Troubleshooting Manual - JLG Equipment Boom Lifts... · Troubleshooting Manual Models 1200SJP 1350SJP 3128463 January 10, ... Troubleshooting Flowchart Is Distress ... Measure the

Troubleshooting Manual

Models1200SJP1350SJP

3128463 January 10, 2011

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INTRODUCTION

SECTION A. INTRODUCTION

A.1 HOW TO USE THIS MANUALTroubleshooting system problems can be difficult. System wiring and hydraulic diagrams are provided in this book to helpisolate problems.

Follow the flow chart of Figure A-1. Troubleshooting Flowchart on Pg. 3. Only perform calibrations when indicated in proce-dures or in section 5.1 Calibration Instructions on Pg. 207.

Each troubleshooting step setup is specified in the step instructions and applies only to that step. Any special wiring, dis-connected connectors, programming modes, etc. should be removed, re-connected, restored, etc. after completingthe step unless directed otherwise. Some procedures call for swapping components, connections, etc. All instructions torepair refer to the machine as assembled before the procedure started. Reinstall to proper locations all swapped compo-nents, connections before repairing machine.

When a function will not operate with the same speed or power as a machine in good working condition, refer to the topicwhich most closely describes the problem.

Conclude each session by rerunning the system test, checking for other problems.

If this method does not identify the problem, contact the factory for assistance.

Figure A-1. Troubleshooting Flowchart

Is Distress Lamp Blinking?

Plug in Analyzer and read Help

MessageNo Yes

Start

Troubleshoot by Help Message in

Section 1

Problem Solved?

No

Yes

Identify Fault

Repair Machine

Done

Using Analyzer, find logged Help

Messages

“Ground/Everything OK”

Using Analyzer, Run Platform and Ground System

Tests

Yes

No

3128463 1200SJP 1350SJP A-3

INTRODUCTION

A.2 VISUAL INSPECTIONPerform a thorough visual and “hands on” inspection before starting any troubleshooting procedure. Also, perform a visualinspection at every connector, sensor, hose, harness, etc. opened or accessed during the procedure. You can quickly findthe cause of many problems just by looking.

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

Inspect Hoses for:

• Correct routing

• Pinches and kinks

• Splits, cuts, or breaks.

Inspect Wiring for:

• Contact with sharp edges

• Contact with hot surfaces

• Pinched, burned or chafed insulation

• Proper routing and connections

Check Sensors and Actuators for Damage.

Check Electrical Connectors for:

• Corrosion on pins

• Moisture in the housing or on the contacts

• Bent or damaged pins

• Contacts not properly seated in housing

• Bad wire crimps to terminals

A.3 READING FAULT CODESCurrent and logged system fault codes and ADE service flash codes can be read from the analyzer. Refer to 4.2 Using theAnalyzer on Pg. 177. Fault logs are separated by POWER CYCLE messages. In Troubleshooting, you may be asked to seeall of the currently active faults. This simply means all of the faults since the latest power cycle. Scroll through the chronolog-ical faults on the analyzer, listing all the faults until the first “POWER CYCLE” message. Troubleshoot each of these itemsseparately unless instructed otherwise.

ADE service flash codes can also be read from the green LED on the face of the ground module or the system distress lampin the platform console, see Figure A-2. Ground Module and Platform Fault (System Distress) Lights on Pg. 4. Use the tableof contents to find possible faults based on the flashed code. Flash codes are the first two digits of Diagnostic TroubleCodes or DTC’s. There is a unique DTC for each fault that occurs on the machine.

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

1705744 A

1705745 B

1702938 1705170 A1705171 A

J1 J4

J2 J3

FAULTCODELIGHT

A-4 1200SJP 1350SJP 3128463

INTRODUCTION

A.4 CONNECTOR REFERENCESElectrical connectors are given a three digit identifier number preceded with “X”. See 2.1 Connector Index on Pg. 137 for alist.

For Example:[X004.21] refers to terminal 21 (pin and socket) of connector X004.[X004.21.soc] refers to the socket side of terminal 21, connector X004.[X004.21.pin] refers to the pin side of terminal 21, connector X004.

A.5 GROUND REFERENCEBattery negative [X117] should be used as the ground reference for voltage measurements, unless stated otherwise.

3128463 1200SJP 1350SJP A-5

INTRODUCTION

A.6 CONTROL MODULE POWER AND COMMUNICATIONSAlways make sure that all of the control models are properly powered. See Figure A-3. Basic Electronic Module Connectionson Pg. 6

1. For Ground Module operation, Terminals [X001.24], and [X008.2] should have a voltage of Vbatt. Terminal [X008.1]should be grounded.

2. CAN communication wires should have 60 resistance between CAN HI and CAN LO whenever both the PlatformModule and Chassis Module are connected or 120 when one of them are disconnected. Both CAN HI and CAN LOshould be isolated (show very high resistance or overload, OL) from the shield and ground. A CAN termination 120resistor is located at both ends of the CAN bus. One is embedded in the platform module. The other terminator is jum-pered in the chassis module.

Figure A-3. Basic Electronic Module Connections

Platform Module

Ground Module

CAN Shield

CAN HICAN LO

Platform Ground

Platform Power

Ground from B-

Vbatt from Power Down Relay

X007

Analyzer PowerAnalyzer RS232 ReceiveAnalyzer RS232 TransmitAnalyzer Ground Analyzer

CAN HI

CAN LO

Constant Battery (Vbatt)

BLAM Module

CAN HI

CAN LO6

7

X086

8CAN Shield

X090Analyzer Power

Analyzer RS232 ReceiveAnalyzer RS232 TransmitAnalyzer

9101112

CAN HICAN LOCAN Shield

Chassis Module

CAN HI

CAN LO

CAN Shield

X233Analyzer Power

Analyzer RS232 ReceiveAnalyzer RS232 Transmit

Analyzer GroundAnalyzer

9101112

Vbatt from Ground Module X008.4

Ground from Ground Module X008.3

5

4

Ignition Power

Chassis Power

J5

J1

J5

Note: BLAM and Chassis Module Analyzer connections for download only

CAN Jumper

Vbatt from EMS

Platform Mode Select

Vbatt from EMS

Mode Select from Ground Module X007.14

X014

X043

X160

X083123

1 2 3

123

X279

X091

X013

X235

AnalyzerX171

X166J2

26282927

X216123

C B A

C B A A

B

C

X269X270

45

Ground

45

12 16

1612

Constant Battery (Vbatt)

Ignition Power

Battery +Battery -CAN HI

CAN LO

X084ABC

X2632 1

X267X2803

2

X097

Ignition Power

Ground from Ground Module X001.8

Ground to Engine Module X240.1

Analyzer Ground

CB

A

CB

A

A B C X278

X268

Gateway Module

X279CB

IGNITION

TCU Module

BATT +

A

Diagnostic Connector

120120

13

14

3

J72418

2

4

13

X008J8

6

7

X229

8

120

5

4

J1

9

10

X169

X1702

1

J8

X288X287

12

BlackGray

10 9 8 7 12

CA

N H

IC

AN

LO

CA

N 2 H

IC

AN

2 LO

IGN

ITIO

NG

RO

UN

D

11

SH

IELD

X001

28293031

24

J1 8

Chassis Power Relay

X26687

30

86

85

Load Pin

ABDE

X06212345

X089J4

X289

E D CBC

AN

2 LO

CA

N 2 H

I

V B

AT

TG

ND

AS

HIE

LD

Engine Module

X240

12

13

14

1

X290

22 7 23

CA

N 2 LO

CA

N 2 H

IV

BA

TT

GR

OU

ND

16

IGN

ITIO

N

15

31

30

120

32

J72

1

CAN 2 HI

CAN 2 LO

A-6 1200SJP 1350SJP 3128463

INTRODUCTION

A.7 CRITICAL SENSORS

Main Boom Angle SensorsMain Boom Rotary Angle Sensor #1 (Right) [X099]

Main Boom Rotary Angle Sensor #2 (Left) [X100]

Measure the angle of the main boom with respect to the turntable. Power is supplied by the Ground Module so the sensorscan be turned on separately at startup for identification and diagnostic purposes. Once initialized, a constant 12 volts shouldbe supplied by the Power Down Relay [X011.87] to Main Boom Angle Sensor #1, [X099.1] and Main Angle Sensor #2,[X100.1]. Each sensor communicates with the BLAM on its own serial bus.

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM A/D ANGLE1: XXX.X

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM A/D ANGLE2: XXX.X

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM ANGLE1: XX.X DEG

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM ANGLE1: XX.X DEG

In transport position approximate typical values are:

MAIN BOOM A/D ANGLE1: -38.0

MAIN BOOM A/D ANGLE2: -38.0

MAIN BOOM ANGLE1: -1.0

MAIN BOOM ANGLE2: -1.0

Main Boom Length SensorMain Boom Length Sensor #1 (Top Right) [X093]

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM LENGTH: XXX.X"

ANALYZER DIAGNOSTICS ENVELOPE MAIN BOOM A/D LENGTH: XXXXX

Measures the total stroke of the main boom using a cable potentiometer. The sensor’s analog outputs are read by the BLAMmodule. It increases as the boom length increases. The sensor is powered by a 5 volt reference and ground from the BLAMmodule. Each sensor should measure 5k resistance between the A and B pins.

In transport position approximate typical values are:

MAIN BOOM LENGTH: 37.3"

MAIN BOOM A/D LENGTH: 395

3128463 1200SJP 1350SJP A-7

INTRODUCTION

This Page Left Blank Intentionally

3128463 1200SJP 1350SJP A-8

SAFETY

3128463 1200SJP 1350SJP B-9

SECTION B. TROUBLESHOOTING SAFETY PRECAUTIONS

B.1 GENERALThis section contains the general safety precautionswhich must be observed during troubleshooting of theaerial platform. It is of utmost importance that mainte-nance personnel pay strict attention to these warningsand precautions to avoid possible injury to themselves orothers, or damage to the equipment. A maintenance pro-gram must be followed to ensure that the machine is safeto operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BYA RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEASTAS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLA-TION.

The specific precautions to be observed during trouble-shooting are inserted at the appropriate point in the man-ual. These precautions are, for the most part, those thatapply when servicing hydraulic and larger machine com-ponent parts.

Your safety, and that of others, is the first considerationwhen engaging in the troubleshooting of equipment.Always be conscious of weight. Never attempt to moveheavy parts without the aid of a mechanical device. Do notallow heavy objects to rest in an unstable position. Whenraising a portion of the equipment, ensure that adequatesupport is provided.

SINCE THE MACHINE MANUFACTURER HAS NODIRECT CONTROL OVER TROUBLESHOOTING,SAFETY IN THIS AREA IS THE RESPONSIBILITY OF

THE OWNER/OPERATOR.

B.2 HYDRAULIC SYSTEM SAFETYIt should be noted that the machines hydraulic systemsoperate at extremely high potentially dangerous pres-sures. Every effort should be made to relieve any systempressure prior to disconnecting or removing any portion ofthe system.

B.3 TROUBLESHOOTING SAFETY

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED INTHIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNELINJURY OR DEATH AND IS A SAFETY VIOLATION.

• No smoking is mandatory. Never refuel during electricalstorms. Ensure that fuel cap is closed and secure at allother times.

• Remove all rings, watches and jewelry when performingany troubleshooting.

• Do not wear long hair unrestrained, or loose-fittingclothing and neckties which are apt to become caughton or entangled in equipment.

• Observe and obey all warnings and cautions onmachine and in service and operators manuals.

• Keep oil, grease, water, etc. wiped from standing sur-faces and hand holds.

• Use caution when checking a hot, pressurized coolantsystem.

• Never work under an elevated boom until boom hasbeen safely restrained from any movement by blockingor overhead sling, or boom safety prop has beenengaged.

• A machine that is damaged or malfunctioning shouldimmediately be tagged and removed from service.

• Repair any machine damage or malfunction beforeoperating the machine.

• Unless otherwise specified, perform any troubleshoot-ing procedure with the machine parked on a flat levelsurface, boom stowed, key switch off and key removed,park brake applied.

• Battery should always be disconnected during replace-ment of electrical components.

• Keep all support equipment and attachments stowed intheir proper place.

• Use only approved, nonflammable cleaning solvents.

10 1200SJP 1350SJP 3128463

REVISION LOG

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

January 10, 2011 - Manual Revised

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION A - INTRODUCTION

A.1 How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3A.2 Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A.3 Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4A.4 Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A.5 Ground Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5A.6 Control Module Power and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6A.7 Critical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

SECTION B - TROUBLESHOOTING SAFETY PRECAUTIONS

B.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9B.2 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9B.3 Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING

DTC 001 - EVERYTHING OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15DTC 002 - GROUND MODE OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15DTC 0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION . . . . . . . . . . . . . . . . . . . . . . 1-15DTC 0011 - FSW OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15DTC 0012 - RUNNING AT CREEP - CREEP SWITCH OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16DTC 0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . 1-17DTC 0014 - CHASSIS TILT SENSOR OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18DTC 0015 - LOAD SENSOR READING UNDER WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . 1-18DTC 0017 - OVER MOMENT - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19DTC 0018 - UNDER MOMENT - HYDRAULICS SUSPENDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19DTC 0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . 1-19DTC 0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . 1-19DTC 211 - POWER CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19DTC 212 - KEYSWITCH FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19DTC 213 - FSW FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 227 - STEER SWITCHES FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2211 - FSW INTERLOCK TRIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . 1-20DTC 2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2215 - D/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2216 - D/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2217 - D/S JOY. CENTER TAP BAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2218 - L/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2219 - L/S JOY. OUT OF RANGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2220 - L/S JOY. CENTER TAP BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20DTC 2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH. . . . . . . . . . . . . . . . 1-21DTC 2222 - WAITING FOR FSW TO BE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21DTC 2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE . . . . . . . . . . . . . . . . . . 1-21DTC 2224 - FOOTSWITCH SELECTED BEFORE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21DTC 234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM . . . . . . . . . . . . . . . . . . . 1-21DTC 235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER . . . . . . . . . . . . . . . 1-21DTC 236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH . . . . . . . . . . . . . 1-21DTC 237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH . . . . . . . . . . . . . . . . . . . . . 1-21DTC 259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS . . . . . . . . . . . . . . . . . . . . 1-21DTC 2513 - GENERATOR MOTION CUTOUT ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22DTC 2514 - BOOM PREVENTED - DRIVE SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22DTC 2515 - DRIVE PREVENTED - BOOM SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

3128463 1200SJP 1350SJP 11

TABLE OF CONTENTS (Continued)

DTC 2516 - DRIVE PREVENTED - ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 2521 - JIB SWING PREVENTED - IN 1000# MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED. . . . . . . . . . . . . . . . . . . . .1-22DTC 2523 - BACKUP BLAM COMMUNICATIONS ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL . . . . . .1-22DTC 331 - BRAKE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 332 - BRAKE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22DTC 3311 - GROUND ALARM - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23DTC 3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3336 - ALTERNATOR/ECM POWER - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3338 - ALTERNATOR POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3339 - ALTERNATOR POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3340 - AUX POWER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3341 - AUX POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3342 - AUX POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3349 - ELECTRIC PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24DTC 3350 - ELECTRIC PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3351 - ELECTRIC PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3358 - MAIN DUMP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3359 - MAIN DUMP VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3360 - MAIN DUMP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3361 - BRAKE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3362 - START SOLENOID - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3363 - START SOLENOID - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3364 - START SOLENOID - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3368 - TWO SPEED VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3369 - TWO SPEED VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25DTC 3370 - TWO SPEED VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3371 - GROUND ALARM - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3372 - GROUND ALARM - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3373 - GEN SET/WELDER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3374 - GEN SET/WELDER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3375 - GEN SET/WELDER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3376 - HEAD TAIL LIGHT - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3377 - HEAD TAIL LIGHT - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3378 - HEAD TAIL LIGHT - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3379 - HOUR METER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3380 - HOUR METER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26DTC 3381 - HOUR METER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . .1-27DTC 3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .1-27DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . .1-27DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . .1-27

12 1200SJP 1350SJP 3128463


DTC 3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . .1-27DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . .1-27DTC 3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-27DTC 3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27DTC 3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . .1-27DTC 3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33100 - JIB LIFT UP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33101 - JIB LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33102 - JIB LIFT UP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33103 - JIB LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33104 - JIB LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33118 - SWING RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33119 - SWING RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28DTC 33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33121 - SWING RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33122 - SWING LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33130 - THROTTLE ACTUATOR - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33131 - THROTTLE ACTUATOR - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33132 - THROTTLE ACTUATOR - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33133 - PLATFORM CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33134 - PLATFORM CONTROL VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33150 - LIFT PILOT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29DTC 33151 - LIFT PILOT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33152 - LIFT PILOT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33153 - LIFT DOWN AUX VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33154 - LIFT DOWN AUX VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE -

SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30DTC 33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUIT. .1-32DTC 33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33181 - MAIN LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32DTC 33183 - MAIN LIFT UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33207 - HORN - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33208 - HORN - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33209 - HORN - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33279 - GLOWPLUG - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33DTC 33280 - GLOWPLUG - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33281 - GLOWPLUG - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33295 - SWING LEFT VALVE - oPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33306 - SWING LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND. . . . . . . . . . . . . . .1-34

3128463 1200SJP 1350SJP 13


DTC 33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . .1-34DTC 33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . .1-34DTC 33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . .1-34DTC 33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . .1-34DTC 33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . .1-34DTC 33329 - MAIN LIFT UP VALVE - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . .1-35DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-35DTC 431 - FUEL SENSOR SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 432 - FUEL SENSOR SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 433 - OIL PRESSURE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 434 - OIL PRESSURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 435 - COOLANT TEMPERATURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35DTC 437 - ENGINE TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36DTC 438 - HIGH ENGINE TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 439 - AIR FILTER BYPASSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4310 - NO ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4311 - LOW OIL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4313 - THROTTLE ACTUATOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4314 - WRONG ENGINE SELECTED - ECM DETECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4322 - LOSS OF ENGINE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 4323 - SPEED SENSOR READING INVALID SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 445 - BATTERY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38DTC 662 - CANBUS FAILURE - PLATFORM MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39DTC 666 - CANBUS FAILURE - ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39DTC 6610 - CANBUS FAILURE - BLAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40DTC 6611 - CANBUS FAILURE - CHASSIS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44DTC 6612 - CANBUS FAILURE - CYLINDER LOAD PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47DTC 6622 - CANBUS FAILURE - TCU MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-50DTC 6623 - CANBUS FAILURE - GATEWAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51DTC 6629 - TELEMATICS CANBUS LOADING TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52DTC 681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP . . . . . . .1-52DTC 813 - CHASSIS TILT SENSOR NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52DTC 815 - CHASSIS TILT SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52DTC 825 - LSS HAS NOT BEEN CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52DTC 826 - RUNNING AT CREEP - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52DTC 827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . .1-53DTC 828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . .1-53DTC 831 - PLATFORM LEVELING OVERRIDE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53DTC 832 - PLATFORM LEVELING OVERRIDE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53DTC 833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . .1-53DTC 834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . .1-54DTC 837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . .1-55DTC 838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . .1-55DTC 8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . .1-55DTC 8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . .1-55DTC 8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56DTC 8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56DTC 8315 - PLATFORM LEVELING SENSOR - DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56DTC 8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-57DTC 8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-58DTC 8318 - PLATFORM LEVELING SYSTEM TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59

14 1200SJP 1350SJP 3128463


DTC 841 - BOOM ANGLE SENSOR DISAGREEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-60DTC 842 - BOOM LENGTH SWITCH FAILED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-61DTC 843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-62DTC 844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE . . . . . . . . . . . . . . . . . . . .1-62DTC 845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-64DTC 846 - BOOM LENGTH SENSOR - OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-65DTC 847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . .1-66DTC 848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . .1-67DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . . .1-67DTC 8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . .1-69DTC 8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-70DTC 8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-71DTC 8413 - WRONG TELESCOPE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-72DTC 8414 - WRONG LIFT RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73DTC 851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73DTC 852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74DTC 855 - MOMENT PIN - SENSOR FAULT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74DTC 857 - NEW MOMENT PIN DETECTED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74DTC 861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESS. SWITCH DISAGREEMENT1-74DTC 862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . .1-76DTC 863 - AXLE EXTEND VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76DTC 864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . .1-76DTC 865 - AXLE RETRACT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76DTC 866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT. . . . . . .1-76DTC 867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-77DTC 868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-77DTC 869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-77DTC 8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-77DTC 8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-78DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-78DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-79DTC 8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-79DTC 8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-79DTC 8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80DTC 8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80DTC 8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80DTC 8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80DTC 8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-80DTC 8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . .1-80DTC 8622 - FRONT RIGHT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-80DTC 8623 - FRONT LEFT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-81DTC 8624 - REAR RIGHT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-82DTC 8625 - REAR LEFT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-83DTC 8626 - FRONT LEFT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-84DTC 8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . .1-85DTC 8628 - REAR LEFT STEER SENSOR - NOT RESPONDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-86DTC 8629 - REAR RIGHT STEER SENSOR - NOT RESPONDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-87DTC 8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT. . . . . . . . . .1-88DTC 8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-89DTC 8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-90DTC 8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-91DTC 8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-92DTC 8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-93DTC 8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . . .1-94DTC 8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-95DTC 8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . .1-96DTC 998 - EEPROM FAILURE - CHECK ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96DTC 9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER .1-96

3128463 1200SJP 1350SJP 15


DTC 9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIRED. . . . . . . . . . . . . . . . . . . . . . . . . .1-96DTC 9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96DTC 9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96DTC 9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST . . . . . . . . . . . . . . . . . . . . . . . . . .1-97DTC 9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97DTC 9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97DTC 9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97DTC 9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY. . . . . . . . . . . . . . .1-98DTC 9922 - PLATFORM MODULE FAILURE - HWFS CODE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-98DTC 9923 - GROUND MODULE FAILURE - HWFS CODE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99DTC 9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER. . .1-99DTC 9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER. . . . . .1-99DTC 9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . .1-99DTC 9928 - ENVELOPE CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99DTC 9929 - MOMENT CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99DTC 9930 - STEER SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100DTC 9931 - BOOM SENSORS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100DTC 9932 - LIFT CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100DTC 9933 - TELESCOPE CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100DTC 9934 - DRIVE CRACKPOINTS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100DTC 9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-101DTC 9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102DTC 9937 - LENGTH SENSOR REF VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102DTC 9938 - LENGTH SENSOR REF VOLTAGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103DTC 9939 - BLAM HIGH RES A/D FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103DTC 9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103DTC 9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104DTC 9944 - CURRENT FEEDBACK GAINS OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104DTC 9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT. . . . . . . . . . . . . . . . . . .1-104DTC 9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER. . .1-105DTC 33xx - COMMON STB OR OC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-105DTC 33XX - COMMON STG PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-106

SECTION 2 - ELECTRICAL REFERENCE

2.1 Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1372.2 BLAM Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442.3 Chassis Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452.4 Ground Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1462.5 Platform Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1482.6 Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150

SECTION 3 - HYDRAULIC REFERENCE

SECTION 4 - JLG ANALYZER

4.1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1774.2 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1774.3 Changing the Access Level of the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1864.4 Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1874.5 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1874.6 Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1994.7 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199

SECTION 5 - CALIBRATIONS

5.1 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2075.2 Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2085.3 Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2105.4 Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2145.5 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-217

16 1200SJP 1350SJP 3128463


5.6 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2215.7 Calibrating Lift Crack Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2225.8 Calibrating Telescope Crack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2255.9 Calibrating the Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2285.10 Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-240

SECTION 6 - GENERAL ELECTRICAL INFORMATION

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2456.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2456.3 Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2476.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2486.5 Working with AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2496.6 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254

LIST OF FIGURES

A-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3A-2. Ground Module and Platform Fault (System Distress) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4A-3. Basic Electronic Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-62-1. Color Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1112-2. Platform Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1132-3. Boom Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1152-4. Engine Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1172-5. Main Valve Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1192-6. Ground Control Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1212-7. Chassis Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1232-8. Ground, Engine and BLAM Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1252-9. Platform Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1272-10. Chassis Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1292-11. Electrical Wiring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1312-12. Electrical Wiring (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1332-13. Telematics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1353-1. Main Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1633-2. Pumps Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1643-3. Platform Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1653-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1663-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1673-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1683-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1693-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1703-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1713-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1723-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1733-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1743-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1754-1. Ground Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1774-2. Platform Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1774-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1794-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . .4-1804-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . .4-1814-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . . .4-1824-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3. . . . . . . . . . .4-1834-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3. . . . . . . . . . .4-1844-9. Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3 . . . . . . . . . . .4-1854-10. System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-201

3128463 1200SJP 1350SJP 17


4-11. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2035-1. Boom Sensor Calibration Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2285-2. Boom Sensor Calibration Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2325-3. Boom Sensor Calibration Position 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2335-4. Boom Sensor Calibration Position 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2345-5. Boom Sensor Calibration Position 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2355-6. Boom Sensor Calibration Position 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2355-7. Boom Sensor Calibration Position 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2365-8. Boom Sensor Calibration Position 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2375-9. Boom Sensor Calibration Position 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2385-10. Boom Sensor Calibration Position 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2395-11. Wire Rope Tensioning Figure A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2405-12. Wire Rope Adjustment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2436-1. Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2466-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2466-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2476-4. Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2476-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2506-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2506-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2516-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2516-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2526-10. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2526-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2536-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2546-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2546-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2546-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2556-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2556-17. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255

18 1200SJP 1350SJP 3128463


LIST OF TABLES

1-1 Common Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-362-1 Limit Switch States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1092-2 Platform Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1122-3 Main Valve Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1182-4 Chassis Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1222-5 Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1372-6 X086 (J1) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442-7 X087 (J2) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442-8 X088 (J3) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442-9 X089 (J4) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442-10 X090 (J5) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1442-11 X229 (J1) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452-12 X230 (J2) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452-13 X231 (J3) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452-14 X232 (J4) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452-15 X233 (J5) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1452-16 X001 (J1) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1462-17 X002 (J2) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1462-18 X004 (J4) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1462-19 X007 (J7) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1472-20 X008 (J8) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1472-21 X165 (J1) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1482-22 X166 (J2) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1482-23 X167 (J5) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1482-24 X168 (J6) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1492-25 X169 (J7) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1492-26 X170 (J8) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1492-27 Connector Loading Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1504-1 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1884-2 Machine Personality Settings and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1944-3 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2045-1 Calibrations Listed by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2075-2 Calibrations Listed by Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207

3128463 1200SJP 1350SJP 19



20 1200SJP 1350SJP 3128463


SECTION 1. DTC DICTIONARY AND SELECTED TROUBLESHOOTINGFor a list of Diagnostic Trouble Codes (DTC’s), see the table of contents.

DTC 001 - EVERYTHING OKEverything OK. The "normal" help message when the analyzer is plugged into the platform. No problem is detected.

DTC 002 - GROUND MODE OKGround mode OK. The "normal" help message when the analyzer is plugged into the ground module. No problem is detected.

DTC 0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITIONRunning at cutback - out of transport position. Drive speed is limited to programmed maximum because the vehicle is out of transport position. Maximum drive speed is set in the Personality of the machine. Transport position is defined as main boom retracted, and the boom angle less than +15.0 (default) from gravity. Sensor failures can change these conditions. .

DTC 0011 - FSW OPENFootswitch open. A drive or boom function has been selected but the platform footswitch [X152] is open. This could be caused by operator not depressing the footswitch before utilizing a machine control in the platform.

Note Pretest Instructions Test Result Corrective Action Step 1 Read faults Are there any length sensor, boom angle sen-

sor, switch or transport length switch faults?Yes Troubleshoot those faults first

No Go to step 2

Step 2 Return machine to transport position

Did fault clear? Yes Troubleshooting Complete

No Go to step 3

Step 3 ANALYZER DIAGNOS-TICS TRANSPORT DATA TRANSPORT MODE

Does it read OUT OF TRANSPORT? Yes Go to step 4

No Reprogram/replace ground module

Step 4 ANALYZER DIAGNOS-TICS TRANSPORT DATA MAIN LIFT STATUS

Does it read STOWED, or can the main boom be lowered to make it read STOWED?

Yes Keep analyzer connected.Go to step 5

No Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228.

Step 5 ANALYZER DIAGNOS-TICS TRANSPORT DATA MAIN TELESCOPE STA-TUS

Does it read RETRACTED, or can the main boom be moved within the transport position envelope to make it read RETRACTED?

Yes Normal operation. Troubleshooting complete.

No Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228.

Note Pretest Instructions Test Result Corrective Action Step 1 Go to ANALYZER DIAG-

NOSTICS SYSTEM FOOTSWITCH INPUT PLAT-FORM

Does the analyzer read OPEN? -AND- Does the analyzer read CLOSED with the footswitch depressed?

Yes If fault is clear, this is normal operation. Otherwise reprogram/replace the ground module

No Go to step 2

Step 2 Locate platform passthru - 15 pos [X164]. Ground meter. See Grounding on Pg. 245 for details. Take the following reading by back-probing. See Backprobing on Pg. 245 for details.

Turn on machine. Is there about 12 VDC on platform passthru terminal 8 [X164.8]?

Yes Keep the test setup in same condition.Go to step 4

No Go to step 3

3128411 1200SJP 1350SJP 1-15


DTC 0012 - RUNNING AT CREEP - CREEP SWITCH OPENRunning at creep - creep switch open. All function speeds are limited to creep because the creep switch is open. This switch is part of the hydraulic speed potentiometer operated by a knob on the platform console. The creep indicator will light when in creep mode or blink in super creep mode. Circumstances that cause the machine to automatically enter creep/super creep mode include encroachment of the operating envelope limit main boom, platform leveling fault, throttle actuator fail-ure, stowed platform, software version faults, boom sensor failures, hydraulic warm-up mode, and hydraulic or electrical retrieval mode.

Step 3 Ground meter. Take the fol-lowing measurement by backprobing.

Turn on machine. Is there about 12 VDC on platform module J2 terminal 3 [X166.3]?

Yes Repair/replace harness between platform mod-ule J2 terminal 3 [X166.3] and platform passthru terminal 8 [X164.8]

No Replace platform module

Step 4 Locate platform passthru [X164]. Ground meter. Take the following reading by backprobing.

Turn on machine. Is there about 12 VDC on platform passthru terminal 7 [X164.7]?

Yes Go to step 5

No Repair/replace footswitch

Step 5 Disconnect platform passthru [X164] and plat-form module J7 [X169]

Is there continuity between platform passthru pin 7 [X164.7.pin] and platform module J7 socket 8 [X169.8.soc]?

Yes Go to step 6

No Repair/replace harness between platform passthru pin 7 [X164.7.pin] and platform module J7 socket 8 [X169.8.soc]

Step 6 Locate platform control box passthru - 19 pos [X160]. Ground meter. Take the fol-lowing reading by backprob-ing.

Turn on machine. Is there about 12 VDC on platform control box terminal 6 [X160.6]?

Yes Repair/replace footswitch

No Keep test setup in place.Go to step 7

Step 7 Locate platform control box passthru - 19 pos [X160]. Ground meter. Take the fol-lowing reading by backprob-ing.

Turn on machine. Depress footswitch. Is there about 12 VDC on platform control box terminal 6 [X160.6]?

Yes Go to step 8

No Repair/replace footswitch

Step 8 Disconnect ground module J7 [X007]. With a helper or an object, hold the foot-switch down. Ground the meter near the main terminal box. Take the following mea-surement by backprobing.

Turn on machine. Is there about 12 VDC on ground module J7 terminal 15 [X007.15]?

Yes Reprogram/replace platform module and/or ground module

No Go to step 9

Step 9 Disconnect ground module J7 [X007] and MTB passthru - 19 pos [X043]

Is there continuity between ground module J7 socket 15 [X007.15.soc] and MTB passthru pin 6 [X043.6.pin]?

Yes Repair/replace harness between MTB passthru socket 6 [X043.6.soc] and platform control box passthru - 19 pos socket 6 [X160.6.soc]

No Repair/replace harness between ground module J7 socket 15 [X007.15.soc] and MTB passthru pin 6 [X043.6.pin]

Note Pretest Instructions Test Result Corrective Action Step 1 Are any of the circumstances that cause creep

or super creep mode automatically present?Yes Clear any condition present

No Go to step 2

Step 2 Rotate function speed con-trol knob fully CCW until it clicks.

Is creep light on? Yes Go to step 7

No Go to step 3

Note Pretest Instructions Test Result Corrective Action

1-16 1200SJP 1350SJP 3128411


DTC 0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATIONRunning at creep - tilted and above elevation. All boom function speeds are limited to creep because the machine is tilted and above elevation. The machine is "Tilted" if the chassis is greater than 5.0 in any direction. If Tilt calibration has not been performed after the ground module or the main terminal box has been removed or replaced the machine will also indicate it

Step 3 Watch creep light while turning on machine from both the platform and the ground. Is creep light on for the lamp check?

Yes Go to step 4

No Replace LED light panel with light that is bad.

Step 4 Disconnect hyd speed pot passthru - 6 pos. [X199]. Ground meter. See Ground-ing on Pg. 245 for details. Turn on machine.

Is there about 12VDC at hyd speed pot passthru socket 3 [X199.3.soc]?

Yes Keep hyd speed pot passthru - 6 pos. [X199] dis-connected.Go to step 6

No Keep hyd speed pot passthru - 6 pos. [X199] dis-connected.Go to step 5

Step 5 Disconnect hyd speed pot passthru - 6 pos. [X199] and platform module J1 [X165]

Is there continuity between hyd speed pot passthru socket 3 [X199.3.soc] and platform module J1 socket 18 [X165.18.soc]?

Yes Replace platform module

No Replace/repair harness between hyd speed pot passthru socket 3 [X199.3.soc] and platform module J1 socket 18 [X165.18.soc]


Is there continuity between hyd speed pot passthru pin 2 [X199.2.pin] and platform module J1socket 32 [X165.32.soc]?

Yes Repair/replace hyd speed pot and/or harness [X199]

No Repair/replace harness between hyd speed pot passthru pin 2 [X199.2.pin] and platform module J1socket 32 [X165.32.soc]

Step 7 Turn on machine. Rotate function speed control knob CW 1/4 turn to 9 o’clock position.

Does creep light turn off? Yes Keep machine in same condition.Go to step 8

No Go to step 9

Step 8 Turn on machine. Rotate function speed control knob CW 1/4 turn to 9 o’clock position.

Does fault message clear? Yes Normal operation. Troubleshooting complete.


Step 9 Rotate function speed con-trol knob CW 1/4 turn to 9 o’clock position. Discon-nect hyd speed pot passthru - 6 pos. [X199].

Is there a short between hyd speed pot passthru socket 2 [X199.2.soc] and pin 3 [X199.3.pin]?

Yes Repair/replace function speed control and/or harness to hyd speed pot passthru - 6 pos. [X199]

No Go to step 10


Is there a short between platform module J1 socket 32 [X165.32.soc] and socket 18 [X165.18.soc]?

Yes Repair/replace harness between platform mod-ule J1 socket 32 [X165.32.soc] and socket 18 [X165.18.soc]

No Keep hyd speed pot passthru - 6 pos. [X199] dis-connected.Go to step 11

Step 11 Disconnect hyd speed pot passthru - 6 pos. [X199].Ground meter. Turn on machine.

Is there about 12 VDC on hyd speed pot passthru pin 2 [X199.2.pin]?

Yes Repair/replace harness between hyd speed pot passthru pin 2 [X199.2.pin]

No Reprogram/replace platform module


3128411 1200SJP 1350SJP 1-17


is tilted. The machine is "Above Elevation" if the boom is greater than +15.0 (default) from gravity. This resets at 10.0. Sen-sor failures can change these conditions..

DTC 0014 - CHASSIS TILT SENSOR OUT OF RANGEChassis tilt sensor out of range. Chassis tilt sensor has indicated a tilt angle greater than 19 for more than 4 seconds.

DTC 0015 - LOAD SENSOR READING UNDER WEIGHTLoad sensor reading under weight. The load sensor is reading 20% or more under the calibrated zero point. This fault may occur if the platform is resting on the ground. Not reported during the 2 second power-up.

DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDEDEnvelope encroached - hydraulics suspended. The system detected a violation of the safe operating area envelope. If plat-form is stuck in the air call JLG for help.

Note Pretest Instructions Test Result Corrective Action Step 1 Return machine to Trans-

port position and level ground

Is fault still active? Yes Go to step 2

No Troubleshooting complete

Step 2 Are there any boom sensor or Chassis tilt sen-sor faults?

Yes Troubleshoot those faults

No Go to step 3

Step 3 Return machine to Trans-port position and level ground. ANALYZER DIAGNOSTICS TRANS-PORT DATA

Does MAIN LIFT read STOWED? Yes Go to step 4

No Perform 5.9 Calibrating the Boom Sensors on Pg. 228

Step 4 Is the Tilt indicator on? Yes Perform 5.6 Calibrating Tilt Sensor on Pg. 221

No Repair/reprogram ground module

Note Pretest Instructions Test Result Corrective Action Step 1 Put machine on level surface Did fault clear? Yes Normal operation. Troubleshooting complete.

No Go to step 2

Step 2 Perform Tilt calibration. See 5.6 Calibrating Tilt Sensor on Pg. 221.

Did it calibrate successfully? Yes Troubleshooting complete

No Replace ground module

Note Pretest Instructions Test Result Corrective Action Step 1 Safely ensure platform is not

resting on anything.Does fault clear? Yes Troubleshooting complete

No Go to step 2

Step 2 Perform 5.9 Calibrating the Boom Sensors on Pg. 228.

Does calibration complete successfully? Yes Troubleshooting complete

No Troubleshoot according to calibration fault

Note Pretest Instructions Test Result Corrective Action Step 1 Is the platform stuck in the air? Yes Call JLG for help

No Go to step 2

Step 2 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228 for details.

Did calibration complete successfully? Yes Go to step 3


1-18 1200SJP 1350SJP 3128411


DTC 0017 - OVER MOMENT - HYDRAULICS SUSPENDEDOver moment - hydraulics suspended. Notification that the system has detected too much force applied to the moment pin, and suspended hydraulics to prevent further encroachment. While the boom is in over-moment violation, the system will pre-vent all jib, lift down, telescope out, drive, steer and swing functions until the over-moment violation clears. All remaining functions are limited to super creep. The BCS indicators are on continuously. The system will flash the BCS indicators and sound the platform alarm while the user commands a disallowed function. Use the APU to telescope in or lift up to return the platform to the ground. See DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.

DTC 0018 - UNDER MOMENT - HYDRAULICS SUSPENDEDUnder moment - hydraulics suspended. The system has detected too little force on the moment pin. If the engine is running, the system suspends all jib, lift up, telescope in, drive, steer and swing functions until the under-moment violation clears. In APU mode, the system suspends swing functions only, but flashes the BCS lamp and sounds the alarm during any com-mand of the jib, lift up, telescope in or swing functions. If the platform is stuck in the air call JLG for help.

DTC 0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDEDMain envelope encroached - hydraulics suspended. Notification that the system has detected a main envelope violation and suspended hydraulics to prevent further encroachment. Use the APU to telescope in or lift down inside the envelope. See DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.

DTC 0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDEDTower envelope encroached - hydraulics suspended. This fault does not occur on a properly configured 1200/1350 SJP. Ensure Machine Setup has proper model configured.

DTC 211 - POWER CYCLEPower cycle. Normal message that appears in DTC stack when power is turned off then on. DTC’s before a power cycle are active, i.e. they occured after power was turned on.

DTC 212 - KEYSWITCH FAULTYKeyswitch faulty. Both platform [X007.2] and ground [X007.3] modes are selected simultaneously. This could be due to a bad keyswitch [X030], wiring, or bad diodes at the power down relay [X011].

Step 3 Calibrate chassis tilt. See 5.6 Calibrating Tilt Sensor on Pg. 229 for details.

Did calibration complete successfully? Yes Troubleshooting complete


Note Pretest Instructions Test Result Corrective Action Step 1 Is the platform stuck in the air? Yes Call JLG for help

No Go to step 2

Step 2 Return boom to transport position

Does fault clear and not return repeatedly? Yes Troubleshooting complete

No Go to step 3

Step 3 Perform boom sensor cali-bration

Did calibration complete successfully? Yes Go to step 4


Step 4 Perform Chassis Tilt calibra-tion




3128411 1200SJP 1350SJP 1-19


DTC 213 - FSW FAULTYFootswitch faulty. The two footswitch inputs [X169.8 X007.15] have read the same state for more than one second. These signals should always be opposite. Check the footswitch and wiring for shorts or open circuits.

DTC 227 - STEER SWITCHES FAULTYSteer switches faulty. Notification that both left and right steer switch inputs [X168.5 X168.6] are active at the same time. This could be due to a faulty steer switch [X176] or wiring.

DTC 2211 - FSW INTERLOCK TRIPPEDFootswitch interlock tripped. Notification that the footswitch was closed for seven seconds with no function selected. Release the footswitch, close the footswitch again, then activate the desired function with seven seconds.

DTC 2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCHDrive locked - joystick moved before footswitch. Notification that drive was selected before and during footswitch signal [X007.15] closure. Can be reported during power-up sequence. Allow the joystick to return to neutral before activating the footswitch. This may also indicated a problem with the footswitch wiring.

DTC 2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCHSteer locked - selected before footswitch. Notification that one of the platform steer inputs [X168.5 X168.6] was selected before the footswitch was closed. Steering will be prevented. Close the footswitch before steering. This could also be due to a faulty steer switch [X176] or wiring.

DTC 2215 - D/S JOY. OUT OF RANGE LOWDrive/Steer joystick out of range low. The drive joystick input [X168.3] is below the working voltage range.

DTC 2216 - D/S JOY. OUT OF RANGE HIGHDrive/Steer joystick out of range high. The drive joystick input [X168.3] is above the working voltage range.

DTC 2217 - D/S JOY. CENTER TAP BADDrive/Steer joystick center tap bad. The drive joystick center tap input [X168.2] is not reading the correct voltage, +/- 10% from the reference voltage middle point.

DTC 2218 - L/S JOY. OUT OF RANGE LOWLift/Swing joystick out of range low. The lift and/or swing joystick input [X167.3 X167.4] is below the working voltage range.

DTC 2219 - L/S JOY. OUT OF RANGE HIGHLift/Swing joystick out of range high. The lift and/or swing joystick input [X167.3 X167.4] is above the working voltage range.

DTC 2220 - L/S JOY. CENTER TAP BADLift/Swing joystick center tap bad. The lift and/or swing joystick center tap inputs [X167.2 X167.5] are not reading the correct voltage, +/- 10% from the reference voltage middle point.

1-20 1200SJP 1350SJP 3128411


DTC 2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCHLift/swing locked - joystick moved before footswitch. Notification that the platform lift and/or swing joystick was not centered before the footswitch was closed. Lift and swing will be prevented. Close the footswitch before selecting any function or moving the joystick. This could also be due to faulty joystick not returning to center.

DTC 2222 - WAITING FOR FSW TO BE OPENWaiting for footswitch to be open. Notification that the platform footswitch input [X169.8] was open when the platform mode was selected. This indicates that the footswitch [X152] was engaged before platform power-on and may be blocked or stuck. This can also be reported during the power-up sequence. The footswitch or its wiring may be faulty.

DTC 2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLEPump switches locked - selected before footswitch. A platform boom function switch input (lower lift, telescope, platform level, platform rotate, jib) was selected before key switch or footswitch input [X169.8] closure. The footswitch must be acti-vated before any function. This may be caused by a problem with a switch or its wiring. Run ANALYZER SYSTEM TEST from the platform controls to find the specific switch.

DTC 2224 - FOOTSWITCH SELECTED BEFORE STARTFootswitch selected before start. Notification that the footswitch was selected before starting the machine. Release the foot-switch before starting the machine.

DTC 234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOMPump switches faulty - check diagnostics/boom. A ground control or platform control boom function switch (lower lift, tele-scope, platform level, platform rotate, jib, etc.) has both directions selected together. This may be caused by a problem with a switch or its wiring. Run ANALYZER SYSTEM TEST from the ground controls and platform controls to find the specific switch.

DTC 235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWERPump switches locked - selected before aux power. A ground function switch input (lower lift, telescope, platform level, plat-form rotate, jib) was selected before the ground auxiliary power switch input [X004.16]. The auxiliary power (enable) switch must be activated before the desired function switch. This also may be caused by a problem with a switch or its wiring. Run ANALYZER SYSTEM TEST from the ground controls to find the specific switch.

DTC 236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCHPump switches locked - selected before start switch. A ground control or platform control boom function switch (lower lift, telescope, platform level, platform rotate, jib, etc.) input was selected before the start switch input [X165.14 X004.4]. The start switch may only be activated when no function is commanded. This also may be caused by a problem with a switch or its wiring. Run ANALYZER SYSTEM TEST from the ground controls and platform controls to find the specific switch.

DTC 237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCHStart switch locked - selected before keyswitch. The start switch input [X004.4] was selected at startup. The engine start switch [X026] is likely stuck or the wiring is shorted.

DTC 259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMSModel changed - hydraulics suspended - cycle emergency stop switch. Notification that the model number was changed using the analyzer. The hydraulics will be suspended until the power is cycled.

3128411 1200SJP 1350SJP 1-21


DTC 2513 - GENERATOR MOTION CUTOUT ACTIVEGenerator motion cutout active. Notification that the generator motion cutout is configured and the machine is in platform mode with the generator active and a function was engaged. Do not engage functions while the generator is active or change the machine configuration.

DTC 2514 - BOOM PREVENTED - DRIVE SELECTEDBoom prevented - drive selected. Notification that ANALYZER MACHINE SETUP FUNCTION CUTOUT is set to BOOM CUTOUT and the machine is driving above elevation and a boom function is being attempted. Operate drive and boom sep-arately or change the machine setup.

DTC 2515 - DRIVE PREVENTED - BOOM SELECTEDDrive prevented - boom selected. Notification that drive was selected while a boom function was selected and drive cutout is configured to prevent simultaneous drive & boom operation.

DTC 2516 - DRIVE PREVENTED - ABOVE ELEVATIONDrive prevented - above elevation. Notification that drive was selected while above elevation and drive cutout is configured to prevent drive.

DTC 2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATIONDrive prevented - tilted & above elevation. Notification that drive was selected while tilted and above elevation and tilt is con-figured to cutout drive.

DTC 2521 - JIB SWING PREVENTED - IN 1000# MODEJib swing prevented - in 1000 pound mode. Notification that the machine is in 1000# mode and the jib swing function was engaged. Swinging the jib is not allowed in 1000# mode.

DTC 2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTEDCAN dongle attached - hydraulics not restricted. Notification the production dongle control tool is connected.

DTC 2523 - BACKUP BLAM COMMUNICATIONS ACTIVEBackup BLAM communications active. This fault should never occur on properly configured machines. Check model in MACHINE SETUP.

DTC 2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVALDisconnect analyzer and cycle EMS to perform boom retrieval. This fault should never occur on properly configured machines. Check model in MACHINE SETUP.

DTC 331 - BRAKE - SHORT TO BATTERYParking brake short to battery. The parking brake output [X001.23] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 332 - BRAKE - OPEN CIRCUITParking brake open circuit. The parking brake output [X001.23] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 113.

1-22 1200SJP 1350SJP 3128411


DTC 3311 - GROUND ALARM - SHORT TO BATTERYGround alarm short to battery. The ground alarm output [X002.27] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUNDRight forward drive pump short to ground. The right forward drive pump output [X087.1] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUITRight forward drive pump open circuit. The right forward drive pump output [X087.1] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERYRight forward drive pump short to battery. The right forward drive pump output [X087.1] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUNDRight reverse drive pump short to ground. The right reverse drive pump output [X087.12] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUITRight reverse drive pump open circuit. The right reverse drive pump output [X087.12] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERYRight reverse drive pump short to battery. The right reverse drive pump output [X087.12] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUNDLeft forward drive pump short to ground. The left forward drive pump output [X090.1] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUITLeft forward drive pump open circuit. The left forward drive pump output [X090.1] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERYLeft forward drive pump short to battery. The left forward drive pump output [X090.1] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUNDLeft reverse drive pump short to ground. The left reverse drive pump output [X090.2] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

3128411 1200SJP 1350SJP 1-23


DTC 3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUITLeft reverse drive pump open circuit. The left reverse drive pump output [X090.2] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERYLeft reverse drive pump short to battery. The left reverse drive pump output [X090.2] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3336 - ALTERNATOR/ECM POWER - SHORT TO GROUNDAlternator power short to ground. The alternator power output [X001.10] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3338 - ALTERNATOR POWER - OPEN CIRCUITAlternator power - open circuit. The alternator power output [X001.10] is shorted to ground. See common OC/STB .

DTC 3339 - ALTERNATOR POWER - SHORT TO BATTERYAlternator power short to ground. The alternator power output [X001.10] is shorted to ground. See common OC/STB.

