLINDERBARREL:

STROKE:

2.48" [63mm]1.57" [40mm]

22.8" [580mm]

V2 V1

Valve

valveBrake

TOP_VIEW

Figure 7-45. Hydraulic Schematic - Sheet 1 of 2

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3121259 7-41

B A

Function Pump

LOWER LIFT CYLINDERBARREL: 2.95"(75mm)ROD: 1.77"(45mm)STROKE: 29.6" (751.8mm)

RETURN FILTERMICRON LEVEL: 6BYPASS VALVE: 45 PSI

FUNCTION PUMP1st Gear: 0.51 cu in (8.4cc) at 1800 RPM, 3.6 GPM2nd Gear: 0.16 cu in (2.62cc) at 1800 RPM, 1.1 GPM

+12VDC at Coil C1 = pressure at M4 = flow out port A+12VDC at Coil C2 = pressure at M5 = flow out port B

DRIVE MOTORFixed 12.2 cu in (200CC)Presurize port A = CW RotationPresurize port B = CCW Rotation

DRIVE GEAR BOXRatio: 4.25:1Brake Torque 4300 in/lbBrake Release 350 PSI (24 BAR)Output Rotation Opposite Input Rotation

SWING DRIVEMOTOR D: 2.2 cu in (36cc)REDUCTION: 170.7:1

CHARGE FILTERMICRON LEVEL: 5BYPASS VALVE: 43 PSI (3 BAR)

DRIVE PUMP2.75 cu in (45 cc)4060 PSI (280 BAR) Max377 PSI (26 BAR) Charge0.73 cu in (12cc) Charge Pump Displacement

P1 Main relief 2500 PSI (172.4 BAR)P2 Main relief 3000 PSI (207 BAR)Swing port relief 1000 PSI (69 BAR)Steer port relief 2500 PSI (172.4 BAR)Platform level up port relief 2800 PSI (193 BAR)Platform level down port relief 1400 PSI (96.5 BAR)

Forward

Reverse

MAIN CONTROL VALVE

STEER FLOW CONTROL UPPER LIFT SWING LOWER LIFTP4 M4 3 4 5 6

MS

T CPP1P2 M1M2

1

2

DRIVE VALVESecondary oscl axle valve

Primary oscl axle valve

1 4 5 8

12 13 15 16 18 17

14

V1

V2

ORF

X

Hydraulic Oil Analysis Sampling Valve

HYDRAULIC RELIEF VALVE SETTINGS:

12

MA

L2MB

C2C1

M4

M5

A

M3

B

S

E

F

L1

X

M14

DRIVEPUMP

X3

Emergency Descent

Hand Pump

Figure 7-46. Hydraulic Schematic - Sheet 2 of 2

1001120020-C

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7-42 3121259

NOTES:

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Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101

Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and choose one of the options to help get the right parts and equipment you are looking for. Please have the machine model and serial number available in order to help us get you the correct parts. If you don’t find the part on the website or on once of the online manuals, please fill out the request form and one of our experienced staff members will get back to you with a quote for the right part that your machine needs.

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,

Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull, Skytrak, Tsurumi, Husquvarna Target, , Stow, Wacker, Sakai, Mi-T- M, Sullair, Basic,

Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, Barreto, EZ Trench, Bil-

Jax, F.S. Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equipment, ,AMida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK,

Rol-Air, Small Line, Wanco, Yanmar



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SECTION 6 - JLG CONTROL SYSTEMSECTION 6 - JLG CONTROL SYSTEM 3121259 6-73 GLOWPLUG – SHORT TO GROUND 33281 The Ground Module detects a shor t to ground at the Glow Plug out-put