DTC 3340 - AUX POWER - SHORT TO GROUNDAuxiliary power short to ground. The auxiliary power output [X001.13] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3341 - AUX POWER - OPEN CIRCUITAuxiliary power open circuit. There is an open circuit in the auxiliary power output [X001.13]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3342 - AUX POWER - SHORT TO BATTERYAuxiliary power short to battery. The auxiliary power output [X001.13] is shorted to battery voltage. See DTC 33xx - COM-MON STB OR OC PROCEDURE on Pg. 113.

DTC 3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUNDCold start advance solenoid short to ground. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.

DTC 3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUITCold start advance solenoid open circuit. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.

DTC 3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERYCold start advance solenoid short to battery. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.

DTC 3349 - ELECTRIC PUMP - SHORT TO GROUNDElectric pump short to ground. This fault should never occur on properly configured machines. Reload ground module soft-ware or replace the ground module.

1-24 1200SJP 1350SJP 3128411


DTC 3350 - ELECTRIC PUMP - OPEN CIRCUITElectric pump open circuit. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.

DTC 3351 - ELECTRIC PUMP - SHORT TO BATTERYElectric pump short to battery. This fault should never occur on properly configured machines. Reload ground module soft-ware or replace the ground module.

DTC 3358 - MAIN DUMP VALVE - SHORT TO GROUNDMain dump short to ground. The main dump output [X002.13] is shorted to ground. See DTC 33XX - COMMON STG PRO-CEDURE on Pg. 106.

DTC 3359 - MAIN DUMP VALVE - OPEN CIRCUITMain dump open circuit. The main dump output [X002.13] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3360 - MAIN DUMP VALVE - SHORT TO BATTERYMain dump short to battery. The main dump output [X002.13] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3361 - BRAKE - SHORT TO GROUNDParking brake short to ground. The parking brake output [X001.23] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3362 - START SOLENOID - SHORT TO GROUNDStart solenoid short to ground. The engine start solenoid output [X001.11] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3363 - START SOLENOID - OPEN CIRCUITStart solenoid open circuit. The engine start solenoid output [X001.11] is open. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 113.

DTC 3364 - START SOLENOID - SHORT TO BATTERYStart solenoid short to battery. The engine start solenoid output [X001.11] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3368 - TWO SPEED VALVE - SHORT TO GROUNDTwo speed short to ground. The two speed valve output [X001.20] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3369 - TWO SPEED VALVE - OPEN CIRCUITTwo speed open circuit. The two speed valve output [X001.20] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 113.

3128411 1200SJP 1350SJP 1-25


DTC 3370 - TWO SPEED VALVE - SHORT TO BATTERYTwo speed short to battery. The two speed valve output [X001.20] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3371 - GROUND ALARM - SHORT TO GROUNDGround alarm short to ground. The ground alarm output [X002.27] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 3372 - GROUND ALARM - OPEN CIRCUITGround alarm open circuit. The ground alarm output [X002.27] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 105.

DTC 3373 - GEN SET/WELDER - SHORT TO GROUNDGenerator set/welder short to ground. The output for the generator [X001.22] is shorted to ground. See DTC 33XX - COM-MON STG PROCEDURE on Pg. 106.

DTC 3374 - GEN SET/WELDER - OPEN CIRCUITGenerator set/welder open circuit. The output for the generator [X001.22] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3375 - GEN SET/WELDER - SHORT TO BATTERYGenerator set/welder short to battery. The output for the generator [X001.22] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3376 - HEAD TAIL LIGHT - SHORT TO GROUNDHead tail light short to ground. The head and tail light output [X002.26] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 3377 - HEAD TAIL LIGHT - OPEN CIRCUITHead tail light open circuit. The head and tail light output [X002.26] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 105.

DTC 3378 - HEAD TAIL LIGHT - SHORT TO BATTERYHead tail light short to battery. The head and tail light output [X002.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3379 - HOUR METER - SHORT TO GROUNDHour meter short to ground. The hourmeter output [X004.12] is shorted to ground. See DTC 33XX - COMMON STG PROCE-DURE on Pg. 106.

DTC 3380 - HOUR METER - OPEN CIRCUITHour meter open circuit. The hourmeter output [X004.12] has an open circuit. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 105.

1-26 1200SJP 1350SJP 3128411


DTC 3381 - HOUR METER - SHORT TO BATTERYHour meter short to battery. The hourmeter output [X004.12] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUNDPlatform up override short to ground. The ground module J2 platform level up override output [X002.5] is shorted to ground. If there are no open wires, the fault DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND on Pg. 35 should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUITPlatform up override open circuit. The ground module J2 platform level up override output [X002.5] is open. If the open is in or near the platform up solenoid [X136], the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERYPlatform up override short to battery. The ground module J2 platform level up override output [X002.5] is shorted to battery. If there are no open wires, the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUNDPlatform down override short to ground. The ground module J2 platform level down override output [X002.7] is shorted to ground. If there are no open wires, the fault DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND on Pg. 35 should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUITPlatform down override open circuit. The ground module J2 platform level down override output [X002.7] is open. If the open is in or near the platform down solenoid [X137], the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERYPlatform down override short to battery. The ground module J2 platform level down override output [X002.7] is shorted to battery. If there are no open wires, the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUNDPlatform left short to ground. The platform module J7 platform rotate left output [X169.5] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUITPlatform left open circuit. The platform module J7 platform rotate left output [X169.5] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERYPlatform left short to battery. The platform module J7 platform rotate left output [X169.5] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

3128411 1200SJP 1350SJP 1-27


DTC 3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUNDPlatform right short to ground. The platform module J7 platform rotate right output [X169.6] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUITPlatform right open circuit. The platform module J7 platform rotate right output [X169.6] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERYPlatform right short to battery. The platform module J7 platform rotate right output [X169.6] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33100 - JIB LIFT UP VALVE - SHORT TO GROUNDJib up short to ground. The jib up output [X169.25] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33101 - JIB LIFT UP VALVE - OPEN CIRCUITJib up open circuit. The jib up output [X169.25] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33102 - JIB LIFT UP VALVE - SHORT TO BATTERYJib up short to battery. The jib up output [X169.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 105.

DTC 33103 - JIB LIFT DOWN VALVE - SHORT TO GROUNDJib down short to ground. The jib down output [X169.26] is shorted to ground. See DTC 33XX - COMMON STG PROCE-DURE on Pg. 106.

DTC 33104 - JIB LIFT DOWN VALVE - OPEN CIRCUITJib down open circuit. The jib down output [X169.26] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERYJib down short to battery. The jib down output [X169.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 105.

DTC 33118 - SWING RIGHT VALVE - SHORT TO GROUNDSwing right valve short to ground. The swing right valve output [X002.35] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33119 - SWING RIGHT VALVE - OPEN CIRCUITSwing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 105.

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DTC 33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERYMain telescope in short to battery. The main telescope in output [X002.4] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33121 - SWING RIGHT VALVE - SHORT TO BATTERYSwing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCE-DURE on Pg. 105.

DTC 33122 - SWING LEFT VALVE - SHORT TO GROUNDSwing right valve short to ground. The swing right valve output [X002.34] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERYMain telescope out short to battery. The main telescope out output [X002.16] is shorted to battery. See DTC 33xx - COM-MON STB OR OC PROCEDURE on Pg. 105.

DTC 33130 - THROTTLE ACTUATOR - SHORT TO GROUNDThrottle actuator short to ground. This fault should only occur on machines configured with non-ECM engines. The engine throttle actuator output [X001.1] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 33131 - THROTTLE ACTUATOR - OPEN CIRCUITThrottle actuator open circuit. This fault should only occur on machines configured with non-ECM engines. The engine throt-tle actuator output [X001.1] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33132 - THROTTLE ACTUATOR - SHORT TO BATTERYThrottle actuator short to battery. This fault should only occur on machines configured with non-ECM engines. The engine throttle actuator output [X001.1] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33133 - PLATFORM CONTROL VALVE - SHORT TO GROUNDPlatform control valve short to ground. The platform dump valve output [X002.3] is shorted to ground. See DTC 33XX - COM-MON STG PROCEDURE on Pg. 114.

DTC 33134 - PLATFORM CONTROL VALVE - OPEN CIRCUITPlatform control valve open circuit. The platform dump valve output [X002.3] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERYPlatform control valve short to battery. The platform dump valve output [X002.3] is shorted to battery. See DTC 33xx - COM-MON STB OR OC PROCEDURE on Pg. 113.

DTC 33150 - LIFT PILOT VALVE - SHORT TO GROUNDLift Pilot Valve Short to Ground. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

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DTC 33151 - LIFT PILOT VALVE - OPEN CIRCUITLift Pilot Valve Open Circuit. The lift down auxiliary select valve output, ground module J2 -10 [X002.10], is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33152 - LIFT PILOT VALVE - SHORT TO BATTERYLift Pilot Valve Short to Battery. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to bat-tery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33153 - LIFT DOWN AUX VALVE - SHORT TO GROUNDLift Down Auxiliary Valve Short to Ground. The lift down auxiliary valve output, ground module J2 - 12 [X002.12] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33154 - LIFT DOWN AUX VALVE - OPEN CIRCUITLift Down Auxiliary Valve Open Circuit. The lift down output, ground module J2 - 12 [X002.12], is open. See DTC 33xx - COM-MON STB OR OC PROCEDURE on Pg. 105.

DTC 33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERYLift Down Auxiliary Valve Short to Battery. The lift down auxiliary valve output, ground module J2 - 12 [X002.12], is shorted to battery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

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

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

Note Pretest Instructions Test Result Corrective Action Step 1 Is the resistance of the axle lockout valve sole-

noid [X212] about 6.2Yes Go to step 2

No Replace the axle lockout valve solenoid

Step 2 Disconnect the axle lockout valve solenoid DIN connec-tor [X212]

Does the voltage between the positive battery terminal [X116] and terminal 2 of the Axle Lockout valve solenoid DIN connector [X212.2.soc] measure 12VDC?

Yes Go to step 10

No Go to step 3

Step 3 Does the voltage between the positive battery terminal [X116] and terminal 2 of the chassis module J4 connector [X232.2.pin] measure 12VDC?

Yes Repair/replace the black wire between terminal 2 of the axle lockout valve solenoid DIN connector [X212.2.soc] and terminal 2 of the chassis mod-ule J4 connector [X232.2.soc]

No Go to step 4

Step 4 Does the voltage between the positive battery terminal [X116] and terminal 4 of the chassis module J1 connector [X229.4] measure 12VDC?

Yes Replace the chassis module

No Go to step 5

Step 5 Does the voltage between the positive battery terminal [X116] and terminal 5 of the chassis (bottom) swivel connector [X216.5] measure 12VDC?

Yes Repair/Replace the black wire between terminal 5 of the chassis (bottom) swivel connector [X216.5] and terminal 4 of the chassis module J1 connector [X229.4]

No Go to step 6

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Step 6 Does the voltage between the positive battery terminal [X116] and terminal 5 of the Turntable (top) Swivel connector [X083.5] measure 12VDC?

Yes Replace the Collector Ring and swivel harness

No Go to step 7

Step 7 Does the voltage between the positive battery terminal [X116] and any terminal of the 12 position MTB ground buss connector [X009] measure 12VDC?

Yes Replace the valve harness

No Go to step 8

Step 8 Does the voltage between the positive battery terminal [X116] and terminal 3 of the ground module J8 connector [X008.3] measure 12VDC?

Yes Repair/Replace the Black wire between terminal 3 of the ground module J8 connector [X008.3] and the MTB ground buss connector [X009]

No Go to step 9

Step 9 Does the voltage between the positive battery terminal [X116] and terminal 1 of the ground module J8 connector [X008.1] measure 12VDC?

Yes Replace the ground module

No Repair/Replace the Black wire from the battery

Step 10 Disconnect the axle lockout valve solenoid DIN connec-tor [X212]

Does the voltage on terminal 1 of the axle lock-out valve solenoid DIN connector [X212.1.soc] measure 12VDC?

Yes Go to step 11

No Go to step 15

Step 11 Remove terminal 8 of the chassis (bottom) swivel connector [X216.8]


Yes Repair/replace the ORANGE 60-2 wire between terminal 1 of the axle lockout valve solenoid con-nector [212.1] and terminal 8 of the chassis (bot-tom) swivel connector [X216.8]

No Go to step 12

Step 12 Remove terminal 8 of the turntable (top) swivel con-nector [X083.8]


Yes Replace the collector ring and swivel harness

No Go to step 13

Step 13 Remove terminal 4 of the 6 position BLAM-Valve har-ness passthru connector [X280.4]


Yes Repair/Replace the ORANGE 60-1 wire between terminal 4 of the 12 position BLAM-Valve harness passthru connector [X280.4] and terminal 8 of the Turntable (top) swivel connector [X083.8]

No Go to step 14

Step 14 Remove terminal 3 of the BLAM module J5 connector [X090.3]


Yes Repair/Replace the ORANGE 60-1 wire between terminal 3 of the BLAM module J5 connector [X090.3] and terminal 4 of the 12 position BLAM-Valve harness passthru connector [X280.4]

No Replace the BLAM module

Step 15 Remove terminal 8 of the chassis (bottom) swivel connector [X216.8] and dis-connect the axle lockout valve solenoid DIN connec-tor [X212]

Is there continuity between terminal 8 of the chassis (bottom) swivel connector [X216.8.pin] and terminal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]?

Yes Go to step 16

No Repair/replace the ORANGE 60-2 wire between terminal 1 of the axle lockout valve solenoid con-nector [212.1] and terminal 8 of the chassis (bot-tom) swivel connector [X216.8]

Step 16 Remove terminal 8 of the Turntable (top) swivel con-nector [X083.8] and discon-nect the axle lockout valve solenoid DIN connector [X212]

Is there continuity between terminal 8 of the Turntable (top) swivel connector [X083.8] and terminal 1 of the axle lockout valve sole-noid DIN connector [X212.1.soc]?

Yes Go to step 17

No Replace the Collector Ring and swivel harness


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DTC 33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUITRestricted to transport - parking brake short to battery. The parking brake output [X001.23] is shorted to battery so the boom cannot go above the transport position. See DTC 331 - BRAKE - SHORT TO BATTERY on Pg. 22.

DTC 33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUITJib left open circuit. The jib swing left output [X169.28] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERYJib left short to battery. The jib swing left output [X169.28] is shorted to battery. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 105.

DTC 33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUNDJib left short to ground. The jib swing left output [X169.28] is shorted to ground. See DTC 33XX - COMMON STG PROCE-DURE on Pg. 106.

DTC 33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUITJib right open circuit. The jib swing right output [X169.27] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERYJib right short to battery. The jib swing right output [X169.27] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUNDJib right short to ground. The jib swing right output [X169.27] is shorted to ground. See DTC 33XX - COMMON STG PROCE-DURE on Pg. 106.

DTC 33181 - MAIN LIFT UP VALVE - OPEN CIRCUITMain cylinder lift up open circuit. The main boom cylinder lift up output [X002-11] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

Step 17 Remove terminal 4 of the 6 position BLAM-Valve har-ness passthru connector [X280.4] and disconnect the axle lockout valve solenoid DIN connector [X212]

Is there continuity between terminal 4 of the 6 position BLAM-Valve harness passthru con-nector [X280.4] and disconnect the axle lock-out valve solenoid DIN connector [X212] and terminal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]?

Yes Go to step 18

No Repair/Replace the ORANGE 60-1 wire between terminal 4 of the 12 position BLAM-Valve harness passthru connector [X280.4] and terminal 8 of the Turntable (top) swivel connector [X083.8]

Step 18 Remove terminal 3 of the BLAM module J5 connector [X090.3] and disconnect the axle lockout valve solenoid DIN connector [X212]

Is there continuity between terminal 3 of the BLAM module J5 connector [X090.3] and ter-minal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]?

Yes Replace the BLAM module

No Repair/Replace the ORANGE 60-1 wire between terminal 3 of the BLAM module J5 connector [X090.3] and terminal 4 of the 6 position BLAM-Valve harness passthru connector [X280.4]


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DTC 33183 - MAIN LIFT UP VALVE - SHORT TO GROUNDMain cylinder lift up valve - short to ground. The main boom cylinder lift up output [X002-11] is shorted to battery (-) terminal/ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUITMain cylinder lift down open circuit. The main boom cylinder lift down output [X002.22] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUNDMain cylinder lift down short to ground. The main boom cylinder lift down output [X002.22] is shorted to battery (-) terminal/ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUITMain telescope out open circuit. The main telescope out output [X002.16] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUNDMain telescope out short to ground. The main telescope out output [X002.16] is shorted to ground. See DTC 33XX - COM-MON STG PROCEDURE on Pg. 106.

DTC 33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUITMain telescope in open circuit. The main telescope in output [X002.4] is open. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 105.f

DTC 33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUNDMain telescope in short to ground. The main telescope in output [X002.4] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33207 - HORN - OPEN CIRCUITHorn open circuit. The ground module horn output [X002.2] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33208 - HORN - SHORT TO BATTERYHorn short to battery. The ground module horn output [X002.2] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33209 - HORN - SHORT TO GROUNDHorn short to ground. The ground module horn output [X002.2] is shorted to ground. See DTC 33XX - COMMON STG PRO-CEDURE on Pg. 106.

DTC 33279 - GLOWPLUG - OPEN CIRCUITGlow plug open circuit. The glow plug / intake heater output [X001.12] is open. See DTC 33xx - COMMON STB OR OC PRO-CEDURE on Pg. 105.

3128411 1200SJP 1350SJP 1-33


DTC 33280 - GLOWPLUG - SHORT TO BATTERYGlow plug short to battery. The glow plug / intake heater output [X001.12] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33281 - GLOWPLUG - SHORT TO GROUNDGlow plug short to ground. The glow plug / intake heater output [X001.12] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33295 - SWING LEFT VALVE - OPEN CIRCUITSwing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33306 - SWING LEFT VALVE - SHORT TO BATTERYSwing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUNDMain cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control flow control output [X002.9] is open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUITMain cylinder telescope flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERYMain cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERYMain cylinder lift down short to battery. The main boom cylinder lift down output [X002.22] is shorted to battery (+) terminal. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUNDMain cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUITMain cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERYMain cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

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DTC 33329 - MAIN LIFT UP VALVE - SHORT TO BATTERYMain cylinder lift up short to battery. The main boom cylinder lift up output [X002-11] is shorted to battery (+) terminal. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.

DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUNDPlatform up short to ground. The platform module J7 platform level up output [X169.15] is shorted to ground. If there are no open wires, the fault DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND on Pg. 27 should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUITPlatform up short to battery or open circuit. The platform module J7 platform level up output [X169.15] is shorted to battery or open. If there are no open wires, the fault DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY on Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUNDPlatform down short to ground. The platform module J7 platform level down output [X169.16] is shorted to ground. If there are no open wires, the fault DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND on Pg. 27 should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUITPlatform down short to battery or open circuit. The platform module J7 platform level down output [X169.16] is shorted to battery or open. If there are no open wires, the fault DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY on Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 431 - FUEL SENSOR SHORT TO BATTERYFuel sensor short to battery. Indicates that the fuel sensor signal [X002.25] may be shorted to battery. See DTC 33xx - COM-MON STB OR OC PROCEDURE on Pg. 105.

DTC 432 - FUEL SENSOR SHORT TO GROUNDFuel sensor short to ground. Indicates that the fuel sensor signal [X002.25] may be shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.

DTC 433 - OIL PRESSURE SHORT TO BATTERYOil pressure short to battery. This fault should only occur on machines configured with non-ECM engines. The engine oil pressure input [X001.15] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 434 - OIL PRESSURE SHORT TO GROUNDOil pressure short to ground. This fault should only occur on machines configured with non-ECM engines. The engine oil pressure input [X001.15] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 435 - COOLANT TEMPERATURE SHORT TO GROUNDCoolant temperature short to ground. This fault is only active for machines configured with older non-ECM Deutz engines. The engine coolant temperature input [X001.14] is shorted to ground.

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DTC 437 - ENGINE TROUBLE CODEEngine trouble code. This fault text is followed by the engine’s specific fault code. This code could represent engine faults like low oil pressure warning, high coolant temperature warning, etc. See Table 1-1. Common Deutz Engine Fault Codes on Pg. 36 or consult the engine control module manual to interpret the engine specific fault code.

Table 1-1. Common Deutz Engine Fault Codes

Fault Code using JLG Analyzer

Fault Code using Deutz SERDIA

Fault Description Cause ResultsTroubleshooting

EngineTroubleshooting

Machine

190:8 1 Speed sensor Engine speed sen-sor failure OR Gap from sensor tip to ring gear too large OR Additional incorrect impulses received OR Wiring to sensor inter-rupted.

Loss of engine speed signal will cause the engine to shut down or not start.

Check distance from sensor to ring gear. Check for contamination on sensor end. Check wiring connection. Check sensor located at flywheel housing and replace if required.

100:2 8 Oil Pressure Fault at corre-sponding sensor OR wiring connec-tion has a short cir-cuit or open circuit.

The engine will con-tinue operating with the failure of either Oil Pressure or Coolant Tempera-ture sensors. How-ever with a failure of the sensor, the associated moni-toring function is de-activated

Check relevant sen-sor replace if required. Check rel-evant wiring and connections between sensor and ECU.

110:2 9 Coolant tempera-ture

100:1 30 Oil Pressure warn-ing

Engine Oil Pressure has fallen below acceptable value.

Fault message occurs. Engine may also shutdown depending on JLG Machine program-ming

Check engine oil level. Check oil pressure sensor and wiring. Check engine for other possible mechani-cal causes. The engine has a 12 second monitoring delay on startup, so proceed carefully not to cause further low oil pressure damage to engine on repeated start attempts

Depending on Machine Program-ming the engine will either Shutdown OR only give a warning

110:0 31 Coolant Tempera-ture warning

Engine Oil Temper-ature has exceeded acceptable value.

Fault message occurs. Engine may also shutdown depending on JLG Machine program-ming. Fault will dis-appear when Oil Temperature drops below preset recov-ery temperature.

Check engine oil level. Check Oil temperature sen-sor and wiring. Check cooling sys-tem for leaks or contamination, etc.

Depending on Machine Program-ming the engine will either Shutdown OR only give a warning

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702:14 35 Overspeed warning (with thrust mode operation).

Engine RPM was or is above maximum allowed RPM limit limit. "Thrust mode" function is active

If engine exceeds maximum RPM set point (3300 RPM) the fuel rack is set to zero position until engine speed returns below acceptable recov-ery speed (2810 RPM).

If condition per-sists: Check fuel rack. Check actua-tor and replace if required. Check wiring to actuator. Check engine speed sensor, ring gear teeth, etc.

Check for external environmental con-ditions that could cause engine over-speed condition

100:1 40 Oil pressure switch off

Oil pressure below switch-off limit.

Normally this would cause an Emer-gency stop of the engine. But EMR is not programmed to directly shutdown the engine in JLG machines. Only if the JLG machine is programmed to shutdown will this occur

See Oil Pressure Warning info

110:0 41 Coolant tempera-ture switch-off

Oil temperature has exceeded switch off limit

Normally this would cause an Emer-gency stop of the engine. But EMR is not programmed to directly shutdown the engine in JLG machines. Only if the JLG machine is programmed to shutdown will this occur

See Coolant Tem-perature Warning info

91:11 67 Error Hand Setp1 Loss of CAN bus input.

Engine will only run at constant speed of 1835 RPM

Check CAN con-nection and wiring connection entering engine ECU from machine. Check ECU for proper CAN bus data flow and correct program-ming.

Check relevant wir-ing and connec-tions between machine and ECU for open or short circuit. Check Ter-minating resistor in machine wiring

898:2 68 Error CAN Setp1

743:12 70 CAN-Bus controller Controller for CAN-bus is faulty. Fault removal despite reinitializing contin-uously not possi-ble.

Engine will shut-down or not restart OR Engine will only run at constant speed of 1835 RPM

743:9 71 CAN interface SAE J 1939

Overflow in input buffer or a trans-mission cannot be placed on the bus.

743:14 74 CAN Passive error Open or Short cir-cuit in wiring

Engine will shut-down or not restart OR engine will only run at constant speed of 1835 RPM

Check CAN con-nection and wiring connection entering engine ECU from machine.

Table 1-1. Common Deutz Engine Fault Codes

Fault Code using JLG Analyzer

Fault Code using Deutz SERDIA

Fault Description Cause ResultsTroubleshooting

EngineTroubleshooting

Machine

3128411 1200SJP 1350SJP 1-37


DTC 438 - HIGH ENGINE TEMPHigh engine temperature. This fault should only occur on machines configured with non-ECM engines. The engine tempera-ture is above 130°C.

DTC 439 - AIR FILTER BYPASSEDAir filter bypassed. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.

DTC 4310 - NO ALTERNATOR OUTPUTNo alternator output. Notification that the engine has been running for 15 seconds or more and the battery voltage is still below 11.5 volts. This probably indicates a problem with the alternator or its wiring.

DTC 4311 - LOW OIL PRESSURELow oil pressure. This fault should only occur on machines configured with non-ECM engines. Notification that the oil pres-sure input [X001.15] is below 8 PSI and the engine has been running for at least 10 seconds.

DTC 4313 - THROTTLE ACTUATOR FAILUREThrottle actuator failure. This fault should only occur on machines configured with non-ECM engines. The engine is over-speeding, reading over 3050 RPM. This probably indicates the throttle actuator has failed.

DTC 4314 - WRONG ENGINE SELECTED - ECM DETECTEDWrong engine selected - ECM present. The machine is configured to be a non-ECM engine, but an ECM signal is detected on the CAN bus. Change the machine engine configuration.

DTC 4322 - LOSS OF ENGINE SPEED SENSORSpeed input lost. This fault should only occur on machines configured with non-ECM engines. Notification that there is no engine speed detected on the engine flywheel speed sensor input [X001.16], but the oil pressure input [X001.15] reads above 8 PSI for more than 3 seconds.

DTC 4323 - SPEED SENSOR READING INVALID SPEEDSpeed sensor reading invalid speed. This fault should only occur on machines configured with non-ECM engines. Notifica-tion that the engine flywheel speed sensor input [X001.16] is indicating a speed that greater than 4000 RPM or approxi-mately 8875 Hz.

DTC 441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWNBattery too low - system shut down. A warning that the voltage at ground module J8 [X008.2] is below 9 volts. The system will shut down after about 5 seconds. Remove any corrosion on battery terminals and battery cable terminals. Recharge or replace battery.

DTC 442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWNBattery too high - system shut down. The voltage at ground module J8 [X008.2] is above 18.6 volts. The system will shut down. Check battery and battery connections or replace battery.

DTC 445 - BATTERY VOLTAGE LOWBattery voltage is too low. A warning that the voltage at ground module J8 [X008.2] is below 11 volts. Remove any corrosion on battery terminals and battery cable terminals. Recharge or replace battery. Check battery charging system.

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DTC 662 - CANBUS FAILURE - PLATFORM MODULEPlatform CAN communications lost. The system cannot communicate with the platform module. This may be due to wiring problems between platform and ground modules.

DTC 666 - CANBUS FAILURE - ENGINE CONTROLLEREngine controller CAN communications lost. The ground module is not receiving CAN messages from the engine controller.

Note Pretest Instructions Test Result Corrective Action Step 1 Check fault log for other

modules having lost com-munication

Have most modules lost communications? Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS on Pg. 55

No Go to step 2

Step 2 Disconnect the platform module J8 connector [X170]. Turn machine on in platform mode

Is there 11VDC or more between platform module J8 socket 2 [X170.2.soc] and socket 1 [ X170.1.soc]?

Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS on Pg. 55 fault step 3

No Keep machine on. Go to step 3

Step 3 Disconnect the platform module J8 connector [X170]. Turn machine on in platform mode

Is there zero VDC between platform module J8 connector socket 1 [X170.1.soc] and socket 2 [X170.2.soc]?

Yes Keep machine on. Go to step 5

No Go to step 4

Step 4 Remove any corrosion on battery terminals and battery cable terminals. Run machine to recharge bat-tery.

Does battery still exhibit low power? Yes Replace battery

No Retry normal vehicle operation

Step 5 Turn machine on in platform mode. Backprobe to take the following measurement. See Backprobing on Pg. 245 for details.

Is there 11VDC or more between the 19 posi-tion platform control box passthru connector terminal 12 [X160.12] and terminal 16 [X160.16]?

Yes Repair/replace harness between the 19 position platform control box passthru connector [X160] and the platform module J8 connector [X170]

No Go to step 6

Step 6 Take the following measure-ment by backprobing

Turn machine on in platform mode. Is there 11VDC or more between MTB pass thru - 19 position connector pin 12 [X043.12.pin] and pin 16 [X043.16.pin]?

Yes Repair/replace harness between the MTB pass thru - 19 position connector [X043] and the plat-form control box passthru - 19 position connec-tor [X160]

No Go to step 7

Step 7 Take the following measure-ment by backprobing

Turn machine on in platform mode. Is there 11VDC or more between ground module J8 connector pin 3 [ X008.3] and pin 4 [X008.4]?

Yes Repair/replace harness between the ground module J8 connector [X008] and the MTB pass thru - 19 position connector [X043]

No Go to step 8

Step 8 Disconnect the ground module J8 connector [X008]. Turn machine on in platform mode

Is there 11VDC or more between ground mod-ule J8 connector pin 3 [X008.3] and pin 4 [X008.4]?

Yes Repair/replace harness between the ground module J8 connector [X008] and the MTB pass thru - 19 position connector [X043]

No Replace the ground module

Note Pretest Instructions Test Result Corrective Action Step 1 Is the 6613 - CANBUS FAILURE - EXCESSIVE

CANBUS ERRORS fault active in the fault log?Yes Troubleshoot DTC 6613 - CANBUS FAILURE -

EXCESSIVE CANBUS ERRORS on Pg. 55 first

No Go to step 2

Step 2 Does the BLAM software version show "??" in ANALYZER DIAGNOSTICS VERSIONS B.L.A. MODULE SOFTWARE:?

Yes See DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48

No Go to step 3

3128411 1200SJP 1350SJP 1-39


DTC 6610 - CANBUS FAILURE - BLAMBLAM CAN communications lost. The system cannot communicate with the Boom Length Angle Module (BLAM). This may be due to wiring problems between the platform and chassis modules. If power is lost to the BLAM, then power will not be provided to the cylinder load pin and the 6612 - CANBUS FAILURE - CYLINDER LOAD PIN fault will also be active.

Step 3 Disconnect the EMR2 ECU equipment connector [X240]. Turn on the machine.

Does the voltage between EMR2 ECU equip-ment connector socket 14 [X240.14.soc] and socket 1 [X240.1.soc] measure 12VDC?

Yes Go to step 5

No Go to step 4

Step 4 Backprobe between any ter-minal of the MTB power bus connector [X010] and the ground module J1 connec-tor terminal 8 [X001.8]. See Backprobing on Pg. 245 for details.

Does the voltage between any terminal of the MTB power bus connector [X010] and the ground module J1 connector terminal 8 [X001.8] measure 12VDC?

Yes Repair the YEL/RED 2-1-99 wire between the MTB power bus connector [X010] and the EMR2 ECU equipment connector terminal 14 [X240.14] and/or the black wire between of the EMR2 ECU equipment connector terminal 1 [X240.1] and the ground module J1 connector terminal 8 [X001.8]

No Check the connections, make sure the machine is turned on, and return to step 3. If the problem per-sists, replace the ground module

Step 5 Backprobe EMR2 ECU equipment connector termi-nal 12 [X240.12] and termi-nal 13 [X240.13]

Does the CAN resistance between EMR2 ECU equipment connector terminal 12 [X240.12] and terminal 13 [X240.13] measure 60?

Yes Go to step 6

No See DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48

Step 6 Disconnect the EMR2 ECU equipment connector [X240] and the BLAM mod-ule J4 connector [X089]. See 6.3 Continuity Measure-ment Over Long Distances on Pg. 247.

Is there CAN HI continuity between socket 12 of the EMR2 ECU equipment connector [X240.12.soc] and socket 3 of the BLAM module J4 connector [X089.3.soc] and CAN LO continuity between socket 13 of the EMR2 ECU equipment connector [X240.13.soc] and socket 4 of the BLAM module J4 connector [X089.4.soc]?

Yes Call Deutz dealer

No Go to step 7

Step 7 Disconnect the EMR2 ECU equipment connector [X240] and the CAN pass thru for EMR2 - 3 position connector [X268]. See 6.3 Continuity Measurement Over Long Distances on Pg. 247.

Is there CAN HI continuity between socket 12 of the EMR2 ECU equipment connector [X240.12.soc] and pin A of the CAN pass thru for EMR2 - 3 position connector [X268.A.pin] and CAN LO continuity between socket 13 of the EMR2 ECU equipment connector [X240.13.soc] and pin B of the CAN pass thru for EMR2 - 3 position connector [X268.B.pin]?

Yes Replace the valve harness between the BLAM module J4 connector [X089] and the CAN pass thru for EMR2 - 3 position connector [X268]

No Check the RED and BLACK wires between the EMR2 ECU equipment connector [X240.12 X240.13] and the CAN pass thru for EMR2 - 3 position connector [X268.A X268.B]

Note Pretest Instructions Test Result Corrective Action Step 1 Check the fault log for other

modules having lost com-munication (6-6 codes)

Is CYLINDER LOAD PIN CAN COMMUNICA-TIONS LOST fault active?

Yes Go to step 2

No Go to 5

Step 2 Disconnect BLAM J1 [X086] connector

Does the voltage between socket 5 [X086.5] and 4 [X086.4] measure 12 VDC?

Yes Keep BLAM J1 [X086] connector disconnected.Go to step 5.

No Go to step 3

Step 3 Disconnect Valve Passthru [X280]

Does the voltage between Valve Passthru socket 1 [X280.1.soc] and socket 6 [X280.6.soc] measure 12 VDC?

Yes Repair wire(s) between Valve Passthru [X280] and BLAM J1 [X086]

No Go to step 4


1-40 1200SJP 1350SJP 3128411


Step 4 Disconnect MTB Power Bus [X010]

Does the voltage between one of the sockets of the MTB Power Bus[X010] and Ground Module J8 terminal 3 [X008.3] measure 12 VDC?

Yes Repair wire(s) between MTB Power Bus[X010] and Valve Passthru socket 1 [X280.1.soc] and/or Ground Module J8 terminal 3 [X008.3] and Valve Passthru socket 6 [X280.6.soc].

No Repair 2-70 wire between MTB Power bus [X010] and Power Down Relay [X011].

Step 5 Disconnect BLAM J1 [X086] connector

Does the resistance between BLAM J1 socket 6 [X086.6.soc] and socket 7 [X086.7.soc] measure 60? -AND- Is there an open circuit between socket 6 [X086.6.soc] and shield [X086.8]. -AND- Is there an open circuit between socket 7 [X086.7.soc] and shield [X086.8]?

Yes Keep BLAM J1 [X086] connector disconnected.Go to step Figure 6

No Go to step 11

Step 6 Disconnect BLAM J1 [X086] connector and Ground Module J7 [X007]

Is there continuity only between the following points?• BLAM J1 socket 6 [X086.6.soc] and

G r o u n d M o d u l e J 7 s o c k e t 1 3[X007.13.soc]

• BLAM J1 socket 7 [X086.7.soc] andG r o u n d M o d u l e J 7 s o c k e t 2 4[X007.24.soc]

• BLAM J1 socket 8 [X086.8.soc] andG r o u n d M o d u l e J 7 s o c k e t 1 8[X007.18.soc]

Yes Ensure BLAM and Ground Module are running proper version. Replace BLAM

No Keep Ground Module J7 [X007] disconnected.Go to step 7

Step 7 Disconnect CAN 3-Way to BLAM [X269] and Ground Module J7 [X008]

Is there continuity only between the following points?• CAN 3-Way to BLAM pin A [X269.A.pin]

and Ground Modu le J7 socke t 13[X007.13.soc]

• CAN 3-Way to BLAM pin B [X269.B.pin]and Ground Modu le J7 socke t 24[X007.24.soc]

• CAN 3-Way to BLAM pin C [X269.C.pin]and Ground Modu le J7 socke t 18[X007.18.soc]

Yes Keep CAN 3-Way to BLAM [X269] disconnected.Go to step 8

No Keep BLAM J1 [X086] disconnected. Go to step 10

Step 8 Disconnect CAN 3-Way to BLAM [X269] and CAN Passthru for EMR2 [X268]

Is there continuity only between the following points?• CAN 3-Way socket A [X269.A.soc] and

CAN Pass th r u fo r EMR2 socke t A[X268.A.soc]

• CAN 3-Way socket B [X269.B.soc] andCAN Pass th r u fo r EMR2 socke t B[X268.B.soc]

• CAN 3-Way socket C [X269.C.soc] andCAN Pass th r u fo r EMR2 socke t C[X268.C.soc]

Yes Go to step 9

No Repair wire(s) between CAN 3-Way to BLAM [X269] and CAN Passthru for EMR2 [X278]


3128411 1200SJP 1350SJP 1-41


Step 9 Disconnect CAN Passthru to BLAM [X278] and BLAM J1 [X086]

Is there continuity only between the following points?• BLAM J1 socket 6 [X086.6.soc] and CAN

Passthru to BLAM socket A [X278.A.soc]• BLAM J1 socket 7 [X086.7.soc] and CAN

Passthru to BLAM socket B [X278.B.soc]• BLAM J1 socket 8 [X086.8.soc] and CAN

Passthru to BLAM socket C [X278.C.soc]

Yes Replace CAN 3-way connected to CAN Passthru to BLAM [X278]

No Repair failing wire(s) between CAN Passthru to BLAM [X278] BLAM J1 [X086]

Step 10 Disconnect CAN 3way - to Ground Module [X014]and Ground Module J7 [X007]

Is there continuity only between the following points?• CAN 3-Way to Ground Module pin A

[X014.A.pin] and Ground Module J7socket 13 [X007.13.soc]

• CAN 3-Way to Ground Module pin B[X014.B.pin] and Ground Module J7socket 24 [X007.24.soc]

• CAN 3-Way to Ground Module pin C[X014.C.pin] and Ground Module J7socket 18 [X007.18.soc]

Yes Replace CAN 3-way connected to CAN 3way - to Ground Module [X014]

No Repair failed wire(s) between CAN 3way - to Ground Module [X014]and Ground Module J7 [X008]

Step 11 Disconnect CAN Passthru for EMR2 [X268]

Does the resistance between CAN Passthru for EMR2 socket A [X268.A.soc] and socket B [X268.B.soc] measure 120? -AND- Is there an open circuit between CAN Passthru for EMR2 socket A [X268.A.soc] and shield socket C [X268.C.soc]. -AND- Is there an open circuit between CAN Passthru for EMR2 socket B [X268.B.soc] and shield socket C [X268.C.soc]?

Yes Go to step 14

No Go to step 12

Step 12 Disconnect CAN 3way - to Platform [X270]

Does the resistance between CAN 3way - to Platform socket A [X270.A.soc] and socket B [X270.B.soc] measure 120? -AND- Is there an open circuit between CAN 3way - to Plat-form socket A [X270.A.soc] and shield socket C [X270.C.soc]. -AND- Is there an open circuit between CAN 3way - to Platform socket B [X270.B.soc] and shield socket C [X270.C.soc]?

Yes Go to step 13

No Go to step 20

Step 13 Is the software in the BLAM and Ground Mod-ule the proper version?

Yes Replace BLAM

No Load proper software

Step 14 Disconnect CAN Passthru to Engine Harness [X279]

Does the resistance between CAN Passthru to Engine Harness socket A [X279.A.soc] and socket B [X279.B.soc] measure 120? -AND- Is there an open circuit between CAN Passthru to Engine Harness socket A [X279.A.soc] and shield socket C [X279.C.soc]. -AND- Is there an open circuit between CAN Passthru to Engine Harness socket B [X279.B.soc] and shield socket C [X279.C.soc]?

Yes Repair wire(s) between CAN Passthru to Engine Harness [X279] CAN T-connector and BLAM J1 [X086]

No Go to step 15


1-42 1200SJP 1350SJP 3128411


Step 15 Disconnect Swivel Top con-nector [X083]

Does the resistance between Swivel Top con-nector pin 1 [X083.1.pin] and pin 2 [X083.2.pin] measure 120? -AND- Is there an open circuit between Swivel Top connector pin 1 [X083.1.pin] and pin 3 [X083.3.pin]? -AND- Is there an open circuit between Swivel Top connector pin 2 [X083.2.pin] and pin 3 [X083.3.pin]?

Yes Go to step 18

No Go to step Figure 16

Step 16 Disconnect Swivel Chassis connector [X216]

Does the resistance between Swivel Chassis connector pin 1 [X216.1.pin] and pin 2 [X216.2.pin] measure 120? -AND- Is there an open circuit between Swivel Chassis con-nector pin 1 [X216.1.pin] and pin 3 [X216.3.pin]? -AND- Is there an open circuit between Swivel Chassis connector pin 2 [X216.2.pin] and pin 3 [X216.3.pin]?

Yes Repair failed wire(s) and/or slip rings between Swivel Top connector [X083] and Swivel Chassis connector [X216]

No Keep Swivel Chassis connector [X216] discon-nected.Go to step 17.

Step 17 Disconnect Chassis Module J1 [X229] and Swivel Chas-sis connector [X216]

Is there continuity only between the following points?• Chassis Module J1 socket 6 [X229.6.soc]

and Swivel Chassis connector pin1[X216.1.pin]

• Chassis Module J1 socket 7 [X229.7.soc]and Swivel Chassis connector pin 2[X216.2.pin]

• Chassis Module J1 socket 8 [X229.8.soc]and Swivel Chassis connector pin 3[X216.3.pin]

• Chassis Module J1 socket 9 [X229.9.soc]and Chass is Module J1 socket 10[X229.10.soc]

Yes Replace Chassis Module

No Repair failed wire(s) between Chassis Module J1 [X229] and Swivel Chassis connector [X216]

Step 18 Disconnect Deutz EMR2 Chassis CAN connector [X084]

Does the resistance between Deutz EMR2 Chassis CAN connector [X084] pin A [X084.A.pin] and pin B [X084.B.pin] measure 120? -AND- Is there an open circuit between Deutz EMR2 Chassis CAN connector pin A [X084.A.pin] and pin C [X084.C.pin]? -AND- Is there an open circuit between Deutz EMR2 Chassis CAN connector pin B [X084.B.pin] and pin C [X084.C.pin]?

Yes Go to step 19

No Repair failed wire(s) between Swivel Top con-nector [X083] and Deutz EMR2 Chassis CAN connector [X084]

Step 19 Disconnect EMR2 ECU Equipment Connector [X240] and CAN Passthru to Engine Harness [X279].

Does the resistance between EMR2 ECU Equipment Connector socket 12 [X240.12.soc] and socket 13 [X240.13.pin] measure 120? -AND- Is there an open cir-cuit between the shield and both EMR2 ECU Equipment Connector socket 12 [X240.12.soc] and socket 13 [X240.13.pin]?

Yes Repair failed wire(s) between EMR2 ECU Equip-ment Connector [X240] and CAN Passthru to Engine Harness [X279]

No Repair failed wire(s) between EMR2 ECU Equip-ment Connector [X240] and Deutz EMR2 Chassis CAN connector [X084]


3128411 1200SJP 1350SJP 1-43


DTC 6611 - CANBUS FAILURE - CHASSIS MODULEChassis CAN communications lost. The system cannot communicate with the chassis module. This may be due to wiring problems between the chassis and ground module.

Step 20 Disconnect Platform Control Box Passthru [X160]

Does the resistance between Platform Control Box Passthru connector pin 2 [X160.2.pin] and pin 3 [X083.3.pin] measure 120? -AND- Is there an open circuit between Plat-form Control Box Passthru connector pin 1 [X160.1.pin] and pin 2 [X160.2.pin]? -AND- Is there an open circuit between Platform Con-trol Box Passthru connector pin 1 [X160.1.pin] and pin 3 [X160.3.pin]?

Yes Go to step 21

No Keep Platform Control Box Passthru [X160] dis-connected.Go to step 22

Step 21 Disconnect MTB Passthru [X043]

Does the resistance between MTB Passthru connector pin 2 [X043.2.pin] and pin 3 [X043.3.pin] measure 120? -AND- Is there an open circuit between MTB Passthru con-nector pin 1 [X043.1.pin] and pin 2 [X043.2.pin]? -AND- Is there an open circuit between MTB Passthru connector pin 1 [X043.1.pin] and pin 3 [X043.3.pin]?

Yes Repair failed wire(s) between MTB Passthru [X043] and CAN 3way - to Platform [X270]

No Repair failed wire(s) between MTB Passthru [X043] and Platform Control Box Passthru [X160]

Step 22 Disconnect Platform Control Box Passthru [X160] and Platform Module J7 [X169]

Is there continuity only between the following points?• Platform Control Box Passthru pin 1

[X160.1.pin] and Platform Module J7socket 32 [X169.32.soc]

• Platform Control Box Passthru pin 2[X160.2.pin] and Platform Module J7socket 30 [X169.30.soc]

• Platform Control Box Passthru pin 3[X160.3.pin] and Platform Module J7socket 31 [X169.31.soc]

Yes Replace Platform Module

No Repair failed wire(s) between Platform Control Box Passthru [X160] and Platform Module J7 [X169]

Note Pretest Instructions Test Result Corrective Action Step 1 Check fault log for other

modules having lost com-munication

Have most modules lost communications? Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS on Pg. 55

No Go to step 2

Step 2 Is Chassis Power fuse [X267] blown? (Located by Aux Power Pump.)

Yes Replace with 30A fuse. If it blows again immedi-ately, repair the short to ground on Chassis Power Relay terminal 30 [X266.30] and/or terminal 87a [X266.87a]. It it blows again, but only after turn-ing on the machine, go to step 16

No Go to step 3

Step 3 Disconnect the chassis module J1 connector [X229]. Turn on machine

Is there 11VDC or more between chassis module J1 connector socket 4 [X229.4.soc] and socket 5 [X229.5.soc]?

Yes See DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS on Pg. 55 fault step 3


Step 4 Disconnect the chassis module J1 connector [X229]. Turn on machine

Is there zero VDC between chassis module J1 connector socket 4 [X229.4.soc] and socket 5 [X229.5.soc]?

Yes Keep machine on. Go to step 6

No Go to step 5


1-44 1200SJP 1350SJP 3128411


Step 5 Remove any corrosion on battery terminals and battery cable terminals. Run machine to recharge bat-tery.

Does battery still exhibit low power? Yes Replace battery

No Retry normal vehicle operation

Step 6 Disconnect Lower Swivel connector [X216]. Turn on machine

Is there 11VDC or more between of the Lower Swivel connector socket 4 [X216.4.soc] and socket 5 [X216.5.soc]?

Yes Inspect/repair/replace harness between the Lower Swivel connector [X216] and the chassis module J1 connector [X229]

No Go to step 7

Step 7 Disconnect Upper Swivel connector [X083]. Turn on machine

Is there 11VDC or more between of the Upper Swivel connector socket 4 [X083.4.soc] and socket 5 [X083.5.soc]?

Yes Repair swivel harness or replace swivel slip rings

No Go to step 8

Step 8 Turn on machine Is there 11VDC or more at the Chassis Power relay terminal 87 [X266.87]?

Yes Repair/replace harness between the Upper Swivel connector [X083] and the Chassis Power relay terminal 87 [X266.87]


Step 9 Disconnect Chassis Power Relay [X266]. Turn on machine

Is there about 12 VDC at the Chassis Power relay terminal 30.soc [X266.30.soc]?

Yes Go to step 11

No Go to step 10

Step 10 Remove the Chassis Power Fuse from the holder [X267]

Is there about 12 VDC at the Auxiliary Pump solenoid side of the Chassis Power fuse holder [X267]?

Yes Replace fuse or repair/replace harness

No Repair/replace harness between the Chassis Power fuse connector [X267] and the battery positive [X116] through the Auxiliary Pump Relay positive terminal [X108].

Step 11 Disconnect Chassis Power Relay [X266]. Turn on machine.

Is there about 12 VDC between Chassis Power relay connector socket 86 [X266.86.soc] and socket 85 [X266.85.soc]?

Yes Replace Chassis Power relay.

No Go to step 12

Step 12 Disconnect the Valve passthru - 6 pos connector [X280]. Turn on machine

Is there about 12 VDC between the Valve passthru - 6 pos connector socket 3 [X280.3.soc] and socket 5 [X280.5.soc]?

Yes Repair/replace harness between the Valve passthru - 6 pos connector [X280] and the chas-sis power relay connector [X266].

No Go to step 13

Step 13 Perform this test by back-probing. See Backprobing on Pg. 245.

Is there about 12 VDC between pin 3 of the Valve passthru - 6 pos connector [X280.3.pin] and Auxiliary Pump B- terminal?

Yes Go to step 14

No Go to step 15

Step 14 Is there continuity between Chassis Power distribution relay socket 85 [X266] and Auxil-iary Pump B- terminal [X110]?

Yes Repair/replace the YEL/RED 2-70-4 wire between the Valve passthru - 6 pos connector ter-minal 3 [X280.3] and the 12 Pos Batt Busbar [X097].

No Repair/replace the Black wire between Chassis Power distribution relay socket 85[X266.85.soc] and Auxiliary Pump B- terminal [X110].

Step 15 Do the faults 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT and 8410 - BOOM ANGLE SENSOR #2 - COMMUNICA-TIONS FAULT both show in the fault log before a power cycle?

Yes See DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT on Pg. 75 to trouble-shoot the power supply.

No Repair/replace harness between the 6 position BLAM passthru connector [X280] and the 12-pin V-Batt+ bus connector [X097] and/or the 12-pin ground bus connector [X098].


3128411 1200SJP 1350SJP 1-45


DTC 6612 - CANBUS FAILURE - CYLINDER LOAD PINCylinder load pin CAN communications lost. The system cannot communicate with the cylinder load pin. This may be due to wiring problems between the cylinder load pin and BLAM module.

Step 16 Disconnect chassis module J1 connector [X229]

Is there a short to ground on socket 5 of chas-sis module J1 connector [X229.5.soc]?

Yes Go to step 18

No Leave chassis module disconnected. Go to step 17

Step 17 Disconnect chassis module J1 connector [X229]

Is there a short between the chassis module J1 connector pin 4 [X229.4.pin] and pin 5 [X229.5.pin]?


No Check the connections at the chassis module J1 connector [X229]

Step 18 Disconnect Lower Swivel connector [X216]

Is there a short between of the Lower Swivel connector pin 4 [X216.4.pin and pin 5 [X216.5.pin]?

Yes Repair/replace Chassis harness between the Lower Swivel connector [X216] and chassis module J1 connector [X229]

No Go to step 19

Step 19 Disconnect Upper Swivel connector [X083]

Is there a short between Upper Swivel connec-tor pin 4 [X083.4.pin] and pin 5 [X083.5.pin]?

Yes Repair Swivel harness or replace Swivel

No Go to step 20

Step 20 Disconnect the chassis power relay connector [X266]

Is there a short between socket 87 of the Chas-sis Power Relay connector [X266.87.soc] and socket 85 of the Chassis Power Relay connector [X266.85.soc] or the negative side of the battery [X117]?

Yes Repair/replace harness between the chassis power relay connector [X266] and the Upper Swivel connector [X083]

No Leave the chassis power relay connector discon-nected. Go to step 21.

Step 21 Disconnect the chassis power relay connector [X266]

Is there a short between socket 30 of the Chas-sis Power Relay connector [X266.30.soc] and socket 85 of the Chassis Power Relay connector [X266.85.soc] or the negative side of the battery [X117]?

Yes Repair/replace harness between the Chassis Power Relay [X266] and the Chassis Power Fuse [X267]

No Replace Chassis Power Relay

Note Pretest Instructions Test Result Corrective Action Step 1 Is the 6613 - CANBUS FAILURE - EXCESSIVE

CANBUS ERRORS fault active in the fault log?Yes Troubleshoot DTC 6613 - CANBUS FAILURE -

EXCESSIVE CANBUS ERRORS on Pg. 55 first

No Go to step 2

Step 2 Does the BLAM software version show "??" in ANALYZER DIAGNOSTICS VERSIONS B.L.A. MODULE SOFTWARE:?

Yes See DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48

No Go to step 3

Step 3 Disconnect the load pin con-nector [X062]. Turn on the machine

Does the voltage between the load pin connec-tor socket A [X062.A.soc] and socket B [X062.B.soc] measure 12VDC?

Yes Go to step 5

No Go to step 4

Step 4 Backprobe BLAM module J4 terminal 1 [X089.1] and ter-minal 2 [X089.2]

Does the voltage between the BLAM module J4 connector terminal 1 [X089.1] and terminal 2 [X089.2] measure 12VDC?

Yes Replace load pin harness

No Replace the BLAM module

Step 5 Backprobe the BLAM mod-ule J4 connector terminal 3 [X089.3], terminal 4 [X089.4], and terminal 5 [X089.5]

Does the CAN resistance between the BLAM module J4 connector terminal 3 [X089.3] and terminal 4 [X089.4] measure 60 and open circuit between terminal 3 [X089.3] and shield terminal 5 [X089.5] and open circuit between terminal 4 [X089.4] and shield terminal 5 [X089.5]?

Yes Go to step 6

No See DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48


1-46 1200SJP 1350SJP 3128411


DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORSExcessive CAN bus communication errors. More than 500 bus off or more than 500 bus passive conditions have been detected by the ground module in the current power cycle. This could be due to faulty bus wiring or termination resistors, capacitance on the bus, or a module not communicating.

Step 6 Disconnect the load pin con-nector [X062] and the BLAM module J4 connector [X089].

Is there CAN HI continuity between socket D of the load pin connector [X062.D.soc] and socket 3 of the BLAM module J4 connector [X089.3.soc] and CAN LO continuity between socket E of the load pin connector [X062.E.soc] and socket 4 of the BLAM mod-ule J4 connector [X089.4.soc]?

Yes Replace the load pin

No Replace the load pin harness

Note Pretest Instructions Test Result Corrective Action Step 1 Does the CAN resistance between ground

module J7 connector terminal 13 [X007.13] and terminal 24 [X007.24] measure 60 and open circuit between terminal 13 [X007.13] and shield [X007.18] and open circuit between terminal 24 [X007.24] and shield [X007.18]?

Yes Go to step 2

No Go to step 17 to examine the CAN termination

Step 2 Does the platform software version show "??" in ANALYZER DIAGNOSTICS VER-SIONS PLATFORM MODULE SOFT-WARE:??

Yes Go to step 3

No Go to step 8

Step 3 For help with this type of test see 6.3 Continuity Measure-ment Over Long Distances on Pg. 247

Is there CAN HI continuity between terminal 31 of the platform module J7 connector [X169.31] and terminal 13 of the ground mod-ule J7 connector [X007.13] and CAN LO conti-nuity between terminal 30 of the platform module J7 connector [X169.30] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Go to step 8

No Go to step 4

Step 4 Is there CAN HI continuity between terminal 3 of the platform control box passthru - 19 posi-tion connector [X160.3] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 2 of the platform control box passthru - 19 position connector [X160.2] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Check the RED, BLACK, and Shield wires between the platform module J7 connector [X169] and the platform control box passthru - 19 position connector [X160]

No Go to step 5

Step 5 Is there CAN HI continuity between terminal 3 of the MTB pass thru - 19 position connector [X043.3] and terminal 13 of the ground mod-ule J7 connector [X007.13] and CAN LO conti-nuity between terminal 2 of the MTB pass thru - 19 position connector [X043.2] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Check the RED, BLACK, and Shield wires between the MTB pass thru - 19 position connec-tor [X043] and the platform control box passthru - 19 position connector [X160].

No Go to step 6


3128411 1200SJP 1350SJP 1-47


Step 6 Is there CAN HI continuity between terminal A of the platform module side of the 3 way CAN connector in the main terminal box [X270.A] and terminal 13 of the ground module J7 con-nector [X007.13] and CAN LO continuity between terminal B of the platform module side of the 3 way CAN connector in the main terminal box [X270.B] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Check the RED, BLACK, and Shield wires between the platform module side of the 3 way CAN connector in the main terminal box [X270] and the MTB pass thru - 19 position connector [X043]

No Go to step 7

Step 7 Is there CAN HI continuity between terminal A of the 3 way CAN connector [X014.A] and ter-minal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal B of the 3 way CAN connector [X014.B] and terminal 24 of the ground mod-ule J7 connector [X007.24]?

Yes Repair/Replace the 3 way CAN connector in the main terminal box [X014] [X269] [X270]

No Repair/Replace the harness between the 3 way CAN connector in the main terminal box [X014] and the ground module J7 connector [X007]

Step 8 Does the BLAM software version show "??" in ANALYZER DIAGNOSTICS VERSIONS B.L.A. MODULE SOFTWARE:??

Yes Go to step 9

No Go to step 10


Is there CAN HI continuity between terminal 6 of the BLAM module J1 connector [X086.6] and terminal 13 of the ground module J7 con-nector [X007.13] and CAN LO continuity between terminal 7 of the BLAM module J1 connector [X086.7] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Go to step 10

No Go to DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48

Step 10 Is the CYLINDER LOAD PIN CAN COMMUNI-CATIONS LOST fault active in the fault log?

Yes Go to step 11

No Go to step 13

Step 11 For help with this type of test see 6.3 Continuity Measure-ment Over Long Distances on Pg. 247. Disconnect Load Pin [X062].

Is there CAN HI continuity between Load Pin pin 3 [X062.3.pin] and ground module J7 con-nector terminal 13 [X007.13]. Also, CAN LO continuity between Load Pin pin 4 [X062.4.pin] and ground module J7 connec-tor terminal 24 [X007.24]?

Yes Go to step 13

No Go to step 12

Step 12 Is there CAN HI continuity between Load Pin pin [X062.3.pin] and BLAM J4 socket 3 [X089.3.soc]; and CAN LO continuity between Load Pin pin 4 [X062.4.pin] and BLAM J4 socket 4 [X089.4.soc]?

Yes Check BLAM internal CAN lines by looking for CAN HI continuity between BLAM J4 pin 3 [X089.3.pin] and J1 pin 6 [X086.6.pin] and CAN LO continuity between J4 pin 4 [X089.4.pin] and J1 pin 7 [X086.7.pin] and shield continuity between J4 pin 5 [X089.5.pin] and J1 pin 8 [X086.8.pin]. Replace BLAM if bad.

No Check the WHITE, GREEN, and BROWN/BLACK wires between the Load Pin [X062] and BLAM J4.

Step 13 Is the 666 - CANBUS FAILURE - ENGINE CONTROLLER fault active in the fault log?

Yes Go to step 14

No Go to step 15


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Is there CAN HI continuity between terminal 12 of the engine module connector [X240.12] and terminal 13 of the ground module J7 con-nector [X007.13] and CAN LO continuity between terminal 13 of the engine module connector [X240.13] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Go to step 15

No Check the RED, BLACK, and shield wires between the engine module connector [X240] and the ground module J7 connector [X007]

Step 15 Does the Chassis software version show "??" in ANALYZER DIAGNOSTICS VER-SIONS CHASSIS MODULE SOFTWARE:??

Yes Go to step 16

No Go to step 17


Is there CAN HI continuity between terminal 6 of the chassis module J1 connector [X229.6] and terminal 13 of the ground module J7 con-nector [X007.13] and CAN LO continuity between terminal 7 of the chassis module J1 connector [X229.7] and terminal 24 of the ground module J7 connector [X007.24]?

Yes Check all CAN connections for moisture and bad connections

No Check the RED, BLACK, and Shield wires between the chassis module J1 connector [X229], through the swivel [X083] [X216] and the ground module J7 connector [X007]

Step 17 Disconnect the platform module J7 connector [X169]

Does the CAN resistance between platform module J7 connector pin 31 [X169.31.pin] and pin 30 [X169.30.pin] measure 120?

Yes Go to step 18

No Replace the platform module

Step 18 Disconnect the chassis module J1 connector [X229]

Does the CAN resistance between of the chas-sis module J1 connector pin 6 [X229.6.pin] and pin 10 [X229.10.pin] measure 120?

Yes Leave the chassis module disconnected and go to step 19

No Replace the chassis module

Step 19 Disconnect the chassis module J1 connector [X229]

Does the CAN resistance between chassis module J1 connector[X229.9.soc] socket 9 and socket 10 [X229.10.soc] measure 0?

Yes Go to step 20

No Repair/Replace the Chassis harness or CAN ter-mination jumper wire between chassis module J1 connector socket 9 of the [X229.9.soc] and socket 10 [X229.10.soc]

Step 20 Disconnect the Top Swivel connector [X083]

Does the CAN resistance between Top Swivel connector socket 1 of the [X083.1.soc] and socket 2 [X083.2.soc] measure 120?

Yes Go to step 21

No Go to step 22

Step 21 Disconnect the Bottom Swivel connector [X216]

Does the CAN resistance between Bottom Swivel connector socket 1 [X216.1.soc] and socket 2 [X216.2.soc] measure 120?

Yes Repair the RED, BLACK, and/or Shield wires between the Bottom Swivel connector [X216] and the chassis module J1 connector [X229]

No Replace the Swivel

Step 22 Disconnect the BLAM mod-ule J1 connector [X086]

Does the CAN resistance between BLAM module J1 connector socket 6 [X086.6.soc] and socket 7 [X086.7.soc] measure 120?

Yes Repair the RED, BLACK, and/or Shield wires between the Top Swivel connector [X083] and the BLAM module J1 connector [X086]

No Repair the RED, BLACK, and/or Shield wires between the ground module J7 connector [X007] and the BLAM module J1 connector [X086]


3128411 1200SJP 1350SJP 1-49


DTC 6622 - CANBUS FAILURE - TCU MODULECAN bus failure - Telematics Communications Unit Module. The TCU cannot comunicate with ground module. Machine Setup indicates that the Telematics system is installed, but there was no comunication from the gateway module for 30 sec-onds.

Note Pretest Instructions Test Result Corrective Action Step 1 Is TCU fuse [X295] blown? Yes Replace fuse. Repeated blowing of fuse requires

repair of wire harness(es) or replacement of TCU.

No Go to step 2

Step 2 Read active DTC’s Is 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS or other DTC on a CAN device that is not an option active?

Yes Go to DTC 6613 - CANBUS FAILURE - EXCES-SIVE CANBUS ERRORS on Pg. 55 or the respec-tive DTC on other device first.

No Go to step 3.

Step 3 Read active DTC’s Is 6623 - CANBUS FAILURE - GATEWAY MOD-ULE?

Yes Go to DTC 6623 - CANBUS FAILURE - GATEWAY MODULE on Pg. 59.

No Go to step 4.

Step 4 Disconnect Telematics Communications Unit [X290]. Turn on machine.

Is there 12 VDC between Telematics Commu-nication Unit connector socket 15 [X290.15.soc] and scoket 16 [X290.16.soc]?

Yes Keep connector disconnected.Go to step 5.

No Repair wire(s) between Telematics Communica-tion Unit connector socket 15 [X290.15.soc]and battery bus connector [X097] -AND- between socket 16 [X290.16.soc] and ground bus con-nector [X098].

Step 5 Disconnect Telematics Communication Unit [X290]. Do not turn on machine. Ground meter. See Grounding on Pg. 245 for details.

Is there 12 VDC on Telematics Communica-tion Unit connector socket 23 [X290.23.soc]?

Yes Go to step 7

No Go to step 6

Step 6 Remove Telematics Com-munication Unit fuse [X295] from holder. Do not turn on unit. Ground meter.

Is there 12VDC on the contact closest to the MTB EMS?

Yes Repair RED 1-100-1 wire between fuse holder and Telematics Communication Unit

No Repair wire between fuse holder and battery side of MTB EMS.

Step 7 Disconnect telematics com-munication unit connector [X290].

Is there 60 Ohms between telematics com-munication unit connector socket 7 [X290.7.soc] and socket 22 [X290.22.soc]?

Yes Go to step8

No Keep connector disconnected.Go to step 10

Step 8 Disconnect gateway mod-ule gray connecor [X287].

Is there 60 Ohms between gateway module black connector socket ?

Yes Go to step 9

No Repair wire(s) between Telematics Communica-tion unit black connector and Gateway CAN 3way connector X291.

Step 9 Disconnect gateway mod-ule black connector [X288] and TCU CAN 3way to TCU [X293].

Gateway module black connector socket 3 [X288.3.soc] should have continuity to TCU CAN 3way to TCU pin C [X293.C.pin]? -AND- Pin C [X293.C.pin] should be open to both pin A [X293.A.pin] and pin B [X293.B.pin] . Are measurements correct?

Yes Reprogram/replace telematics communication unit [X290].

No Repair wire as needed.

Step 10 Disconnect telematics communication unit con-nector [X290] and TCU CAN 3way to harness [X294].

Is there 120 Ohms between telematics com-munication unit connector socket 7 [X290.7.soc] and socket 22 [X290.22.soc]?

Yes Keep TCU CAN 3 way to harness [X294] discon-nected. Go to step 12

No Keep telematics communication unit connector [X290] disconnected. Go to step 11

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DTC 6623 - CANBUS FAILURE - GATEWAY MODULECAN bus failure - Gateway Module. Telematics gateway module cannot comunicate with ground module. Machine Setup indicates Telematics system is installed, but there was no comunication from the gateway module for 30 seconds.

Step 11 Disconnect telematics communication unit con-nector [X290] and TCU CAN 3way to TCU [X293].

Is there continuity between telematics com-munication unit connector socket 7 [X290.7.soc] to TCU CAN 3 way to TCU socket A [X293.A.soc]?

Yes Repair/replace TCU CAN 3 way and/or resistor

No Repair/replace wire(s) without continuity.

Step 12 Disconnect TCU CAN 3 way to harness [X294] and Gate-way CAN 3 way to Harness connector [X292].

There should be continuity be tween TCU CAN 3 way to harness connector socket A [X294.A.soc] to Gateway CAN 3 way to Har-ness socket A [X292.A.soc] and open to the other terminals. Check terminals B and C the same way. Are measurements correct?

Yes Go to step 13

No Repair bad wire(s)

Step 13 Disconnect gateway mod-ule gray [X287] and black [X288] connectors. Also, disconnect Gateway CAN 3 way to Gateway [X291].

There should be continuity be tween Gateway CAN 3 way to gateway connector socket A [X291.A.soc] to gateway module gray con-nector socket 8 [X287.8.soc] and open to the other terminals. There should be continuity be tween Gateway CAN 3 way to Gateway con-nector socket A [X291.B.soc] to gateway module gray connector socket 7 [X287.7.soc] and open to the other terminals. There should be continuity be tween Gateway CAN 3 way to Gateway connector socket A [X291.C.soc] to gateway module black connector socket 3 [X288.3.soc] and open to the other terminals. Are measurements correct?

Yes Repair/replace Gateway CAN 3 way to Gateway [X291]

No Repair bad wire(s)

Note Pretest Instructions Test Result Corrective Action Step 1 Read active faults Is the fault DTC 6613 - CANBUS FAILURE -

EXCESSIVE CANBUS ERRORS or other fault on a CAN device that is not an option active?

Yes Go to DTC 6613 - CANBUS FAILURE - EXCES-SIVE CANBUS ERRORS on Pg. 55 or the respec-tive fault on other device first.

No Go to step 3.

Step 2 Disconnect gateway mod-ule gray connector [X287]. Turn on machine.

Is there 12 VDC between socket 12 [X287.12.soc] and socket 11 [X287.11.soc]?

Yes Keep connector disconnected. Go to step 3.

No Repair wire(s) between gateway module gray connector socket 11 [X287.11.soc] and ground bus [X098]; and/or between gateway module gray connector socket 12 [X287.12.soc]and battery bus connector [X097].

Step 3 Disconnect gateway mod-ule gray connector [X287].

Is there 60 Ohms between socket 9 [X287.9.soc] and socket 10 [X287.10.soc]?

Yes Reprogram/replace gateway module

No Go to step 4


3128411 1200SJP 1350SJP 1-51


DTC 6629 - TELEMATICS CANBUS LOADING TOO HIGHThe Telematics Gateway Module has detected CAN message traffic levels that are too high. Communications between the machine and the telematics system are restricted. This DTC will stay active at least until a power cycle.

DTC 681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEPThe control system has received a command to disable the machine from the Telematics control center. This condition remains in effect until the enable command is received from the Telematics control center. Call the control center to send the enable signal.

DTC 813 - CHASSIS TILT SENSOR NOT CALIBRATEDChassis tilt sensor not calibrated. Notification that the chassis tilt sensor calibration information has been lost. Machine will indicate that it is tilted at all times. Perform tilt calibration. See 5.6 Calibrating Tilt Sensor on Pg. 221.

DTC 815 - CHASSIS TILT SENSOR DISAGREEMENTChassis tilt sensor disagreement. Reserved for future use. Should not occur on current machine.

DTC 825 - LSS HAS NOT BEEN CALIBRATEDLoad sensor not calibrated. The load sense system (LSS) sensors require calibration. See the calibration procedure in the LSS manual for more details.

DTC 826 - RUNNING AT CREEP - PLATFORM OVERLOADEDRunning at creep - platform overloaded. Reported when the platform is overloaded, causing the machine to be in creep mode. Only displayed when the load sensor machine configuration is set to WARN ONLY.

Step 4 Disconnect gateway mod-ule gray connector [X287] and the two connectors on the same harness, T-ed in at the CAN passthru to Engine Hns [X279].

Is there continuity between gateway module gray connector socket 10 [X287.10.soc]and both "A" terminals at the connectors discon-nected from the CAN passthru to the Engine harness [X279.A]? -AND- Is there continuity between [X287.9] and both B terminals [X279.B]? -AND- Is there continuity between both C terminals [X279.C].

Yes Go to DTC 6610 - CANBUS FAILURE - BLAM on Pg. 48.

No Repair wire(s) without continuity.

Note Pretest Instructions Test Result Corrective Action Step 1 Are there any other CAN bus DTC’s? Yes Troubleshoot those first.

No Go to Step 2

Step 2 Cycle power. Did DTC clear? Yes Troubleshooting complete

No Call JLG

Note Pretest Instructions Test Result Corrective Action Step 1 Go to ANALYZER

MACHINE SETUPAre parameters and configuration set properly in Machine Setup?

Yes Go to Step 2 .


Step 2 Reprogram ground module. Does fault clear? Yes Troubleshooting complete



1-52 1200SJP 1350SJP 3128411


DTC 827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADEDDrive & boom prevented - platform overloaded. Only applies to machines configured with platform load sensing. Drive and boom functions will be prevented while the platform is overloaded.

DTC 828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADEDLift up & telescope out prevented - platform overloaded. Notification that the machine is configured with load system cut-outs, the platform is overloaded, and lift up or tele out is selected. Lift up and telescope out are prevented while the platform is overloaded.

DTC 831 - PLATFORM LEVELING OVERRIDE ONPlatform leveling override on. This fault only applies to service access levels. Notification that the user has forced platform leveling on.

DTC 832 - PLATFORM LEVELING OVERRIDE OFFPlatform leveling override off. This fault only applies to service access levels. Notification that the user has forced platform leveling off.

DTC 833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATEDPlatform leveling crackpoint up not calibrated. The control system detected there was no stored calibration data for the plat-form leveling up valve current crackpoint. This could be due to installing a new ground module that has not yet been cali-brated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic platform leveling will be disabled. Platform leveling can still be performed manually, but the PLATFORM LEVELING SYSTEM TIME-OUT fault will still be enabled. Complete a level up crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217

Note Pretest Instructions Test Result Corrective Action Step 1 Run a system test Are there any platform leveling sensor faults? Yes Troubleshoot those faults first.

No Go to step 2

Step 2 Complete a level up crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217. Did it complete successfully?

Yes Troubleshooting complete

No Go to step 3

Step 3 Install a high pressure gauge on port M1 of the platform valve. Start engine.

Activate level up to end of stroke. Does gauge read or adjust to about 2500 psi?

Yes Go to step 4

No Keep machine in same condition.Go to step 5.

Step 4 Remove hose from platform valve port L2. - Cap port L2. Install a high pressure gauge on end of hose.

Start engine. Activate level down. Does pres-sure on gauge read about 2500 psi?

Yes Repair/replace level circuit check valve

No Repair/replace level cylinder holding valve.

Step 5 Install a high pressure gauge on port MP of the platform valve. Start engine.

Activate level down to end of stroke. Does gauge read about 3400psi?

Yes Go to step 8

No Go to step 6

Step 6 Install a high pressure gauge on port MP of the main valve. Start engine.


Yes Unclog/repair/replace pressure filter at the plat-form and/or hose from main valve port P3 to plat-form valve port P.


3128411 1200SJP 1350SJP 1-53


DTC 834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATEDPlatform leveling crackpoint down not calibrated. The control system detected there was no stored calibration data for the platform leveling down valve current crackpoint. This could be due to installing a new ground module that has not yet been calibrated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic plat-form leveling will be disabled. Platform leveling can still be performed manually, but the PLATFORM LEVELING SYSTEM TIMEOUT fault will still be enabled. Complete a level down crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217


Activate level down to end of stroke. Adjust high pressure relief to 3400psi. See Figure 3-2. Pumps Layout on Pg. 164 for location. Can it be adjusted to proper pressure?

Yes Inspect/repair/replace hydraulics between main valve and platform valve, including filter at plat-form valve.

No Repair/replace function pump and/or high pres-sure relief

Step 8 Start engine. Do the other platform functions operate? Yes Go to step 10

No Go to step 9

Step 9 Turn off machine. Discon-nect platform dump sole-noid [X135].

Does the platform dump solenoid [X135] measure about 6.4 ?

Yes Clean/repair/replace platform dump valve [X135] cartridge.

No Replace platform dump solenoid [X135]

Step 10 In the platform valve, swap cartridge common to level up solenoid [X136] and level down solenoid [X135] with the cartridge common to rotate right [X138] and rotate left [X139]. Does the crackpoint calibrate?

Yes Repair/replace cartridge that was originally installed common to level up solenoid [X136] and level down solenoid [X135]

No Go to step 11

Step 11 Cap platform valve port L2 and its hose. Install a high pressure gauge in port M2. Start engine.

Operate level up to end of stroke. Adjust pres-sure of the platform level down relief for 2500psi. See Figure 3-3. Platform Valve Lay-out on Pg. 165 for location. Does gauge read the proper pressure?

Yes Repair/replace platform level cylinder

No Repair/replace platform level up relief

Note Pretest Instructions Test Result Corrective Action Step 1 Run a system test Are there any platform leveling sensor faults? Yes Troubleshoot those faults first.

No Go to step 2

Step 2 Complete a level down crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217. Did it complete successfully?


No Go to step 3

Step 3 Install a high pressure gauge on port M2 of the platform valve. Start engine.

Activate level down to end of stroke. Does gauge read or adjust to about 1500 psi?

Yes Go to step 4

No Keep machine in same condition.Go to step Step 5 .

Step 4 Remove hose from platform valve port L1. - Cap port L1. Install a high pressure gauge on end of hose.

Start engine. Activate level down. Does pres-sure on gauge read about 1500 psi?

Yes Repair/replace level circuit check valve

No Repair/replace level cylinder holding valve.



Yes Go to step 8

No Go to step 6


1-54 1200SJP 1350SJP 3128411


DTC 837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERYPlatform leveling sensor 1 short to battery. The platform module J1 right platform level sensor communication terminal [X016.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUITPlatform leveling sensor 1 short to ground or open circuit. The platform module J1 right platform level sensor communication terminal [X016.25] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERYPlatform leveling sensor 2 short to battery. The platform module J1 left platform level sensor communication terminal [X016.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUITPlatform leveling sensor 2 short to ground or open circuit. The platform module J1 left platform level sensor communication terminal [X016.26] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.



Yes Unclog/repair/replace pressure filter at the plat-form and/or hose from main valve port P3 to plat-form valve port P.


Step 7 Install a high pressure gauge on port MP of the main valve. start engine.




Step 8 Start engine. Do the other platform functions operate? Yes Go to step 10

No Go to step 9





Step 10 In the platform valve, swap cartridge common to level up solenoid [X136] and level down solenoid [X135] with the cartridge common to rotate right [X138] and rotate left [X139]. Does the crackpoint calibrate?

Yes Repair/replace cartridge that was originally installed common to level up solenoid [X136] and level down solenoid [X135]

No Go to step 11

Step 11 Cap platform valve port L2 and its hose. Install a high pressure gauge in port M2. Start engine.

Operate level down to end of stroke. Adjust pressure of the platform level down relief for 1500psi. See Figure 3-3. Platform Valve Lay-out on Pg. 165 for location. Does gauge read the proper pressure?

Yes Repair/replace platform level cylinder

No Repair/replace platform level down relief


3128411 1200SJP 1350SJP 1-55


DTC 8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGEPlatform leveling tilt reference 1 out of range. Platform J7, terminal 11 [X169.11] is reading outside of the expected range of 4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is present only in software before version P7.0.

DTC 8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGEPlatform leveling tilt reference 2 out of range. Platform J7, terminal 12 [X169.12] is reading outside of the expected range of 4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is present only in software before version P7.0.

DTC 8315 - PLATFORM LEVELING SENSOR - DISAGREEMENTPlatform leveling tilt sensors disagree. The platform leveling tilt readings from platform tilt sensor #1 and #2 both appear to be good, but their measurements are not within 5.0° of each other. This value is programmable. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Is fault still present? Yes Go to step 2


Step 2 Inspect harness and at platform module J7. Is there a wire or short to terminal 11 [X169.11]?

Yes Repair/replace harness


Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Is fault still present? Yes Go to step 2


Step 2 Inspect harness and at platform module J7. Is there a wire or short to terminal 12 [X169.12]?

Yes Repair/replace harness


Note Pretest Instructions Test Result Corrective Action Step 1 Are there any other platform leveling faults? Yes Troubleshoot them first

No Go to step 2

Step 2 Are both sensors mounted properly and securely?

Yes Go to step 3

No Repair as needed

Step 3 Disconnect platform level sensor #1 (Right) [X150]

Turn on machine. Does the PLATFORM LEV-ELING TILT SENSOR 1 COMMUNICATIONS LOST fault appear?

Yes Go to step 4

No Wires to wrong sensor. Swap harness connec-tions and ensure they attach to the correct sen-sor.

Step 4 Perform 5.5 Calibrating Platform Level on Pg. 217. (There is also helpful infor-mation in section 5.4 Elec-tronic Platform Leveling on Pg. 214.)

Does it calibrate successfully? -AND- Does fault clear?


No Replace both platform level sensors, #1 [X148] and #2 [X150]

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DTC 8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOSTPlatform leveling tilt sensor 1 communications lost. The control system lost serial communications with platform tilt angle sensor #1 (right). A power cycle is required.

Note Pretest Instructions Test Result Corrective Action Step 1 Is harness from platform level sensor 1 [X150]

plugged into the platform level passthru 1 [X162]? Also, are those connections in good condition?

Yes Go to step 2

No Correct wiring

Step 2 Check the faults. Is the fault PLATFORM LEVELING TILT SEN-SOR 2 COMMUNICATIONS LOST active?

Yes Go to step 9

No Go to step 3

Step 3 Plug platform level sensor 2 (left) [X148] into connector for platform level sensor 1 (right) [X150]

Does the PLATFORM LEVELING TILT SEN-SOR 1 COMMUNICATIONS LOST fault clear?

Yes Replace original platform level sensor 1 (RIGHT) [X150]

No Go to step 4

Step 4 Disconnect platform level sensor 1 [X150]. Turn on machine.

Measure voltage between platform level sen-sor 1 pin1[X150.1.pin] and pin 3 [X150.3.pin]. Does it measure about 12VDC?

Yes Go to step 5

No Go to step 7

Step 5 Disconnect platform level sensor 1 [X150] and plat-form module J1

Is there continuity between platform level sen-sor 1 pin 2 [X150.2.pin] and platform module J1 socket 25 [X165.25.soc]?

Yes Replace platform level sensor 1 [X150]

No Go to step 6

Step 6 Disconnect platform level passthru 1 [X162] and plat-form module J1 [X165]

Is there continuity between platform level passthru 1 pin 2 [X162.2.pin] and platform module J1 socket 25 [X165.25.soc]?

Yes Repair/replace harness between platform level passthru 1 [X162] and platform level sensor 1 [X150]

No Repair/replace harness between platform level passthru 1 [X162] and platform module J1 [X165]

Step 7 Disconnect platform module J2 [X166]. Ground meter. See Grounding on Pg. 245 for details.

Turn on machine. Measure voltage between platform module J2 pin 32 [X166.32] and ground. Does it measure about 12VDC?

Yes Go to step 8


Step 8 Disconnect platform level passthru 1 [X162]. Turn on machine.

Measure voltage between platform level passthru 1 pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Does it measure about 12VDC?


No Repair/replace harness between platform level passthru 1 [X162] and platform module J7 [X169] and/or J1 [X165]

Step 9 Take the following measure-ment by backprobing. See Backprobing on Pg. 245 for details.

Is there about 12 VDC between platform mod-ule J2 terminal 32 [X166.32] and platform module J7 terminal 21 [X169.21]?

Yes Go to step 10


Step 10 Turn on machine. Measure voltage between platform level sen-sor 1 pin 1 [X150.1.pin] and pin 3 [X150.3.pin]. Also, between platform level sensor 2 pin 1 [X148.1.pin] and pin 3 [X148.3.pin]. Do they measure about 12 VDC?

Yes Go to step 12

No Go to step 11

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DTC 8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOSTPlatform leveling tilt sensor 2 communications lost. The control system lost serial communications with platform tilt angle sensor #2 (Left).

Step 11 Turn on machine. Discon-nect platform level passthru 1 [X162] and platform level passthru 2 [X163]

Measure voltage between platform level passthru pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Also, measure voltage between platform level passthru 2 pin 1 [X163.1.pin] and pin 3 [X163.3.pin]. Do they measure about 12 VDC?

Yes Repair/replace harness between the platform level sensor and platform level passthru connec-tor that did not have the proper voltage.

No Repair/Replace harness between the platform level passthru connector +1 [X162] and 2 [X163] and the platform module connector J1 [X165] that did not have the proper voltage.

Step 12 Disconnect platform level passthru 1 [X162] and plat-form level passthru 2 [X163]. Ground meter.

Is there continuity between platform level passthru 1 pin 3 [X162.3.pin] and ground? Also, is there continuity between platform level passthru 2 pin 3 [X163.3.pin] and ground?

Yes Go to step 13

No Repair/replace harness between platform mod-ule J7 [X169] and the connectors platform level passthru 1 [X162] and platform level passthru 2 [X163].

Step 13 Disconnect platform level sensor 1 [X150] and plat-form level sensor 2 [X148]. Ground meter.

Is there continuity between platform level sen-sor 1 pin 3 [X150.3.pin] and ground. Also, is there continuity between platform level sensor 2 pin 3 [X148.3.pin] and ground.

Yes Replace both platform level sensors

No Repair/replace harness(es) that did not have con-tinuity.

Note Pretest Instructions Test Result Corrective Action Step 1 Is harness from platform level sensor 2 [X148]

plugged into the platform level passthru 2 [X163]? Also, are those connections in good condition?

Yes Go to step 2

No Correct wiring

Step 2 Check the faults. Is the fault PLATFORM LEVELING TILT SEN-SOR 1 COMMUNICATIONS LOST active?

Yes Go to step 9

No Go to step 3

Step 3 Plug platform level sensor 1 (right) [X150] into connec-tor for platform level sensor 2 (left) [X148]

Does the PLATFORM LEVELING TILT SEN-SOR 2 COMMUNICATIONS LOST fault clear?

Yes Replace original platform level sensor 2 (left) [X148]

No Go to step 4

Step 4 Disconnect platform level sensor 2 (left) [X148]. Turn on machine.

Measure voltage between platform level sen-sor 2 pin1[X148.1.pin] and pin 3 [X148.3.pin]. Does it measure about 12VDC?

Yes Go to step 5

No Go to step 7

Step 5 Disconnect platform level sensor 2 (left) [X148] and platform module J1

Is there continuity between platform level sen-sor 1 pin 2 [X148.2.pin] and platform module J1 socket 26 [X165.26.soc]?

Yes Replace platform level sensor 2 (left) [X148]

No Go to step 6

Step 6 Disconnect platform level passthru 2 [X163] and plat-form module J1 [X165]

Is there continuity between platform level passthru 2 pin 5 [X163.5.pin] and platform module J1 socket 26 [X165.26.soc]?

Yes Repair/replace harness between platform level passthru 2 [X163] and platform level sensor 2 (LEFT) [X148]

No Repair/replace harness between platform level passthru 2 [X163] and platform module J1 [X165]

Step 7 Disconnect platform module J2 [X166]. Ground meter. See Grounding on Pg. 245 for details.

Turn on machine. Measure voltage between platform module J2 pin 32 [X166.32] and ground. Does it measure about 12VDC?

Yes Go to step 8



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DTC 8318 - PLATFORM LEVELING SYSTEM TIMEOUTPlatform leveling system time-out. The control system detected the platform tilt angle was not within 5.0° of the setpoint for at least 2 seconds while out of transport or for at least 15 seconds while in the transport position. These values are program-able. This fault can happen when driving too fast over abrupt terrain changes because the platform leveling system cannot respond fast enough. Platform operations will be disabled.

Step 8 Disconnect platform level passthru 1 [X162]. Turn on machine.

Measure voltage between platform level passthru 1 pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Does it measure about 12VDC?


No Repair/replace harness between platform level passthru 1 [X162] and platform module J7 [X169] and/or J1 [X165]

Step 9 Take the following measure-ment by backprobing. See Backprobing on Pg. 245 for details.

Is there about 12 VDC between platform mod-ule J2 terminal 32 [X166.32] and platform module J7 terminal 21 [X169.21]?

Yes Go to step 10


Step 10 Turn on machine. Measure voltage between platform level sen-sor 1 pin 1 [X150.1.pin] and pin 3 [X150.3.pin]. -AND- measure voltage between platform level sensor 2 pin 1 [X148.1.pin] and pin 3 [X148.3.pin]. Do they measure about 12 VDC?

Yes Go to step 12

No Go to step 11

Step 11 Turn on machine. Discon-nect platform level passthru 1 [X162] and platform level passthru 2 [X163]

Measure voltage between platform level passthru pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. -AND- measure voltage between platform level passthru 2 pin 1 [X163.1.pin] and pin 3 [X163.3.pin]. Do they measure about 12 VDC?

Yes Repair/Replace harness between the platform level sensor and platform level passthru connec-tor that did not have the proper voltage.

No Repair/Replace harness between the platform level passthru connector 1 [X162] and 2 [X163] and the platform module connector J1 [X165] that did not have the proper voltage.

Step 12 Disconnect platform level passthru 1 [X162] and plat-form level passthru 2 [X163]. Ground meter.

Is there continuity between platform level passthru 1 pin 3 [X162.3.pin] and ground? -AND- Is there continuity between platform level passthru 2 pin 3 [X163.3.pin] and ground?

Yes Go to step 13

No Repair/replace harness between platform mod-ule J7 [X169] and the connectors platform level passthru 1 [X162] and platform level passthru 2 [X163].

Step 13 Disconnect platform level sensor 1 [X150] and plat-form level sensor 2 [X148]. Ground meter.

Is there continuity between platform level sen-sor 1 pin 3 [X150.3.pin] and ground. -AND- Is there continuity between platform level sensor 2 pin 3 [X148.3.pin] and ground.

Yes Replace both platform level sensors

No Repair/replace harness(es) that did not have con-tinuity.

Note Pretest Instructions Test Result Corrective Action Step 1 Examine active faults Are there any other platform leveling faults? Yes Troubleshoot those first

No Go to step 2

Step 2 Does the fault only occur when driving over changing terrain?

Yes Drive slower. If fault still occurs, go to step 3

No Go to step 3

Step 3 Are the mounting blocks for both sensors properly assembled? -AND- Is the hardware tight?

Yes Go to step 4

No Repair as needed


3128411 1200SJP 1350SJP 1-59


DTC 841 - BOOM ANGLE SENSOR DISAGREEMENTThe control system detected a difference in angle measurements from the Boom Angle Sensors of greater than 2.5 for longer than 2 seconds.

Step 4 Disconnect platform level sensor #1 (Right) connec-tor [X150]

Is the fault PLATFORM LEVELING TILT SEN-SOR 1 COMMUNICATIONS LOST now an active fault?

Yes Go to step 5

No Connections are swapped. Make proper harness connections to sensors.

Step 5 Does the platform move slowly or not at all when commanded?

Yes Perform platform leveling calibration. See 5.5 Calibrating Platform Level on Pg. 217. If this does not fix problem go to step 6

No Go to step 6

Step 6 Do the other platform functions operate? Yes Go to step 10

No Go to step 7



Yes Go to step 9

No Go to step 8









Step 10 Turn off machine. Discon-nect platform level UP [X136] and level DOWN [X137].

Do both solenoids measure 10.1? Yes Go to step 11

No Replace platform level valve coil [X136] [X137]

Step 11 Take cartridge from platform level valve [X136] [X137] and swap it with the one in the jib swing valve [X140] [X141]

Does problem clear or move? Yes Replace cartridge originally in the platform level valve [X136] [X137].

No Go to step 12

Step 12 Install a high pressure gauge on ports M1 and M2 of the platform valve. Start engine.

Activate level down to end of stroke. Does pressure measure or adjust to about 1500 psi? Also, activate level up to end of stroke. Does pressure measure or adjust to about 2500 psi?

Yes Repair/replace 75psi check valve and/or level cylinder assembly

No Repair/replace relief valve that does not produce proper pressure.

Note Pretest Instructions Test Result Corrective Action Step 1 Connect Analyzer. Read

active faults. (Logged faults before power cycle.)

Are there another Boom Angle Sensor faults? Yes Troubleshoot those first.

No Go to step 2

Step 2 Put boom in transport posi-tion. Navigate to ANALYZER ACCESS LEVEL 1 DIAGNOSTICS ENVE-LOPE

Do the readings on the machine approximately agree with the following?• MAIN LIFT 1 ANGLE A/D: -38.7• MAIN LIFT 2 ANGLE A/D: -38.9• MAIN LIFT 1 ANGLE: -1.1• MAIN LIFT 2 ANGLE: -1.0

Yes Keep ANALYZER connected. Go to step 4

No Go to step 3


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DTC 842 - BOOM LENGTH SWITCH FAILEDBoom Length Switch Failed. Both Boom Length (Transport) Limit Switches show same state, when they should be reading opposite.

Step 3 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228.

Do sensors calibrate successfully? Yes Troubleshooting complete


Step 4Turn off vehicle. Disconnect Boom Angle Sensor 1. Con-nect Analyzer. Turn on vehi-cle.

Is the fault BOOM ANGLE SENSOR 2# COM-MUNICATIONS FAULT active?

Yes Sensor wires are swapped. Connect harnesses to proper sensors.

No Go to step 5

Step 5Navigate to ANALYZER ACCESS LEVEL 1 DIAG-NOSTICS ENVELOPE.

Observe MAIN LIFT 1 ANGLE A/D value while slowly raising and lowering boom. The value should change smoothly and consistently without jumping or stopping. Does it? Repeat for sensor MAIN LIFT 2 ANGLE A/D.

Yes Repeat test several times. If no bad behavior is observed calibrate and go to step.3

No Replace sensor that exhibits bad behavior.

Note Pretest Instructions Test Result Corrective Action Step 1 Is Boom Length Limit Switch [X281] jammed,

obstructed, loose or mounted incorrectly? Also, is the switch prevented from properly contacting the boom?

Yes Repair as needed

No Go to step 2

Step 2 Disconnect Boom Transport Switch Passthru [X017]

Check continuity between Boom Transport Switch Passthru socket 1 [X017.1.soc] and both socket 2 [X017.2.soc] and socket 6 [X017.6.soc]. One measurement should have continuity and the other should not. Operate the limit switch arm 90 to the opposite switched position and measure again. These measurements should be opposite to previous measurements. Are measurements proper?

Yes Leave Boom Transport Switch Passthru [X017] disconnected.Go to step 3

No Leave Boom Transport Switch Passthru [X017] disconnected.Go to step 4

Step 3 Disconnect Boom Transport Switch Passthru [X017] and Ground Module J7 [X007]

Is there continuity between all of the follow-ing? Boom Transport Switch Passthru pin 1 [X017.1.pin] to Ground Module J7 pin socket 29 [X007.29.pin]; [X017.2.pin] to [X007.11.soc]; and[X017.6.pin] to [X007.35.soc]

Yes Replace Ground Module

No Repair/Replace wire that did not have continuity.

Step 4 Disconnect Boom Transport Switch Passthru [X017] and gain access wires inside Boom Length Limit Switch [X281]

Is there continuity between all of the follow-ing? Boom Transport Switch Passthru socket 1 [X017.1.soc] to both Boom Length Limit Switch terminal 14 [X281.14] and terminal 22 [X281.22];[X017.2.soc] to [X281.21][X017.6.soc] to [X281.13]

Yes Replace Boom Transport Switch [X281]

No Repair/Replace wire that did not have continuity.


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DTC 843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENTBoom Length Switch/Sensor Disagreement. The control system did not detect a change in the boom length switch at the calibrated point. This could be a problem with the Boom Length Sensor or Boom Length Limit Switch, or the boom sensor calibration.

DTC 844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGEBoom Length Sensor Not Detecting Length Change. The control system has not detected a minimum change in length while the user commanded telescope. The minimum change is 0.3" over 3 seconds when command is at least 45%. This fault check is enabled when the boom is greater than 5 inches from the maximum or minimum mechanical length. An EMS cycle is required.

Note Pretest Instructions Test Result Corrective Action Step 1 Is Boom Length Limit Switch [X281] jammed,

obstructed, loose or mounted incorrectly?Yes Repair as needed

No Go to step 2

Step 2 Is the Boom Length Sensor [X273] jammed, obstructed, loose, have cable stuck or mounted incorrectly?


No Goo to step 3

Step 3Check active faults (before first power cycle)

Is there a Boom Length Sensor or Boom Length Limit Switch fault present?

Yes Troubleshoot those first

No Go to step 4

Step 4 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228. Does machine calibrate without faults?


No Troubleshoot in accordance with calibration fault.

Note Pretest Instructions Test Result Corrective Action Step 1 Have swing, lift, telescope, and platform func-

tions stopped operating?Yes Go to step 17

No Go to step 2

Step 2 Check active faults. (Fault log before power cycle.)

Are there any other Boom Length sensor faults?

Yes Troubleshoot those first

No Go to step 3

Step 3 Examine the electrical connections at the boom length sensor [X273], Boom Length Sensor Passthru [X272] and BLAM module J3 connector [X088]. Are there any loose con-nections, moisture or corrosion?

Yes Clean or replace any bad connections

No Go to step 4

Step 4 Is the boom length sensor [X273] properly mounted to the machine. -AND- Is the sensor cable free to move with boom?

Yes Go to step 5

No Remount/repair sensor, etc.

Step 5 Extend boom completely Apply lubricant to wear pad tracks on booms. Move boom in and out completely. Does fault clear?


No Go to step 6

Step 6 Raise and extend boom. Plug main valve port 8.

Does boom retract without command? Yes Keep test setup in place. Go to step 7

No Go to step 8

Step 7 Raise and extend boom. Plug main valve port 8.

Does fluid flow from hose previously in port 8? Yes Replace telescope cylinder port block

No Replace telescope cylinder piston seal

Step 8 Torque boom wire ropes per procedure. See 5.10 Wire Rope Tensioning Procedure on Pg. 240. Does fault clear?


No Go to step 9

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Step 9 Connect a 5000 psi pres-sure gauge to MP port on the main valve manifold

Adjust the low pressure relief on the function pump until gauge reads 400 psi. See Figure 3-2. Pumps Layout on Pg. 164 for location. Can adjustment be made to correct pressure?

Yes Keep gauge installed. Make note of results.Go to step 10.

No Replace function pump compensating valve.

Step 10 Connect a 5000 psi pres-sure gauge to MP on the main valve manifold. Remove the solenoid from the main tele proportional valve.

While activating main telescope in, adjust the high pressure relief on the function pump till the gauge reads 3400 psi. See Figure 3-2. Pumps Layout on Pg. 164 for location. Can adjustment be made to correct pressure?

Yes Keep gauge connected. Make note of results. Go to step 12

No Go to step 17

Step 11 Remove Main Tele Extend [X071] and Main Tele Retract [X073] connectors

Measure resistances. Do they both measure about 5 Ohms?

Yes Replace Main Tele Extend/Retract valve cartridge

No Replace Main Tele Extend/Retract coil.

Step 12 Connect a 5000 psi pres-sure gauge to M8 on the main valve manifold. Cap the hose and port on port 8.

Activate telescope out. Does pressure read or adjust to 3000 psi? See Figure 3-1. Main Valve Layout on Pg. 163 for location of extend pres-sure adjustment.

Yes Make note of results.Go to step 13

No Make note of results.Go to step 13

Step 13 Connect a 5000 psi pres-sure gauge to M7 on the main valve manifold. Cap the hose and port on port 7.

Activate telescope in. Does pressure read or adjust to 3200psi? See Figure 3-1. Main Valve Layout on Pg. 163 for location of retract pres-sure adjustment.

Yes Make note of resultsGo to step 14

No Make note of resultsGo to step 14

Step 14 Did ONE of either M7 or M8 fail to adjust to pressure listed above?

Yes Replace relief that did not adjust to proper pres-sure.

No Go to step 15

Step 15 Did both M7 and M8 pressures fail to adjust to pressures above

Yes Go to step 16

No Go to step 6

Step 16 Swap Tele proportional valve [X072] cartridge with the Lift proportional [X286] cartridge.

Does fault move? Yes Replace cartridge originally in Tele proportional valve [X072]

No Go to step 17

Step 17 Disconnect main dump [X074]

Measure resistance. Is coil resistance about 5 Ohms?

Yes Go to step 18

No Replace main dump coil.

Step 18 On main valve, cap port B and P2 (to aux pump). Install 5000psi gauge on MP port and.

Activate telescope in. Does pressure read or adjust to 3400 psi with high pressure relief?

Yes Keep test setup in place.Go to step 19

No Go to step 20

Step 19 Remove cap from port B and restore connection.

Activate telescope in. Does pressure read or adjust to 3400psi with high pressure relief?

Yes Repack/reseal swivel

No Replace check valve in aux pump.

Step 20 Replace main dump car-tridge.

Does fault clear? Yes Troubleshooting complete

No Replace function pump compensating valve.


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DTC 845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGHBoom Length Sensor Out of Range High. The control system reads a boom length greater than 1480.9" for the 1350 or 1294.4" for the 1200. This could be caused by a mechanical problem with the sensor or cable, the sensor ground wire being broken, or a sensor failure.

Note Pretest Instructions Test Result Corrective Action Step 1 Is the boom length sensor [X273] securely

mounted to the machine and is cable free to move?

Yes Go to step 2

No Repair as needed

Step 2 Disconnect boom length sensor [X273]

Does the boom length sensor connector [X273] have moisture, damage or corrosion?


No Keep boom length sensor [X273] disconnected. Go to step 3

Step 3 Turn on machine. Discon-nect boom length sensor [X093]

Is there about 5VDC between boom length sensor socket A [X273.A.soc] and socket B [X273.B.soc]?

Yes Go to step 6.

No Keep machine in same state. Go to step 4

Step 4 Turn on machine. Discon-nect BLAM J 3 [X088]

Is there about 5VDC between BLAM J 3 pin 7 [X088.7.pin] and pin 9 [X088.7.pin]?

Yes Go to step 5

No Replace BLAM

Step 5 Turn on machine. Discon-nect Boom Length Sensor Passthru [X272].

Is there about 5VDC between Boom Length Sensor Passthru pin 1 [X272.1.pin] and pin 2 [X272.2.pin]?

Yes Repair/replace harness between Boom Length Sensor [X273] and Boom Length Sensor Passthru [X272]

No Repair/replace harness between BLAM J3 [X088] and Boom Length Sensor Passthru [X273]

Step 6 Unclip sensor cable from boom. Observe resistance between boom length sen-sor pin A [X273.A.pin] and pin C [X273.C.pin].

Have second person slowly walk cable out and back completely. The sensor cable extends 350 inches (29’ 2"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 ± 500 and back?

Yes Go to step 7

No Replace boom length sensor [X273]

Step 7 Disconnect boom length sensor [X273] and BLAM module J3 connector [X088].

Is there a short between the Blue wire in boom length sensor socket C [X273.C.soc] and red wire in socket A [X273.A.soc] -OR- between boom length sensor socket C [X273.C.soc] and battery positive [X116]?

Yes Keep boom length sensor [X273] disconnected. Go to step 8

No Leave boom length sensor [X273] and BLAM module J3 [X088] disconnected. Go to step 9

Step 8 Disconnect boom length sensor [X273] and boom length sensor passthru [X272]

Is there a short between the Blue wire in boom length sensor socket C [X273.C.soc] and red wire in socket A [X273.A.soc] -OR- between boom length sensor socket C [X273.C.soc] and battery positive [X116]?

Yes Repair short or replace harness between boom length sensor [X273] and boom length sensor passthru [X272]

No Repair short or replace harness between boom length sensor [X272] and BLAM J3 [X088]

Step 9 Disconnect boom length sensor [X273] and BLAM module J3 connector [X088]

Is there continuity between boom length sen-sor socket C [X273.C.soc] and BLAM module J3 socket 8 [X088.8.soc]?

Yes Go to step 11

No Go to step 10


Is there continuity between boom length sen-sor passthru socket 3 [X272.3.soc] and boom length sensor socket C [X273.C.soc]?

Yes Repair or replace harness between BLAM J3 [X088] and boom length sensor [X273]

No Repair/replace harness between boom length sensor [X093] and BLAM module J3 connector [X088].

1-64 1200SJP 1350SJP 3128411


DTC 846 - BOOM LENGTH SENSOR - OUT OF RANGE LOWBoom Length Sensor Out of Range Low. The control system reads a boom length less than 443.0" for the 1350 or 394.9" for the 1200. This could be caused by a mechanical problem with the sensor or cable, a disconnected or broken sensor cable clip, the sensor power and/or signal wire being broken, or sensor failure.

Step 11 Disconnect boom length sensor [X273] and BLAM module J3 connector [X088]

Is there continuity between boom length sen-sor socket B [X273.B.soc] and BLAM module J3 connector socket 9 [X088.9.soc]?

Yes Leave boom length sensor [X273] disconnected. Go to step 13

No Go to step 12

Step 12 Disconnect boom length sensor [X273] and boom length sensor passthru[X272]

Is there continuity between boom length sen-sor socket B [X273.B.soc] and boom length sensor passthru socket 2 [X272.2.soc]?

Yes Repair/replace harness between boom length sensor passthru [X272] and BLAM J3 [X088]

No Repair/replace harness between boom length sensor [X273] and boom length sensor passthru [X272]

Step 13 Turn on machine. Discon-nect boom length sensor [X273]

Does the fault become inactive -AND- the fault BOOM LENGTH SENSOR ONE VALUE OUT OF RANGE LOW appear?

Yes Replace boom length sensor [X273]

No Reprogram/replace BLAM

Note Pretest Instructions Test Result Corrective Action Step 1 Is the boom length sensor [X273] securely

mounted to the machine, is cable free to move and is it connected correctly?

Yes Go to step 2

No Repair as needed

Step 2 Disconnect boom length sensor [X273]

Does the boom length sensor connector [X273] have moisture, damage or corrosion?


No Keep boom length sensor [X273] disconnected and machine on. Go to step 3

Step 3 Disconnect boom length sensor [X273]. Turn on machine.

Is there about 5VDC between boom length sensor socket A [X273.A.soc] and socket B [X273.B.soc]?

Yes Leave machine on. Go to step6

No Go to step 4

Step 4 Disconnect BLAM J3 X088]. Turn on machine.

Is there about 5VDC between BLAM J3 pin 7 [X088.7.pin] and pin 9 [X088.9.pin]?

Yes Go to step 5

No Replace BLAM

Step 5 Disconnect boom length sensor passthru [X272]. Turn on machine

Is there about 5VDC between boom length sensor passthru pin 1 [X272.1.pin] and pin 2 [X272.2.pin]?

Yes Repair/replace harness between boom length sensor passthru [X272] and boom length sensor [X273]

No Repair/replace harness between boom length sensor passthru [X272] and BLAM J3 [X088]

Step 6 Unclip sensor cable from boom. Observe resistance between boom length sen-sor pin A [X273.A.pin] and pin C [X273.C.pin].

Have second person slowly walk cable out and back completely. The sensor cable extends 350 inches (29’ 2"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 ± 500 and back?

Yes Go to step 7

No Replace boom length sensor [X273]

Step 7 Disconnect boom length sensor [X273] and BLAM J3 [X088]

Is there a short between boom length sensor socket C [X273.C.soc] or BLAM J3 socket 8 [X088.8.soc] to battery negative [X117]?

Yes Repair/replace harness between boom length sensor socket C [X273.C.soc], BLAM J3 socket 8 [X088.8.soc] and battery negative [X117]

No Leave boom length sensor [X273] and BLAM J3 [X088] disconnected. Go to step 8


3128411 1200SJP 1350SJP 1-65


DTC 847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGHBoom Length Sensor Value Out of Range High. The control system detected the boom length sensor input voltage is above acceptable range.


Is there continuity between boom length sen-sor socket C [X273.C.soc] and BLAM J3 socket 8 [X088.8.soc]?

Yes Go to step 10

No Go to step 9


Is there continuity between boom length sen-sor socket C [X273.C.soc] and boom length sensor passthru socket 3 [X272.3.soc]?

Yes Repair/replace harness between boom length sensor socket C [X273.C.soc], BLAM J3 socket 8 [X088.8.soc]

No Repair/replace harness between boom length sensor [X273] and boom length sensor passthru [X272]


Is there a short between boom length sensor socket C [X273.C.soc] and socket B [X273.B.soc]?

Yes Go to step 11


Step 11 Disconnect boom length sensor passthru [X272] and boom length sensor [X273]

Is there a short between boom length sensor socket C [X273.C.soc] and socket B [X273.B.soc]?

Yes Repair/replace harness between boom length sensor socket C [X273.C.soc] and socket B [X273.B.soc]

No Repair/replace harness between boom length sensor passthru [X272] and BLAM J3 [X088]

Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Does fault clear? Yes Troubleshooting complete

No Go to step 2

Step 2 Ensure all optional power sources are de-energized, including welding and off-board power.

Does fault clear? Yes Leave all optional power sources de-energized.Go to step 3.

No Go to step 4


Re-energize one source and re-check faults. Does fault re-appear?

Yes Look for shorts in the harness for that system to harness at BLAM J3.

No Go to "Test" box in this step.

Step 4 Disconnect BLAM J3 [X088]. Turn on machine.

Is there between 5.5 V and 4.5 volts measured between the following points on BLAM J3:pin 1 [X088.8.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?

Yes Go to step 5

No Replace BLAM

Step 5 Disconnect BLAM J3 [X088]. Disconnect battery (+) terminal [X116]

Is there a short between the battery (+) termi-nal [X116] and any of the following: BLAM J3, socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]?

Yes Troubleshoot BLAM J3 [X088] harness wire with short



1-66 1200SJP 1350SJP 3128411


DTC 848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOWBoom Length Sensor Value Out of Range Low. The control system detected the boom length sensor input voltage is below acceptable range.

DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULTBoom angle sensor #1 communications fault. The control system lost serial communications with #1 angle sensor (Opera-tor’s right side).


No Go to step 2

Step 2 Disconnect BLAM J3 [X088] and Boom Length Sensor [X273].

Is there continuity measured between BLAM J3 [X088] and Boom Length Sensor [X273] at the following locations:Pin 7 [X088.7.pin] to pin A [X273.A.pin];Pin 8 [X088.8.pin] to pin C [X273.C.pin];Pin 9 [X088.9.pin] to pin B [X273.B.pin]?

Yes Go to step 3

No Repair Harness


Is there between 4.5 V and 5.5 V measured between all of the following points on BLAM J3:pin 1 [X088.1.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?

Yes Go to step 4

No Replace BLAM

Step 4 Unclip sensor cable from boom. Observe resistance between Boom Length Sen-sor pin A [X273.A. pin] and pin C [X273.C.pin]

Have a second person slowly walk the cable out and back completely. The sensor extends 350 inches (29'). (Do not allow the cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does the resistance change smoothly and consistently up to 5000 ohm and back?

Yes Reprogram BLAM and calibrate boom sensors

No Replace Boom Length Sensor

Note Pretest Instructions Test Result Corrective Action Step 1 Are there loose or damaged connections at the

#1 boom angle sensor connector [X099]?Yes Repair any loose or damaged wires or connec-

tors

No Go to step 2

Step 2 Does the fault log show BOOM ANGLE SEN-SOR #2 COMMUNICATIONS FAULT before a power cycle?

Yes Go to step 4

No Go to step 3

Step 3 Turn on machine. Discon-nect #1 boom angle sensor connector [X099]

Is there 12VDC on #1 boom angle sensor connector socket 1 [X099.1.soc] and socket 3 [X099.3.soc]?

Yes Leave connector disconnected. Go to step 8.

No Go to step 4

Step 4 Turn on machine. Back-probe between the 12-pin ground bus connector [X098] and 12-pin V-Batt+ bus connector [X097] by the BLAM. (See 6.2 Multimeter Basics on Pg. 245 for details on backprobing.)

Is there 12VDC between 12-pin V-Batt+ bus connector[X097] and 12-pin ground bus con-nector [X098]?

Yes Repair/replace 12-pin V-Batt+ bus connector [X097] and/or 12-pin ground bus connector [X098].

No Leave machine on. Go to step 5.

3128411 1200SJP 1350SJP 1-67


Step 5 Turn on machine. Discon-nect 6-pin Deutsch connec-tor [X280].

Is there 12VDC between 6-pin Deutsch pin 2 [X280.2.pin] and pin 5 [X280.5.pin]?

Yes Go to step 11

No Leave 6-pin Deutsch connector [X280] dicon-nected. Go to step 6.

Step 6 Disconnect 6-pin Deutsch connector [X280] and Power Down Relay [X011]

Is there continuity between 6-pin Deutsch connector socket 2 [X280.2.soc] and Power Down Relay socket 87 [X011.87.soc]?

Yes Leave 6-pin Deutsch connector [X280] discon-nected. Go to step 7.

No Repair/Replace harness between 6-pin Deutsch connector [X280], including the bus connector itself [X010] and the Power Down Relay [X011]

Step 7 Disconnect 6-pin Deutsch connector [X280] and ground control module J8 [X008]

Is there continuity between 6-pin Deutsch connector pin 5 [X280.5.pin] and ground con-trol module J8 socket 3 [X008.3.soc]?

Yes Ensure both contacts of the 6-pin Deutsch con-nector pin 5 [X280.2.pin] are seated properly in the connector bodies and that there is continuity between all pins.

No Repair/replace harness and or connectors between 6-pin Deutsch connector [X280] and ground control module J3 socket 3 [X008.3]

Step 8 Plug the #2 boom angle sensor connector [X100] into the #1 sensor and the boom angle sensor #1 con-nector [X099] into the #2 sensor. Read faults.

Does the BOOM ANGLE SENSOR #2 COM-MUNICATIONS FAULT appear?

Yes Replace sensor #1

No Leave the #1 boom angle sensor [X099] discon-nected. Go to step 9

Step 9 Disconnect #1 boom angle sensor connector [X099] and BLAM J2 [X087]

Is there continuity between #1 boom angle sensor pin 2 [X099.2.pin] and BLAM J2 socket 8 [X087.8.soc]?

Yes Go to step 11

No Leave the #1 boom angle sensor [X099] discon-nected. Go to step 10.

Step 10 Disconnect the #1boom angle sensor [X099] and boom angle sensor 1 passthru [X095] (See Figure 2-5. Main Valve Area Con-nectors on Pg. 119 for loca-tion).

Is there continuity between #1 boom angle sensor pin 2 [X099.2.pin] and boom angle sensor 1 passthru pin 2 [X095.2.pin]? Also, are the contacts free from damage and seated correctly?

Yes Repair/replace harness between boom angle sensor 1 pass through [X095] and BLAM J2 [X087]

No Repair/replace harness between #1 boom angle sensor pin 2 [X099.2.pin] and #1 boom angle sensor passthru - 4 position pin 2 [X095.2.pin]

Step 11 Disconnect the #1 boom angle sensor passthru - 4 position [X095]. Turn on the machine.

Is there 12VDC between the #1 boom angle sensor passthru socket 1 [X095.1.soc] and socket 3 [X095.3.soc]?

Yes Leave the connector disconnected and machine on. Go to step 13.

No Go to step 12

Step 12 Disconnect battery busbar - 12 pos. [X097] and ground busbar - 12 pos. [X098]

Is there 12VDC between ANY of the sockets in battery busbar [X097] and ANY of the sockets in ground busbar [X098]? This measurement may also be taken by backprobing the connec-tor without disconnecting it. (See Backprob-ing on Pg. 245.)

Yes Repair/replace harness and or connectors between #1 boom angle sensor passthru [X095] and the 12-pin V-Batt+ bus connector sockets [X097] and/or 12-pin ground bus connector sockets [X098].

No Repair/replace harness and or connectors between battery busbar - 12 pos. [X097] and 6-pin Deutsch connector socket 2 [X280.2.soc] and/or the ground busbar - 12 pos. [X098] and 6-pin Deutsch connector socket 5 [X280.5.soc]


1-68 1200SJP 1350SJP 3128411


DTC 8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULTBoom angle sensor #2 communications fault. The control system lost serial communications with #2 boom angle sensor (Operator’s left side).

Step 13 Disconnect the #1 boom angle sensor [X099]. Turn on the machine.

Is there 12VDC between the #1 boom angle sensor harness connector closest to the sen-sor socket 1 [X099.1.soc] and socket 3 [X099.3.soc]?

Yes Leave the connector disconnected. Go to step 14.

No Repair/replace the harness and or connectors between the #1 boom angle sensor [X099] and #1 boom angle sensor passthru [X095]

Step 14 Disconnect the #1 boom angle sensor [X099] and the BLAM connector J2 [X087]

Is there continuity between #1 boom angle sensor socket 2 [X099.2.soc] and the BLAM connector J2 socket 8 [X087.8.soc]? Also, are the contacts free from damage?

Yes Reprogram/replace the BLAM

No Repair/replace harness and/or contacts as needed

Note Pretest Instructions Test Result Corrective Action Step 1 Are there loose or damaged connections at the

#2 boom angle sensor connector [X100]?Yes Repair any loose or damaged wires or connec-

tors

No Go to step 2

Step 2 Does the fault log show BOOM ANGLE SEN-SOR #1 COMMUNICATIONS FAULT before a power cycle?

Yes Go to step 4

No Go to step 3

Step 3 Turn on machine. Discon-nect #2 boom angle sensor connector [X100]

Is there 12VDC on #2 boom angle sensor connector socket 1 [X100.1.soc] and socket 3 [X100.3.soc]?

Yes Leave connector disconnected. Go to step 8.

No Go to step 4

Step 4 Turn on machine. Back-probe between the 12-pin ground bus connector [X098] and 12-pin V-Batt+ bus connector [X097] by the BLAM. (See Backprobing on Pg. 245 for details on backprobing.)

Is there 12VDC between 12-pin V-Batt+ bus connector[X097] and 12-pin ground bus con-nector [X098]?

Yes Repair/replace 12-pin V-Batt+ bus connector [X097] and/or 12-pin ground bus connector [X098].

No Leave machine on. Go to step 5.

Step 5 Turn on machine. Discon-nect 6-pin Deutsch connec-tor [X280].

Is there 12VDC between 6-pin Deutsch pin 2 [X280.2.pin] and pin 5 [X280.5.pin]?

Yes Go to step 11

No Leave 6-pin Deutsch connector [X280] dicon-nected. Go to step 6.

Step 6 Disconnect 6-pin Deutsch connector [X280] and Power Down Relay [X011]

Is there a short between 6-pin Deutsch con-nector pin 2 [X280.2.pin] and Power Down Relay socket 87 [X011.87.soc]?

Yes Leave 6-pin Deutsch connector [X280] discon-nected. Go to step 7.

No Repair/Replace harness between 6-pin Deutsch connector [X280], including the bus connector itself and the Power Down Relay [X011]

Step 7 Disconnect 6-pin Deutsch connector [X280] and ground control module J8 [X008]

Is there a short between 6-pin Deutsch con-nector pin 2 [X280.2.pin] and ground control module J8 socket 3 [X008.3.soc]?

Yes Ensure both contacts of the 6-pin Deutsch con-nector terminal 2 [X280.2] are seated properly in the connector bodies and that there is continuity between all pins.

No Repair/replace harness and or connectors between 6-pin Deutsch connector [X280] and ground control module J3 socket 3 [X008.3]


3128411 1200SJP 1350SJP 1-69


DTC 8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE Angle sensor number 1 invalid angle. Boom angle sensor 1 (right) is reading over +80 degrees or less than -25 degrees.

Step 8 Plug the #1 boom angle sensor connector [X099] into the #2 sensor and the #2 boom angle sensor con-nector [X100] into the #1 sensor. Read faults.

Does the BOOM ANGLE SENSOR #1 COM-MUNICATIONS FAULT appear?

Yes Replace sensor #2

No Go to step 9

Step 9 Disconnect #2 boom angle sensor connector [X100] and BLAM J2 [X087]

Is there continuity between #2 boom angle sensor pin 2 [X100.2.pin] and BLAM J2 socket 9 [X087.9.soc]?

Yes Go to step 11

No Leave the #2 boom angle sensor [X100] discon-nected. Go to step 10.

Step 10 Disconnect the #2 boom angle sensor [X100] and #2 angle sensor passthru [X096] (See Figure 2-5. Main Valve Area Connectors on Pg. 119 for location).

Is there continuity between #2 boom angle sensor socket 2 [X100.2.soc] and #2 boom angle sensor passthru pin 2 [X096.2.pin]? Also, are the contacts free from damage and seated correctly?

Yes Repair/replace harness between #2 angle sen-sor pass through [X096] and BLAM J2 [X087]

No Repair/replace harness between #2 boo m angle sensor socket 2 [X100.2.soc] and #2 boom angle sensor passthru - 4 position pin 2 [X096.2.pin]

Step 11 Disconnect the #2 boom angle sensor passthru - 4 position [X096]. Turn on the machine.

Is there 12VDC between the #2 boom angle sensor passthru socket 1 [X096.1.soc] and socket 3 [X096.3.soc]?

Yes Leave the connector disconnected and machine on. Go to step 13

No Go to step 12

Step 12 Disconnect battery busbar - 12 pos. [X097] and ground busbar - 12 pos. [X098]

Is there 12VDC ANY of the sockets in battery busbar [X097] and ANY of the sockets in ground busbar [X098]? This measurement may also be taken by backprobing the connec-tor without disconnecting it. (See Backprob-ing on Pg. 245.)

Yes Repair/replace harness and or connectors between #2 boom angle sensor passthru [X096] and the 12-pin V-Batt+ bus connector sockets [X097] and/or 12-pin ground bus connector sockets [X098].

No Repair/replace harness and or connectors between battery busbar - 12 pos. [X097] and 6-pin Deutsch connector socket 2 [X280.2.soc] and/or the ground Busbar - 12 pos. [X098] and 6-pin Deutsch connector socket 5 [X280.5.soc]

Step 13 Disconnect the #2 boom angle sensor [X100]. Turn on the machine.

Is there 12VDC between the #2 boom angle sensor harness connector closest to the sen-sor socket 1 [X100.1.soc] and socket 3 [X100.3.soc]?

Yes Leave the connector disconnected. Go to step 14

No Repair/replace the harness and or connectors between the #2 boom angle sensor [X100] and #2 boom angle sensor passthru [X096].

Step 14 Disconnect the #2 boom angle sensor [X100] and the BLAM connector J2 [X087]

Is there continuity between #2 boom angle sensor socket 2 [X100.2.soc] and the BLAM connector J2 socket 9 [X087.9.soc]? Also, are the contacts free from damage?

Yes Reprogram/replace the BLAM

No Repair/replace harness and/or contacts as needed

Note Pretest Instructions Test Result Corrective Action Step 1 Check fault log for active

faults.Is BOOM ANGLE SENSOR #1 COMMUNICA-TIONS FAULT present?

Yes Troubleshoot that fault first

No Go to step 2

Step 2 Is sensor mounted correctly and undamaged? Yes Go to step 3

No Repair as needed


1-70 1200SJP 1350SJP 3128411


DTC 8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLEAngle sensor number 2 invalid angle. Boom Angle sensor 2 (left) is reading over +80 degrees or less than -25 degrees.

Step 3 Disconnect Boom Angle Sensor #1 (Right) [X099].

Does BOOM ANGLE SENSOR #2 COMMUNI-CATIONS FAULT appear?

Yes Sensor connections between sensor #1 [X099] and #2 [X100] are swapped. Restore proper connections.

No Go to step 4

Step 4 Disconnect Boom Angle Sensor #1 (Right) [X099].

Turn on the machine. Is there about 12 VDC between Boom Angle Sensor #1 socket1 [X099.1.soc] and socket 3 [X099.2.soc]?

Yes Keep sensor disconnected. Go to step 6

No Go to step 5

Step 5 Disconnect Boom Angle Sensor #1 Passthru [X095]

Turn on the machine. Is there about 12 VDC between Boom Angle Sensor #1 Passthru socket 1 [X095.1.soc] and socket 3 [X095.3.soc]?

Yes Repair/replace harness between Boom Angle sensor #1 Passthru [X095] and Boom Angle Sensor #1 [X099].

No Repair/replace harness between Boom angle Sensor #1 Passthru [X095] and both the Battery bus Bar [X097X] and Ground Bus Bar [X098]

Step 6 Disconnect Boom Angle Sensor #1 (Right) [X099] and Boom Angle Sensor #1 Passthrough [X095]

Is there continuity between Boom Angle Sen-sor #1 (Right) socket 2 [X099.2.soc] and Boom Angle Sensor #1 Passthrough pin 2 [X095.2.pin]?

Yes Go to step 7

No Repair/replace harness between Boom Angle Sensor #1 (Right) socket 2 [X099.2.soc] and Boom Angle Sensor #1 Passthrough pin 2 [X095.2.pin]

Step 7 Disconnect Boom Angle Sensor #1 Passthru [X095] and BLAM J2 [X087]

Is there continuity between Boom Angle Sen-sor #1 Passthru socket 2 [X095.2.soc] and BLAM J2 socket 8 [X087.8.soc]?

Yes Go to step 8

No Repair /replace harness between Boom Angle Sensor #1 Passthru socket 2 [X095.2.soc] and BLAM J2 socket 8 [X087.8.soc]

Step 8 Put boom in transport posi-tion. Go to ANALYZER DIAGNOSTICS ENVE-LOPE MAIN BOOM A/D ANGLE #1.

Observe value while operating boom lift up through normal range of operation. Does the value change slowly and smoothly starting at about -39 and then increase?

Yes Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228.

No Replace Boom Angle Sensor #1 (Right) [X099]

Note Pretest Instructions Test Result Corrective Action Step 1 Check fault log for active

faults.Is BOOM ANGLE SENSOR #1 COMMUNICA-TIONS FAULT present?

Yes Troubleshoot that fault first

No Go to step 2

Step 2 Is sensor mounted correctly and undamaged? Yes Go to step 3

No Repair as needed

Step 3 Disconnect Boom Angle Sensor #2 (Left) [X100].

Does BOOM ANGLE SENSOR #1 COMMUNI-CATIONS FAULT appear?

Yes Sensor connections between sensor #1 [X099] and #2 [X100] are swapped. Restore proper connections.

No Go to step 4

Step 4 Disconnect Boom Angle Sensor #2 (Left) [X100].

Turn on the machine. Is there about 12 VDC between Boom Angle Sensor #2 socket1 [X100.1.soc] and socket 3 [X100.2.soc]?

Yes Keep sensor disconnected. Go to step 6

No Go to step 5


3128411 1200SJP 1350SJP 1-71


DTC 8413 - WRONG TELESCOPE RESPONSEWrong telescope response. Boom telescope movement contrary to user command. This could be caused by a hydraulic problem preventing the boom from telescoping in the direction commanded.

Step 5 Disconnect Boom Angle Sensor #2 Passthru [X096]

Turn on the machine. Is there about 12 VDC between Boom Angle Sensor #2 Passthru socket 1 [X096.1.soc] and socket 3 [X096.3.soc]?

Yes Repair/replace harness between Boom Angle sensor #2 Passthru [X096] and Boom Angle Sensor #2 [X100].

No Repair/replace harness between Boom angle Sensor #2 Passthru [X096] and both the Battery bus Bar [X097X] and Ground Bus Bar [X098].

Step 6 Disconnect Boom Angle Sensor #2 (Left) [X100] and Boom Angle Sensor #2 Passthrough [X096]

Is there continuity between Boom Angle Sen-sor #2 (Left) socket 2 [X100.2.soc] and Boom Angle Sensor #2 Passthrough pin 2 [X096.2.pin]?

Yes Go to step 7

No Repair/replace harness between Boom Angle Sensor #2 (Left) socket 2 [X100.2.soc] and Boom Angle Sensor #2 Passthrough pin 2 [X096.2.pin]

Step 7 Disconnect Boom Angle Sensor #2 Passthru [X096] and BLAM J2 [X087]

Is there continuity between Boom Angle Sen-sor #2 Passthru socket 2 [X096.2.soc] and BLAM J2 socket 9[X087.9.soc]?

Yes Go to step 8

No Repair /replace harness between Boom Angle Sensor #2 Passthru socket 2 [X096.2.soc] and BLAM J2 socket 9 [X087.9.soc]

Step 8 Put boom in transport posi-tion. Go to ANALYZER DIAGNOSTICS ENVE-LOPE MAIN BOOM A/D ANGLE #2.

Observe value while operating boom lift up through normal range of operation. Does the value change slowly and smoothly starting at about -39 and then increase?

Yes Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228.

No Replace boom Angle Sensor #2 (Left) [X100]

Note Pretest Instructions Test Result Corrective Action Step 1 Are there any faults for the Boom Length Sen-

sor [X273], Boom Length Limit Switch [X281], Main Tele In[X073] or Main Tele Out [X071]?

Yes Troubleshoot those faults first

No Go to step 2

Step 2 Raise and extend boom. Operate main boom telescope IN and OUT. Is the response correct?

Yes Go to step 3

No Go to step 6

Step 3 Extend boom completely Apply lubricant to wear pad tracks on booms. Move boom in and out completely. Does fault clear?


No Go to step 4

Step 4 Torque boom wire ropes. See 5.10 Wire Rope Tensioning Procedure on Pg. 240. Does fault clear?


No Go to step 5

Step 5 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228. Also, calibrate telescope crack points. See 5.8 Cali-brating Telescope Crack point on Pg. 225.

Does calibration complete successfully? Yes Troubleshooting complete

No Repair according to calibration fault

Step 6 Disconnect main tele in [X073] connector

Does the fault MAIN OUT OPEN CIRCUIT appear?

Yes Harnesses for main tele in [X073] and main tele out [X071] are swapped. Correct them.

No Go to step 7


1-72 1200SJP 1350SJP 3128411


DTC 8414 - WRONG LIFT RESPONSEWrong lift response. Boom lift movement contrary to user command. This could be caused by a hydraulic problem prevent-ing the boom from lifting in the direction commanded.

DTC 851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGEMoment pin - horizontal force out of range. The control system has detected that the force applied to the horizontal axis of the moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is required.

Step 7 Does the hosing between the main valve - main tele section and main tele cylinder match the schematic in Figure 3-12. Hydraulic Sche-matic - Boom Control - Sheet 1 of 2 on Pg. 174?

Yes Repair/replace main tele cylinder holding valve

No Correct hosing as needed

Note Pretest Instructions Test Result Corrective Action Step 1 Are there any faults for the Boom Angle Sen-

sors [X099] & [X100], or Main lift UP [X276] and Main lift Down [X277]?

Yes Troubleshoot them first

No Go to step 2

Step 2 Raise and extend boom. Operate main boom lift UP and DOWN. Is the response correct?

Yes Go to step 3

No Go to step 4

Step 3 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228. Also, calibrate lift crack points. See 5.7 Calibrating Lift Crack Point on Pg. 222.

Do both calibrations complete successfully? Yes Troubleshooting complete

No Repair according to calibration fault

Step 4 Does the main lift up solenoid have a tan 3-3 wire? -AND- Does main lift down solenoid have a tan 4-3 wire?

Yes Go to step 5

No Harnesses for main lift up [X276] and main lift down [X277] are swapped. Correct them.

Step 5 Does the hosing between the main valve - main lift valves and main lift cylinder match the schematic in Figure 3-12. Hydraulic Sche-matic - Boom Control - Sheet 1 of 2 on Pg. 174?

Yes Repair/replace main tele cylinder holding valve

No Correct hosing as needed

Note Pretest Instructions Test Result Corrective Action Step 1 Calibrate boom sensors.

See 5.9 Calibrating the Boom Sensors on Pg. 228 for details.

Does fault still occur? -OR- Does pin fail to cal-ibrate?

Yes Replace moment pin



3128411 1200SJP 1350SJP 1-73


DTC 852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGEMoment pin - vertical force out of range. The control system has detected that the force applied to the vertical axis of the

moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is required.

DTC 855 - MOMENT PIN - SENSOR FAULTMoment pin sensor fault. The control system has detected a fault in the moment pin.

DTC 857 - NEW MOMENT PIN DETECTED FAULTNew moment pin detected fault. The moment pin detected by the system is different from the one used to calibrate machine.

DTC 861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH DISAGREEMENT

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



Does fault still occur? -OR- Does pin fail to cal-ibrate?

Yes Replace moment pin




Does fault still occur? Yes Replace moment pin




Does fault still occur? Yes Replace moment pin


Note Pretest Instructions Test Result Corrective Action Step 1 Is the primary fault, 33173 - RESTRICTED TO

TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT present in the fault log?

Yes Troubleshoot any primary faults first

No Go to step 2

Step 2 With the machine idling, does ANALYZER DIAGNOSTICS SYSTEM OSCILATING AXLE PRES. SW. read CLOSED?

Yes Go to step 14

No Go to step 3

1-74 1200SJP 1350SJP 3128411


Step 3 While drive is activated in the transport posi-tion does ANALYZER DIAGNOSTICS SYSTEM OSCILATING AXLE PRES. SW. read CLOSED?

Yes Go to step 4

No Go to step 5

Step 4 While drive is activated in the elevated position does ANALYZER DIAGNOSTICS SYS-TEM OSCILATING AXLE PRES. SW. read OPEN?

Yes Perform drive calibration. See 5.3 Calibrating Drive on Pg. 210.

No Check the fault log. Troubleshoot any 3-3 codes in the fault log first

Step 5 Tee in a 1000 psi pressure gauge next to the pressure switch on the traction con-trol valve manifold

While drive is activated in the transport posi-tion does the gauge read above 200 psi?

Yes Go to step 11

No Go to step 6

Step 6 Connect a 1000 psi pres-sure gauge to the MP port on the traction control valve manifold

With the machine idling, can the pressure be adjusted with the adjacent charge relief valve so that the gauge reads 500psi?

Yes Replace the axle lockout valve cartridge

No Go to step 7

Step 7 Disconnect, plug and cap all four drive hoses at the top of the swivel (ports 3, 4, 5, and 6). Tee a gauge in with the hoses at the charge (pres-sure) filter (on engine side). Plug open lines.

Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi?

Yes Reassemble, but keep gauge installed. Go to step 9.

No Shut down, and reassemble, but keep gauge installed. Go to step 8.

Step 8 Tee a gauge in with the hoses at the charge filter. Disconnect the front drive pump charge pressure lines (ports Fa and Fe). A jumper hose between the fittings on the pump is required to pre-vent pump damage.


Yes Repair/replace right side drive pump

No Repair/replace left side drive pump.

Step 9 Disconnect, plug and cap all four drive hoses at the bot-tom of the swivel (ports 3, 4, 5, and 6). Tee a gauge in with the hoses at the charge filter. Plug open lines.


Yes Shut down, and reassemble, but keep gauge installed. Go to step 10.

No Repair seals in swivel.

Step 10 Disconnect hoses to trac-tion valve ports A3, A4, A5, A6, B3, B4, B5, and B6. Plug/cap open lines and ports. Tee a gauge in with the hoses at the charge filter.


Yes Repair drive motor leakage or replace.

No Repair/replace traction valve.

Step 11 Does the voltage at the axle lockout pressure switch connector YEL/RED 2-1-7 wire [X213.1.soc] measure 12VDC?

Yes Go to step 12

No Check YEL/RED 2-1-7 wire for breaks between the axle lockout pressure switch [X213] and ter-minal 1 of the Chassis module J4 connector [X232.1]

Step 12 While drive is activated in the transport posi-tion, does the voltage at the axle lockout pres-sure switch connector ORN/RED 49-107 wire [X213.3] measure 12VDC?

Yes Go to step 13

No Replace the axle lockout pressure switch


3128411 1200SJP 1350SJP 1-75


DTC 862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUITAxle extend short to battery or open circuit. The control system detected a short to battery or open circuit on the axle exten-sion valve output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 863 - AXLE EXTEND VALVE - SHORT TO GROUNDAxle extend short to ground. The control system detected a short to ground on the axle extension valves output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PRO-CEDURE on Pg. 114.

DTC 864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUITAxle retract short to battery or open circuit. The control system detected a short to battery or open circuit on the axle retract valves output [X230.12] controlling the front axles retract solenoid [X209] and the rear axles retract solenoid [X221]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 865 - AXLE RETRACT VALVE - SHORT TO GROUNDAxle retract short to ground. The control system detected a short to ground on the axle retract valves output [X230.12] con-trolling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PROCE-DURE on Pg. 114.

DTC 866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUITRight front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right front steer right valve output [X233.1]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

Step 13 While drive is activated in the transport posi-tion, does the voltage at terminal 7 of the chas-sis module J2 connector ORN/RED 49-107 wire [X230.7.soc] measure 12VDC?


No Check ORN/RED 49-107 wire for breaks between the axle lockout pressure switch [X213] and ter-minal 7 of the Chassis module J2 connector [X230.7]

Step 14 Plumb a 1000 psi pressure gauge to the pressure switch port on the traction control valve manifold

With the machine idling, does the gauge read any pressure?

Yes Go to step 15

No Go to step 16

Step 15 Remove the axle lockout valve solenoid from the valve. Tee in a 1000 psi pressure gauge next to the pressure switch on the trac-tion control valve manifold

With the machine idling, does the gauge read any pressure?


No Go to DTC 33173 - RESTRICTED TO TRANS-PORT - AXLE LOCKOUT VALVE - SHORT TO BAT-TERY OR OPEN CIRCUIT

Step 16 Disconnect the axle lockout pressure switch DIN con-nector [X213]

With the machine idling, does ANALYZER DIAGNOSTICS SYSTEM OSCILATING AXLE PRES. SW. read CLOSED?

Yes Go to step 17

No Replace the axle lockout pressure switch

Step 17 Remove socket 7 from the chassis module J2 connec-tor [X230.7.soc]

With the machine idling, does ANALYZER DIAGNOSTICS SYSTEM OSCILATING AXLE PRES. SW. read CLOSED?


No Check the ORN/RED 49-107 wire for shorts between the axle lockout pressure switch [X213] and terminal 7 of the Chassis module J2 connec-tor [X230.7]


1-76 1200SJP 1350SJP 3128411


DTC 867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUNDRight front steer right short to ground. The control system detected a short to ground on the chassis module right front steer right valve output [X233.1]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUITRight front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right front steer left valve output [X233.2]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUNDRight front steer left short to ground. The control system detected a short to ground on the chassis module right front steer left valve output [X233.2]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUITLeft front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module left front steer left valve output [X233.3].

Note Pretest Instructions Test Result Corrective Action Step 1 Connect analyzer and read

fault log Does fault log shows other steer STB or OC faults.

Yes Go to step 2

No Go to step 4

Step 2 Disconnect chassis module J1 [X230] and battery nega-tive terminal [X117]

Check for an open between chassis module J1 [X229] socket 4 [X229.4.soc] and the nega-tive battery terminal

Yes Leave negative battery terminal disconnected. Go to step 8

No Go to step 3

Step 3 Is there a bad connection at chassis module J5 connector [X233] or the left front steer right solenoid connector [X207]?

Yes Re-connect connector

No Go to step 4

Step 4 Disconnect the left front steer right solenoid connec-tor [X207]. Measure the solenoid resistance.

Is the solenoid resistance about 4.9 ? Yes Go to step 5

No Replace solenoid

Step 5 Disconnect the left front steer right solenoid connec-tor [X207] and chassis module J5 [X233].

Are all contacts good and is there continuity between left front steer right solenoid connec-tor [X207] YELLOW wire and Chassis module J5 socket 4 [X233.4.soc]?

Yes Leave solenoid connector and chassis module J5 disconnected. Go to step 6

No Repair/Replace harness

Step 6 Disconnect positive battery terminal [X116], left front steer right solenoid [X207] and chassis module J5 [X233].

Is there a short between left front steer right solenoid [X207] YELLOW 9-1 wire and posi-tive battery terminal [X116]?

Yes Repair/Replace harness

No Go to step 7

Step 7 Check black ground wire between terminal 5 of the bottom swivel connector [X216.5.soc] and the left front steer right solenoid connector [X207]

Are there loose, bent, broken or corroded wires or contacts or moisture in the connec-tors?


No Repair/Replace connector as needed.

Step 8 Disconnect Upper Swivel connector [X083] and nega-tive battery terminal [X117].

Is there an open between socket 5 [X083.5.soc] and battery negative terminal [X117]?


No Leave negative battery terminal disconnected. Go to step 9

3128411 1200SJP 1350SJP 1-77


DTC 8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUNDLeft front steer right short to ground. The control system detected a short to ground on the chassis module left front steer right valve output [X233.3].

DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUITLeft front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chas-sis module left front steer left valve output [X233.4].

Step 9 Disconnect negative battery terminal [X117] and Lower Swivel connector [X216].

Is there an open between negative battery ter-minal [X117] and Lower Swivel connector pin 5 [X216.5.pin]?

Yes Replace swivel

No Repair/replace harness to Chassis module.

Step 10 Disconnect negative battery terminal [X117]

Is there an open between Auxiliary Power Pump negative terminal and the negative bat-tery terminal [X117].

Yes Repair/replace harness between Auxiliary Power Pump negative terminal and negative battery ter-minal.

No Repair/replace harness between Upper Swivel connector and Auxiliary Power Pump negative connector.

Note Pretest Instructions Test Result Corrective Action Step 1 Disconnect the left front

steer right solenoid connec-tor [X207]

Is the solenoid about 4.9 ? Yes Leave the left front steer right solenoid connector [X207] disconnected. Go to step

No Replace solenoid

Step 2 Disconnect the left front steer right solenoid connec-tor [X207], the chassis module J5 connector and the and the Lower Swivel connector [X216].

Is there a short between the left front steer right solenoid connector [X207] YELLOW 10-1 wire and the Lower Swivel connector socket 5 [X216.5.soc]?


No Check for loose, bent or corroded contacts or moisture in the connectors. Repair/Replace con-nector as needed.

Note Pretest Instructions Test Result Corrective Action Step 1 Connect analyzer and read

fault log Does fault log shows other steer STB or OC faults.

Yes Go to step 2

No Go to step 4

Step 2 Disconnect chassis module J1 [X230] and battery nega-tive terminal [X117]

Check for an open between chassis module J1 [X229] socket 4 [X229.4.soc] and the nega-tive battery terminal


No Go to step 3

Step 3 Is there a bad connection at chassis module J5 connector [X233] or the left front steer left solenoid connector [X210]?

Yes Re-connect connector

No Go to step 4

Step 4 Disconnect the left front steer left solenoid connector [X210]. Measure the sole-noid resistance.

Is the solenoid resistance about 4.9 ? Yes Go to step 5

No Replace solenoid

Step 5 Disconnect the left front steer left solenoid connector [X210] and chassis module J5 [X233].

Are all contacts good and is there continuity between left front steer left solenoid connector yellow wire and Chassis module J5 socket 4 [X233.4.soc]?

Yes Leave solenoid connector and chassis module J5 disconnected. Go to step 6

No Repair/Replace harness


1-78 1200SJP 1350SJP 3128411


DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUNDLeft front steer left short to ground. The control system detected a short to ground on the chassis module left front steer left valve output [X233.4].

DTC 8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUITRight rear steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right rear steer right valve output [233.5]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUNDRight rear steer right short to ground. The control system detected a short to ground on the chassis module right rear steer right valve output [233.5]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

Step 6 Disconnect positive battery terminal [X116], left front steer left solenoid [X210] and chassis module J5 [X233].

Is there a short between left front steer left solenoid [X210] YELLOW 9-1 wire and posi-tive battery terminal [X116]?


No Go to step 7

Step 7 Check black ground wire between terminal 5 of the bottom (chassis) swivel connector [X216.5.soc] and the left front steer left sole-noid connector [X210]

Are there loose, bent, broken or corroded wires or contacts or moisture in the connec-tors?


No Repair/Replace connector as needed.

Step 8 Disconnect Upper Swivel connector [X083] and nega-tive battery terminal [X117].

Is there an open between socket 5 [X083.5.soc] and battery negative terminal [X117]?


No Leave negative battery terminal disconnected. Go to step 9

Step 9 Disconnect negative battery terminal [X117] and Lower Swivel connector [X216].

Is there an open between negative battery ter-minal [X117] and Lower Swivel connector pin 5 [X216.5.pin]?

Yes Replace swivel

No Repair/replace harness to Chassis module.

Step 10 Disconnect negative battery terminal [X117]

Is there an open between Auxiliary Power Pump negative terminal and the negative bat-tery terminal [X117].

Yes Repair/replace harness between Auxiliary Power Pump negative terminal and negative battery ter-minal.

No Repair/replace harness between Upper Swivel connector and Auxiliary Power Pump negative connector.

Note Pretest Instructions Test Result Corrective Action Step 1 Disconnect the left front

steer left solenoid connector [X210].

Is the solenoid about 4.9 ? Yes Leave the left front steer left solenoid [X210]dis-connected. Go to step 2

No Replace the solenoid

Step 2 Disconnect chassis module connector J5 [X233] left front steer left solenoid con-nector [X210] and the Lower Swivel connector [X216]

Is there a short between YELLOW 9-1 on the left front steer left solenoid connector [X210] and the Lower Swivel connector socket 5 [X216.5.soc]?


No Check for loose, bent or corroded contacts or moisture in the connectors. Repair/Replace con-nector as needed.


3128411 1200SJP 1350SJP 1-79


DTC 8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUITRight rear steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right rear steer left valve output [233.6]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUNDRight rear steer left short to ground. The control system detected a short to ground on the chassis module right rear steer left valve output [233.6]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUITLeft rear steer right short to battery or open circuit. the control system detected a short to battery or open circuit on the chas-sis module left rear steer right valve output [X233.7]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUNDLeft rear steer right short to ground. The control system detected a short to ground on the chassis module left rear steer right valve output [X233.7]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUITLeft rear steer left short to battery or open circuit. the control system detected a short to battery or open circuit on the chassis module left rear steer left valve output [X233.8]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.

DTC 8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUNDLeft rear steer left short to ground. The control system detected a short to ground on the chassis module left rear steer left valve output [X233.8]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.

DTC 8622 - FRONT RIGHT STEER SENSOR - DECOUPLEDFront right wheel steering sensor decoupled. The control system detected the front right steer angle sensor value was below the mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the sensor may be faulty.

Note Pretest Instructions Test Result Corrective Action Step 1 Check faults Is the fault FRONT RIGHT WHEEL BLOCKED

present?Yes Troubleshoot that first

No Go to step 2

Step 2 Disconnect front right steer sensor [X200]

Do the connectors have any loose, damaged, corroded contacts or moisture inside?


No Go to step 3

Step 3 Is the front right wheel sensor [X200] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sensor is properly tensioned.

Yes Go to step 4

No Reinstall and recheck

Step 4 Extend axles. Go to ANA-LYZER DIAGNOSTICS DRIVE R FRONT WHEEL ANGL

Monitor value while operating steering. Steer fully to the left, then fully to the right. Does the displayed angle ever climb above ±42.11? -OR- Does the value pause, jump or act errati-cally?

Yes Repair/replace sensor and mounting as needed

No Go to step 5

Step 5 Swap front right wheel sen-sor [X200] with a sensor that doesn’t have a fault.

Check faults. Does the new location now have a wheel sensor fault?

Yes Replace sensor originally at the front right wheel.

No Go to step 6

1-80 1200SJP 1350SJP 3128411


DTC 8623 - FRONT LEFT STEER SENSOR - DECOUPLEDFront left wheel steering sensor not sensing movement. The control system detected the front left steer angle sensor value was below the mechanical minimum angle while the steer sensor is attached to the wheel. The mechanical limitations on the maximum steering angle depend on the axle extension. When fully retracted, the steering will be mechanically limited to about 25°. As the axle is extended, the mechanical limit will increase to about 45°, however the control system will maintain a 25° limit until the axle is fully extended, when the control system allows the full 45° of steering. The sensor may be mounted improperly or the sensor may be faulty.

Step 6 Calibrate steering. Does fault clear? Yes Troubleshooting complete

No Go to step 7

Step 7 Disconnect front right wheel sensor [X200]

Turn on machine. Is there 5VDC between front right wheel sensor socket A [X200.A.soc] and socket C [X200.C.soc]?

Yes Keep sensor disconnected.Go to step 8.

No Go to step 10

Step 8 Disconnect front right wheel sensor [X200] and chassis module J3 [X231]

Is there continuity between front left wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]?

Yes Reprogram/replace ground module

No Keep front right wheel sensor [X200] discon-nected.Go to step 9

Step 9 Disconnect front right wheel sensor [X200] and front right steer passthru - 4 pos. [X201]

Is there continuity between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]?

Yes Repair harness between front right steer passthru socket 2 [X201.2.soc] and chassis module J3 socket 2 [X231.2.soc]

No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]

Step 10 Disconnect front right steer passthru - 4 pos. [X201]. Turn on machine.

Is there 5VDC between front right steer passthru socket 1 [X201.1.soc] and socket 3 [X201.3.soc]?

Yes Repair/replace harness between front right steer passthru [X201] and front right wheel sensor [X200]

No Go to step 11

Step 11 Disconnect chassis module J3. Turn on machine.

Is there 5VDC between chassis module J3 pin 1 [X231.1.pin] and pin 3 [X231.3.pin]?

Yes Repair/Replace harness between front right steer passthru [X201] and chassis module J3 [X231]

No Replace chassis module

Note Pretest Instructions Test Result Corrective Action Step 1 Check faults Is the fault FRONT LEFT WHEEL BLOCKED


No 2

Step 2 Disconnect front left steer sensor [X203]



No Go to step 3

Step 3 Is the front left wheel sensor X203] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sen-sor is properly tensioned.

Yes Go to step 4


Step 4 Extend axles. Go to ANA-LYZER DIAGNOSTICS DRIVE L FRONT WHEEL ANGL



No Go to step 5

Step 5 Swap front left wheel sensor [X203] with a sensor that doesn’t have a fault.


Yes Replace sensor originally at the front left wheel.

No Go to step 6


3128411 1200SJP 1350SJP 1-81


DTC 8624 - REAR RIGHT STEER SENSOR - DECOUPLEDRear right wheel sensor decoupled. The control system detected the rear right steer angle sensor value was below the mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the sensor may be faulty.


No Go to step 7

Step 7 Disconnect front left wheel sensor [X203]

Turn on machine. Is there 5VDC between front left wheel sensor socket A [X203.A.soc] and socket C [X203.C.soc]?


No Go to step 10

Step 8 Disconnect front left wheel sensor [X203] and chassis module J3 [X231]



No Keep front left wheel sensor [X203] discon-nected.Go to step 9

Step 9 Disconnect front left wheel sensor [X203] and front left steer passthru - 4 pos. [X202]

Is there continuity between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin]?

Yes Repair harness between front left steer passthru socket 2 [X202.2.soc] and chassis module J3 socket 5 [X231.5.soc]

No Repair/replace harness between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin]

Step 10 Disconnect front left steer passthru - 4 pos. [X202]. Turn on machine.

Is there 5VDC between front left steer passthru socket 1 [X202.1.soc] and socket 3 [X202.3.soc]?

Yes Repair/replace harness between front left steer passthru [X202] and front left wheel sensor [X203]

No Go to step 11



Yes Repair/Replace harness between front left steer passthru [X202] and chassis module J3 [X231]


Note Pretest Instructions Test Result Corrective Action Step 1 Check faults Is the fault REAR RIGHT WHEEL BLOCKED


No 2

Step 2 Disconnect rear right steer sensor [X239]



No Go to step 3

Step 3 Is the rear right wheel sensor [X239] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sensor is properly tensioned.

Yes Go to step 4


Step 4 Extend axles. Go to ANA-LYZER DIAGNOSTICS DRIVE R REAR WHEEL ANGL



No Go to step 5

Step 5 Swap rear right wheel sen-sor [X239] with a sensor that doesn’t have a fault.


Yes Replace sensor originally at the rear right wheel.

No Go to step 6


No Go to step 7


1-82 1200SJP 1350SJP 3128411


DTC 8625 - REAR LEFT STEER SENSOR - DECOUPLEDRear left wheel sensor decoupled. The control system detected the rear left steer angle sensor value was below the mechan-ical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the sensor may be faulty.

Step 7 Disconnect rear right wheel sensor [X239]

Turn on machine. Is there 5VDC between rear right wheel sensor socket A [X239.A.soc] and socket C [X239.C.soc]?


No Go to step 10

Step 8 Disconnect rear right wheel sensor [X239] and chassis module J3 [X231]

Is there continuity between rear right wheel sensor socket B [X239.B.soc] and chassis module J3 socket 8 [X231.8.soc]?


No Keep rear right wheel sensor [X239] discon-nected.Go to step 9

Step 9 Disconnect rear right wheel sensor [X239] and rear right steer passthru - 4 pos. [X236]

Is there continuity between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin]?

Yes Repair harness between rear right steer passthru socket 2 [X236.2.soc] and chassis module J3 socket 8 [X231.8.soc]

No Repair/replace harness between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin]

Step 10 Disconnect rear left steer passthru - 4 pos. [X237]. Turn on machine.

Is there 5VDC between rear right steer passthru socket 1 [X236.1.soc] and socket 3 [X236.3.soc]?

Yes Repair/replace harness between rear left steer passthru [X237] and rear left wheel sensor [X238]

No Go to step 11



Yes Repair/Replace harness between rear right steer passthru [X236] and chassis module J3 [X231]


Note Pretest Instructions Test Result Corrective Action Step 1 Check faults Is the fault REAR LEFT WHEEL BLOCKED


No 2

Step 2 Disconnect rear left steer sensor [X238]



No Go to step 3

Step 3 Is the rear left wheel sensor [X238] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sen-sor is properly tensioned.

Yes Go to step 4


Step 4 Extend axles. Go to ANA-LYZER DIAGNOSTICS DRIVE L REAR WHEEL ANGL



No Go to step 5

Step 5 Swap rear left wheel sensor [X238] with a sensor that doesn’t have a fault.


Yes Replace sensor originally at the rear left wheel.

No Go to step 6


No Go to step 7


3128411 1200SJP 1350SJP 1-83


DTC 8626 - FRONT LEFT STEER SENSOR - NOT RESPONDINGFront left wheel steering sensor not sensing movement. The control system is unable to steer the front left wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front left steer angle sen-sor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.

Step 7 Disconnect rear left wheel sensor [X238]

Turn on machine. Is there 5VDC between rear left wheel sensor socket A [X238.A.soc] and socket C [X238.C.soc]?


No Go to step 10

Step 8 Disconnect rear left wheel sensor [X238] and chassis module J3 [X231]

Is there continuity between rear left wheel sen-sor socket B [X238.B.soc] and chassis mod-ule J3 socket 11 [X231.11.soc]?


No Keep rear left wheel sensor [X238] disconnected.Go to step 9

Step 9 Disconnect rear left wheel sensor [X238] and rear left steer passthru - 4 pos. [X237]

Is there continuity between rear left wheel sen-sor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin]?

Yes Repair harness between rear left steer passthru socket 2 [X238.2.soc] and chassis module J3 socket 11 [X231.11.soc]

No Repair/replace harness between rear left wheel sensor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin]


Is there 5VDC between rear left steer passthru socket 1 [X237.1.soc] and socket 3 [X237.3.soc]?


No Go to step 11



Yes Repair/Replace harness between rear left steer passthru [X237] and chassis module J3 [X231]


Note Pretest Instructions Test Result Corrective Action Step 1 Is the front left wheel kept from moving? Yes Free the wheel from any obstructions

No Go to step 2

Step 2 Check the fault log for primary faults, LT FNT STEER LT STB OR OC, LT FNT STEER LT STG, LT FNT STEER RT STB OR OC, LT FNT STEER RT STG, or any steering angle sensor fault

Yes If a primary fault is found, troubleshoot it before this fault

No Go to step 3

Step 3 Note that glow plug’s large power draw can aggravate existing problems with power distribution wiring and low battery power. Fre-quent starting can drain bat-tery when preheating.

When engine coolant temperature is below 140°F (60°C), air temperature is below 59°F (15°C), and battery voltage is less than 11VDC before starting, does fault mainly occur within 30 seconds after starting engine?

Yes Examine the battery condition and contacts within the Chassis power distribution wiring. Repair/replace as needed.

No Go to step 4

Step 4 Watch the angle sensor value on ANALYZER ACCESS LEVEL 1 CALI-BRATIONS STEER CALIBRATE? Press Enter to view raw value FRONT LT STEER VALUE = XX. Do not press Enter.

Steer completely left, pause, then completely right, pause. Does the value continuously and smoothly change while steering?

Yes ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Go to step 5

No Repair/Replace the sensor and calibrate.

Step 5 If the wheel will not steer in either direction, check the steer valve for a stuck spool.

Yes Repair/Replace the valve

No Go to step 6


1-84 1200SJP 1350SJP 3128411


DTC 8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDINGFront right wheel steering sensor not sensing movement. The control system is unable to steer the front right wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front right steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.

Step 6 Are there any bent, damaged, or seized steer-ing components?

Yes Repair/Replace the component

No Go to step 7

Step 7 Ensure proper pressure with ANALYZER ACCESS LEVEL 1 CALIBRATIONS STEER FRONT LT STEER VALUE = XX.

Install a 3000 psi gauge or higher on Front Steer Axle valve port MS1 and MS2 Adjust steer pressures on Front Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on gauge on port MS1. Adjust relief next to port to 2000 psi ± 10% on port MS2. ESC out of cali-brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear?


No Do not remove gauges. Go to step 8

Step 8 Install a low pressure gauge (1000 psi) on main manifold MP1 and adjust to 450 psi ± 10% on load sense

Is condition clear? Yes Troubleshooting complete


Step 9 Swap valve section with the one on the other side of machine.

Does condition follow valve section to other side of machine?

Yes Repair/replace valve section

No Repair/replace front left steer cylinder and/or hoses.

Note Pretest Instructions Test Result Corrective Action Step 1 Is the front right wheel kept from moving? Yes Free the wheel from any obstructions

No Go to step 2

Step 2 Check the fault log for primary faults, RT FNT STEER LT STB OR OC, RT FNT STEER LT STG, RT FNT STEER RT STB OR OC, RT FNT STEER RT STG, or any sensor value too high or too low


No Go to step 3




No Go to step 4

Step 4 Watch the angle sensor value on ANALYZER ACCESS LEVEL 1 CALI-BRATIONS STEER CALIBRATE? Press Enter then right arrow to view FRONT RT STEER VALUE = XX Do not press Enter.






No Go to step 6


3128411 1200SJP 1350SJP 1-85


DTC 8628 - REAR LEFT STEER SENSOR - NOT RESPONDINGRear left wheel steering sensor not sensing movement. The control system is unable to steer the rear left wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear left steer angle sen-sor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.



No Go to step 7

Step 7 Ensure proper pressure with ANALYZER ACCESS LEVEL 1 CALIBRATIONS STEER FRONT RT STEER VALUE = XX.

Install a 3000 psi gauge or higher on Front Steer Axle valve port MS3 and MS4 Adjust steer pressures on Front Steer/Axle valve. Adjust proper cartridge for 2600 psi ± 10% on gauge on port MS3. Adjust proper cartridge for 2000 psi ± 10% on port MS4. ESC out of cali-brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear?










Note Pretest Instructions Test Result Corrective Action Step 1 Is the rear left wheel kept from moving? Yes Free the wheel from any obstructions

No Go to step 2

Step 2 Check the fault log for primary faults, LT REAR STEER LT STB OR OC, LT REAR STEER LT STG, LT REAR STEER RT STB OR OC, LT REAR STEER RT STG, or any steer angle sen-sor fault


No Go to step 3




No Go to step 4

Step 4 Watch the angle sensor value on ANALYZER ACCESS LEVEL 1 CALI-BRATIONS STEER CALIBRATE? Press Enter to view raw value REAR LT STEER VALUE = XX Do not press Enter.






No Go to step 6


1-86 1200SJP 1350SJP 3128411


DTC 8629 - REAR RIGHT STEER SENSOR - NOT RESPONDINGRear right wheel steering sensor not sensing movement. The control system is unable to steer the rear right wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear right steer angle sen-sor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.



No Go to step 7

Step 7 Ensure proper pressure with ANALYZER ACCESS LEVEL 1 CALIBRATIONS STEER REAR LT STEER VALUE = XX.

Install a 3000 psi gauge or higher on Rear Steer Axle valve port MS1 and MS2 Adjust steer pressures on Rear Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on gauge on port MS1. Adjust relief next to port to 2000 psi ± 10% on port MS2. ESC out of cali-brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear?









No Repair/replace rear left steer cylinder and/or hoses.

Note Pretest Instructions Test Result Corrective Action Step 1 Is the right rear wheel kept from moving? Yes Free the wheel from any obstructions

No Go to step 2

Step 2 Check the fault log for primary faults, RT REAR STEER LT STB OR OC, RT REAR STEER LT STG, RT REAR STEER RT STB OR OC, RT REAR STEER RT STG, or any steer angle sen-sor fault


No Go to step 3




No Go to step 4

Step 4 Watch the angle sensor value on ANALYZER ACCESS LEVEL 1 CALI-BRATIONS STEER CALIBRATE? Press Enter to view raw value REAR RT STEER VALUE = XX Do not press Enter.






No Go to step 6


3128411 1200SJP 1350SJP 1-87


DTC 8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUITFront right wheel sensor short to ground or open circuit. The control system detected the front right steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection.



No Go to step 7

Step 7 Ensure proper pressure with ANALYZER ACCESS LEVEL 1 CALIBRATIONS STEER REAR RT STEER VALUE = XX.

Install a 3000 psi gauge or higher on Rear Steer Axle valve port MS1 and MS2 Adjust steer pressures on Rear Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on gauge on port MS1. Adjust relief next to port to 2000 psi ± 10% on port MS2. ESC out of cali-brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear?










Note Pretest Instructions Test Result Corrective Action Step 1 Is the front right steer angle sensor [X200]

installed and connected properly?Yes Go to step 2

No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE R FRONT WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to 5


Check faults. Does the new location now have a wheel sensor out of range low fault?


No Go to step 4


No Go to step 5




No Go to step 8


Is there continuity between front right wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]?




1-88 1200SJP 1350SJP 3128411


DTC 8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERYFront right wheel sensor short to battery. The control system detected the front right steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem.




No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front left steer passthru pin 2 [X201.2.pin]




No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the front right steer angle sensor [X200]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE R FRONT WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the right front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5


Check faults. Does the new location now have a wheel sensor out of range high fault?


No Go to step 4


No Go to step 5




No Go to step 8


Is there continuity between front right wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]?




3128411 1200SJP 1350SJP 1-89


DTC 8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUITFront left wheel sensor short to ground or open circuit. The control system detected the front left steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection.




No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]




No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the front left steer angle sensor [X203]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE L FRONT WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5




No Go to step 4


No Go to step 5




No Go to step 8






1-90 1200SJP 1350SJP 3128411


DTC 8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERYFront left wheel sensor shorted to battery. The control system detected the front left steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem.








No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the front left steer angle sensor [X203]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE L FRONT WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5




No Go to step 4


No Go to step 5




No Go to step 8






3128411 1200SJP 1350SJP 1-91


DTC 8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUITRear right wheel sensor short to ground or open circuit. The control system detected the rear right steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection.








No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the rear right steer angle sensor [X239]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE R REAR WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5




No Go to step 4


No Go to step 5




No Go to step 8






1-92 1200SJP 1350SJP 3128411


DTC 8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERYRear right wheel sensor short to battery. The control system detected the rear right steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem.

Step 7 Disconnect rear right wheel sensor [X239] and rear right steer passthru - 4 pos. [X236]




Step 8 Disconnect rear right steer passthru - 4 pos. [X236]. Turn on machine.


Yes Repair/replace harness between rear right steer passthru [X236] and rear right wheel sensor [X239]

No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the rear right steer angle sensor [X239]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE R REAR WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the right rear wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5




No Go to step 4


No Go to step 5




No Go to step 8






3128411 1200SJP 1350SJP 1-93


DTC 8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUITRear left wheel sensor short to ground or open circuit. The control system detected the rear left steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection.

Step 7 Disconnect rear right wheel sensor [X239] and rear left steer passthru - 4 pos. [X236]




Step 8 Disconnect rear right steer passthru - 4 pos. [X236]. Turn on machine.


Yes Repair/replace harness between rear right steer passthru [X236] and rear right wheel sensor [X239]

No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the rear left steer angle sensor [X238]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE L REAR WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5




No Go to step 4


No Go to step 5




No Go to step 8










1-94 1200SJP 1350SJP 3128411


DTC 8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERYRear left wheel sensor short to battery. The control system detected the rear left steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem.




No Go to step 9





Note Pretest Instructions Test Result Corrective Action Step 1 Is the rear left steer angle sensor [X238]


No Repair as needed

Step 2 Extend axles. Enable crab steering mode. Go to ANA-LYZER DIAGNOSTICS DRIVE L REAR WHEEL ANGL.

Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left rear wheel angle more than 2° difference from other wheels?

Yes Go to step 3

No Go to step 5



Yes Replace sensor originally at the rear left wheel.

No Go to step 4


No Go to step 5




No Go to step 8












No Go to step 9


3128411 1200SJP 1350SJP 1-95


DTC 8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULTEngine shutdown - axle lockout valve fault. The control system detected a short to battery or open circuit on the axle lockout valve and detects pressure on the pressure switch and the boom is out of transport position. Engine starting will be pre-vented while this fault is active. Use auxiliary power to lower the boom to transport. See DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 30.

DTC 998 - EEPROM FAILURE - CHECK ALL SETTINGSEEPROM failure - check all settings. A critical failure occurred with the EEPROM. Personalities, machine configuration digits, etc. may be reset to default values and should be checked. A power cycle is required. This can occur if new software that adds a personality or other configurations, is downloaded to the machine.

DTC 9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPERFunctions locked out - platform module software version improper. Notification that the functions have been locked out because the major version of the platform module software does not match the major version of the ground module soft-ware. Load the same version of software in the platform and ground modules.

DTC 9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIREDPlatform module software update required. The platform module software is a different major version than the ground mod-ule. Load new platform module software.

DTC 9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATEDChassis tilt sensor not gain calibrated. Chassis tilt sensor calibration information has been lost. Machine will indicate that it is tilted at all times. This calibration data is programmed into the ground module during its manufacture, not in the field.

DTC 9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGEChassis tilt sensor gain out of range. Chassis tilt sensor calibration information has been corrupted. This calibration data is programmed into the ground module during its manufacture, not in the field.












1-96 1200SJP 1350SJP 3128411


DTC 9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOSTHigh resolution analog to digital failure-interrupt lost. This fault should only occur with software versions prior to 7.0. There is an internal problem with the platform module.

DTC 9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMITHigh resolution analog to digital failure - reinit limit. This fault should only occur with software versions prior to 7.0. There is an internal problem with the platform module.

DTC 9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGEGround sensor reference voltage out of range. The ground module 7VDC reference voltage is out of acceptable range. This reference voltage is unused at this time. Possible causes of this fault include bad supply circuit in the module, or wires mis-takenly connected to the following pins on ground module J7 [X007]: J7-5, J7-16, J7-26, or J7-27.

DTC 9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGEPlatform sensor reference voltage out of range. The platform module 7VDC reference voltage is out of acceptable range. This supply is used for the lift, swing, drive and pump controls.

Note Pretest Instructions Test Result Corrective Action Step 1 Are there any wires present in any of the fol-

lowing terminals: ground module J7 terminal 5 [X007.5], terminal 16 [X007.16], terminal 26 [X007.26], or terminal 27 [X007.27]?

Yes Make note of other faults then remove one wire. If any new faults appear or faults go away, use that information to find proper place for the wire. Repeat until all wires are placed correctly.

No Go to step 2

Step 2 Use backprobing for follow-ing measurement. See Backprobing on Pg. 245 for details.

Is there 6.6VDC - 7.5VDC at the following ter-minals: ground module J7 terminal 5 [X007.5], terminal 16 [X007.16], terminal 26 [X007.26], or terminal 27 [X007.27]?

Yes Reprogram/replace the ground module

No Replace the ground module

Note Pretest Instructions Test Result Corrective Action Step 1 Disconnect platform module

J5 [X167]Is there about 2.5k between platform mod-ule J5 socket 1 [X167.1.soc] and J5 socket 7 [X167.7.soc]?

Yes Keep connector disconnected.Go to step 2.

No Repair/replace Lift & Swing joystick assembly and/or wiring

Step 2 Disconnect platform module J5 [X167] and J6 [X168] and hyd speed pot passthru - 6 pos [X199]. Turn on machine.

Is there 6.6V - 7.5V between platform module J5 pin 1 [X167.1.pin] and J5 pin 7 [X167.7.pin]?

Yes Keep J5 [X167] disconnected.Go to step 3.

No Go to step 12

Step 3 Disconnect platform module J5 [X167]. Ground multime-ter. See Grounding on Pg. 245 for details.

Is there a short between platform module J5 socket 1 [X167.1.soc] and ground?

Yes Repair/replace harness affecting Lift & Swing joystick wiring.

No Go to step 4


Turn on machine. Is there about 12 VDC between platform module J5 socket 1 [X167.1.soc] and ground?

Yes Short to battery. Repair/replace harness affecting the Lift & Swing joystick wiring.

No Go to step 5

Step 5 Disconnect platform module J6 [X168]

Is there about 5k between platform module J6 socket 1 [X168.1.soc] and J6 socket 7 [X168.7.soc]?

Yes Go to step 6

No Repair/replace Drive joystick and/or wiring

3128411 1200SJP 1350SJP 1-97


DTC 9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTYGround module failure: high side driver cutout faulty. There is an internal problem with the ground module.

DTC 9922 - PLATFORM MODULE FAILURE - HWFS CODE 1Platform module failure: hardware fail-safe code 1. Platform module V(low) FET has failed. A power cycle is required.


Is there a short between platform module J6 socket 1 [X168.1.soc] and ground?

Yes Short to ground. Repair/replace harness affecting Drive joystick assembly.

No Go to step 7


Turn on machine. Is there about 12 VDC between platform module J6 socket 1 [X168.1.soc] and ground?

Yes Short to battery. Repair/replace harness affecting Drive joystick wiring.

No Go to step 8

Step 8 Disconnect hyd speed pot passthru - 6 pos. [X199]

Measure resistance between hyd speed pot passthru socket 4 [X199.4.soc] and socket 5 [X199.5.soc]. Is there a short or open?

Yes Repair/replace hyd speed pot passthru [X199] and or Speed Controller [X192]

No Keep hyd speed pot passthru [X199] discon-nected.Go to step 9

Step 9 Disconnect hyd speed pot passthru - 6 pos. [X199].

Measure resistance from hyd speed pot passthru pin 4 [X199.4.pin] and pin 5 [X199.5.pin]. Is there a short?

Yes Keep hyd speed pot passthru [X199] discon-nected.Go to step 10


Step 10 Disconnect hyd speed pot passthru [X199] and plat-form module J1 [X165].

Measure resistance from platform module J1 socket 13 [X165.13.soc] and socket 34 [X165.34.soc]. Is there a short?

Yes Repair/replace harness between hyd speed pot passthru [X199] pin 4 [X199.4.pin] and pin 6 [X199.6.pin] and platform module J1 [X 165] socket 13 [X165.13.soc] and socket 34 [X165.34.soc]

No Short inside module. Replace platform module

Step 11 Disconnect hyd speed pot passthru [X199]

Measure resistance between hyd speed pot passthru socket 3 [X199.3.soc] and socket 4 [X199.4.soc]. Is there a short?

Yes Repair/replace Speed Controller [X192]


Step 12 Disconnect hyd speed pot passthru [X199]

Measure resistance between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin]. Is there a short?

Yes Keep hyd speed pot passthru [X199] discon-nected.Go to step 13.


Step 13 Disconnect hyd speed pot passthru [X199] and plat-form module J1 [X165]

Measure resistance between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin]. Is there a short?

Yes Repair/replace harness between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin]

No Short inside module. Replace platform module.




1-98 1200SJP 1350SJP 3128411


DTC 9923 - GROUND MODULE FAILURE - HWFS CODE 1Ground module failure: hardware fail-safe code 1. The ground module V(low) FET has failed. A power cycle is required.

DTC 9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPERFunctions locked out - chassis module software version improper. Notification that the functions have been locked out because the major version of the chassis module software does not match the major version of the ground module software. Load the same version of software in the chassis and ground modules.

DTC 9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPERFunctions locked out - BLAM module software version improper. Notification that the functions have been locked out because the major version of the BLAM module software does not match the major version of the ground module software. Load the same version of software in the BLAM and ground modules.

DTC 9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIREDGround module constant data update required. The ground module has old constant data that is not compatible with the current ground module software. The ground module constant data must be updated to a newer version. A power cycle is required.

DTC 9928 - ENVELOPE CONTROL DISABLEDEnvelope control disabled. The user has forced envelope control off with the analyzer from access level 0. This can happen if calibration procedure is not followed properly.

DTC 9929 - MOMENT CONTROL DISABLEDMoment control disabled. The user has forced envelope control off with the analyzer from access level 0.







Did fault clear? Yes Troubleshooting complete


Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Does fault still occur? Yes Go to step 2


Step 2 Calibrate boom sensors. See 5.9 Calibrating the Boom Sensors on Pg. 228 for details.

Does fault still occur? Yes Replace ground module


3128411 1200SJP 1350SJP 1-99


DTC 9930 - STEER SENSORS NOT CALIBRATEDSteer sensors not calibrated. The steering sensors require calibration. This fault can happen if calibration is incorrect or a new chassis module has been installed and steering calibration is not done. See 5.2 Calibrating Steer on Pg. 208 for instruc-tions 5.2 Calibrating Steer on Pg. 208.

DTC 9931 - BOOM SENSORS NOT CALIBRATEDBoom sensors not calibrated. The Boom sensors require calibration. See 5.1 Calibration Instructions on Pg. 207, Table 5-2. Calibrations Listed by Service Action on Pg. 207 and 5.9 Calibrating the Boom Sensors on Pg. 228 for more details. The machine will be in electrical retrieval mode until in transport position. Then, controlled angle, auto main lift, and main lift up will be disabled.

DTC 9932 - LIFT CRACKPOINTS NOT CALIBRATEDLift crackpoints not calibrated. The lift valves require a calibration that has not yet been performed. See 5.7 Calibrating Lift Crack Point on Pg. 222 for instructions.

DTC 9933 - TELESCOPE CRACKPOINTS NOT CALIBRATEDThe telescope valves require a calibration that has not yet been performed. See 5.8 Calibrating Telescope Crack point on Pg. 225 for instructions.

DTC 9934 - DRIVE CRACKPOINTS NOT CALIBRATEDDrive crackpoints not calibrated. The drive valves require a calibration that has not been performed.

Note Pretest Instructions Test Result Corrective Action Step 1 Read active faults Are there any boom sensor faults? Yes Troubleshoot those faults first

No Go to step 2

Step 2 Perform boom sensor cali-bration.

Does machine calibrate successfully? Yes Troubleshooting complete

No Troubleshoot in accordance with calibration fault

Note Pretest Instructions Test Result Corrective Action Step 1 Are there any Drive faults? Yes Troubleshoot those first

No Go to step 2

Step 2 Perform dive calibration. See 5.3 Calibrating Drive on Pg. 210.


No Go to step 3

Step 3 Were there any calibration faults? Yes Troubleshoot all calibration faults

No Go to step 4

Step 4 Tee in a 1000 psi pressure gauge next to the pressure switch on the traction con-trol valve manifold

While drive is activated in the transport posi-tion does the gauge read about 500 psi?

Yes Replace the ground module

No Go to step 5

Step 5 Connect a 1000 psi pres-sure gauge to the MP port on the traction control valve manifold

With the machine idling, can the pressure be adjusted with the adjacent charge relief valve so that the gauge reads 500psi?


No Go to step 6

1-100 1200SJP 1350SJP 3128411


DTC 9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGHBLAM sensor supply out of range high. BLAM sensor power supply voltage for the boom angle sensors is above the expected range. A power cycle is required.

Step 6 Disconnect, plug and cap all four drive hoses at the top of the swivel (ports 3, 4, 5, and 6). Tee in a gauge with the hoses at the charge (pres-sure) filter (on engine side). Plug open lines.


Yes Reassemble, but keep gauge installed. Go to step 8.

No Shut down, and reassemble, but keep gauge installed. Go to step 7.

Step 7 Tee in a gauge with the hoses at the charge filter. Disconnect the front drive pump charge pressure lines (ports Fa and Fe). A jumper hose between the fittings on the pump is required to pre-vent pump damage.


Yes Repair/replace right side drive pump

No Repair/replace left side drive pump.

Step 8 Disconnect, plug and cap all four drive hoses at the bot-tom of the swivel (ports 3, 4, 5, and 6). Tee in a gauge with the hoses at the charge filter. Plug open lines.


Yes Shut down, and reassemble, but keep gauge installed. Go to step 9.

No Repair seals in swivel.

Step 9 Disconnect hoses to trac-tion valve ports A3, A4, A5, A6, B3, B4, B5, and B6. Plug/cap open lines and ports. Tee a gauge in with the hoses at the charge filter.


Yes Repair drive motor leakage or replace drive motor.

No Repair/replace traction valve.


No Go to step 2



No Go to step 4



Yes Look for shorts in the harness for that system to harness at BLAM J3.

No Go to "Test" box in this step.


Is there between 5.5 V and 4.5 volts measured between the following points on BLAM J3?pin 1 [X088.8.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]

Yes Go to step 5

No Replace BLAM


3128411 1200SJP 1350SJP 1-101


DTC 9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOWBLAM sensor supply out of range low. BLAM sensor power supply voltage for the boom angle sensors is below the expected range. A power cycle is required.

DTC 9937 - LENGTH SENSOR REF VOLTAGE HIGHLength sensor reference voltage high. Supply voltage for the boom length sensors is above 5.5VDC. A power cycle is required.

Step 5 Disconnect BLAM J3 [X088]. Disconnect battery (+) terminal [X116]

Is there a short between the battery (+) termi-nal [X116] and any of the following: BLAM J3, socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]?




No Go to step 2


Is there between 5.5 V and 4.5 volts measured between the following points on BLAM J3?pin 1 [X088.8.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin];

Yes Go to step 3

No Replace BLAM

Step 3 Disconnect BLAM J3 [X088]. Disconnect battery ( - ) terminal [X117]

Is there a short between the battery ( - ) termi-nal [X117] and any of the following: chassis module J3, socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]?



Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Did fault clear? Yes Troubleshooting complete

No Go to step 2

Step 2 Disconnect all on-board and off-board optional power systems such as 110VAC and welders to keep them from energizing

Did fault clear? Yes Isolate system by turing on each optional power system individually and checking fault. Then look for shorts between length sensor harness and faulty system harness.

No Go to step 3


Is there between 5.5 VDC and 4.5 VDC mea-sured between all of the following points on BLAM J3:pin 1 [X088.1.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin];pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?

Yes Go to step 4

No Replace BLAM

Step 4 Disconnect BLAM J3 [X088] and battery + termi-nal [X116].

Is there a short between the battery (+) termi-nal [X116] and any of the following: BLAM J3 socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]?

Yes Troubleshoot BLAM J3 [X088] harness wire(s) with short



1-102 1200SJP 1350SJP 3128411


DTC 9938 - LENGTH SENSOR REF VOLTAGE LOWLength sensor reference voltage low. Supply voltage for the boom length sensors is below 4.5VDC. A power cycle is required.

DTC 9939 - BLAM HIGH RES A/D FAILUREBLAM high resolution analog to digital converter failure. A BLAM internal circuit to measure sensor output had a failure. A power cycle is required.

DTC 9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGHChassis sensor supply out of range high. The supply voltage for steer angle sensors is above the expected range. A power cycle is required.

Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power Did fault clear? Yes Troubleshooting complete

No Go to step 3


Is there between 5.5 VDC and 4.5 VDC mea-sured between the following points on BLAM J3:pin 1 [X088.1.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]?

Yes Go to step 4

No Replace BLAM

Step 3 Disconnect BLAM J3 [X088]. Ground meter. See Grounding on Pg. 245 for details.

Is there a short between ground and any of the following: BLAM J3 socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]?

Yes Troubleshoot BLAM J3 [X088] harness wire(s) with short


Note Pretest Instructions Test Result Corrective Action Step 1 Cycle power. Check faults. Does fault continue to occur after cycling

power? Yes Replace BLAM



No Go to step 2



No Go to step 4



Yes Look for shorts in the harness for the system just energized to harness at chassis module J3.

No Go to "Test" box in this step. Repeat until source of fault is found.

Step 4 Disconnect chassis module J3 [X231]. Turn on machine.

Is there between 5.5 V and 4.5 volts measured between all of the following points on chassis module J3:pin 1 [X231.1.pin] to pin 3 [X231.3.pin]; pin 4 [X231.4.pin] to pin 6 [X231.6.pin]; pin 7 [X231.7.pin] to pin 9 [X231.9.pin]; pin 10 [X231.10.pin] to pin 12 [X231.12.pin]?

Yes Go to step 5


3128411 1200SJP 1350SJP 1-103


DTC 9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOWChassis sensor supply out of range low. The supply voltage for chassis steer angle sensors is below the expected range. A power cycle is required.

DTC 9944 - CURRENT FEEDBACK GAINS OUT OF RANGECurrent feedback gains out of range. Reserved for future use. Should not occur on current machine..

DTC 9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECTCurrent feedback calibration checksum incorrect. Reserved for future use. Should not occur on current machine..

Step 5 Disconnect chassis module J3 [X231]. Disconnect bat-tery (+) terminal [X116]

Is there a short between the battery (+) termi-nal [X116] and any of the following: chassis module J3, socket 1 [X231.1.soc], socket 4 [X231.4.soc], socket 7 [X231.7.soc], or socket 10 [X231.10.soc]?

Yes Troubleshoot chassis module J3 [X231] harness wire with short

No Reprogram/replace chassis module


No Go to step 2

Step 2 Disconnect chassis module J3 [X231]. Turn on machine.

Is there between 5.5 V and 4.5 volts measured between the following points on chassis module J3:pin 1 [X231.1.pin] to pin 3 [X231.3.pin]; pin 4 [X231.4.pin] to pin 6 [X231.6.pin]; pin 7 [X231.7.pin] to pin 9 [X231.9.pin]; pin 10 [X231.10.pin] to pin 12 [X231.12.pin]?

Yes Go to step 3


Step 3 Disconnect chassis module J3 [X231]. Disconnect bat-tery - terminal [X117]

Is there a short between the battery(-) terminal [X117] and any of the following: chassis mod-ule J3, socket 1 [X231.1.soc], socket 4 [X231.4.soc], socket 7 [X231.7.soc], or socket 10 [X231.10.soc]?

Yes Troubleshoot chassis module J3 [X231] harness wire with short

No Reprogram/replace chassis module


MACHINE SETUPAre parameters set properly in Machine Setup?

Yes Go to step 2





MACHINE SETUPAre parameters and configuration set properly in Machine Setup?

Yes Go to step 2





1-104 1200SJP 1350SJP 3128411


DTC 9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPERFunctions locked out - ground module software version improper. All functions are locked out because ground module soft-ware version is improper for machine configuration...

DTC 33XX - COMMON STB OR OC PROCEDURECommon short to battery or open circuit procedure. A module input or output pin has been shorted to battery or the circuit has an open in it. All driver faults are detected in a similar manner. Open circuit faults are detected when the analog feedback reads too high and the output is commanded off. Short to battery is detected when the analog feedback reads Vbat and the output is commanded off. See the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting to battery voltage. This procedure applies to a number of faults, so it leaves the determination of specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate module, such as the main boom angle sensors. When opening any electrical connec-tion, inspect the connectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several exam-ples are given starting at DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 86.

Note Pretest Instructions Test Result Corrective Action Step 1 Is machine fitted with telematics equipment? Yes Go to step 2.

No Go to ANALYZER MACHINE SETUP. Set TELEMATICS to NO.

Step 2 Go to ANALYZER MACHINE SETUP.

Is model is correct? Yes Reprogram ground module with proper software.

No Set correct model.

Note Pretest Instructions Test Result Corrective Action Step 1 Are other STB/OC faults in the fault log? Yes Check for an open at a point in circuit common to

this fault and the others.

No Go to step 2

Step 2 Find component on sche-matic and on the machine.

Is the component good? Check the compo-nent resistance. Resistances of coils are given in Section 2. Electrical Reference on Pg. 109. Other loads or sensors should be neither short nor open. Some values are given on the sche-matics. For details on what some switch posi-tions mean see Table 2-1. Limit Switch States on Pg. 109. Also, inspect the connector for pins that are damaged, loose pushed out, etc.

Pass Go to step 3

Fail Repair as needed

Step 3 Find component power con-tacts.

Is the component power good? Turn on machine and check the harness connector contacts for power. Not all components are powered by 12VDC.

Pass Go to step 4

Fail Follow power connections back to source check-ing for power or continuity. Typically, the failure isn’t too close to the battery ground terminal because then so many things wouldn’t work, this fault would not be detected. Repair as needed

3128411 1200SJP 1350SJP 1-105


DTC 33XX - COMMON STG PROCEDURECommon short to ground procedure. A module input or output pin has been shorted to ground. All driver faults are detected in a similar manner. Short to ground is detected when the analog feedback reads low and the output is commanded on. See the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting ground. This procedure applies to a number of faults so it leaves the determination of specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate module, such as the main boom angle sensors and PVG valves. When opening any electrical connection, inspect the con-nectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several examples are given start-ing at DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND on Pg. 87.

Step 4 Is the signal wire good? Check the signal wire between the component and the signal input/output on the module. Signal lists start with section 2.2 BLAM Module Connector Pinouts on Pg. 152. The information is also on the schematics. There should only be continuity between the component and the proper pin on the module in accordance with the schematic. There should not be shorts between the wire and battery + or - terminals, etc. Isolate har-ness sections that may have a problem by dis-connecting connectors as needed. Be sure to check for pins that are damaged, loose or pushed out of the connector, etc.

Pass Go to step 5


Step 5 Are the other wires good? Check wire from the component in question ground connection to the nearest major component. It should have continuity to the module, swivel or bus con-nector in accordance with the schematic.

Pass Recheck measurements or try troubleshooting a different fault. If the component and wiring are good, reprogram/replace the associated module.


Note Pretest Instructions Test Result Corrective Action Step 1 Find component on sche-

matic and on the machine.Is the component good? Check the compo-nent resistance. Resistances of coils are given in Section 2. Electrical Reference on Pg. 109. Other loads or sensors should be neither short nor open. Also, inspect the connector for pins that are damaged, loose or pushed out, etc.

Pass Go to step 3


Step 2 Find component power con-tacts.

Is the component power good? Turn on machine and check the harness connector contacts for power. Not all components are powered by 12VDC.

Pass Go to step 4

Fail Follow power connections back to source check-ing for power or continuity. Typically, the failure isn’t too close to the battery ground terminal because then so many things wouldn’t work, this fault would not be detected. Repair as needed


1-106 1200SJP 1350SJP 3128411


Step 3 Is the signal wire good? Check the signal wire between the component and the signal input/output on the module. Signal lists start with section 2.2 BLAM Module Connector Pinouts on Pg. 152. The information is also on the schematics. There should only be continuity between the component and the proper pin on the module in accordance with the schematic. There should not be shorts between the wire and battery + or - terminals, etc. Isolate har-ness sections that may have a problem by dis-connecting connectors as needed. Be sure to include checking for pins that are damaged, loose or pushed out of the connector.

Pass Go to step 4


Step 4 Are the other wires good? If it does not go to ground, check other wire from the component in question connection to the nearest major component. It should have continuity to the module, swivel, bus or other connector in accordance with the schematic.

Pass Recheck measurements or try troubleshooting a different fault. If the component and wiring are good, reprogram/replace the associated module.



3128411 1200SJP 1350SJP 1-107



1-108 1200SJP 1350SJP 3128411


SECTION 2. ELECTRICAL REFERENCELimit Switch States

Table 2-1. Limit Switch States

Connector SwitchNormally Open or

ClosedReference State

X146 Jib Stow NC Open = Stowed (Jib > 70° Right)X147 Jib Center NC Open = Jib Centered ±5°X204 RF Axle Extension NC Closed = ExtendedX205 LF Axle Extension NC Closed = ExtendedX213 Osc Axle Lockout Pressure NO Closed = Pressure > 200psiX216 Drive Orientation NO Open = Normal OrientationX225 LR Axle Extension NC Closed = ExtendedX226 RR Axle Extension NC Closed = ExtendedX281 Transport Limit Switch NC & NO NC (White to Black) = Closed -AND- NO (White to Red) = Open

= Transport positionX282 Broken Cable Proximity Switch NO Closed (Black to Blue = 12 V) = Cable in tact

3128463 1200SJP 1350SJP 2-109



2-110 1200SJP 1350SJP 3128463


31 2-111

Color Key

28463 1200SJP 1350SJP

Figure 2-1. Color Key

SECTION

2-112 3128463

Platform Area Solenoids

Table 2-2. Platform Area Solenoids

Connector FunctionNominal Resistance

(Ohms)

X135 Platform Dump 6.4

X136 Level Up 10.1

X137 Level Down 10.1

X138 Rotate Right 10.1

X139 Rotate Left 10.1

X140 Jig Swing Right 10.1

X141 Jib Swing Left 10.1

X142 Jib Up 10.1

X143 Jib Down 10.1

2 - ELECTRICAL REFERENCE

1200SJP 1350SJP


31 2-113

Platform A

PLATFORM CONTROL AREA

wer/Emergency Stopgine Start / Aux Power

apacity Selectrive Orientation Overriderive/Steerain Boom Telescopeghtsb Liftft Touch Override

b Swingwer Boom Lift (1250 Only)

12. Soft Touch Indicator13. Platform Rotate14. Jib Stow Override15. Function Speed Control16. Main Lift / Swing17. Drive Speed / Torque Select18. Steer Select19. Platform Level Override20. Axle Extend / Retract21. Horn22. Indicator Panel23. Boom Control Select

X135

X141

X143

X142

X140

UP

JIB SWINGLEFT

JIB DOWN

JIB UP

JIB SWINGRIGHT

PLATFORM DUMP

VALVEROTATED

FORCLARITY

28463 1200SJP 1350SJP

rea Connectors

Figure 2-2. Platform Area Connectors

1705744 A

1705745 B

1702938 1705170 A

1702565 A

1705171 A

17 18 19 20 21

J1 J4

J2 J3

22

5679 8101314 12 111516

1 23 2 3 4

1. Po2. En3. C4. D5. D6. M7. Li8. Ji9. So10. Ji11. To

X197

X198

X192

X196

X189

X195 X194

X188

X193X190 X191 X182 X183

X187 X186 X185 X184

X179 X285

X180 X181

X177

X178

X175

X176

X174

X153

X154

X155

X152

X136

X137

X138

X139

LEVEL

LEVEL DOWN

ROTATE RIGHT

ROTATE LEFT

SECTION

2-114 3128463


1200SJP 1350SJP



31 2-115

Boom Area

BOOM AREA

LOAD SENSING PIN(VIEW ROTATED. CONNECTOR

ON VALVE SIDE.)

X089

X062

X099

X100

BOOM ANGLE

SENSOR #1 RIGHT

BOOM ANGLE

SENSOR #2 LEFT

X273

BOOM LENGTH SENSOR

X282

CABLE BREAK PROXIMITY

SWITCH

28463 1200SJP 1350SJP

Connectors

Figure 2-3. Boom Area Connectors

X281

X150

X148

PLATFORM LEVELSENSOR RIGHT

PLATFORM LEVELSENSOR LEFT

X105(NEAR SIDE)

(FAR SIDE)X104

TAILLIGHT

TAILLIGHT

BOOM LENGTHLIMIT SWITCH

X147

X146

JIBPOSITIONSWITCH

JIBSTOW

SWITCH

SECTION

2-116 3128463


1200SJP 1350SJP



31 2-117

Engine Are

ENGINE SIDE AREA

THESE VIEWS SHOWN FOR CLARITY

X113

X241

X103

X240

STARTER

RIVE FWD

RIVE FWD

RIVE REV

DRIVE REV

X084

28463 1200SJP 1350SJP

a Connectors

Figure 2-4. Engine Area Connectors

X250X251

7500WGENERATOR

X120

X121

X118

X119

RIGHT D

LEFT D

RIGHT D

LEFT

SECTION

2-118 3128463

Main Valve Area Solenoids

Table 2-3. Main Valve Area Solenoids


(Ohms)

X069 Swing Right 5.2

X070 Swing left 5.2

X071 Main Tele Extend 4.7

X072 Tele Proportional 4.7

X073 Tele Retract 4.7

X074 Main Dump 7.2

X274 Aux Lift Down Select 5.0

X275 Aux Lift Down 5.0

X276 Lift Up 5.0

X277 Lift Down 5.0

X286 Lift Flow Control 5.0


1200SJP 1350SJP


31 2-119

Main Valve

MAIN VALVE AREA

X107

X069

SWINGRIGHT

X074

MAINDUMP

16

X083

28463 1200SJP 1350SJP

Area Connectors

Figure 2-5. Main Valve Area Connectors

X057

X102

J1J3

J4

X091

ANALYZERCONNECTION

X090

X088

X089

X087

X086

B.L.A.M.

J2J5

X097

BATTERY BUSSBAR

X098

X280

VIEW ROTATEDFOR CLARITY

X272

BOOM LENGTHSENSOR PASSTHRU

(6 POS.)

LOCATIONAPPROXIMATE

GROUNDBUSSBAR

X286

MAINLIFT FLOWCONTROL

X275

LIFT DOWNAUXILIARY

X071

MAIN TELEEXTEND

X073

MAIN TELERETRACT

X277

MAIN LIFTDOWN

X276

MAIN LIFT UP

X070

SWINGLEFT

X072

MAIN TELEPROPORTIONAL

X1

LIFT DOWNAUX SELECT

X274

X117

X110X263

X106

BLAM PUMPPASSTHRU

(6 POS.)

X279 CAN to Engine

X278 CAN to BLAM

X268 CAN to MTB

VALVE PASSTHRU (6 POS.)

X096

BOOM ANGLE SENSOR

2 PASSTHRU (4 POS.)

X095

BOOM ANGLE SENSOR

1 PASSTHRU (4 POS.)

SECTION

2-120 3128463


1200SJP 1350SJP



31 2-121

Ground Co

GROUND CONTROL BOX AREA

X024

X022

X029

X026

X028

X025

X030

28463 1200SJP 1350SJP

ntrol Connectors

Figure 2-6. Ground Control Connectors

X270 CAN to Platform

X014 CAN to Ground Module

X269 CAN to BLAM

X010

X271X001

X008

X017

X004

X012

X011

X002

X003

X043

X023

X020

X018

X021

X007

SECTION

2-122 3128463

Chassis Area Solenoids

Table 2-4. Chassis Area Solenoids


(Ohms)

X206 Front Axles Extend 4.9

X207 Front Left Steer Right 4.9

X208 Front Right Steer Right 4.9

X209 Front Axles Retract 4.9

X210 Front Left Steer Left 4.9

X211 Front Right Steer Left 4.9

X212 Axle Lockout Solenoid 6.2

X214 2 Speed Solenoid 6.2

X215 Brake Release Solenoid 6.3

X219 Rear Right Steer Left 4.9

X220 Rear Left Steer left 4.9

X221 Rear Axles Retract 4.9

X222 Rear Right Steer Right 4.9

X223 Rear Left Steer Right 4.9

X224 Rear Axles Extend 4.9


1200SJP 1350SJP


31 2-123

Chassis Ar

CHASSIS AREA

FRONTSTEERVALVE

AXLE LIMITSWITCHES(FRONT)

X209

X210

X211

X206

X207

X208

X204

X200X205

X203

T LEFTR LEFT

FRONT LEFTSTEER RIGHT

T RIGHTR LEFT

FRONT RIGHTSTEER RIGHT

TRACT

FRONT RIGHTSTEER ANGLE

FRONT LEFTSTEER ANGLE

FRONT LEFTAXLE SWITCH

FRONT REARAXLE SWITCH

EXTEND

28463 1200SJP 1350SJP

ea Connectors

Figure 2-7. Chassis Area Connectors

VALVES TURNED FOR CLARITY

CHASSIS MODULE

REARSTEERVALVE

TRACTION CONTROL VALVE

AXLE LIMITSWITCHES(REAR)

ANALYZERCONNECTION

X231

X233

X235

X229

X232

X230

X225

X238

X083

X212X216

X213

X215

X222

X223

X224

X219

X220

X221

X239

X226

X214

J1J3

J4

J5 J2

REAR LEFTSTEER LEFT

FRONSTEE

AXLELOCKOUT

BRAKERELEASE

AXLELOCKOUT

PRESSURESWITCH

2 SPEED

REAR LEFTSTEER RIGHT

REAR RIGHTSTEER LEFT

FRONSTEE

REAR RIGHTSTEER RIGHT

RETRACT

RE

REAR RIGHTSTEER ANGLE

REAR LEFTSTEER ANGLE

REAR LEFTAXLE SWITCH

REAR REARAXLE SWITCH

EXTEND

SECTION

2-124 3128463


1200SJP 1350SJP



31 2-125

Ground, E

atic

A

B

C

D

E

F

G

H

123

3 2 1

DRAWING NUMBER REV.

1870214 B

AUXILIARY POWER

PUMP MOTOR

M

B+

FUSIBLE

LINK

RECTIFER

REGULATOR

ALTERNATOR

STATOR

SENSING ANDSWITCHINGCIRCUITS

WHT

/YEL

48-1

2(12

)

INTAKE HEATERS

D+

sol.

sol.

0)

B+

RED 1-1(10)

STARTER

MOTOR

SOL.

STARTER

MOTOR

BRN/WHT 47-8

WHT

/YEL

48-

3

12 VDC

BATTERY

DEUT

Z EN

GINE

BATT

ERY

CABL

E (1

GA.

)

WHT

/YEL

48-

9

DEUTZ ENGINE

1

3

2

4K

RED

BLUE

BLACK

BRN/BLK

5

6

A

C

B

BOOM LENGTH SENSOR

STRING POT

1

212

23

9

10

11

12

6

5

2

1

ORANGE 8-3

ORANGE 8-2

J5

ORANGE 8-3

ORANGE 8-2

3

4

12

11

9

12

8

1

2

3

4

YEL/RED 2-82

ORN/RED 49-112

BLACK

BRN/BLK

J2

ORANGE

YELLOW

BLACK

BRN/BLK

#2 LEFT SIDE BOOM

ANGLE SENSOR

SERIAL OUTPUT

1

2

3

4

YEL/RED 2-81

ORN/RED 49-111

BLACK

BRN/BLK

RED

BLUE

BLACK

BRN/BLK

RED

WHITE

BLACK

RED

WHITE

BLACK

1

2

3

1

2

3

#1 RIGHT SIDE BOOM

ANGLE SENSOR

SERIAL OUTPUT

ORANGE 7-3

ORANGE 7-2

ORANGE 7-2

ORANGE 7-3

LEFT FORWARD DRIVE PUMP

LEFT REVERSE DRIVE PUMP

RIGHT FORWARD DRIVE PUMP

RIGHT REVERSE DRIVE PUMP

ANALYZER POWER

ANALYZER RECEIVE

ANALYZER TRANSMIT

ANALYZER GROUND

RED

GREEN

WHITE

BLACK/SHIELD

1

2

3

4

3

J4

1

2

3

4

5

LIFT

CYL. PIN

A

B

D

E

SHIELD

BOOM LENGTH ANGLE MODULE

T + BLACK

GRAY

BROWN

ORN/RED 49-198

1

2

10

11

12

13

14

MTB

TO

EMR2

ENG

INE

CONT

ROL

ORN/RED 49-199

BLACK 0-1

A

K

L

BDEUTZ

DIANOSTICS

PLUG

(SPEED)

D

mpAll)

(ACD2)

EMP1)

f(ADC2)

f(ADC4)

DC4)

t

t

easCom

MeasRef

easSignal

TEMP3)

EMR2

ENG

INE

CONT

ROL

TO E

NGIN

E

YEL/RED 2-1-98

INK

RED

BLACK

GREEN

WHITE

WHT/YEL 48-10 (10)

WHT/YEL 48-11 (10)

WHT

/YEL

48-

13 (8

) IN HEAD GLOW PLUG

NOTE: ENGINE WILL ONLY

HAVE INTAKE HEATERS OR

GLOW PLUGS NOT BOTH.

X113

X112

X241

X125

X242

X240

X090

X106

X273

X272

X091

X098

X087

X089

X096

X099X095

X116X108

X110

X097

X100

X117

X062

X119

X118

X120

X121

X111

28463 1200SJP 1350SJP

ngine and BLAM Schematic

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

45678

G

H

E

F

C

D

A

B

8 7 6 5 4

ALARM

MAIN TELEX021

X024

X025

RIGHT

LEFT

X026

UP

DOWN

X072UP

DOWN

MTB MODE OUTPUT

X020

X028

START SWITCH

AUX POWER/ENABLE

LEFT

RIGHT

DOWNUP

ENGINE LOW

OIL PRESSURE

ENGINE HIGH

TEMPERATURE

GLOW PLUGS

GROUND CONTROL MODULE

HOURMETER

MAIN TELE.OUT

IN

MAIN LIFTUP

DOWN

LEFT

RIGHT

SWING

MAIN DUMP

TELE. FLOW CONTROL

172

13

1

9

33

4

24

7

30

18

6

17

5

4

16

19

823

33

35

34

19

20

11

22

25

32

12

29

28

26

15

13

1

14

2

27

3

31

16

10

12

1122

35

34

19

20

14

30

27

29

26

18

24

28

25

6

HEAD/TAIL

LIGHTS

FUEL SENSOR (SIGNAL)

SENSOR (GROUND)

J4 (BLUE)

8

19

12

13

20

22

7

25

23

27

31

30

2928

32

33

34

35

153

2

14

9

17

30

23

31

10

12

3216

19

35

25

7

13

24

18

58

28

FOOTSWITCHMTB MODE SELECT

MTB

EMS

2

3

4

1MTB EMS input

GND FROM BATTERY

GND TO PLATFORM

MTB EMS TO PLATFORM

TO B

ATTE

RY N

EG.

J2 (GRAY)

J8

J7 (BLACK)

J1 (WHITE)

2

4

8

9

6

713

14

3

10

11

1

5

12

HORN OUTPUT

HORN GND

BLACK

BLU/ORN 52-2

RED/WHT 50-1

BROWN 55-10

BROWN 13-3

BROWN 14-3

TAN 3-3

TAN 4-3

WHITE 22-3

WHITE 21-3

BLU/ORN 52-10

BLACK

BRN/WHT 47-12

BRN/ORN 53-3

BLU/ORN 52-5

BROWN 13-2

BROWN 14-2

GRAY 24-2

GRAY 23-2

PINK 25-2

PINK 26-2

WHT/YEL 48-1

BRN/ORN 53-2

BLUE 27-2

BLUE 28-2TAN 3-2

TAN 4-2

WHITE 58-2

WHITE 60-2

BRN/WHT 47-8

BRN/WHT 47-5-1

BRN/WHT 47-6-1

WHT/YEL 48-6

BLACK

BLAC

K (1

0)

BLACK (12)

YEL/RED 2-1-2(12)

YEL/RED 2-30

YEL/RED 2-30-1

2-40

BLACK

ANALYZER POWER

ANALYZER RECEIVE

ANALYZER TRANSMIT

ANALYZER GROUND

RED

GREEN

WHITE

BLACK/SHIELD

1

2

3

4

3

185

6

24

5

YEL/RED 2-21

RED 1-2(1

10

15

4

14

11

2

10

9

19

17

16

30 AMP

1

3

4

22

34

19

20

29

11

BLACK

BROWN

BLUE

1

2

4

1621

26

1

2

7

8

9

12

23

YEL/RED 2-80

ORN/RED 49-110

BLACK

BRN/BL

J3

ORN/RED

1

2

6

7

8

9

12

5

4

3

J1

RED

BLACK

SHIELD

CAN HI

CAN LO

CAN SHIELD

A

B

C

A

B

C

RED

BLACK

SHIELD

A B C

1 2 3

2

3

4

1

6

YEL/RED 2-70-2 (14)

BLACK (16)

ORANGE 60-1

4

YEL/RED 2-70-3 (14)

YEL/RED 2-70-4 (14)

8

BLAC

K (1

4)

ORAN

GE

55-4

7

ORAN

GE 5

5-45

5 6 7

5 BLACK 5 (16)

ORN/RED 49-103

WHT/YEL 39-1-1

ORN/RED 49-100

RED/YEL 54-2-1

RED/YEL 54-3-1

ORN/RED 49-101

AXLES SET

PLATFORM

OVERLOAD

500# CAP

1000# CAP

86 85

87

30

87a

8685

87

30

87a

2

4

1

3

B1

B2

YEL/RED 2-2 (12)

YEL/RED 2-5

YEL/RED 2-30-4

YEL/RED 20-70-1

YEL/RED 2-4 (12)

YEL/RED 2-1 (12)

YEL/

RED

2-70

(14)

YEL/RED 2-4-1

BLAC

K

BLACK

IGN. ON RELAY

POWER DOWNRELAY

YEL/RED 2-30

YEL/RED 2-3-1

YEL/RED 2-1-1(12)

YEL/RED 2-1-3 (12)

ORN/RED 49-88

YEL/RED 2-61

BLACK

BROKEN CABLE

PROX. SWITCH

RED

BLACK

SHIELD

CAN HI

CAN LO

CAN SHIELD

A

B

C

A

B

C

RED(18)

BLACK

SHIELD

3

2

1

C B A

SHEI

LD

BLAC

KRE

D

WHITE

BLACK

RED

YEL/RED 2-60

ORN/RED 49-64

ORN/RED 49-65

13

10

16

12

11

SLIP RING CONNECTOR TO CHASSIS

YEL/RED 2-6-2

5

7

3 RED/WHT 50-2-1

PINK 26-3-1

PINK 25-3-1

5

7

9

4

MOMENT CONTROL

TEST

BOOM SYSTEM

CONTROL

YEL/RED 2-3-2

YEL/RED 2-2-1

LIFT DOWN AUX. SELECTTAN 55-21

TAN 55-22 LIFT DOWN AUX.

TAN 55-20 LIFT FLOW CONTROL

WHT/YEL 48-9

GENERATOR

BLACK (14)

BLACK (14)

6

ORN/RED 49-102

BOOM CONTROL SYSTEM

X281

4

5

3

1

2

6

BOOM LENGTH LIMIT SWITCH

13 14

21 22

86 85

87

30

87a

V-BA

GND -

GRAY

GREEN

YEL/

RED

2-40

-9

BLACK (16)

ENGINE OIL

PRESSURE

COOLANT

TEMPERATURE

EMR

ACTUATOR

ENGINE

SPEED

CAMSHAFT

CHARGE

AIR

PRESSURE

8

9

13

12

23

4

25

24

22

21

20

14

15

17

19

GRD

SPEE

GRD(Te

GRD

ADC5(T

+5Vre

ADC2

+5Vre

ADC4

GND (A

ActorOu

ActorOu

RackM

Rack18

RackM

ADC7(

YEL/RED 2-1-99

CAN HIRED (18)

CAN LOBLACK (18)

CAN SHIELD

86 85

87

30

87a

7500 W GENERATOR

8685

87

30

87a

RED

RED

BLU/ORN 52-6

YEL/RED 2-20

C

A

BGENERATOR

CONTROL

BOX

2

1

2

1

1

2

3

4

1

2

3

1

2

3

4

5

A B C

CAN

HIRE

D (1

8)CA

N LO

BLAC

K (1

8)

CAN

SHIE

LD

RED

(18)

BLAC

K (1

8)

CAN

SHIE

LD

WHT/YEL 48-3

86 85

87

30

87aBLU/ORN 52-12

RED

1-1

(12)

14 GA. FUSE L

RED 1-3 (12) 14 GA. FUSE LINK

2500W

GENERATOR

5 AMP

BRN/WHT 47-20

BLACK

BLACK (12)18

V BAT

BLACK

33

27

V REF

CHASSIS POWER

DISTRIBUTION

RELAY

86 85

87

30

87a

30 AMP

YEL/

RED

2-70

-5

YEL/

RED

2-70

-4

YELL

OW

YEL/RED 2-40-10

BLU/ORN 52-6 (12)

IN

OUT

ROTATE

LEVEL

JIB

MAIN LIFT

JIB SWING

X018LEFT

RIGHT WHITE 22-2

WHITE 21-2SWING

X022

X023

X035

X034

X036

X033

X032

X038

X031

X037

X008

X040

NO CHARGE BRN/WHT 47-8-1

X001

X039

TEST SWITCH

X283, X284

X270

X282

X014

X269

X017

X007

X004

X002

X017

X073

X071

X274

X275

X276

X277

X069

X070

X101

X011

X286

X084

X010

X063

X013

X271

X074

X124

X030

X012

X027

X088

X256

X257

X126

X279

X127

X278

X029

X268

X280

X246

X248

X247

X083

X122

X086

X109

X266

X267

SECTION

2-126 3128463


1200SJP 1350SJP



31 2-127

Pleatform

A

B

C

D

E

F

G

H

123

3 2 1

DRAWING NUMBER REV.

1870214 B

RED

BLACK

BLACK

RED

PLATFORM WORK LIGHTS

FOOTSWITCH

output

PLATFORM

EMS

X057

SELECT

SWITCH

STROBE LIGHT

BLK/WHT (12)

BLU/ORN 52-11

YEL/RED

2-3(16)

YEL/RED

2-2(12)ORN(12)

RED (18)

BLACK (18)

SHIELD

ORN (18)

18

YEL/BLK(18) BLU/ORN 52-1115 15

13 13YEL/RED

2-5ORN/BLK(18)

1010

3

2

14

3

2

1

4

6YELLOW (18)

16

12

16

12

11 11BLU/BLK

RED (18)

BLACK (18)

YEL/RED 2-3-1

YEL/RED 2-30-1

BLACK (12)

YEL/RED 2-1-2 (12)

HOLE PLUG (12)

HOLE PLUG (18)

HOLE PLUG (18)

14

17

19 19

17

14

GREEN

20 AMP C.B.

18

2

1

TO MTB97

5

8BLACK (12)8

BLACK (12)

RED (12)

BLACK

WHITE

WHITE(10)

BLACK(10)GREEN(10)

BROWN(18)

RED/BLK

BLUE(18)

X16012= 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX

= 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX

= 19 POSITION DEUTSCH CONNECTOR TO MAIN TERMINAL/GROUND BOX12

8 6

= TERMINAL STRIP IN PLATFORM BOX

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

X152

X153

X154

X179

12

X043

X164

X161

MTB

28463 1200SJP 1350SJP

Schematic

Figure 2-9. Platform Electrical Schematic

45678

G

H

E

F

C

D

A

B

8 7 6 5 4

LEVEL

JIB

UP

DOWN

RIGHT

LEFT

DOWN

UP

ROTATE

ALARM

FUEL

GAG

E FULL

3/4

1/2

1/4

MAIN TELEX178

X188 ROTATE

X195

X199

LEVEL

JIB

EMS PTF TO MTB

PTF EMS

GND MODE

GND EMS

GND FROM GND MODULE

CAN LO

CAN HI

START SWITCH

AUX POWER

CRAB STEERCOORDINATED STEER

TWO SPEED

ENGINE SPEED

SOFT TOUCH OVERIDE

HEAD/TAIL LIGHTS

HORN

CREEP

GENERATOR

TILT

AUTO LEVEL SYSTEM

FOOTSWITCH/ENABLE

CREEP

BROKEN CABLE

OVERLOAD

226KG/500# CAPACITY

453KG/1000# CAPACITY

AXLE SET

GENERATOR ON

SOFT TOUCH

GLOW PLUG

BOOM CONTROL SYSTEM

DRIVE ORIENTATION

LEFT

RIGHT

PUMP

POTENTIOMETER

JIB SWING

ANALYZER POWER

ANALYZER RECEIVE

ANALYZER TRANSMIT

ANALYZER GROUND

STEERLEFT

RIGHT

J1 (WHITE)

BRN/WHT 47-13

YEL/RED 2-21

ORN/RED 49-15

RED/YEL 54-3-1

WHT/YEL 39-1

GRAY 23-3

GRAY 24-3

PINK 25-3-2

PINK 26-3-2

BLUE 27-3

BLUE 28-3

SWING

LIFT

DRIVE

BLU/ORN 52-12

BLUE 27-1

BLUE 28-1

PINK 26-1

PINK 25-1

GRAY 23-1

GRAY 24-1

BROWN 14-1

BROWN 13-1

J2 (GRAY)

J5 (WHITE)

J6 (BLACK)

CAN SHIELD

5

6

7

8

9

10

11

12

33

34

35

13

32

18

1

2

3

4

16

17

20

21

22

23

24

14

15

28

27

31

29

30

J8 (BLACK)

J7 (BLACK)

19

5

6

15

16

25

26

27

28

29

2

31

30

32

3

1

8

19

18

9

1

2

35

23

24

22

25

16

9

7

21

18

19

14

30

13

10

8

15

11

12

6

17

33

26

28

29

6

5

6

4

2

1

3

7

Ref.V

WIPER

GND

20

27

WHT/YEL 48-1

BRN/ORN 53-1

WHT/YEL 48-5

BLU/ORN 52-1

RED

GREEN

WHITE

BLACK/SHIELD

1

2

3

4

4

6

5

3 2

YEL/RED 2-10

RED/WHT 55-30

RED/WHT 55-31

BLACK

ORN/RED 49-11

ORN 55-46

ORN/RED 49-40

BLU/ORN 52-4

ORN/RED 49-1000

YELLOW 55-16

YELLOW 55-17

ORN/RED 49-101

ORN/RED 49-42

BRN/WHT 47-4

BRN/WHT 47-3

BRN/WHT 47-2

BRN/WHT 47-1

BLACK

5K

5K

5

1

4

2

3

7

GRAY 23-3

GRAY 24-3

PINK 25-3-3

PINK 26-3-3

BLUE 27-3

BLUE 28-3

WHITE 60-3

WHITE 59-3

BLACK

WHITE 60-3

WHITE 59-3

BLACK

8

9

10

11

19

20

12

4

33

1

2

3

7

21

1

2

3

BRN/BLK (18)BRAIDED SHIELD

ORN/RED 49-12 21

PINK 26-3-3

PINK 25-3-3

PINK 26-3-1

PINK 25-3-1

6

7

RED/WHT 50-2-1

RED/WHT 50-2-35 PLATFORM DUMP

RED

WHITE

BLACK

RED

WHITE

BLACK

25

26

19

ORN/RED 49-10 14

YEL/RED 2-11YEL/RED 2-11 13YEL/RED 2-11-1 1

YEL/RED 2-11-2 1

ORN/RED 49-11 2

ORN/RED 49-12 2

17

32

BASKET LEVEL SENSOR #1

BASKET LEVEL SENSOR #2

MOUNTED ON LEFT

SIDE OF BOOM

MOUNTED ON RIGHT

SIDE OF BOOM

AXLE SETRET

EXT YEL/WHT 43-1

YEL/WHT 44-1

RED/YEL 54-1

500#

1000#

X177

1

2

3

6

1

2

3

4

5

6

1

2

3

4

6

3

2

4

1

SYSTEM DISTRESS

J3

J2

J1

5

6

J4

BLACK

BRN/WHT 47-12

BRN/WHT 47-10

RED/YEL 54-2

ORN/RED 49-3

WHT/YEL 48-6

ORN/RED 49-100

BLU/ORN 52-4-1

ORANGE 55-51

ORN/RED 49-92

ORN/RED 49-91

ORN/RED 49-90

ORN/RED 49-89

LEFT

RIGHT

DRIVE ORIENTATION OVERIDE

JIB STOW

2

34

1

4

3

5

WHITE 59-1

YEL/RED 2-10-14

WHITE 60-1

JIB SWING

ORANGE 55-50

YEL/RED 2-16

YEL/RED 2-16-1

WHITE 59-60

ORN/RED 49-70

YEL/RED 2-16-2

5

5

4

RED/YEL 54-3

BLU/ORN 52-3

20

JIB INLINE LIMIT SWITCH

JIB STOW LIMIT SWITCH

1

2

BLU/ORN 52-4

BLU/

ORN

52-3

ORN/RED 49-69 3

7

BLACK

ORN/RED 49-4

YEL/RED 2-3715

11

10

9

8

ORN/RED 49-63

YEL/RED 2-12-2

ORN/RED 49-68

1

2

3

RED

BLUE

BLACK

BRN/BLK (18)BRAIDED SHIELD

4

5

6

ORANGE

YELLOW

BLACK

YEL/RED 2-12-1

ORN/RED 49-80

ORN/RED 49-81

10

11

12

13

14

22

23

24

34

35

RED/WHT 50-2-3

31

YEL/RED 2-16-2

YEL/RED 2-16-3

SOFT TOUCH LIMIT SWITCHS

8

WHITEBLACK4ORN/RED 49-675WHITEBLACK

6

8

8

V BAT.

X146

YEL/RED 2-3614

ORN/RED 49-120BOOM CONTROL SELECT

X172

OUT

RIGHTLEFT

UPDOWN

UPDOWN

IN

X192

X196

X180

CAPACITY

X285

X175

X198

X184

X181

X193

X190

X166

X194

X191

X182

X173

X187

X183

X185

X174

X189

X171

V REF. X162

X163

X150

X136

X144

X165

X155

X169

X197

X176

X167

X168

X170

X147

X145

X148

X137

X139

X138

X142

X143

X140

X141

X135

SECTION

2-128 3128463


1200SJP 1350SJP



31 2-129

Chassis El

A

B

C

D

E

F

G

H

123

3 2 1

DRAWING NUMBER REV.

1870214 B

DRIVE ORIENTATION

SWITCH

1

2

3

4

5

6

7

8

1

2

3

4

5

6

ORN/RED

ORN/RED

YEL/RED 2-1-7

BLACK

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

RED

WHT

BLK

BLK

RED

WHT

BLK

BLK

RED

WHT

BLK

BLK

RED

WHT

BLK

BLK

BRN/BLK

BRN/BLK

BRN/BLK

BRN/BLK

RED

BLUE

BLK

BRN/BLK

RED

BLUE

BLK

BRN/BLK

RED

BLUE

BLK

BRN/BLK

RED

BLUE

BLK

BRN/BLK

A

B

C

A

B

C

A

B

C

A

B

C

RIGHT FRONT

STEER SENSOR

LEFT FRONT

STEER SENSOR

RIGHT REAR

STEER SENSOR

LEFT REAR

STEER SENSOR

6 PIN

BUSS

CONNECTOR

OSC. AXLE

LOCK-OUT

PRESSURE

SWITCH J4 G

RAY

X213

X201

X202

X236

X237

X200

X203

X239

X238

X232

X227

28463 1200SJP 1350SJP

ectric Schematic

Figure 2-10. Chassis Electrical Schematic

45678

G

H

E

F

C

D

A

B

8 7 6 5 4

2SPDVALVE

BRAKEVALVE

RIGHT FRONT STEER RIGHT

RIGHT FRONT STEER LEFT

LEFT FRONT STEER RIGHT

LEFT FRONT STEER LEFT

RIGHT REAR STEER RIGHT

RIGHT REAR STEER LEFT

LEFT REAR STEER RIGHT

LEFT REAR STEER LEFT

1

RED

R

ED

2

BLK

B

LK

3

SHIE

LD

SHI

ELD

4

YEL/

BLK

14G

RED

14G

A

5

BLK

14GA

BLK

14G

A

6

ORAN

GE 5

5-47

YEL

LOW

(16)

7

ORAN

GE

55-4

5 O

RANG

E (1

6)

8

ORAN

GE

60-2

VIO

LET

9 10 11

YEL/

RED

B

LK

12

ORN/

RED

49-1

06

BLK

1

2

3

4

5

6

7

8

9

10

11

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

1

2

3

4

5

6

7

8

9

10

11

12

X225

BLK

WHT

WHT

BLK

BLK

WHT

WHT

LEFT FRONT AXLE

EXTEND LIMIT SWITCH

RIGHT FRONT AXLE

EXTEND LIMIT SWITCH

LEFT REAR AXLE

EXTEND LIMIT SWITCHRIGHT REAR AXLE

EXTEND LIMIT SWITCH

OSC. AXLE

LOCK-OUT

VALVE

YEL/WHT 39-2

YEL/WHT 43-1

YEL/WHT 44-1

FRONT AXLE EXTEND

REAR AXLE EXTEND

REAR AXLE RETRACT

FRONT AXLE RETRACT

YEL/RED 2-1-3

YEL/RED 2-1-2

YEL/WHT 40-2

YEL/WHT 39-2-43-1

YEL/WHT 40-2-44-1

ORN/RED 49-105

ORN/RED 49-104

ORN/RED 49-106

ORN/RED 49-107

1

2

3

4

5

6

7

8

9

10

11

12

BLK

14GA

YEL/

RED

2-1-

1 (1

4GA)

J2 B

LACK

J5 R

UST

J3 G

REEN

J1 GRAY

YEL 10-2

YEL 9-2

YEL 10-1

YEL 9-1

YEL 12-2

YEL 11-2

YEL 12-1

YEL 11-1

X233

GRN

WHT

BLK

BLAC

K

YEL/

RED

2-1-

5

RED

BLK

SHIE

LD

YEL/

RED

2-1-

61234

BLK

X226

X212

X206

X224

X221

X209

X205

X230

X211

RED

X207

X210

X222

X219

X223

X235

X208

X220

X204

X229

X214

X083

X216

X215

SECTION

2-130 3128463


1200SJP 1350SJP



31 2-131

Electrical W

HYDRAULICPUMPS

GENERATORCONTROL BOX

STARTER ENGINEHARNESS(DEUTZ)

7500WGENERATOR

CONTROL BOX7500W

GENERATORRELAYS

7500WSKYPOWER

GENERATOR

OILPRESSURE

SWITCHTEMP

SWITCH

ENGINESPEED

SENSOR

CHARGEPRESSURE

OILPRESSURE

ERNATOR

FUELLEVEL

SENSOR

HASSISPOWERTRIBUTIONRELAY

HORN

AUXPOWERRELAY

ALARM

SWIVEL

LIFTCYLINDERPIVOTPIN

B.L.A.M.MODULE

ANALYZERCONNECTION

BOOMENGTHENSOR

GLOWPLUGRELAY

ENGINE CONTROL(DEUTZ EMR2)

J2J5

J1 J3

J4

MAINCONTROL

VALVE

X122

X113

X240

X249

X251

X248

X246

X247

X083

X064

X268

X279

X274

X063

X108

72

X106

X280

X278

X097

X087

X062

X086

X089

X090

X091

X088

X084

X132

X109X111

X130

41

X243

X245

X244

X256

X257 X121

X112X112

X123

X264

X119X118

X120

X250

X265

X124

TO CHASSISPOWER RELAY

X098

X071

X072

X275

X073

X278

X070

X110

X069

X276

X074

X277

X107

28463 1200SJP 1350SJP

iring Sheet 1

Figure 2-11. Electrical Wiring (Sheet 1 of 2)

DIAGNOSTICANALYZER

PLATFORMCONTROL

VALVE

PLATFORMCONTROL

BOX

GROUNDCONTROL

BOX

JIB STOWSWITCH

DUAL CAPACITYJIB POSITION

SWITCH

FOOTSWITCH

BROKENCABLE

PROXIMITYSWITCH

TRANSPORTLIMIT

SWITCH

GENERATORSWITCH

STROBELIGHT

PLATFORMWORK LIGHTS

PLATFORMFLOODLIGHTS

2500WGENERATOR

GENERATORRELAY

7500WGENERATORPLATFORM

BOX

THROTTLEACTUATOR

AIR FILTERPRESSURE

SWITCH

ALT

LIGHTSRELAY

C

DIS

BOOMANGLE

SENSOR#1 (RIGHT)

BOOMANGLE

SENSOR#2 (LEFT)

LS

HEADLIGHTS

TAILLIGHTS

J5J6

J7

J2J2

J1

J8

J3J1

J8

J4

J7

X160

X163

X145

X142

X152

X165

X171

X173

X166

X170

X140

X285

X174

X177

X167X168

X164

X169

X172

X057

X281

X155

X043

X002

X010X001

X020X018X022

X023

X029

X270

X014X269X008

X007

X282

X030

X013

X017X004

X178

X184

X143

X153

X148

X150

X156

X158 X159

X157

X242

X099

X133X129

X128

X254

X255

X252

X266X267

X103X101

X102

X273

X2

X095

X096

X100

X134

X161 X162

X176

X175

X179X181

X182X183

X190X191

X180

X185

X187X188X189

X192X193X199X194

X196

X194

X198X197

X195

X037X031

X028

X032X038X033 X039

X034X040

X271X035

X036

X283

X024

X025

X021X026

X027

X011 X012

X141

X138X139

X137

X146

X147

X144

Platform LevelSensor (Right)

Platform LevelSensor (Left)

X154

X104 X105

X126

X258

X253

X127

X2

X125

SECTION

2-132 3128463


1200SJP 1350SJP



31 2-133

Electrical W

J2 J5

J1 J3

J4

DIAGNOSTICCONNECTIONTO ANALYZER

CHASSISMODULE

AXLELIMIT

SWITCH

AXLELIMIT

SWITCH

STEERANGLE

SENSOR

REAR

AXLEPOWERTRACK

STEERANGLE

SENSOR

STEERVALVE

AUX PUMP

AUXPOWERRELAY

START RELAYTARTER

BATTERY CABLE CONNECTIONS

AXLEPOWERTRACK

X220

X224

X230

X226

X227

X229 X231

X233X232

X235

X237

X236

X239

X225

X112

X113

117

X221X219

X223X222

X228

X238

X110

X108

28463 1200SJP 1350SJP

iring Sheet 2

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

STEERANGLE

SENSOR

FRONT

AXLEPOWERTRACK

AXLELIMIT

SWITCH

AXLELIMIT

SWITCH

STEERVALVE

TRACTIONVALVE

STEERANGLE

SENSOR

SWIVEL

S

+

AXLEPOWERTRACK

X203

X200

X205

X204

X213

X212X216

XX116

X202

X201

X215

X214

X207

X211

X208X206

X210X209

SECTION

2-134 3128463


1200SJP 1350SJP



31 2-135

Telematics

1001102417

(BLACK) X288

CA

N

SH

IEL

D

(GRAY) X287

CA

N 2

LO

CA

N 2 H

I

CA

N 1

LO

CA

N 1 H

I

B-

B+

TELEMATICS DIAGNOSTIC CONNECTOR

X289

378910 1112

CA

N LO

CA

N H

I

CA

N S

HIE

LD

GR

OU

ND

BA

TT

ER

Y +

C D E AB

TELEMATICS COMMUNICATION

UNITX290

IGN

ITIO

N

GR

OU

ND

CA

N LO

CA

N H

I

1516 227

CBA

C

B

A

C

B

A

120Ohms

CBA

C

B

A

C

B

A120Ohms

RED

BLK

SHIELD

RE

D

BLK

BLK

RE

D

RE

D

BL

K

BA

TT

ER

Y +

23

YE

L/RE

D

2-100-1

BLK

10 A

RE

D

1-100

-2

YEL/RED 2-100-2

10 A

X029 GROUND E-STOP

SWITCH BATTERY SIDE

RE

D1-1

00-1

GATEWAY MODULE

C

B

ATO ENGINECAN HARNESSX279

X292

X291 X293

X294

X296X295

A

28463 1200SJP 1350SJP

System

Figure 2-13. Telematics System

MTB GROUND BUS

MTB BATTERY BUS

BLACK

C

B

ATO MTB CAN

HARNESSX279

X098

X097

X291, X292

GATEWAY MODULE

X289 TELEMATICS DIAGNOSTIC CONNECTOR

TELEMATICS COMMUNICATION UNIT

X289

ANTENNA

CELLULAR CABLE

GPS CABLE

X290

X287

SECTION

2-136 3128463


1200SJP 1350SJP



2.1 CONNECTOR INDEX Table 2-5. Connector Index

Connector Description End1 End2 Schematic Drawings

X001 Ground J1, White/Natural - 35 Position AMP352P (Neu-tral)

-- 2-8. (6D) 2-6.

X002 Ground J2, Gray - 35 Position AMP354P (Gray) -- 2-8. (6F) 2-6.X004 Ground J4, Blue - 35 Position AMP355P (Blue) -- 2-8. (7F) 2-6.X007 Ground J7, Black - 35 Position AMP351P

(Black)-- 2-8. (7C) 2-6.

X008 Ground J8 - 4 Position MMF04P -- 2-8. (7E) 2-6.X009 MTB Ground Bus - 12 Position DT12BP --X010 MTB Power Bus - 6 Position DT06AP -- 2-8. (5E) 2-6.X011 Power Down Relay -- -- 2-8. (5G) 2-6.X012 Ignition On Relay -- -- 2-8. (4H) 2-6.X013 Ground Analyzer - 4 Position AMP04R AMP04P 2-8. (5D)X014 CAN 3way - to Ground Module, Green DT03P032BP

(Blue)-- 2-8. (7B) 2-6.

X015 RS232 passthru DT08AP DT08ARX016 Ground Panel Relay -- --X017 Boom Transport Switch Pass thru AMP06P AMP06R 2-8. (7C) 2-6.X018 Ground Swing Switch E06P -- 2-8. (7F) 2-6.X019 Ground Tower Lift Switch E06P --X020 Ground Main Lift Switch E06P -- 2-8. (7F) 2-6.X021 Ground Main Tele Switch E06P -- 2-8. (7G) 2-6.X022 Ground Jib Lift Switch E06P -- 2-8. (7F) 2-6.X023 Ground Jib Swing Switch E06P -- 2-8. (7F) 2-6.X024 Ground Rotate Switch E06P -- 2-8. (7G) 2-6.X025 Ground Level Switch E06P -- 2-8. (7G) 2-6.X026 Ground Start Switch E06P -- 2-8. (7G) 2-6.X027 Fuseholder with Cover -- -- 2-8. (4H)X028 Ground Hourmeter -- -- 2-8. (7F) 2-6.X029 Ground EMS Switch -- -- 2-8. (4H) 2-6.X030 Ground Key Switch -- -- 2-8. (5H) 2-6.X031 500 Capacity Light PACKARD2LR -- 2-8. (7E)X032 Axle Lock Light PACKARD2LR -- 2-8. (7E)X033 Glow Plugs Light PACKARD2LR -- 2-8. (7E)X034 High Engine Temperature Light PACKARD2LR -- 2-8. (7E)X035 Oil Pressure Light PACKARD2LR -- 2-8. (7F)X036 Battery Voltage Light PACKARD2LR -- 2-8. (7E)X037 1000 Capacity Light PACKARD2LR -- 2-8. (7E)X038 Platform Overload (Euro) Light PACKARD2LR -- 2-8. (7E)X039 Envelope Light (BCS) PACKARD2LR -- 2-8. (7E)X040 Test Light PACKARD2LR -- 2-8. (7E)X042 MTB pass thru - 21 Position DHD21R DHD21PX043 MTB pass thru - 19 Position DHD19R DHD19P 2-8. (8)

2-9. (1)2-6.

X044 Turntable pass thru - 21 Position DHD21R DHD21PX045 Turntable pass thru - 19 Position DHD19R DHD19PX046 Dual Capacity Switch Passthru - 3 Position DT03P DT03R

3128463 1200SJP 1350SJP 2-137


X047 Main Boom Transport Switch Passthru - 3 Position DT03R DT03PX048 Main Rotary Angle Sensor Right - 5 Position PHEONIX5P --X049 Main Rotary Angle Sensor Left - 5 Position PHEONIX5P --X050 Boom Sensor Passthru - 19 Position DHD19R DHD19PX051 Main Boom Angle Switch DTM04P --X052 Dual Capacity Switch #1 -- --X053 Dual Capacity Switch #2 -- --X054 Main Boom Transport Switch #1 -- --X055 Main Boom Transport Switch #2 -- --X056 Tower Boom Transport Switch -- --X057 Strobe Light AMP02R -- 2-9. (1G)X058 BLAM passthru - 12 Position DT12AR DT12APX059 RS232 Backup passthru DT03R --X060 Load Pin Pass Thru - 8 Position (Gray) DT08AR DT08APX061 Filter Module -- --X062 Load Pin panel - 6 Position ANL06P -- 2-8. (2C) 2-3.X063 Alarm Connector AMP02P -- 2-8. (6E)X064 Fuel Level Sensor - 2 Position PACKARD2P --X065 Main Lift PVG - 4 Position (Black) AMPPVG4P

(Black)--

X066 Tower Lift PVG - 4 Position (Black) AMPPVG4P (Black)

--

X067 Tower Tele PVG - 4 Position (Black) AMPPVG4P (Black)

--

X068 PVG Enable Solenoid DIN43650P --X069 Swing Right Solenoid DIN43650P -- 2-8. (6F)X070 Swing Left Solenoid DIN43650P -- 2-8. (6F)X071 Main Tele Extend Solenoid DIN43650P -- 2-8. (6F)X072 Main Tele Proportional Solenoid DIN43650P -- 2-8. (6F)X073 Main Tele Retract Solenoid DIN43650P -- 2-8. (6F)X074 Main Dump Solenoid DIN43650P -- 2-8. (6G)X075 Tower Lift Pilot Solenoid DIN43650P --X076 Tower Tele Pilot Solenoid DIN43650P --X077 Main Lift Pilot Solenoid DIN43650P --X078 Hyd Oil Temp Switch - 2 Position DT02P --X079 Pressure Switch DIN43650P --X080 Tower Lift Enable Solenoid DIN43650P --X081 Tower Tele Enable Solenoid DIN43650P --X082 Main Lift Enable Solenoid DIN43650P --X083 Swivel - 12 Position (Black) DT12BP -- 2-8. (5B)

2-10. (5H)2-5.,2-7.

X084 Deutz EMR2 Chassis CAN - 3 Position DT03R DT03P 2-8. (4E) 2-4.X086 BLAM J1 - 12 Position (Gray) DT12AP -- 2-8. (4D) 2-5.X087 BLAM J2 - 12 Position (Black) DT12BP -- 2-8. (3C) 2-5.X088 BLAM J3 - 12 Position DT12CP -- 2-8. (4E) 2-5.X089 BLAM J4 - 8 Position DT08AP -- 2-8. (3C) 2-5.X090 BLAM J5 - 12 Position (Green) DT12DP -- 2-8. (3E) 2-5.

Table 2-5. Connector IndexConnector Description End1 End2 Schematic Drawings

2-138 1200SJP 1350SJP 3128463


X091 Blam Analyzer - 4 Position AMP04R -- 2-8. (2D) 2-5.X092 Tower Lift Cyl Angle Sensor - 3 Position DT03P DT03RX093 Boom Length Sensor 1(Top) - 3 Position DT03P DT03RX094 Tower Boom Length Sensor 2 (Bottom) - 3 Position DT03P DT03RX095 Boom Angle Sensor1 Passthrough - 4 Position (Gray) DT04R DT04P 2-8. (2C) 2-5.X096 Boom Angle Sensor2 Passthrough - 4 Position (Gray) DT04P DT04R 2-8. (2C) 2-5.X097 12 Pos Batt Busbar DT12BP -- 2-8. (3C) 2-5.X098 12 Pos Ground Busbar DT12BP -- 2-8. (3C) 2-5.X099 Boom Angle Sensor #1 (Right) DTM03P DTM03R 2-8. (2C) 2-3.X100 Boom Angle Sensor #2 (Left) DTM03P DTM03R 2-8. (2C) 2-3.X101 Lights Relay -- -- 2-8. (6E)X102 Headlight -- -- 2-5.X103 Headlight -- -- 2-4.X104 Taillight -- -- 2-3.X105 Taillight -- -- 2-3.X106 BLAM Pump Passthru DT06R -- 2-8. (2E) 2-5.X107 Horn -- -- 2-5.X108 Aux Power Relay -- -- 2-8. (2B)X109 Power Relay Fuse -- -- 2-8. (4B)X110 Aux Pump -- -- 2-8. (2B) 2-5.X111 Glow Plug Relay -- -- 2-8. (2G)X112 Start Relay -- -- 2-8. (2G)X113 Starter -- -- 2-8. (2H) 2-4.X116 Battery Positive -- -- 2-8. (1B) 2-5.X117 Battery Negative -- -- 2-8. (1B) 2-5.X118 Right Side Drive Reverse Solenoid DIN43650P -- 2-8. (2E) 2-4.X119 Left Side Drive Reverse Solenoid DIN43650P -- 2-8. (2E) 2-4.X120 Right Side Drive Forward Solenoid DIN43650P -- 2-8. (2E) 2-4.X121 Left Side Drive Forward Solenoid DIN43650P -- 2-8. (2D) 2-4.X122 Engine Speed Sensor - 2 Position AMPJT826008P -- 2-8. (4H)X123 Engine Oil Pressure Switch -- --X124 Engine Coolant Temp Switch -- -- 2-8. (4H)X125 Engine Alternator -- -- 2-8. (1H)X126 Engine Throttle Actuator DIN43650P -- 2-8. (4F)X127 Generator Relay -- -- 2-8. (5B)X128 Generator Connector -- --X129 Generator Control Box -- --X130 Generator Extension -- --X131 Generator Extension -- --X132 Generator Outlet -- --X133 Generator -- --X134 Worklight passthru - 3 Position PACKARD3P PACKARD3RX135 Platform Dump Solenoid DIN43650P -- 2-9. (4F) 2-2.X136 Platform Level Up Solenoid DIN43650P -- 2-9. (4F) 2-2.X137 Platform Level Down Solenoid DIN43650P -- 2-9. (4F) 2-2.X138 Platform Rotate Right Solenoid DIN43650P -- 2-9. (4F) 2-2.X139 Platform Rotate Left Solenoid DIN43650P -- 2-9. (4F) 2-2.


3128463 1200SJP 1350SJP 2-139


X140 Platform Jib Swing Right DIN43650P -- 2-9. (4F) 2-2.X141 Platform Jib Swing Left DIN43650P -- 2-9. (4F) 2-2.X142 Platform Jib Up DIN43650P -- 2-9. (4F) 2-2.X143 Platform Jib Down DIN43650P -- 2-9. (4F) 2-2.X144 Jib Stow Pass Thru - 2 Position DT02R -- 2-9. (5H)X145 Jib Limit Switch Pass Thru - 2 Position DT02P -- 2-9. (5H)X146 Jib Stow Switch -- -- 2-9. (4H) 2-3.X147 Jib Position Switch -- -- 2-9. (4H) 2-3.X148 Platform Level Sensor 2 (Left) DTM03R DTM03P 2-9. (4G) 2-3.X150 Platform Level Sensor 1 (Right) DTM03R DTM03P 2-9. (4G) 2-3.X152 Footswitch -- -- 2-9. (3E) 2-2.X153 Platform Worklight -- -- 2-9. (2H) 2-2.X154 Platform Worklight -- -- 2-9. (2G) 2-2.X155 Generator Switch -- -- 2-9. (5E) 2-2.X156 Floodlights passthru - 3 Position PACKARD3P PACKARD3RX157 Platform Floodlights component -- --X158 Floodlight passthru - 2 Position AMP02P AMP02RX159 Floodlight passthru - 2 Position AMP02P AMP02RX160 Platform Control Box Passthrough - HD34-24-19-PE DHD19R DHD19P 2-9. (2)X161 Platform Valve passthru - Deutsch 21 Pin DHD1821R DHD1821P 2-9. (5F)X162 Platform Level Passthru #1 PHEONIX7P -- 2-9. (5G)X163 Platform Level Passthru #2 PHEONIX7P -- 2-9. (5G)X164 Platform passthru - Amp 15 Position AMP15R AMP15P 2-9. (A7,A6,

E5,5D,3E,7F)X165 Platform J1 Connector - 35 Position (Natural) AMP352P (Neu-

tral)-- 2-9. (7F)

X166 Platform J2 Connector - 35 Position (Blue) AMP355P (Blue) -- 2-9. (7D)X167 Platform J5 Connector, Male - 8 Position AMP08NP -- 2-9. (6C)X168 Platform J6 Connector, Female - 8 Position AMP08BP -- 2-9. (6B)X169 Platform J7 Connector - 35 Position (Black) AMP351P

(Black)-- 2-9. (6F)

X170 Platform J8 Connector, Male - 2 Position MMF02P -- 2-9. (6D)X171 Platform Diagnostics Connector AMP04R -- 2-9. (8B)X172 Platform Alarm MMF02P -- 2-9. (5E)X173 Platform Analyzer Pass Thru AMP15R AMP15P 2-9. (7B)X174 Drive Orientation Override Switch - 6 Position E06P -- 2-9. (7A) 2-2.X175 Platform Capacity Select Switch - 6 Position E06P -- 2-9. (7F) 2-2.X176 Controller Harness/Circuit Board Assembly (Drive and Steer) -- -- 2-9. (6B) 2-2.X177 Platform Engine Start/ Aux Power Switch - 6 Position E06P -- 2-9. (7E) 2-2.X178 Platform Boom Telescope Switch - 6 Position E06P -- 2-9. (7G) 2-2.X179 Platform EMS Switch -- -- 2-9. (2F) 2-2.X180 Platform Jib Lift Switch - 6 Position E06P -- 2-9. (7G) 2-2.X181 Platform Lights Switch -- -- 2-9. (7E) 2-2.X182 Platform LED J4 - 6 Position AMP06P -- 2-9. (8C) 2-2.X183 Platform LED J3 - 6 Position AMP06P -- 2-9. (8C) 2-2.X184 Platform Soft Touch Override Switch -- -- 2-9. (7E) 2-2.X185 Platform Jib Swing Switch - 6 Position E06P -- 2-9. (7B) 2-2.


2-140 1200SJP 1350SJP 3128463


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


3128463 1200SJP 1350SJP 2-141


X236 Rear Right Steer Passthrough Connector, Gray - 4 Position DT04P DT04R 2-10. (2C)X237 Rear Left Steer Passthrough Connector, Gray - 4 Position DT04P -- 2-10. (2C)X238 Rear Left Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2C) 2-7.X239 Rear Right Steer Angle Sensor - 3 Position DT03P DT03R 2-10. (2C) 2-4.X240 EMR2 ECU Equipment Connector AMP25RP -- 2-8. (3G) 2-4.X241 EMR2 ECU Engine Connector AMP25LP -- 2-8. (3G) 2-4.X242 EMR2 Engine Diagnostics Connector ITTC12P -- 2-8. (2F)X243 EMR2 Capped 12 position Plug DEUTZ12ENGR --X244 EMR2 16 position sensor passthru DEUTZ16P DEUTZ16RX245 EMR2 12 position passthru DEUTZ12R DEUTZ12PX246 Skypower Relay -- -- 2-8. (5A)X247 Skypower Relay -- -- 2-8. (5A)X248 Skypower Control Box -- -- 2-8. (5A)X249 Skypower Control Box -- --X250 Skypower Generator -- -- 2-4.X251 Skypower Generator -- -- 2-4.X252 Skypower Distribution Box -- --X253 Skypower Outlet -- --X254 Skypower Outlet -- --X255 Skypower Outlet -- --X256 EMR2 charge air pressure - 4 position DEUTZE -- 2-8. (4G)X257 EMR2 engine oil pressure -- -- 2-8. (4G)X258 EMR2 air filter pressure switch DEUTZG --X259 Main Lift PVG unused (Gray) AMPPVG4GP

(Gray)--

X260 Tower Lift PVG unused (Gray) AMPPVG4GP (Gray)

--

X261 Tower Tele PVG unused (Gray) AMPPVG4GP (Gray)

--

X262 Load Pin CAN Pass thru - 3 position DT03P DT03RX263 Chassis Power - 2 position DT02P DT02RX264 Generator Platform Box Pass Thru -- --X265 Generator Platform Box Pass Thru -- --X266 Chassis Power Relay BOSCH05P -- 2-8. (4B)X267 Chassis Power Fuse -- -- 2-8. (4B)X268 CAN pass thru for EMR2 - 3 position DT03P DT03R 2-8. (5D) 2-5.X269 CAN 3way - to BLAM, Blue DT03P032BP

(Blue)-- 2-8. (7B) 2-6.

X270 CAN 3way - to Platform, Blue DT03P032BP (Blue)

-- 2-8. (8B) 2-6.

X271 MTB Ground Bus - 6 Position DT06AP -- 2-8. (6C) 2-6.X272 Boom Length Sensor Passthru DT06R DT06AP 2-8. (3E) 2-5.X273 Boom Length Sensor DT03P DT03R 2-8. (3E) 2-3.X274 Lift Down Auxiliary Select DIN43650P -- 2-8. (6F) 2-5.X275 Lift Down Auxiliary DIN43650P -- 2-8. (6F) 2-5.X276 Main Lift Up DIN43650P -- 2-8. (6F) 2-5.X277 Main Lift Down DIN43650P -- 2-8. (6F) 2-5.


2-142 1200SJP 1350SJP 3128463


X278 CAN passthru to BLAM - 3 position (Green) DT03P032BP (Blue)

-- 2-8. (4D)

X279 CAN passthru to Engine Hns - 3 position (Green) DT03P032GP (Green)

-- 2-8. (5D)

X280 Valve passthru DT06AP DT06R 2-8. (5D,5C) 2-5.X281 Transport Limit Switch -- -- 2-8. (8C) 2-3.X282 Broken Cable Proximity Switch -- -- 2-8. (8C) 2-3.X283 Boom Control System Test Switch -- -- 2-8. (8D)X284 Boom Control System Test Switch -- -- 2-8. (8D)X285 Boom Control Select E06P -- 2-9. (7F) 2-2.X286 Main Lift Flow Control DIN43650P -- 2-8. (6F) 2-5.X287 Gateway Module (Gray) DTM12AP -- 2-13. 2-13.X288 Gateway Module (Black) DTM12BP -- 2-13. 2-13.X289 Telematics Diagnostic Connector DHD1939R -- 2-13. 2-13.X290 Telematics Communication Unit (TCU) AMP23P -- 2-13. 2-13.X291 Gateway CAN 3-way to Gateway DT03P032OP

(Orange)-- 2-13. 2-13.

X292 Gateway CAN 3-way to Harness DT03P032OP (Orange)

-- 2-13. 2-13.

X293 TCU CAN 3-way to TCU DT03P032OP (Orange)

-- 2-13. 2-13.

X294 TCU CAN 3-way to Harness DT03P032OP (Orange)

-- 2-13. 2-13.

X295 TCU Fuse -- -- 2-13. 2-13.X296 Telematics Diagnostic Connetor Fuse -- -- 2-13. 2-13.


3128463 1200SJP 1350SJP 2-143


2.2 BLAM MODULE CONNECTOR PINOUTS Table 2-6. X086 (J1) BLAM Module Pinout

Pin Function Type Range (V)

1 Not Used -- --2 Not Used -- --3 Not Used -- --4 Ground Ground 0VDC5 V Bat Battery Vbatt6 CAN HI Input/Output Comm7 CAN LO Input/Output Comm8 CAN Shield Ground 0VDC9 CAN Termination Connection Input/Output Comm

10 CAN Termination Connection Input/Output Comm11 Not Used -- --12 Not Used -- --

Table 2-7. X087 (J2) BLAM Module PinoutPin Function Type Range (V)

1 Not Used Input --2 Not Used Input --3 -- -- --4 Not Used -- --5 Not Used -- --6 Not Used -- --7 Not Used -- --8 Boom Angle 1 (Right) Input/Output Comm9 Boom Angle 2 (Left) Input/Output Comm

10 Not Used -- --11 Right Drive Pump Forward Output PWM12 Right Drive Pump Reverse Output PWM


1 Reference Voltage Other Voltage 5VDC2 Reference Voltage From J3-1 Analog Input 5VDC3 Not Used -- --4 Not Used -- --5 Not Used -- --6 Not Used -- --7 Reference Voltage Other Voltage 5VDC8 Boom Length Sensor Analog Input 5VDC9 Ground Ground 0VDC

10 Not Used -- --11 Not Used -- --12 Not Used -- --


1 V Bat Battery Vbatt2 Ground Ground 0VDC3 CAN HI Input/Output Comm4 CAN LO Input/Output Comm5 CAN Shield Ground 0VDC6 Not Used -- --7 Not Used -- --8 Not Used -- --


1 Left Drive Pump Forward Output PWM2 Left Drive Pump Reverse Output PWM3 Oscillating Axles Output PWM4 Not Used -- --5 Not Used -- --6 Not Used -- --7 Not Used -- --8 Not Used -- --9 Analyzer Power Other Voltage Vbatt

10 RS232 Receive Input/Output Comm11 RS232 Transmit Input/Output Comm12 Ground Ground 0VDC

2-144 1200SJP 1350SJP 3128463


2.3 CHASSIS MODULE CONNECTOR PINOUTSTable 2-11. X229 (J1) Chassis Module Pinout


1 Not Used -- --2 Not Used -- --3 Not Used -- --4 Main Ground Ground 0VDC5 Main Ignition Vbatt Vbatt6 CAN HI Input/Output Comm7 CAN LOW Input/Output Comm8 CAN Shield Input/Output 0VDC9 CAN Terminator (Connected to

J1-10)Input/Output Comm

10 CAN Terminator (Connected to J1-9)

Input/Output Comm

11 Ignition Vbatt Vbatt12 Not used -- --

Table 2-12. X230 (J2) Chassis Module PinoutPin Function Type Range (V)

1 Not Used -- --2 Not Used -- --3 Ground Ground 0VDC4 Front Axle Extend Limit Switches Input Vbatt5 Rear Axle Extend Limit Switches Input Vbatt6 Drive Orientation Switch Input Vbatt7 Axle Lockout Pressure Switch Input Vbatt8 Not Used -- --9 Not Used -- --

10 Not Used -- --11 Axle Extend Output Vbatt12 Axle Retract Output Vbatt


1 Reference Voltage Other Voltage 5VDC2 Front Right Steer Angle Sensor Analog Input 0 - 5VDC3 Ground Ground 0VDC4 Reference Voltage Other Voltage 5VDC5 Front Left Steer Angle Sensor Analog Input 0 - 5VDC6 Ground Ground 0VDC7 Reference Voltage Other Voltage 5VDC8 Rear Right Steer Angle Sensor Analog Input 0 - 5VDC9 Ground Ground 0VDC

10 Reference Voltage Other Voltage 5VDC11 Rear Left Steer Angle Sensor Analog Input 0 - 5VDC12 Ground Ground 0VDC


1 Axle Lockout Pressure Switch Power

Vbatt Vbatt

2 Axle Lockout Solenoid Ground 0VDC3 Not Used -- --4 Not Used -- --5 Not Used -- --6 Not Used -- --7 Not Used -- --8 Not Used -- --


1 Right Front Steer Right Solenoid Output Vbatt2 Right Front Steer Left Solenoid Outupt Vbatt3 Left Front Steer Right Solenoid Output Vbatt4 Left Front Steer Left Solenoid Output Vbatt5 Right Rear Steer Right Solenoid Output Vbatt6 Right Rear Steer Left Solenoid Output Vbatt7 Left Rear Steer Right Solenoid Output Vbatt8 Left Rear Steer Left Solenoid Output Vbatt9 Analyzer Power Vbatt Vbatt

10 Analyzer RS-232 Receive Input Comm11 Analyzer RS-232 Transmit Output Comm12 Analyzer Ground Ground 0VDC

3128463 1200SJP 1350SJP 2-145


2.4 GROUND MODULE CONNECTOR PINOUTSTable 2-16. X001 (J1) Ground Module Pinout


1 Not Used -- --2 Not Used -- --3 Not Used -- --4 Not Used -- --5 Ground Ground 0VDC6 Not Used -- --7 Not Used Output --8 Ground Ground 0VDC9 Not Used -- --

10 Ignition On Relay Output Vbatt11 Start Solenoid (Diesel Only) Output Vbatt12 Glow Plug (Diesel Only Option) Output Vbatt13 Auxiliary Power Output Vbatt14 Not Used -- --15 Not Used -- --16 Not Used -- --17 Not Used -- --18 Not Used -- --19 Ground Ground 0VDC20 Two Speed Output Vbatt21 Not Used -- --22 Generator/Welder (Option) Output Vbatt23 Parking Brake Output Vbatt24 Constant Battery Battery Vbatt25 Not Used -- --26 Not Used -- --27 Not Used -- --28 Analyzer Power Other Voltage 9.5VDC29 Analyzer RS-232 Receive Input Comm30 Analyzer RS-232 Transmit Output Comm31 Analyzer Ground Ground 0VDC32 Not Used -- --33 Not Used -- --34 Not Used -- --35 Not Used -- --

Table 2-17. X002 (J2) Ground Module PinoutPin Function Type Range (V)

1 Not Used -- --2 Horn Output Vbatt3 Platform Control Valve Output Vbatt4 Main Telescope In Output Vbatt5 Basket Level Up Override Output Vbatt6 Ground Ground 0VDC7 Basket Level Down Override Output Vbatt8 Not Used -- --

9 Main Telescope Flow Control Output PWM10 Lift Down Auxiliary Select Output Vbatt11 Main Lift Up Output PWM12 Lift Down Auxiliary Output Vbatt13 Main Dump Output Vbatt14 Ground Ground 0VDC15 Not Used -- --16 Main Telescope Out Output Vbatt17 Ground Ground Vbatt18 Not Used -- --19 Lift Flow Control Output PWM20 Not Used -- --21 Not Used -- --22 Main Lift Down Output Vbatt23 Not Used -- --24 Not Used -- --25 Fuel Sensor Input Vbatt26 Head/Tail Light Output Vbatt27 Alarm Output Vbatt28 Not Used -- --29 Ground Ground 0VDC30 Ground Ground 0VDC31 Not Used -- --32 Not Used -- --33 Not Used -- --34 Swing Left Output PWM35 Swing Right Output PWM


1 Axles Set Lamp Output Vbatt2 500# Capacity Lamp Output Vbatt3 Boom Control System Lamp Output Vbatt4 Start Switch Input Vbatt5 Basket Level Down Switch Input Vbatt6 Basket Rotate Left Switch Input Vbatt7 Upper Telescope In Switch Input Vbatt8 Jib Down Switch Input Vbatt9 Jib Left Switch Input Vbatt

10 Not Used -- --11 Not Used -- --12 Hour Meter Output Vbatt13 Moment Control Test Lamp Output Vbatt14 Platform Overload Lamp Output Vbatt15 Glow Plugs Output Vbatt16 Auxiliary Power / Enable Input Vbatt


2-146 1200SJP 1350SJP 3128463


17 Basket Level Up Switch Input Vbatt18 Basket Rotate Right Switch Input Vbatt19 Jib Up Switch Input Vbatt20 Jib Right Switch Input Vbatt21 Not Used -- --22 Not Used -- --23 Boom Lift Up Switch Input Vbatt24 V Bat Battery Vbatt25 V Bat Battery Vbatt26 No Charge Lamp Output Vbatt27 1000# Capacity Lamp Output Vbatt28 Engine High Temperature Lamp Output Vbatt29 Engine Low Oil Pressure Lamp Output Vbatt30 Boom Telescope Out Switch Input Vbatt31 Ground Ground 0VDC32 Not Used -- --33 Main Boom Lift Down Input Vbatt34 Swing Left Switch Input Vbatt35 Swing Right Switch Input Vbatt


1 Platform EMS Input Vbatt2 Platform Mode Input Vbatt3 Ground Mode Input Vbatt4 Not Used -- --5 Not Used -- --6 Not Used -- --7 Not Used -- --8 Not Used -- --9 Not Used -- --

10 Not Used -- --11 Boom Length Limit Closed Input Vbatt12 Broken Cable Prox Switch Input Vbatt13 CAN Hi Input/Output Comm14 Ground Mode Out to Platform Input Vbatt15 Footswitch Engage Input Vbatt16 Not Used -- --17 Not Used -- --18 CAN Shield Ground 0VDC19 Ground Ground 0VDC20 Not Used -- --21 Boom Control System Test

SwitchInput Vbatt

22 Not Used -- --23 Ground Control Enable Input Vbatt24 CAN Lo Input/Output Comm


25 Not Used -- --26 Not Used -- --27 Not Used -- --28 Not Used -- --29 V Bat Battery Vbatt30 Not Used -- --31 Not Used -- --32 V Bat Battery Vbatt33 Not Used -- --34 Not Used -- --35 Boom Length Limit Switch Open Input Vbatt


1 Ground from Battery Ground 0VDC2 Ground EMS Output Vbatt3 Ground to Platform Ground 0VDC4 Ground EMS Out to Platform Output Vbatt


3128463 1200SJP 1350SJP 2-147


2.5 PLATFORM MODULE CONNECTOR PINOUTSTable 2-21. X165 (J1) Platform Module Pinout


1 Not Used -- --2 Not Used -- --3 Not Used -- --4 Not Used -- --5 Main Telescope In Switch Input Vbatt6 Main Telescope Out Switch Input Vbatt7 Basket Rotate Right Switch Input Vbatt8 Basket Rotate Left Switch Input Vbatt9 Basket Level Up Switch Input Vbatt

10 Basket Level Down Switch Input Vbatt11 Jib Up Switch Input Vbatt12 Jib Down Switch Input Vbatt13 Pump Potentiometer Return Ground 0VDC14 Start Switch Input Vbatt15 Auxiliary Switch Input Vbatt16 Crab Steer Select Switch Input Vbatt17 Coordinated Steer Select Switch Input Vbatt18 Switch Input Battery Output Vbatt19 Inline Limit Switch Input Vbatt20 LSS Platform Overload Input Vbatt21 500/1000 # Capacity Select

SwitchInput Vbatt

22 Boom Control Select Switch Input Vbatt23 Axle Extend Switch Input Vbatt24 Axle Retract Switch Input Vbatt25 Serial Tilt Sensor Input 1 Input/Output Comm26 Serial Tilt Sensor input 2 Input/Output Comm27 Two Speed Switch Input Vbatt28 Engine Speed Switch Input Vbatt29 Soft Touch Override Switch Input Vbatt30 Head/Tail Light Switch Input Vbatt31 Horn Switch Input Vbatt32 Creep Switch Input Vbatt33 Not Used -- --34 Pump Potentiometer Ref. Volt-

ageOther Voltage 7VDC

35 Pump Potentiometer Input 7 VDC

Table 2-22. X166 (J2) Platform Module PinoutPin Function Type Range (V)

1 Jib Right Switch Input Vbatt2 Jib Left Switch Input Vbatt3 Switch Input Battery Vbatt Vbatt4 Drive Orientation Override

SwitchInput Vbatt

5 Basket Stow Switch Input Vbatt

6 Tilt Lamp Output Vbatt7 Enable Lamp Output Vbatt8 System Distress/Fault Lamp Output Vbatt9 Creep Lamp Output Vbatt

10 Broken Cable Lamp Output Vbatt11 Overload Lamp Output Vbatt12 500# Capacity Lamp Output Vbatt13 1000# Capacity Lamp Output Vbatt14 Axle Set Lamp Output Vbatt15 Generator On Lamp Output Vbatt16 Soft Touch Lamp Output Vbatt17 Glow Plug Lamp Output Vbatt18 Lamp Return Ground 0VDC19 Boom Control System Warning

LampOutput Vbatt

20 Auto Leveling System Lamp Output Vbatt21 Not Used -- --22 Fuel 1/4 Full Lamp Output Vbatt23 Fuel 3/4 Full Lamp Output Vbatt24 Fuel 1/2 Full Lamp Output Vbatt25 Fuel Lamp Return Output Vbatt26 Analyzer PWR Vbatt Vbatt27 Analyzer Ground Ground 0VDC28 Analyzer RS232 Receive Input/Output Comm29 Analyzer RS232 Transmit Input/Output Comm30 Drive Orientation Lamp Output Vbatt31 Not Used -- --32 Battery Vbatt Vbatt33 Battery Vbatt Vbatt34 Switch Input Battery Vbatt Vbatt35 Fuel Full Lamp Output Vbatt


1 Swing & Lift Joystick Supply Vref 7VDC2 Lift Center Tap Input 7VDC3 Lift Signal Input 7VDC4 Swing Signal Input 7VDC5 Swing Center Tap Input 7VDC6 Not Used -- --7 Ground Ground 0VDC8 Not Used -- --


2-148 1200SJP 1350SJP 3128463



1 Steer & Drive Joystick Supply Vref 7VDC2 Drive Center Tap Input 7VDC3 Drive Signal Input 7VDC4 Not Used -- --5 Steer Left Switch Input 7VDC6 Steer Right Switch Input 7VDC7 Ground Ground 0VDC8 Not Used -- --


1 GND Mode Switch Input Vbatt2 Platform EMS Switch Input Vbatt3 Platform EMS to GND Module Input Vbatt4 Not Used -- --5 Rotate Left Coil Output PWM6 Rotate Right Coil Output PWM7 Not Used -- --8 Footswitch Disengage Input Vbatt9 Generator On Input Vbatt

10 Not used -- --11 Not Used -- --12 Not Used -- --13 Not Used -- --14 Not Used -- --15 Basket Level Up Coil Output PWM16 Basket Level Down Coil Output PWM17 Jib Block Limit Switch Input Vbatt18 Soft Touch Limit Switch Input Vbatt19 Platform Alarm Output Vbatt20 Platform Alarm Return Ground 0VDC21 Primary Tilt Sensor Ground Ground 0VDC22 Not used -- --23 Not used -- --24 Not used -- --25 Jib Up Coil Output PWM26 Jib Down Coil Output PWM27 Jib Right Coil Output PWM28 Jib Left Coil Output PWM29 Digital Output Return Ground 0VDC30 CAN LO Input/Output Comm31 CAN HI Input/Output Comm32 CAN Shield Ground 0VDC33 Secondary Tilt Sensor Ground Ground 0VDC34 Not Used -- --35 Not Used -- --


1 Ground from Ground Module Ground 0VDC2 Ground EMS Ground 0VDC

3128463 1200SJP 1350SJP 2-149


2.6 CONNECTOR LOADING DIAGRAMS Table 2-27. Connector Loading Diagrams

ID Description Diagram

AMP02P Amp 2 position plug

AMP02R Amp 2 position recepta-cle

AMPJT826008P

Amp 2 position plug





1

2

2

1

1 2

4321

4

3

1

32 1

6 5 4

321

654

2-150 1200SJP 1350SJP 3128463


AMP08BP Amp 8 position black plug

AMP08NP Amp 8 position natural plug


AMP15R Amp 15 position recep-tacle

AMP25LP Amp Rectangular 25 position plug with key for left

AMP25RP Amp Rectangular 25 position plug with key for right

AMPPVG4P (Black)

Amp PVG Valve 4 posi-tion plug

AMPPVG4GP (Gray)

Table 2-27. Connector Loading DiagramsID Description Diagram

1 3

6 8

1

2

34679

10121315

14

1

2

34 67 9

10 1213 15

14

12

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

13

25

1 2

14

3

15

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

13

25

1234

3128463 1200SJP 1350SJP 2-151


AMP14P Ampseal 14 position

AMP23P Ampseal 23 position

AMP351P(Black)

Ampseal 35 position

AMP352P(Neutral)AMP354P(Gray)AMP355P(Blue)

AN350P Anderson Power Con-nector

ANL06P Amphenol 6 Position Sealed Plug


1 5

1410 AMP

Socket Rear Insert

1 8

2316

Socket Rear Insert

1 12

3524 AMP

Socket Rear Insert

2-152 1200SJP 1350SJP 3128463


BOSCH05P Bosch Relay Sealed Plug

DEUTZ12ENGR

Deutz Supplied 12 posi-tion receptacle

DEUTZ12P Deutz Supplied 12 posi-tion plug

DEUTZ12R Deutz Supplied 12 posi-tion receptacle

DEUTZ16P Deutz Supplied 16 posi-tion plug


1

9

4

12

10 11

2 3

12

4

9

1

23

1011

12

4

9

1

2 3

10 11

1

9

4

12

1415

2 3

13

5 8

16

3128463 1200SJP 1350SJP 2-153


DEUTZ16R Deutz Supplied 16 posi-tion receptacle

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

DEUTZG Deutz Supplied 2 posi-tion air filter pressure switch Receptacle

DIN43650P Din 43650 4 position plug

DHD1939R Deutsch 9 position HD series J1939. Recepta-cle


1

9

4

12

1415

23

13

58

16

1

3

2

4

2-154 1200SJP 1350SJP 3128463


DHD14P Deutsch 14 position HD series alum. Plug

DHD14R Deutsch 14 position HD series alum. Receptacle





Rear View

Rear View

3128463 1200SJP 1350SJP 2-155





DHTP31R(receptacle)

Deutsch HDP 31 posi-tion

DHTP31P(plug)

DT02P Deutsch 2 position DT series plug

DT02R Deutsch 2 position DT series receptacle


28

29

3031 20

21

22

23

252426

27

1819

89

10

11

1213

1415

16

177

2

16

54

3

Socket Rear Insert

1 2

2 1

2-156 1200SJP 1350SJP 3128463




DT03P032GP (Green)

Deutsch 3 position DT series plug with over-mold adaptorDT03P032BP

(Blue)DT03P032OP (Orange)



DT06AP Deutsch 6 position DT series plug

DT06EP032R Deutsch 6 position bus receptacle



B

C

A

B

C

A

B

C

AB A

C

3128463 1200SJP 1350SJP 2-157


DT08AP Deutsch 8 position DT series plug with A keys

DT08AR Deutsch 8 position DT series receptacle with A keys

DT12AP Deutsch 12 position DT series plug with A keys

DT12AR Deutsch 12 position DT series receptacle with A keys

DT12BP Deutsch 12 position DT series plug with B keys

DT12BR Deutsch 12 position DT series receptacle with B keys


121110987 6

54321

1211109

87 6

54321

121110987 6

54321

121110987 6

54321

2-158 1200SJP 1350SJP 3128463


DT12CP Deutsch 12 position DT series plug with C keys

DT12DP Deutsch 12 position DT series plug with D keys

DT12PBR Deutsch 12 position bus receptacle

DTM03P Deutsch 3 position DTM series mini plug

DTM03R Deutsch 3 position DTM series mini receptacle

DTM04P Deutsch 4 position DTM series mini plug

DTM04R Deutsch 4 position DTM series mini receptacle

DTM12AP Deutsch 12 position DT series mini plug with A key


121110987 6

54321

1234567

89

101112

1234567

89

101112

123

1 2 3

43

12

12

43

7 8 9 10 11 12

6 5 4 3 2 1

3128463 1200SJP 1350SJP 2-159


DTM12BP Deutsch 12 position DT series mini plug with B key

DTP02P Deutsch 2 position DTP series plug

DTP02R Deutsch 2 position DTP series receptacle

E06P Eaton Toggle Switch

ITTC12P ITT Cannon 12 position plug

MMF02P Molex 2 position plug

MMF04P Molex 4 position plug


7 8 9 10 11 12

6 5 4 3 2 1

1 2

2 1

1

2

3

4

5

6

12

12

34

2-160 1200SJP 1350SJP 3128463


MMF08P Molex Mini Fit 8 position plug

MMF10P Molex Mini Fit 10 posi-tion plug



PHEONIX5P Pheonix 5 position M-12 Plug


Rear View

12

34

5

109

87

6

121110987

1 2 3 4 5 6

1

13

4

16

5

17

6

18

7

19

8

20

9

21

10

22

11

23

12

24

2

14

3

15

3128463 1200SJP 1350SJP 2-161


PHEONIX7P Pheonix 7 position M-12 Plug

PACKARD2LR Packard Light Recepta-cle

PACKARD2P Packard 2 position plug

PACKARD3P Packard 3 position receptacle

PACKARD3R Packard 3 position receptacle

SUM02N Sumitomo 2 position natural

SUM06N Sumitomo 6 position natural


A B

C B A

1 2

1

2

3

4

5

6

2-162 1200SJP 1350SJP 3128463


SECTION 3. HYDRAULIC REFERENCE

Figure 3-1. Main Valve Layout

MAIN VALVE

MPSWINGRELIEF

ADJ

M4LIFT UPRELIEF

ADJTELE INRELIEF

ADJ

TELE OUTRELIEF

ADJ

M7

M5

MS

M8

LIFTDOWNRELIEF

ADJ

3128463 1200SJP 1350SJP 3-163


Figure 3-2. Pumps Layout

LEFT SIDE DRIVE PUMP

FUNCTION PUMP

RIGHT SIDE DRIVE PUMP

LOW PRESS RELIEF ADJ.

HIGH PRESS RELIEF ADJ.

PUMPS

VIEW ROTATED

3-164 1200SJP 1350SJP 3128463


Platform Valve Layout

Figure 3-3. Platform Valve Layout

PLATFORM LEVELDOWN RELIEFADJUST

JIB UP/DOWNRELIEF ADJUST

JIB UP/DOWNSHUTTLEVALVE

JIB UP/DOWN2.0 GPM

PLATFORM LEVELUP RELIEF ADJUST

2.0 GPM

0.3 GPM

0.2 GPM

75 PSICHECKVALVE

BASKET SUPPORT

10 MICRONFILTER

MP

M1

M2

M3

P

L1

L2

R1

R2

S1S2

J1

J2T

3128463 1200SJP 1350SJP 3-165


Pump Circuit Schematic

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

ab

Ps

Ma

THROTTLEPOSITION

G (Fa) (Fe) B

SWIVEL PORT#5

SWIVEL PORT#6

1.2mm

"OPTION"

2792771 C

.37in 3

5000 PSI

5000 PSI

1.7in 3

PUMP CIRCUIT.1200SJP, 1350SJP, 1250AJP

T2T1R

Mb

X1 X2 S A

#1 - TT - #1

#2 - P P - #2

#5 - B1B1 - #5

#4 - B2B2 - #4

#3 - A2A2 - #3

#6 - A1A1 - #6

#7 - CDCD - #7

SWIVEL

OIL COOLER

3-166 1200SJP 1350SJP 3128463


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

L1

"P1"SHT. #1

Ps

ab

Ma

G (Fa) (Fe) B

Mb

B

LS

SWIVEL PORT#4

SWIVEL PORT#3

RESERVOIR

"T3"SHT. #1

SWIVEL PORT#7

SWIVEL PORT#1

SET AT 300 PSI

SET AT3400PSI

"LS"SHT. #1

X

2.74in 3

.37in3

550 PSI

5000 PSI

5000 PSI

1.7in3

R T2T1 X1 X2 S A

2792771 C

3128463 1200SJP 1350SJP 3-167


Platform Control Schematic

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

1

3

2

1

2

1

2 1

2

1

2

1

2

1

2

"T2"SHT. #1

"P3"SHT. #1

LEVEL CYLINDER1200SJP-1350SJP Bore: 5.00" 19.63 sq. in.Rod: 2.00" 3.14 sq. in.Annulus: 16.49 sq. in.Cyl. Area Ratio: 1.19:1Stroke: 13.375"

PLATFORM ROTATOR

Displacement: 14 c.i.r.

IN OUT

PLATFORM CONTROL

1500 PSI

2500 PSI

75 PSI

1200SJP,1350SJP,1250AJP

(1200SJP-1350SJP)

(1200SJP-1350SJP)

10 MICRON ABSB10 >= 1000

100 PSIBYPASS

S1S2

2 4

13 3 1

2 4

S2

M1 L1 L2 M2 R1 R2

T

P

2.0 GPM

0.2 GPM

C2

V2V1

C1

MP

S1

2792771 C

3-168 1200SJP 1350SJP 3128463


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

1

2 2

1

2

1

1 2

3

JIB SWING ROTATOR

Displacement: 74.2 cu. in. for 244 degreesDisplacement: 54.7 cu. in. for 180 degrees

JIB CYLINDER

Bore: 3.00" 7.06 sq. in.Rod: 1.50" 1.76 sq. in.Annulus: 5.3 sq. in.Cyl. Area Ratio: 1.33:1Stroke: 23.5"

.047

2750 PSI

3

S1

2

1

S2

4

3

S1

2

1

S2

4

S1 S2 M3 J1 J2

0.3 GPM 2.0 GPM

C2

V2V1

C1

PLATFORM CONTROL1200SJP,1350SJP,1250AJP

2792771 C

3128463 1200SJP 1350SJP 3-169


Axle Steer Control Schematic

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

2

b

P

T

a

A

B

1

2

1

P

T

a

1

2

A

B

b

1

2

A3

A1

A2

A4

S1

S2

P

T

b

1

2

A

B

1

a

2

PT

S3

S4

REAR AXLE

LEF

T S

IDE

LEF

T S

IDE

REAR STEER

RIG

HT

SID

ER

IGH

T S

IDE

SWIVEL PORT #1

V2

V1

V1

V2

LEFT

RIGHT

RIGHT

LEFT

STEERING CYLINDERS

BORE: 4.00" 12.56 SQ. IN.ROD: 1.75" 2.40 SQ. IN.ANNULUS: 10.16 SQ. IN.CYL. AREA RATIO: 1.23:1STROKE: 9.25"

AXLE EXTENSION CYLINDERS

BORE: 3.50" 9.62 SQ. IN.ROD: 2.00" 3.14 SQ. IN.ANNULUS: 6.48 SQ. IN.CYL. AREA RATIO: 1.48:1STROKE: 27.125"

AXLESTEER

MS1

MS2

MS3

MS4

2500 PSI

2500 PSI

MA3

MA4

2600 PSI

2000 PSI

2600 PSI

2000 PSI

P3 TRACTION CONTROL

(PAGE 5)

2792771 C

3-170 1200SJP 1350SJP 3128463


Figure 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 22792771 C

2

1

2

1

2

1

2

1

1

2

1

2

B

A

a

T

P

b

B

A

a

T

P

b

a

P

T

b

A

B

A3

A1

A2

S2

S1

S3

S4

TP

FRONT AXLE

LE

FT

SID

ER

IGH

T S

IDE

LEF

T S

IDE

FRONT STEER

RIG

HT

SID

E

A4

V2

V1

V1

V2

LEF

TR

IGH

TR

IGH

TL

EF

T

AXLE

MA3

MA4

MS1

MS2

MS3

MS4

2000 PSI

2600 PSI

2000 PSI

2600 PSI

2500 PSI

2500 PSI

P4TRACTION CONTROL

(PAGE5)

3128463 1200SJP 1350SJP 3-171


Traction Control Schematic

Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2

REAR

2.74 CU. IN. MAX1.0 CU. IN. MIN

TRACTION CONTROL


RE

DU

CT

ION

88.2

: 1

RA

TIO

PLA

NE

TAR

Y G

EA

RP

LAN

ETA

RY

GE

AR

88.2

: 1

RA

TIO

RE

DU

CT

ION

RIG

HT

B

G1

G

A

Br

LL1

B

G1

A

L1L

Br

LEF

T

G

B1 A1B2

AXLE LOCKOUT

3

3

24

.047

2

2

1

11

3

1

.047

2

2

4

3

2

BrakeRelease

1

1

ShiftSpeedTwo

2

2

1 3

A5

B5

LOP

MLOP

2

BR

MBR

TS

B3

A3

P1 P2

P3

P4

.025 DIA.ORIFICE

SWIVEL PORT#6

SWIVEL PORT#5

SWIVEL PORT#4

3

1

2

4

SWIVEL PORT# 2

SEE SHT #4 AXLESTEER CONTROL

SWIVEL PORT# 2

2792771 C

3-172 1200SJP 1350SJP 3128463


Figure 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 22792771 C

SWIVEL PORT#7

TRACTION CONTROL



PLA

NE

TAR

Y G

EA

R

88.2

: 1

RA

TIO

RE

DU

CT

ION

RIG

HT

FR

ON

T

G

G1

B

B

G1

88.2

: 1

RA

TIO

PL

AN

ETA

RY

GE

AR

RE

DU

CT

ION

LL1

Br

A

A

L

BrL1

LE

FT

G

"OPTION"AXLE LOCK OUT CYLINDERS

BORE: 5.00" 19.63 SQ. IN.ROD: 2.00" 3.14 SQ. IN.ANNULUS: 16.49 SQ. IN.CYL AREA RATIO: 6.25:1

STROKE: 5.00"

OSC. AXLE L.O. CYL.

OSC. AXLE L.O. CYL.

A2 D

B6

A6

MP

1

2SE

T A

T 5

00

PS

I

B4

3

42

A4

SWIVEL PORT#1

SWIVEL PORT#3

3128463 1200SJP 1350SJP 3-173


Boom Control Schematic

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

RESERVOIRSHT. #2

SWIVEL PORT#2

"X"SHT. #2

G

T3

P2

B

W MP

2792771 C

LS

SWING DRIVE

Bearing to Pinion Ratio: 103:20Gearbox Ratio: 54.58:1

Motor Disc.: 6.00 c.i.r. LIFT CYLINDER

Bore: 9.00" 63.61 sq. in.Rod: 4.00" 12.56 sq. in.Annulus: 51.05 sq. in.

Cyl. Area Ratio: 1.24:1Stroke: 62.125"

AUX. PUMP

A

B

1 2 3 MS

1 3

2

1

2

1

2

2

13

TO "X" PORT OFFUNCTION PUMP

SHT. #2

FROM"LS" PORT OF

MAIN VALVE

BOOM CONTROL

M1

1500 PSI

1500 PSI

SWING

LIFT DOWNAUX SELECT

GR

TO GR PORTOF MAIN VALVE

GENERATOR RETURN OIL

TO RESERVOIR

T1

LS

LS1

FROM GR PORTOF GENERATOR

1

2

21

3

12

2

P

A

BL

GR

W

"OPTION"GENERATOR CONTROL

1200SJP / 1350SJP

a

P T

b

A B

MS

P

EMERGENCYLOWER

MAINDUMP

SWING

3-174 1200SJP 1350SJP 3128463


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

"T"SHT. #3

"P"SHT. #3

"B"SHT. #2

21

5 PSI

T2

P3

P1

5 GPM

LIFTTELESCOPE

TELESCOPE CYLINDER Bore: 5.00" 19.63 sq. in.Rod: 4.00" 12.56 sq. in.Annulus: 7.07 sq. in.Cyl. Area Ratio: 2.77:1Stroke: 344.625"

4 5 M5 6 M7 7 8 M8

1

2

1

2

1

2

2

1

M4

MP3

1

2

2

1

2

1

75 PSI

3200 PSI 3000 PSI

LIFT DOWNAUXILIARY

15 PSI

LIFT

2750 PSI

75 PSI

V2 V1

B

T

a

P

A

b

P

a

A

T

B

b

TELESCOPE

2792771 C

3128463 1200SJP 1350SJP 3-175



3-176 1200SJP 1350SJP 3128463


SECTION 4. JLG ANALYZER

4.1 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER

1. Connect the cable supplied with the analyzer, to thecontroller module located in the platform box or atthe controller module in the ground control box andconnect the remaining end of the cable to the ana-lyzer.

NOTE: The cable has a four pin connector at each end ofthe cable; the cable cannot be connected back-wards.

2. Power up the Control System by turning the key tothe platform or ground position and pulling bothemergency stop buttons on.

Figure 4-1. Ground Analyzer Connection Point

Figure 4-2. Platform Analyzer Connection Point

4.2 USING THE ANALYZERWith the machine power on and the analyzer connectedproperly, the analyzer will display the following:

HELP:PRESS ENTER

At this point, using the RIGHT and LEFT arrow keys, youcan move between the top level menu items. To select adisplayed menu item, press ENTER. To cancel a selectedmenu item, press ESC.; then you will be able to scrollusing the right and left arrow keys to select a differentmenu item.

The top level menus are as follows:

HELPDIAGNOSTICSSYSTEM TESTACCESS LEVELPERSONALITIESMACHINE SETUPCALIBRATIONS (view only)

If you press ENTER, at the HELP: PRESS ENTER display,and a fault is present, the analyzer display will scroll thefault across the screen. If there was no fault detected, thedisplay will read: HELP: EVERYTHING OK. If powered upat the ground station, the display will read: GROUND OK.

3128463 1200SJP 1350SJP 4-177


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

LOGGED HELP1: POWER CYCLE (0/0)

At this point, the analyzer will display the last fault the sys-tem has seen, if any are present. You may scroll throughthe fault logs to view what the last 25 faults were. Use theright and left arrow keys to scroll through the fault logs. Toreturn to the beginning, press ESC. two times. POWERCYCLE (0/0) indicates a power up.

When a top level menu is selected, a new set of menuitems may be offered: for example:

DRIVEBOOMSYSTEMDATALOGVERSIONS

Pressing ENTER with any of the above displayed menus,will display additional sub-menus within the selectedmenu. In some cases, such as DRIVE, the next level is theparameter or information to be changed. Refer to the flowchart for what menus are available within the top levelmenus. You may only view the personality settings forselected menus while in access level 2. Remember, youmay always cancel a selected menu item by pressing theESC. key.

4-178 1200SJP 1350SJP 3128463


Figure 4-3. Analyzer Flow Chart

NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not beavailable depending upon machine configuration.

3128463 1200SJP 1350SJP 4-179


Figure 4-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present)


MENU:

FROM:

PERSONALITIES

ACCESS LEVEL 1

MENU:

PERSONALITIES

PERSONALITIES:

DRIVE

PERSONALITIES:

STEER

PERSONALITIES:

MAIN LIFT

PERSONALITIES:

SWING

PERSONALITIES:

TOWER LIFT

PERSONALITIES:

MAIN TELESCOPE

PERSONALITIES:

PLATFORM LEVEL

PERSONALITIES:

TOWER TELESCOPE

PERSONALITIES:

PLATFORM ROTATE

PERSONALITIES:

JIB LIFT

PERSONALITIES:

GROUND MODE

PERSONALITIES:

GEN SET/WELDER

DRIVE:

ACCEL X.XS

DRIVE:

DECEL X.XS

DRIVE:

TO:

MIN FORWARD X%

MACHINE SETUP

DRIVE:

MAX FORWARD X%

DRIVE:

MIN REVERSE X%

DRIVE:

MAX REVERSE X%

DRIVE:

ELEV. MAX X%

DRIVE:

CREEP MAX X%

STEER:

MAX SPEED X%

MAIN LIFT:

ACCEL X.XS

MAIN LIFT:

DECEL X.XS

MAIN LIFT:

MIN UP X%

MAIN LIFT:

MAX UP X%

MAIN LIFT:

CREEP UP X%

MAIN LIFT:

MIN DOWN X%

MAIN LIFT:

MAX DOWN X%

MAIN LIFT:

CREEP DOWN X%

SWING:

ACCEL X.XS

SWING:

DECEL X.XS

SWING:

MIN LEFT X%

SWING:

MAX LEFT X%

SWING:

CREEP LEFT X%

SWING:

MIN RIGHT X%

SWING:

MAX RIGHT X%

SWING:

CREEP RIGHT X%

TOWER LIFT:

ACCEL X.XS

TOWER LIFT:

DECEL MEDIUM

TOWER LIFT:

MIN UP X%

TOWER LIFT:

MAX UP X%

TOWER LIFT:

MIN DOWN X%

TOWER LIFT:

MAX DOWN X%

MAIN TELESCOPE:

ACCEL X.XS

MAIN TELESCOPE:

DECEL X.XS

MAIN TELESCOPE:

MIN IN X%

MAIN TELESCOPE:

MAX IN X%

MAIN TELESCOPE:

MIN OUT X%

MAIN TELESCOPE:

MAX OUT X%

TOWER TELESCOPE:

ACCEL X.XS

TOWER TELESCOPE:

DECEL X.XS

TOWER TELESCOPE:

MIN IN X%

TOWER TELESCOPE:

MAX IN X%

TOWER TELESCOPE:

MIN OUT X%

TOWER TELESCOPE:

MAX OUT X%

PLATFORM LEVEL:

ACCEL X.XS

PLATFORM LEVEL:

DECEL X.XS

PLATFORM LEVEL:

MIN UP X%

PLATFORM LEVEL:

MAX UP X%

PLATFORM LEVEL:

MIN DOWN X%

PLATFORM LEVEL:

MAX DOWN X%

PLATFORM ROTATE:

ACCEL X.XS

PLATFORM ROTATE:

DECEL X.XS

PLATFORM ROTATE:

MIN LEFT X%

PLATFORM ROTATE:

MAX LEFT X%

PLATFORM ROTATE:

MIN RIGHT X%

PLATFORM ROTATE:

MAX RIGHT X%

JIB LIFT:

ACCEL X.XS

JIB LIFT:

DECEL X.XS

JIB LIFT:

MIN UP X%

JIB LIFT:

MAX UP X%

JIB LIFT:

MIN DOWN X%

JIB LIFT:

MAX DOWN X%

GROUND MODE:

MAIN UP: XXX%

GROUND MODE:

MAIN DOWN: XXX%

GROUND MODE:

SWING: XXX%

GROUND MODE:

PLT LEVEL: XXX%

GROUND MODE:

PLT ROTATE: XXX%

GROUND MODE:

MAIN TELE: XXX%

GROUND MODE:

TOWER TELE: XXX%

GROUND MODE:

TOWER UP: XXX%

GROUND MODE:

TOWER DOWN: XXX%

GROUND MODE:

JIB (U/D): XXX%

GEN SET/WELDER:

ENGINE 1800 RPM

PERSONALITIES:

JIB SWING

JIB LIFT:

ACCEL X.XS

JIB LIFT:

DECEL X.XS

JIB LIFT:

MIN LEFT X%

JIB LIFT:

MAX LEFT X%

JIB LIFT:

MIN RIGHT X%

JIB LIFT:

MAX RIGHT X%

GROUND MODE:

JIB (L/R): XXX%

4-180 1200SJP 1350SJP 3128463


Figure 4-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present)


FROM:

TO:

PERSONALITIES

CALIBRATIONS

TILT:

1=5 DEG

TILT:

2=4 DEG

TILT:

3=3 DEG

TILT:

4=4 DEG PLUS CUT

TILT:

5=3 DEG PLUS CUT

MENU:

MACHINE SETUP

MODEL NUMBER:

1200S

ENGINE:

DEUTZ F4 TIER1

GLOW PLUG:

NO GLOW PLUGS

ENGINE SHUTDOWN:

STARTER LOCKOUT:

ENABLED

DISABLED

CHASSIS TILT:

5 DEGREES

SOFT TOUCH:

NO

GEN SET/WELDER:

NO

H & T LIGHTS:

NO

LOAD SYSTEM:

NO

FUNCTION CUTOUT:

NO

GROUND ALARM:

NO

OSCILLATING

AXLE: YES

MODEL NUMBER:

1250A

MODEL NUMBER:

1350S

ENGINE:

DEUTZ F4 TIER2

GLOW PLUG:

AIR INTAKE

ENGINE SHUTDOWN:

STARTER LOCKOUT:

DISABLED

ENABLED

CHASSIS TILT:

4 DEGREES

CHASSIS TILT:

3 DEGREES

CHASSIS TILT:

4 DEGREES + CUT

CHASSIS TILT:

3 DEGREES + CUT

SOFT TOUCH:

YES

GEN SET/WELDER:

BELT DRIVE

GEN SET/WELDER:

HYDRAULIC DRIVE

H & T LIGHTS:

YES

LOAD SYSTEM:

WARN ONLY

LOAD SYSTEM:

CUTOUT PLATFORM

LOAD SYSTEM:

CUTOUT ALL

LOAD SYSTEM:

SPECIAL 1

FUNCTION CUTOUT:

BOOM CUTOUT

FUNCTION CUTOUT:

DRIVE CUTOUT

FUNCTION CUTOUT:

DRIVE CUT E&T

GROUND ALARM:

DRIVE

GROUND ALARM:

DESCENT

GROUND ALARM:

MOTION

OSCILLATING

AXLE: NO

GLOW PLUG:

IN-CYLINDER*

ENVELOPE HEIGHT:

1350S: 135' MAX

ENVELOPE HEIGHT:

1350S: 125' MAX

ENVELOPE HEIGHT:

1350S: 120' MAX

ENVELOPE HEIGHT:

1350S: 110' MAX

ENVELOPE HEIGHT:

1200S: 120' MAX

ENVELOPE HEIGHT:

1200S: 110' MAX

ENVELOPE HEIGHT:

1250A: 125' MAX

ENVELOPE HEIGHT:

1250A: 100' MAX

ENVELOPE HEIGHT:

1250A: 80' MAX

MARKET:

ANSI USA

MARKET:

ANSI EXPORT

MARKET:

CSA

MARKET:

CE

MARKET:

AUSTRALIA

MARKET:

JAPAN

ENGINE:

DEUTZ ECM

GEN SET CUTOUT:

MOTION ENABLED

GEN SET CUTOUT:

MOTION CUTOUT

TEMP DISPLAY:

CELSIUS

TEMP DISPLAY:

FAHRENHEIT

3128463 1200SJP 1350SJP 4-181


Figure 4-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present)


FROM:

MACHINE SETUP

MENU:

CALIBRATIONS

CALIBRATIONS:

STEER

CALIBRATIONS:

DRIVE

CALIBRATE

STEER?

CALIBRATE

DRIVE?

CALIBRATIONS:

LEVEL UP CRKPT

CALIBRATIONS:

LEVEL DOWN CRKPT

CALIBRATE LEVEL

UP CRACKPOINT?

CALIBRATE LEVEL

DOWN CRACKPOINT?

CALIBRATIONS:

MAIN LIFT CRKPT

CALIBRATIONS:

MAIN TELE CRKPT

CALIBRATE MAIN

LIFT CRACKPOINT?

CALIBRATE MAIN

TELE CRACKPOINT?

CALIBRATIONS:

TILT SENSOR

CALIBRATIONS:

BOOM SENSORS

POSITION 1:

CHECK SYSTEM?

POSITION 1:

CHECK SYSTEM?

CALIBRATIONS:

CALIBRATIONS:

DEUTZ SETUP:

NONE AVAILABLE

CALIBRATIONS:

BOOM VALVES

CALIBRATE

BOOM VALVES?

DEUTZ SETUP:

DEUTZ SETUP:

DEUTZ SETUP:

DEUTZ SETUP:

SETUP 1

SETUP 2

SETUP 3

SETUP 4

4-182 1200SJP 1350SJP 3128463


Figure 4-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3


TO:

SHEET 2

FROM:

TO:

HELP:PRESS ENTER

SYSTEM TEST

MENU:

DIAGNOSTICS

DIAGNOSTICS:

DRIVE

DIAGNOSTICS:

BOOM FUNCTIONS

DIAGNOSTICS:

ENGINE

DIAGNOSTICS:

SYSTEM

JOYSTICK LIFT:

MAIN UP XXX%

JOYSTICK SWING:

LEFT XXX%

PLATFORM LEVEL:

UP XXX%

PLATFORM ROTATE:

LEFT XXX%

MAIN TELESCOPE:

IN XXX%

TOWER TELESCOPE:

IN XXX%

TOWER LIFT:

UP XXX%

JIB LIFT:

UP XXX%

FUNCTION SPEED:

PUMP POT XXX%

CREEP

SWITCH: CLOSED

CREEP MODE:

OFF

GROUND MODULE

BATTERY: XX.XV

PLATFORM MODULE

BATTERY: XX.XV

AMBIENT

TEMPERATURE:XXXC

PLATFORM SELECT

KEYSWITCH:CLOSED

GROUND SELECT

KEYSWITCH: OPEN

STATION CONTROL:

GROUND

CREEP

SWITCH: CLOSED

CREEP MODE:

OFF

JOYSTICK DRIVE:

FORWARD XXX%

JOYSTICK STEER:

LEFT XXX%

STEER TYPE:

NORMAL

BRAKES STATUS:

LOCKED

CREEP

SWITCH: CLOSED

CREEP MODE:

OFF

2-SPEED

SWITCH: CLOSED

2-SPEED VALVE

OUTPUT: OFF

HIGH ENGINE

SWITCH: OPEN

START SEQUENCE:

NOT ACTIVE

BATTERY VOLTAGE:

XX.XV

COOLANT

TEMPERATURE:XXXC

ENGINE OIL

PRESSURE:XXXXPSI

AMBIENT

TEMPERATURE:XXXC

FUEL LEVEL

SENSOR: OK

STARTER

CRANK TIME: XX S

ENGINE SPEED

ACTUAL: XXXX RPM

L FRONT WHEEL

ANGLE: XX.X

R FRONT WHEEL

ANGLE: XX.X

L REAR WHEEL

ANGLE: XX.X

R REAR WHEEL

ANGLE: XX.X

DRV. ORIENTATION

SWITCH: CLOSED

DRV. ORIENTATION

OVERRIDE: OPEN

JIB SWING:

LEFT XXX%

PLATFORM CONTROL

VALVE: OFF

CHASSIS TILT:

XX.X DEGREES

CHASSIS TILT

X-AXIS: X.X

CHASSIS TILT

Y-AXIS: X.X

AUXILIARY POWER

SWITCH: OPEN

HORN

SWITCH: OPEN

SOFT TOUCH LIMIT

SWITCH: OPEN

SOFT TOUCH

OVERRIDE: OPEN

GENSET/WELDER

SWITCH: OPEN

LIGHTS

SWITCH: OPEN

PLATFORM TILT1

ANGLE: XX.X DEG

PLATFORM TILT2

ANGLE: XX.X DEG

OSCILATING AXLE

PRES. SW.: OPEN

HYDRAULIC OIL

TEMP. SW.: OPEN

HYDRAULIC OIL:

WARM UP NOT DONE

MAIN LIFT PILOT

PRES. SW.: OPEN

CABLE BREAK

SWITCH: CLOSED

DRIVE OUTPUT:

FORWARD XXX%

STEER OUTPUT:

LEFT XXX%

DRIVE MODE:

MID ENGINE

LIFT OUTPUT:

MAIN UP XXX%

SWING OUTPUT:

LEFT XXX%

ENGINE SPEED

TARGET: XXXX RPM

TRANSPORT MODE:

OUT OF TRANSPORT

PLATFORM TILT1

RAW: XXXX

PLATFORM TILT2

RAW: XXXX

FOOTSWITCH INPUT

GROUND: OPEN

FOOTSWITCH INPUT

PLATFORM: CLOSED

3128463 1200SJP 1350SJP 4-183


Figure 4-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3


FROM:

TO:

SHEET 1

SHEET 3

BCS STATUS:

NORMAL

JIB STOWED LIMIT

SWITCH: CLOSED

JIB STOWED LIMIT

OVERRIDE: OPEN

AXLE INPUT SW.:

EXTEND CLOSED

DIAGNOSTICS:

BCS

MAIN BOOM ANGLE

ZONE: 4

MAIN BOOM LENGTH

ZONE: A

DIAGNOSTICS:

LOAD PIN

DIAGNOSTICS:

ENVELOPE

DIAGNOSTICS:

BOOM SENSORS

LOAD PIN MOMENT

VALUE: XXXX

LOAD PIN RATIO

VALUE: XX.XXX

LOAD PIN ANGLE

VALUE: XXX.X

LOAD PIN VECTOR

FORCE: XXXXXX

LOAD PIN MOMENT

RAW: XXXXX

LOAD PIN RATIO

RAW: XX.XXX

LOAD PIN ANGLE

RAW: XXX.X

LOAD PIN V-FORCE

RAW: XXXXXXXX

LOAD PIN ANGLE

CAL POINT: XXX.X

LOAD PIN V-FORCE

CAL: XXXXX

LOAD PIN MOMENT

CAL POINT: XXXXX

LOAD PIN ERROR

FLAGS: 0X0000

LOAD PIN X-AXIS

VALUE: XXX

LOAD PIN Y-AXIS

VALUE: XXX

LOAD PIN X-AXIS

RAW VALUE: XXX

LOAD PIN Y-AXIS

RAW VALUE: XXX

TOWER LENGTH 1

SENSOR: X.X"

TOWER LENGTH 2

SENSOR: X.X"

TOWER ANGLE 1

SENSOR: XX.X

TOWER ANGLE 2

SENSOR: XX.X

TOWER CYLINDER

ANGLE: XX.X

MAIN ANGLE 1 TO

TOWER: XX.X

MAIN ANGLE 2 TO

TOWER: XX.X

TOWER LENGTH 2

A/D: XXXXX

TOWER ANGLE 2

A/D: XX.X

TOWER CYLINDER

ANGLE A/D: XXXXX

MAIN LIFT 1

ANGLE A/D: XXXXX

MAIN LIFT 2

ANGLE A/D: XXXXX

MAIN LIFT 1 RAW

ANGLE: XXX.X

MAIN LIFT 2 RAW

ANGLE: XXX.X

TOWER RETRACTED

LENGTH 1: XXXXXX

TOWER RETRACTED

LENGTH 2: XXXXXX

TOWER EXTENDED

LENGTH 1: XXXXXX

TOWER EXTENDED

LENGTH 2: XXXXXX

TOWER TRIP POINT

LENGTH: XXXX.X"

TOWER ANGLE 1

LOW CAL: XXX.X

TOWER ANGLE 2

LOW CAL: XXX.X

TOWER ANGLE 1

HIGH CAL: XXX.X

TOWER ANGLE 2

HIGH CAL: XXX.X

TOWER CYLINDER

LOW CAL: XXXXXX

TOWER CYLINDER

HIGH CAL: XXXXXX

MAIN ANGLE 1

LOW CAL: XXXXXX

MAIN ANGLE 2

LOW CAL: XXXXXX

MAIN ANGLE 1

HIGH CAL: XXXXXX

MAIN ANGLE 2

HIGH CAL: XXXXXX

MAIN TRIP POINT

ANGLE: XXX.X

MAIN ANGLE L TO

GRAVITY: XXX.X

MAIN ANGLE H TO

GRAVITY: XXX.X

TOWER LENGTH 1

A/D: XXXXX

TOWER ANGLE 1

A/D: XX.X

MAIN BOOM

LENGTH: XXX.X"

MAIN BOOM

ANGLE1: XX.X DEG

MAIN BOOM

ANGLE2: XX.X DEG

MAIN BOOM A/D

LENGTH: XXXXX

MAIN BOOM A/D

BOOM CONTROL:

ANGLE1: XXX.X

AUTOMATIC

MAIN BOOM A/D

ANGLE2: XXX.X

MODE SW: OPEN

PLATFORM

STOWED: NO

MAIN ENVELOPE

STATUS: NOMINAL

TOWER ENVELOPE

STATUS: NOMINAL

DIAGNOSTICS:

TRANSPORT DATA

TOWER LIFT

STATUS: STOWED

TOWER TELESCOPE

STATUS:RETRACTED

MAIN LIFT

STATUS: ELEVATED

MAIN TELESCOPE

STATUS:RETRACTED

AXLE STATUS:

EXTENDED

MAIN BOOM LENGTH

SWITCH NC: OPEN

MAIN BOOM LENGTH

SWITCH NO:CLOSED

MAIN BOOM LENGTH

ZONE: A/D

DUAL CAPACITY

SWITCH NC: OPEN

DUAL CAPACITY

SWITCH NO:CLOSED

DUAL CAPACITY

LENGTH ZONE: A/B

TOWER TELESCOPE

SWITCH NC: OPEN

TOWER TELESCOPE

SWITCH NO:CLOSED

TOWER TELESCOPE

STATUS:RETRACTED

TOWER LIFT ANGLE

SWITCH: OPEN

MAIN LIFT ANGLE

SWITCH NC: OPEN

MAIN LIFT ANGLE

SWITCH NO:CLOSED

MAIN LIFT ANGLE

STATUS:TRANSPORT

TRANSPORT MODE:

OUT OF TRANSPORT

DIAGNOSTICS:

BOOM SWITCHES

MAIN ENVELOPE

LOW: NOMINAL

ELEC. RETRIEVAL:

NOT ACTIVE

HYD. RETRIEVAL:

NOT ACTIVE

4-184 1200SJP 1350SJP 3128463


Figure 4-9. Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3


FROM:

SHEET 2

DIAGNOSTICS:

LOAD

DIAGNOSTICS:

CAN STATISTICS

DIAGNOSTICS:

DATALOG

DIAGNOSTICS:

VERSIONS

DIAGNOSTICS:

CALIBRATION DATA

PLATFORM LOAD

STATE: OK

CAN STATISTICS

RX/SEC: X

CAN STATISTICS

TX/SEC: X

CAN STATISTICS

BUS OFF X

CAN STATISTICS

PASSIVE XXXXX

DATALOG:

ON XXH XXM

DATALOG:

ENGINE XH XM

DATALOG:

DRIVE XH XM

DATALOG:

LIFT XH XM

DATALOG:

SWING XH XM

DATALOG:

TELE XH XM

DATALOG:

MAX TEMP XXC

DATALOG:

MIN TEMP XXC

DATALOG:

MAX VOLTS XX.XV

DATALOG:

RENTAL XH XM

DATALOG:

ERASE RENTAL?

GROUND MODULE

SOFTWARE: P7.X

GROUND MODULE

HARDWARE: REV 4

GROUND MODULE

S/N: XXXXXX

PLATFORM MODULE

SOFTWARE: P7.X

PLATFORM MODULE

HARDWARE: REV 2

PLATFORM MODULE

S/N: XXXXXX

DIAGNOSTICS:

MOMENT

CAN STATISTICS

MSG ERROR: XXXX

PLATFORM UP

CAL: X

PLATFORM DOWN

CAL: X

LEFT FORWARD

DRIVE CAL: XXXX

RIGHT FORWARD

DRIVE CAL: XXXX

LEFT REVERSE

DRIVE CAL: XXXX

RIGHT REVERSE

DRIVE CAL: XXXX

L FRONT STEER

CAL: XXXXX

R FRONT STEER

CAL: XXXXX

L REAR STEER

CAL: XXXXX

R REAR STEER

CAL: XXXXX

MAIN LIFT UP

CAL: XXXXX

MAIN LIFT DOWN

CAL: XXXX

MAIN TELESCOPE

IN CAL: XXXXX

MAIN TELESCOPE

OUT CAL: XXXXX

MAIN ANGLE 1

LO CAL: X

MAIN ANGLE 1

HI CAL: X

MAIN ANGLE 2

LO CAL: X

MAIN ANGLE 2

HI CAL: X

LENGTH RETRACTED

CAL: XXXXX

LENGTH EXTENDED

CAL: XXXXX

YELLOW WITNESS

MARK CAL: X

LENGTH SWITCH

CAL: XXXXX

CHASSIS MODULE

SOFTWARE: P7.X

B.L.A. MODULE

SOFTWARE: P7.X

ACTUAL MOMENT

XXXXXXXX LB*IN

OVER MOMENT

XXXXXXXX LB*IN

UNDER MOMENT

XXXXXXXX LB*IN

UNDER MOMENT CAL

POINT: X

YELLOW WITNESS

CAL: XXXXXXXX

GREEN WITNESS

CAL: XXXXXXXX

LOAD PIN RATIO

VALUE: XX.XXX

LOAD PIN ERROR

FLAGS: 0X0000

SKY WELDER

INSTALLED: NO

SKY CUTTER

INSTALLED: NO

SKY GLAZIER

INSTALLED: NO

SKY BRIGHT

INSTALLED: NO

PIPE RACKS

INSTALLED: NO

CAMERA MOUNT

INSTALLED: NO

CYLINDER PIN

SOFTWARE: RX.XX

CYLINDER PIN

S/N: XXXXXX

MAIN ANGLE 1

S/N: XXXXXX

MAIN ANGLE 1

REV X.X

VERSIONS:

ANALYZER V6.3

MAIN ANGLE 2

S/N: XXXXXX

MAIN ANGLE 2

REV X.X

DUAL CAPACITY

SWITCH NC: OPEN

DUAL CAPACITY

SWITCH NO:CLOSED

DUAL CAPACITY

LENGTH ZONE: A/B

PLATFORM

CAPACITY:1000 LB

JIB IN-LINE

SWITCH: OPEN

GROUND MODULE

CNST DATA: P7.X

3128463 1200SJP 1350SJP 4-185


4.3 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER

When the analyzer is first connected, you will be in accesslevel 2 which enables you to only view most settingswhich cannot be changed until you enter a password toadvance to a lower level. This ensures that a setting can-not be accidentally altered. To change the access level,the correct password must be entered. To enter the pass-word, scroll to the ACCESS LEVEL menu. For example:

MENU:ACCESS LEVEL 2

Press ENTER to select the ACCESS LEVEL menu.

Using the UP or DOWN arrow keys, enter the first digit ofthe password, 3.

Then using the RIGHT arrow key, position the cursor tothe right one space to enter the second digit of the pass-word.

Use the UP or DOWN arrow key to enter the second digitof the password which is 33271.

Continue using the arrow keys until all the remaining digitsof the password is shown.

Once the correct password is displayed, press ENTER.The access level should display the following, if the pass-word was entered correctly:

MENU: ACCESS LEVEL 1

Repeat the above steps if the correct access level is notdisplayed or you can not adjust the personality settings.

4-186 1200SJP 1350SJP 3128463


4.4 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER

Once you have gained access to level 1, and a personalityitem is selected, press the UP or DOWN arrow keys toadjust its value, for example:

PERSONALITIES:DRIVE ACCEL 1.0s

There will be a minimum and maximum for the value toensure efficient operation. The Value will not increase ifthe UP arrow is pressed when at the maximum value norwill the value decrease if the DOWN arrow is pressed andthe value is at the minimum value for any particular per-sonality. If the value does not change when pressing theup and down arrows, check the access level to ensureyou are at access level 1.

4.5 MACHINE SETUPWhen a machine digit item is selected, press the UP orDOWN arrow keys to adjust its value, for example:

GROUND ALARM:2 = LIFT DOWN

The effect of the machine digit value is displayed alongwith its value. The above display would be selected if themachine was equipped with a ground alarm and youwanted it to sound when lifting down. There are certainsettings allowed to install optional features or select themachine model.

When selection the machine model to match the size ofthe machine, the personality settings will all default to thefactory recommended setting.

NOTE: Refer to Table 4-2. Machine Personality Settings andSpeeds on Pg. 202 in this manual for the recom-mended factory settings.

NOTE: Password 33271 will give you access to level 1,which will permit you to change all machine person-ality settings.

There is a setting that JLG strongly recommends that youdo not change. This setting is so noted below:

ELEVATION CUTBACK

CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER-FORMANCE OF YOUR MACHINE.

3128463 1200SJP 1350SJP 4-187


Table 4-1. Machine Configuration Programming Information

Configuration Digit Number DescriptionDefault Number

NOTE: The machine configuration must be completed before any personality settings can be changed. Changingthe personality settings first and then changing the model number of the machine configuration will causethe personality settings to return to default

MODEL NUMBER:1

1 1200S 1

2 1250A

3 1350S

ENVELOPE HEIGHT:2

1 1350S: 135' MAX 5

2 1350S: 125' MAX

3 1350S: 120' MAX

4 1350S: 110' MAX

5 1200S: 120' MAX

6 1200S: 110' MAX

7 1250A: 125' MAX

8 1250A: 100' MAX

9 1250A: 80' MAX

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

MARKET:3

0 ANSI USA 0

1 ANSI EXPORT

2 CSA

3 CE

4 AUSTRALIA

5 JAPAN

ENGINE:4

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

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

3 DEUTZ ECM: Engine Control Module

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GLOW PLUG:5

0 NO GLOW PLUGS: No glow plugs installed. 2

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

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

STARTER LOCKOUT:6

0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow.

0

1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished.

ENGINE SHUTDOWN:7

0 DISABLED: No engine shutdown. 1

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

TILT:8

1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep.

1



4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up.

5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up.

NOTE: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platformalarm when the machine is also above elevation.

SOFT TOUCH:9

0 NO: No soft touch system installed. 0

1 YES: Soft touch system installed.



3128463 1200SJP 1350SJP 4-189


GEN SET/WELDER:10

0 NO: No generator installed. 1

1 BELT DRIVE: Belt driven setup.

2 HYDRAULIC DRIVE: Hydraulic driven setup.

GEN SET CUTOUT:11*

0 MOTION ENABLED: Motion enabled when generator is ON. 0

1 MOTION CUTOUT: Motion cutout in platform mode only.

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

H & T LIGHTS:12

0 NO: No head and tail lights installed. 0

1 YES: Head and tail lights installed.

LOAD SYSTEM:13*

0 NO: No load sensor installed. 0

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

2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF).

3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), plat-form alarm beeps (5 sec ON, 2 sec OFF).

4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform alarm beeps (5 sec ON, 2 sec OFF).

* Only visible under certain market selections.

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



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FUNCTION CUTOUT:14*

0 NO: No drive cutout. 0

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

2 DRIVE CUTOUT: Drive cutout above elevation.

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

* Only visible under certain market selections.

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

GROUND ALARM:15*

0 NO: No ground alarm installed. 0

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

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

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

* Certain market selections will alter default setting.

OSCILLATING AXLE:16

0 NO: No oscillating axle system installed. 1

1 YES: Oscillating axle system installed.

TEMPERATURE:17*

0 CELSIUS: Celsius unit selection. 1

1 FAHRENHEIT: Fahrenheit unit selection.

* Certain market selections will alter default setting.

4150364-15



3128463 1200SJP 1350SJP 4-191


NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlinednumbers indicate the default when the option is factory installed.

1200SJPM

ODEL

NUM

BER

ENVE

LOPE

HEI

GHT

MAR

KET

ENGI

NE

GLOW

PLU

GS

ENGI

NE S

HUTD

OWN

TILT

SOFT

TOU

CH

GEN

SET

/ WEL

DER

GEN

SET

CUTO

UT

HEAD

& T

AIL

LIGH

TS

ANSI USA 1 5 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

ANSI EXPORT 1 5 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

CSA 1 5 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

CE 1 5 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

AUSTRALIA 1 5 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

JAPAN 1 5 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

1200SJP

LOAD

SYS

TEM

FUNC

TION

CUT

OUT

GROU

ND A

LARM

OSCI

LLAT

ING

AXLE

TEM

PERA

TURE

ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1

ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1

CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1

AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

4-192 1200SJP 1350SJP 3128463


NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlinednumbers indicate the default when the option is factory installed.

1350SJPM

ODEL

NU

MBE

R

ENVE

LOPE

HEI

GHT

MAR

KET

ENGI

NE

GLOW

PLU

GS

ENGI

NE S

HUTD

OWN

TILT

SOFT

TOU

CH

GEN

SET

/ WEL

DER

GEN

SET

CUT

OUT

HEAD

& T

AIL

LIGH

TS

ANSI USA 3 1 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

ANSI EXPORT 3 1 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

CSA 3 1 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

CE 3 1 3 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

AUSTRALIA 3 1 4 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

JAPAN 3 1 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1

1350SJP

LOAD

SYS

TEM

FUN

CTIO

N CU

TOU

T

GROU

ND A

LARM

OSCI

LLAT

ING

AXLE

TEM

PERA

TURE

ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1

ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1

CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1

AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1

3128463 1200SJP 1350SJP 4-193


NOTE: Machine personality settings can be adjusted anywhere within the adjustment range in order to achieve optimummachine performance.Stop watch should start when the function is activated. Not with the controller or switch.Unless noted, function speeds should be measured from platform.Platform speed knob must be at full speed (fully clockwise).All test should be done with the oil temp above 100° F (38° C).

Table 4-2. Machine Personality Settings and Speeds

SUBMENU(DISPLAYED ON ANALYZER 1ST

LINE)

PARAMETER(DISPLAYED ON ANALYZER

2ND LINE)DESCRIPTION RANGE

DEFAULT VALUES

TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds WHEN SETTING

SPEEDS)

1200 1350 1200S 1350S

DRIVE:

ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 2.0

DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3 1.3

MIN FORWARD XX% Displays/adjusts minimum forward drive speed

0 to 35% 1 1

MAX FORWARD XXX% Displays/adjusts maximum forward drive speed

0 to 100% 100 100 36-38 36-38

MIN REVERSE XX% Displays/adjusts minimum reverse drive speed

0 to 35% 1 1

MAX REVERSE XXX% Displays/adjusts maximum reverse drive speed

0 to 100% 100 100 36-38 36-38

ELEV. MAX XX% Displays/adjusts maximum drive speedNOTE: used when elevation cutout switches are limiting maximum speed

0 to 50% 25 25 93-104 93-104

CREEP MAX XX% Displays/adjusts maximum drive speedNOTE: used when creep switch on pump pot is active

0 to 50% 35 35 79-87 79-87

STEER:

MAX SPEED XXX% Displays/adjusts maximum steer speed.

0 to 100% 100 100

4-194 1200SJP 1350SJP 3128463


MAIN LIFT:

ACCEL X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 1.0

DECEL X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0 1.0

MIN UP XX% Displays/adjusts minimum main lift up speed

0 to 60% 20 20

MAX UP XX% Displays/adjusts maximum main lift up speed

0 to 100% 50 50 75-100 75-100

MIN DOWN XX% Displays/adjusts minimum main lift down speed

0 to 60% 10 10

MAX DOWN XXX% Displays/adjusts maximum main lift down speed

0 to 100% 50 50 85-110 85-110

CREEP UP XX% Displays/adjusts maximum main lift up speedNOTE: used when creep switch on pump pot is active

0 to 65% 50 50

CREEP DOWN XX% Displays/adjusts maximum main lift down speedNOTE: used when creep switch on pump pot is active

0 to 75% 45 45

SWING:

ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 2.0

DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 1.5

MIN LEFT XX% Displays/adjusts minimum swing left speed

0 to 50% 40 40

MAX LEFT XXX% Displays/adjusts maximum swing left speed

0 to 100% 65 65 115-125 115-125

MIN RIGHT XX% Displays/adjusts minimum swing right speed

0 to 50% 40 40

MAX RIGHT XXX% Displays/adjusts maximum swing right speed

0 to 100% 65 65 115-125 115-125

CREEP LEFT XX% Displays/adjusts maximum swing left speedNOTE: used when creep switch on pump pot is active

0 to 65% 50 50

CREEP RIGHT XX% Displays/adjusts maximum swing right speedNOTE: used when creep switch on pump pot is active

0 to 65% 50 50



LINE)



DEFAULT VALUES


SPEEDS)

1200 1350 1200S 1350S

3128463 1200SJP 1350SJP 4-195


MAIN TELESCOPE:

ACCEL X.Xs Displays/adjusts main telescope acceleration

0.1 to 5.0 sec 1.5 1.5

DECEL X.Xs Displays/adjusts main telescope deceleration

0.1 to 3.0 sec 1.0 1.0

MIN IN XX% Displays/adjusts minimum main tele-scope in speed. Same as Creep speed

0 to 65% 15 15

MAX IN XXX% Displays/adjusts maximum main tele-scope in speed

0 to 100% 65 65 58-68 65-75

MIN OUT XX% Displays/adjusts minimum main tele-scope out speed. Same as Creep speed

0 to 65% 15 15

MAX OUT XXX% Displays/adjusts maximum main tele-scope out speed

0 to 100% 60 60 45-55 50-60

BASKET LEVEL:

ACCEL X.Xs Displays/adjusts basket level acceler-ation

0.1 to 5.0 sec 1.5 1.5

DECEL X.Xs Displays/adjusts basket level deceler-ation

0.1 to 3.0 sec 0.5 0.5

MIN UP XX% Displays/adjusts minimum basket level up speed. Same as Creep speed

0 to 65% 40 40

MAX UP XXX% Displays/adjusts maximum basket level up speed

0 to 100% 70 70

MIN DOWN XX% Displays/adjusts minimum basket level down speed. Same as Creep speed

0 to 65% 40 40

MAX DOWN XXX% Displays/adjusts maximum basket level down speed

0 to 100% 70 70

BASKET ROTATE:

ACCEL X.Xs Displays/adjusts basket rotate accel-eration

0.1 to 5.0 sec 1.0 1.0

DECEL X.Xs Displays/adjusts basket rotate decel-eration

0.1 to 3.0 sec 0.5 0.5

MIN LEFT XX% Displays/adjusts minimum basket rotate left speed. Same as Creep speed

0 to 100% 60 60

MAX LEFT XXX% Displays/adjusts maximum basket rotate left speed

0 to 100% 60 60 24-30 (180)

24-30 (180)

MIN RIGHT XX% Displays/adjusts minimum basket rotate right speed. Same as Creep speed

0 to 100% 60 60

MAX RIGHT XXX% Displays/adjusts maximum basket rotate right speed

0 to 100% 60 60 24-30 (180)

24-30 (180)



LINE)



DEFAULT VALUES


SPEEDS)

1200 1350 1200S 1350S

4-196 1200SJP 1350SJP 3128463


JIB LIFT:

ACCEL X.Xs 0.1 to 5.0 sec 1.5 1.5

DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 1.0

MIN UP XX% Displays/adjusts minimum jib up speed. Same as Creep speed

0 to 65% 40 40

MAX UP XXX% Displays/adjusts maximum jib up speed

0 to 100% 65 65 30-36 30-36

MIN DOWN XX% Displays/adjusts minimum jib down speed. Same as Creep speed

0 to 65% 40 40

MAX DOWN XXX% Displays/adjusts maximum jib down speed

0 to 100% 60 60 30-36 30-36

JIB SWING:

ACCEL X.Xs Displays/adjusts jib swing accelera-tion

0.1 to 5.0 sec 1.5 1.5

DECEL X.Xs Displays/adjusts jib swing decelera-tion

0.1 to 3.0 sec 0.5 0.5

MIN LEFT XX% Displays/adjusts minimum jib left speed. Same as Creep speed

0 to 65% 40 40

MAX LEFT XXX% Displays/adjusts maximum jib left speed

0 to 100% 70 70 60-68 (180)

60-68 (180)

MIN RIGHT XX% Displays/adjusts minimum jib right speed. Same as Creep speed

0 to 65% 40 40

MAX RIGHT XXX% Displays/adjusts maximum jib right speed

0 to 100% 70 70 60-68 (180)

60-68 (180)



LINE)



DEFAULT VALUES


SPEEDS)

1200 1350 1200S 1350S

3128463 1200SJP 1350SJP 4-197


GROUND MODE:

U. LIFT UP XXX% Displays/adjusts fixed main lift up speed

0 to 100% 60 60

U. LIFT DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 60

SWING XXX% Displays/adjusts fixed swing speed 0 to 100% 60 60

BASKET LVL XXX% Displays/adjusts fixed basket level speed

0 to 100% 75 75

BASKET ROT XXX% Displays/adjusts fixed basket rotate speed

0 to 100% 75 75

MAIN TELE XXX% Displays/adjusts fixed main telescope speed

0 to 100% 60 60

TOWER TELE XXX% Displays/adjusts fixed tower tele-scope speedNot displayed if TOWER TELE=NO

0 to 100% 100 100

T. LIFT UP XXX% Displays/adjusts fixed tower lift up speedNot displayed if TOWER LIFT=NO

0 to 100% 100 100

T. LIFT DN XXX% Displays/adjusts fixed tower lift down speedNot displayed if TOWER LIFT=NO

0 to 100% 100 100

JIB (U/D) XXX% Displays/adjusts jib lift speedNot displayed if JIB = 0

0 to 100% 60 60

JIB (L/R) XXX% Displays/adjusts jib swing speed Displayed if JIB = 2

0 to 100% 70 70

GEN SET/WELDER:

ENGINE XXXX RPM Control generator/welder RPM. Not displayed if GEN SET/WELDER = 0

1200-2800 1800 1800

NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine perfor-mance.Stop watch should start when the function is activated. Not with the controller or switch.Unless noted, function speeds should be measured from platform.Platform speed knob must be at full speed (fully clockwise).All test should be done with the oil temp above 100° F (38° C).

4150453-D



LINE)



DEFAULT VALUES


SPEEDS)

1200 1350 1200S 1350S

4-198 1200SJP 1350SJP 3128463


4.6 MACHINE ORIENTATION WHEN SETTING SPEEDS

Lift Up: From platform control, lowest elevation up to max-imum elevation, boom retracted.

Lift Down: From platform control, maximum elevationdown to minimum elevation, boom retracted.

Swing Right (Max): 360 Degrees, from platform control,boom approximately 45° elevation, boom retracted.

Swing Left (Max): 360 Degrees, from platform control,boom approximately 45° elevation, boom retracted.

Telescope Out: From platform control, boom horizontal,500 lb. (230 kg) capacity selected.

Telescope In: From platform control, boom horizontal,500 lb. (230 kg) capacity selected.

Drive Forward (Max): Test should be done on a smoothlevel surface. High Speed - Low Torque setting, drive 200ft. (61 m) front wheels to front wheels. Timed aftermachine has obtained maximum speed.

Drive Reverse (Max): Test should be done on a smoothlevel surface. High Speed - Low Torque setting, drive 200ft. (61 m) front wheels to front wheels. Timed aftermachine has obtained maximum speed.

Drive Forward (Creep Max): Test should be done on asmooth level surface. High Torque - Low Speed setting,platform speed knob at full creep.

Drive Reverse (Creep Max): Test should be done on asmooth level surface. High Torque - Low Speed setting,platform speed knob at full creep.

Drive Forward (Elevated Max - Boom Beyond Trans-port): Test should be done on a smooth level surface.High speed - Low Torque setting, platform speed knob outof creep, Lift boom above transport, drive forward 50 ft.(15.2 m).

Drive Reverse (Elevated Max - Boom Beyond Trans-port): Test should be done on a smooth level surface.High speed - Low Torque setting, platform speed knob outof creep, Lift boom above transport, drive forward 50 ft.(15.2 m).

Platform Rotate: Platform level and completely rotatedone direction. Rotate the opposite direction, Record Time.Rotate the other direction, Record Time.

Articulating Jib: Platform level and centered with theboom. Start with the Jib down. Jib Up, Record Time. JibDown, Record Time.

Test Notes1. Personality settings can be adjusted anywhere

within the adjustment range in order to achieve opti-mum machine performance

2. Stop watch should start when the function is acti-vated.Not with the controller or switch.

3. Unless noted, function speeds should be measuredfrom platform.

4. Platform speed knob must be at full speed (fullyclockwise).

5. All test should be done with the oil temp above 100°F (38° C).

4.7 SYSTEM TESTThe Control System Incorporates a built-in system test tocheck the system components and functions. To use thisfunction, use the following procedures.

Test from the Platform1. Position the Platform/Ground select switch to the

Platform position.

3128463 1200SJP 1350SJP 4-199


2. Plug the analyzer into the connector at the base ofthe platform control box.

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

4. The analyzer screen should read:

5. Use the arrow button to reach SYSTEM TEST. HitEnter. The analyzer will prompt you asking if youwant to activate the system test; hit Enter again toactivate.

6. Follow the flow path in Figure 4-10. System TestFlow Chart - Platform Tests on Pg. 209 and gothrough the component tests. Hit the ESC key dur-ing any part of the test to return to the main menuwithout completing all tests or wait until all tests arecomplete. During the TEST ALL INPUTS sequence,the analyzer allows control switches to be operatedand shows if they are closed (CL) or open (OP).

4-200 1200SJP 1350SJP 3128463


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

3128463 1200SJP 1350SJP 4-201


Test from the Ground Station

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

2. Plug the analyzer into the connector inside theGround control box.

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


5. Use the arrow button to reach SYSTEM TEST. HitEnter. The analyzer will prompt you asking if youwant to activate the system test; hit Enter again toactivate.

6. Follow the flow path in Figure 4-11. System TestFlow Chart - Ground Station Tests on Pg. 211 andgo through the component tests. Hit the ESC keyduring any part of the test to return to the main menuwithout completing all tests or wait until all tests arecomplete. During the TEST ALL INPUTS sequence,the analyzer allows control switches to be operatedand shows if they are closed (CL) or open (OP).

4-202 1200SJP 1350SJP 3128463


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

3128463 1200SJP 1350SJP 4-203


Table 4-3. System Test Messages

Message Displayed onAnalyzer


Description

RUNNING Initial display when system test is run; certain “critical” checks are made. Prob-lems that can be reported include below messages.

ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test.

BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V).

BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V).

CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and ground modules. The system test cannot run in ground mode unless data is being received from the platform module.

CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder.

BAD GROUND MODULE An internal problem was detected in the ground module.

HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor.

HOT ENGINE The engine temperature exceeds 100C. This is only a warning.

BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also detected, the controller may need replacing.

SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on. Check and, if necessary correct, all personality settings.

OPEN FSW In platform mode, the footswitch must be open at the start of the test.

CLOSE FSW In platform mode, the footswitch must be closed when this message is dis-played; the footswitch MUST BE KEPT CLOSED during the valve & contactor tests.

BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the platform module. Check footswitch and wir-ing.

TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils.NOTE: In platform mode, the footswitch must be closed.NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT AXLES=NO. Four wheel steer valves are not tested if 4WS=NO.NOTE: Left/right jib valves are not tested unless JIB = SIDESWING.Problems that can be reported include below messages.

CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning cor-rectly. Check valve wiring. Check ground alarm & hour meter wiring.

XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-cir-cuited. Check valve wiring.

XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wiring.

4-204 1200SJP 1350SJP 3128463


CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral.In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are reported.In ground mode any non-neutral ground switches is reported; any active cut-outs are reported.NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked.NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep to maximum.Problems that can be reported include below messages.

CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring.

CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick.

TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit.ENTER must be pressed or clicked to continue the test.NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked.NOTE: Platform Lamps are only tested in platform mode.NOTE: The GM overload lamp and 500# capacity lamp are not tested.NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine digit.

TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding.ENTER must be pressed or clicked to continue the test.NOTE: The platform alarm and the horn are only tested in platform mode.NOTE: The ground alarm is not tested if GROUND ALARM = NO.

TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends. If ENTER is pressed or clicked, each operator input is prompted for in turn.In platform mode every platform switch and joystick is tested.In ground mode every ground switch is tested.NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO.NOTE: Left/right jib switches are not tested unless JIB = SIDESWING.Prompts displayed during the operator input test below messages.

CLOSE XXXXXXX The named switch should be closed.

OPEN XXXXXXX The named switch should be opened.

XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction.

XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction.

PUMP POT TO MAX The pump pot should be turned to maximum.

PUMP POT TO MIN The pump pot should be turned to minimum.

MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short between two inputs.

TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu.

Table 4-3. System Test Messages



Description

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SECTION 5. CALIBRATIONS

5.1 CALIBRATION INSTRUCTIONSThis machine incorporates a variety of sensors and a highdegree of function interaction. For safety and propermachine functionality, the calibration procedures must berepeated for any control module replacement, system cal-ibration related fault, or removal or replacement of anysensors, valves, coils, motors, or pumps. The chart belowlists the calibrations required and potential reasons for re-calibration.

All calibration procedures are menu driven through theuse of the standard JLG analyzer. With the exception ofsteering calibration, no external tools are required to com-plete the calibration procedures. The user is prompted toexercise the machine in a specific order to use themachines physical properties to consistently establishsensor response and the interaction of valves, pumps,and motors. Steering calibration also uses the analyzerand is performed on one side of the machine at a timerequiring the use of a string or other means to determinewhen the tires are in line with each other. With the excep-tion of the load control calibration, all calibrations areaccessed by connecting the analyzer into the control sys-tem inside the main terminal box or on the bottom of theplatform control box. Calibration of the platform load sens-ing system is accessed by connecting the analyzerdirectly into the LSS module.

Table 5-1. Calibrations Listed by Symptom

Symptom Calibration

Boom control system inaccuracy Boom Sensors

Boom telescope problems Wire Rope Tensioning

Drive lugs engine Drive

Drive pulls to one side Drive

Load control inaccuracy Platform Load Sensing

Platform leveling erratic Platform Level Crack Point

Speed control for slow speed is poor Drive

Tilt indication inaccuracy Chassis Tilt

Wheel misaligned persistently Steering

Table 5-2. Calibrations Listed by Service Action

Service Action Calibration

BLAM removal Boom Sensors

BLAM replacement Boom SensorsDrive

Boom angle sensor removal or replace-ment

Boom Sensors

Boom length sensor removal or replace-ment

Boom Sensors

Boom lift flow control valve/coil replace-ment

Lift Crack Point

Boom telescope flow control valve/coil replacement

Tele Crack Point

Chassis Module replacement Steering

Drive pump/coil replacement Drive

Ground Module removal Boom SensorsChassis Tilt

Ground Module replacement Boom SensorsChassis Tilt DriveLift Crack PointTele Crack PointPlatform Level Crack PointSteering

Load cell removal or replacement Platform Load Sensing

LSS module replacement Platform Load Sensing

Main terminal box removal or replacement Chassis Tilt

Moment pin removal or replacement Boom Sensors

Platform level valve/coil replacement Platform Level Crack Point

Platform module replacement Platform Level Crack Point

Steer Angle Sensor replacement Steering

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5.2 CALIBRATING STEERWhen calibrating steering, each individual wheel must becalibrated in order to make the tire and wheel parallel withthe frame. Two methods to help ensure proper calibrationare the use of a carpenter’s square to square the spindleto the axle or aligning the two wheels on one side using astretched string.

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



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

6. Enter the Access Code, 33271.

7. Use the right Arrow key to reach CALIBRATIONS. HitEnter.

8. Use the arrow keys to reach Steer. The screen willread:

9. Hit Enter. The screen will read:

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11. Hit Enter again. The screen will read:

12. Activate the steer control until the tire and wheel arestraight in relationship with the chassis, then leaveoff the control. The display will read FRT LEFT =and show the numeric calibration value for thatwheel.


14. Repeat steps 10 thru 12 for left rear steer.

15. Left Rear Steer Calibration will be followed by RightForward Steer Calibration which will be followed byRight Rear Steer Calibration.

16. After completing all the Steer Calibrations, hit ESCtwice to go back to CALIBRATIONS.

5.3 CALIBRATING DRIVE

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

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8. Use the arrow keys to reach DRIVE.




12. Activate the Drive Joystick forward full stroke untilthe machine just begins to move, then leave off thejoystick immediately. The display will read CRK PT =and show the numeric crack point value.

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13. Hit Enter. The number displayed will be the valuethat the crack point is set to. The screen will show:


15. Repeat steps 10 thru 12 for left reverse drive.

16. Left Reverse Drive Calibration will be followed byRight Forward Drive Calibration which will be fol-lowed by Right Reverse Calibration.

17. After completing all the Drive Calibrations, hit ESCtwice to go back to CALIBRATIONS.

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5.4 ELECTRONIC PLATFORM LEVELING

Platform Leveling Fault WarningIf a fault occurs in the platform leveling system the follow-ing will occur:

1. Automatic platform leveling will stop (except whenthere is a fault in only one sensor automatic levelingwill remain active as the control system will use theother sensor to control leveling)

2. The level fault lamp will flash

3. The audible alarm will sound

4. All functions will default to creep speed if the plat-form is out of the transport position.

To reset the fault the emergency stop switch should berecycled.

IF THE FAULT PERSISTS BRING THE PLATFORM TO THEGROUND POSITION, SWITCH THE MACHINE OFF AND CONTACTA QUALIFIED SERVICE REPRESENTATIVE TO INVESTIGATE THEFAULT.

Fault ResponseERROR RESPONSE

If basket level varies from the current setpoint by ± 5.5° formore than 1.5 seconds when the platform is not in thetransport position, the following events will occur:

1. The platform dump valve will be disabled (level,rotate and jib functions disabled).

2. The level system fault lamp will flash (to indicate thatthe leveling function has been lost).

3. The platform alarm will sound.

4. A system fault will be logged.

5. All function speeds (lift, swing, telescope and drive)will be placed in creep mode (except when the plat-form is in the transport position see below).

When the unit is in the transport position and driving andthe current setpoint varies by ± 5.5° for more than 8 sec-onds the events 1,2,3 & 4 above will occur. (note functionspeeds will operate normally). Cycling the EMS will clearthe fault and allow the operator to operate the machine asa new level setpoint is taken.

VALVE DRIVER ERRORS

There are three possible level valve driver errors, short tobattery, short to ground, and open circuit.

1. In the case of a short to ground or an open circuit,the platform valve cannot be turned on and the fol-lowing will occur:

a. All interactions with platform leveling shall cease

b. The Electronic Leveling System Fault Lamp shallflash (to indicate that the leveling function hasbeen lost).

c. The platform alarm will sound.

d. A system fault will be logged.

e. All function speeds (lift, swing, telescope anddrive) will be placed in creep mode (exceptwhen the platform is in the transport position).

2. In the case of a short to battery on one of the plat-form leveling valves, the valve cannot be turned offand the following will occur:

a. The platform dump valve will be turned off toprevent unintended tilting of the platform.

b. All interactions with platform leveling shallcease.

c. The Electronic Leveling System Fault Lamp shallflash (to indicate that the leveling function hasbeen lost).

d. The platform alarm will sound.

e. A system fault will be logged.

f. All function speeds (lift, swing, telescope anddrive) will be placed in creep mode (exceptwhen the platform is in the transport position)

3. In the case of a short to battery on the platformdump valve, the valve cannot be turned off. The con-trollability of the platform leveling function will beimpaired and the following will occur:

a. All interactions with platform leveling shallcease.

b. The Electronic Leveling System Fault Lamp shallflash (to indicate that the leveling function hasbeen lost).

c. The platform alarm will sound.

d. A system fault will be logged.

e. All function speeds (lift, swing, telescope anddrive) will be placed in creep mode (exceptwhen the platform is in the transport position).

Lift, swing, drive and telescope will continue to operate

In each of the cases above it shall be necessary to re-cycle the EMS to clear the fault. Operable functions shallbe in the creep mode except while below elevation.

TILT SENSOR ERRORS

If the secondary tilt sensor is faulty, the control system willcontinue to utilize information from the primary sensor.

If the primary sensor is faulty, the control system willswitch to the backup sensor for control.

In both cases above the following will occur:

1. The Electronic Leveling System Fault Lamp will flash(to indicate that there is a leveling fault).


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4. All function speeds (lift, swing, telescope, jib anddrive) will be placed in creep mode (except whenthe platform is in the transport position).

5. Automatic leveling remains active.

Lift, swing, drive and telescope will continue to operate.

In each of the cases above it will be necessary to re-cyclethe EMS to clear the fault. Operable functions shall be inthe creep mode except while below elevation.

When both sensors appear to be working but have mea-surements that disagree by ±5.5° The following will occur:

1. All interactions with platform leveling shall cease.

2. The Electronic Leveling System Fault Lamp shallflash (to indicate that the leveling function has beenlost).



5. All function speeds (lift, swing, telescope and drive)will be placed in creep mode (except when the plat-form is in the transport position)

At this point, the operator must use the level up and downtoggle switch to manually level during descent. It shall benecessary to re-cycle the EMS to clear the fault.

CAN ErrorsThe Ground Module has two direct outputs dedicated tooverriding the Platform Module’s control of the levelingvalves. The Ground Module “Platform Level Up/Down”outputs are used to control the platform level up anddown valves.

When in ground mode, if the Ground Module reads a plat-form leveling switch command, the switch command iscommunicated over CAN to the Platform Module where itis handled normally.

If Ground Module determines that CAN communication isinoperable, it turns on the platform control valve and theappropriate platform leveling override outputs while theswitch is engaged.

If the Platform Module is still running when CAN is downnothing will operate when in platform mode. When theoperator switches to ground mode, the platform will notcontrol any of its valve outputs and a CAN error messageis signaled.

Additional Platform and Jib ValvesThe high side drivers for the platform left and right and thejib up and down valves are be located in the PlatformModule and are proportional. Flow through the valves isindividually controllable. The individually controlled duty

cycle will be the same as would otherwise have beencommanded to the flow control valve.

Only one platform or jib function is allowed at one time tolimit the amount of current draw, minimizing the voltagedrop on the supply to the Platform Module.

The function is enabled first shall remain active until it isreleased. Any other function commanded while anotherfunction is active is ignored.

Platform Leveling Calibration ProcedureSTEP 1: SETTING THE PLATFORM VALVE MINIMUMS

1. Put machine into “Ground Mode”.

2. Start machine and plug in Analyzer.

3. Go to the “Access Level 2” screen.

4. Enter “33271” to get into Access Level 1 mode.

5. Go to the “Personalities” menu and adjust the fol-lowing personalities. Refer to Table 4-2. MachinePersonality Settings and Speeds on page 202 forproper setting values.

Basket Level Up MinBasket Level Up MaxBasket Level Down MaxJib Up MinJib Down Min

6. Recycle EMS.

STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS



3. Manually level the platform with the switch on theMTB.



6. Go to the “Calibrations” menu and hit ENTER.

7. Use RIGHT ARROW go to “Plat. Leveling” screen.

8. Hit ENTER. “Calibrate?” prompt should appear.

9. Hit ENTER again to calibrate level sensors.

10. When calibration has been successful “Cal. Com-plete” should appear.

11. Cycle power to the machine.

STEP 3: BLEEDING THE PLATFORM VALVES



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5. Go to the “Personalities” menu.

6. Using the left arrow button, go to the “GroundMode” menu.

7. Hit ENTER.

8. Using the UP/DOWN arrows, adjust the followingpersonalities to 100%.

Basket RotateBasket LevelJib U/D (if configured)

Start up the machine and exercise each above plat-form function (from the ground) eight (8) to ten (10)times for 5 seconds in each direction.

9. Return the personality settings back to the values asshown in Table 4-2. Machine Personality Settingsand Speeds on page 202.

10. Recycle EMS.

STEP 4: CALIBRATING THE PLATFORM LEVEL UP ANDDOWN VALVE CRACKPOINTS





5. Go to the “Calibrations” menu and hit ENTER.

6. Go to the “Basket U Crkpt” Screen. Hit ENTER.

7. “Calibrate?” prompt should appear. Hit ENTERagain.

8. You will hear engine go to 1800 rpm.

9. Using UP ARROW, increase the value until you seethe basket up movement.

10. Hit ENTER again. “Cal. Complete” message shouldappear

11. Engine should again return to idle.

12. Hit ESC should return to “Basket U Crkpt” screen.

13. Hit RIGHT ARROWto get to the “Basket D Crkpt”screen. Hit ENTER.

14. “Calibrate?” prompt should appear. Hit ENTERagain.


Using DOWN ARROW, decrease the value until you seethe basket down movement.

Hit ENTER again. “Cal. Complete” message shouldappear

Engine should again return to idle.

Hit ESC to exit.

Cycle power to the machine.

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5.5 CALIBRATING PLATFORM LEVEL

STEP 1: SETTING THE PLATFORM VALVE MINIMUMS



3. Pull out the Emergency Stop switch and start theengine.




7. Use the arrow button to reach PERSONALITIESadjust the following personalities. Refer to Table 4-2.Machine Personality Settings and Speeds on page202 for proper setting values.

Basket Level Up MinBasket Level Up MaxBasket Level Down MaxJib Up MinJib Down Min

8. Recycle EMS.

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STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS




4. Manually level the platform with the switch on theMain Terminal Box.




8. Use the arrow button to reach CALIBRATIONS menuand hit ENTER.

9. Use right arrow go to PLAT. LEVELING screen.

10. Hit ENTER. The screen should read:

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11. Hit ENTER again to calibrate level sensors.

12. When calibration has been successful CAL. COM-PLETE should appear.

13. Cycle power to the machine.

STEP 3: BLEEDING THE PLATFORM VALVES1. Position the Platform/Ground select switch to the

Ground position.






7. Go to the PERSONALITIES menu.

8. Using the left arrow button, go to the GROUNDMODE menu.

9. Hit ENTER.

10. Using the UP/DOWN arrows, adjust the followingpersonalities to 100%.

Basket RotateBasket LevelJib U/D (if configured)

Start up the machine and exercise each above plat-form function (from the ground) eight (8) to ten (10)times for 5 seconds in each direction.

11. Return the personality settings back to the values asshown in Table 4-2. Machine Personality Settingsand Speeds on page 202.

12. Recycle EMS.

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STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS







7. Go to the CALIBRATIONS menu and hit ENTER.

8. Go to the BASKET U CRKPT Screen. Hit ENTER.

9. CALIBRATE? prompt should appear. Hit ENTERagain.


11. Using UP ARROW, increase the value until you seethe basket up movement.

12. Hit ENTER again. CAL. COMPLETE messageshould appear

13. Engine should again return to idle.

14. Hit ESC should return to BASKET U CRKPT screen.

15. Hit RIGHT ARROW to get to the “BASKET D CRKPT”screen. Hit ENTER.

16. CALIBRATE? prompt should appear. Hit ENTERagain.


Using DOWN ARROW, decrease the value until you seethe basket down movement.

Hit ENTER again. CAL. COMPLETE message shouldappear

Engine should again return to idle.

Hit ESC to exit and cycle power to the machine.

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5.6 CALIBRATING TILT SENSOR

A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THETIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.

DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVELSURFACE.

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

Before the tilt sensor can be calibrated, the followingconditions must be met:

a. Steering previously calibrated.

b. Axles extended.

c. Wheels straight.

d. Turntable centered.

e. Boom fully retracted.

f. Boom angle is less than 45°.

g. Machine on firm, level ground.








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9. Use the arrow keys to reach the TILT SENSOR. Thescreen should read:

10. Press ENTER.

11. When prompted, swing turntable 180° to oppositeend of chassis.

12. Press ENTER. The screen should read:

13. Upon completing swing calibration, swing turntable180° back to the stowed position.

14. Hit ESC twice to go back to CALIBRATIONS.

5.7 CALIBRATING LIFT CRACK POINT1. Position the Platform/Ground select switch to the

Platform position.


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8. Use the arrow keys to reach Upper Lift Crack Point(UPPER LIFT CRKPT). The screen will read:

9. Hit enter. The screen will read:

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12. Activate the Lift Up function by fully stroking the joy-stick until the boom starts to move, then leave offimmediately. The display will read CRK PT = andshow the numeric crack point value.

13. Hit enter. The number displayed will be the valuethat the crack point is set to. The screen will show:


15. Repeat steps 10 thru 12 for the Lift Down function.

16. After completing all the Tele Calibrations, hit ESCtwice to go back to CALIBRATIONS.

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5.8 CALIBRATING TELESCOPE CRACK POINT1. Position the Platform/Ground select switch to the

Platform position.







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8. Use the arrow keys to reach Upper Telescope CrackPoint (UPPER TELE CRKPT). The screen will read:



11. Hit enter again. The screen will read:

12. Activate the Tele Out function until the boom starts tomove, then leave off immediately. The display willread CRK PT = and show the numeric crack pointvalue.

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13. Hit enter. The number displayed will be the valuethat the crack point is set to. The screen will show:



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

17. After completing all the Tele Calibrations, hit ESCtwice to go back to CALIBRATIONS.

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5.9 CALIBRATING THE BOOM SENSORS

DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT ISNORMAL FOR THE REAR WHEEL TO LIFT FROM THE GROUNDAPPROXIMATELY 1 INCH (2.5 CM). IF THE WHEEL RAISESAPPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10 CM] ORMORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPEROPERATION OR THE NEED FOR BLEEDING, THEN PROCEEDWITH THE BOOM SENSOR CALIBRATION PROCEDURE.

Use the following step-by-step procedure to calibrate theboom sensors.

1. Before the boom sensors can be calibrated, the fol-lowing conditions must be met:

a. Steering, telescope crack points, and tilt previ-ously calibrated

b. Axles Extended

c. Wheels Straight

d. Platform Unloaded

e. Jib Horizontal

f. Jib Swing Centered

g. Platform Level

h. Platform Centered

i. Turntable Centered

j. Boom Fully Retracted

k. Level Ground (within 1.5°)








Figure 5-1. Boom Sensor Calibration Position 1

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9. Use the arrow keys to reach BOOM SENSORS. Thescreen should read:


11. After verifying all the conditions listed in step 1 aremet, hit Enter. The screen will read:

12. After verifying all load (personnel or material) isremoved from the platform, hit Enter. The screen willread:

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13. After visually verifying that the jib is horizontal, hitEnter. The screen will read:

14. After visually verifying the platform is level, hit Enter.The screen will read:

15. After visually verifying the platform is centered, hitEnter. The screen will read:

16. After operating telescope in to verify the boom isfully retracted, hit Enter. The screen will read:

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17. Use the up/down arrows to select YES if the acces-sory is installed, NO if it is not installed and hit enter.The screen will read:




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

23. After making sure the machine is in Calibration Posi-tion 1, hit Enter. The screen will read:

24. Lift up to stop (full stroke of cylinder) for CalibrationPosition 2. When the machine is in that position, hitEnter.


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The screen will read:

Swing 180 degrees (centered over opposite end of chas-sis) for Calibration Position 3.

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

When Position 3 calibrating is complete the screen willread:


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25. Press Enter. The screen will read:

26. Swing the machine back 180 degrees (centeredover original end of chassis) for Calibration Position4.


When Position 4 calibrating is complete, the screen willread:


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27. Press Enter. The screen will read:

Telescope out to stop (boom must be fully extended) forCalibration Position 5.


28. Retract to stop (boom must be fully retracted) forCalibration Position 6.



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

29. Lift down to stop (boom must be on boom rest) forCalibration Position 7.

When the machine is in the proper position, hit Enter. Thescreen will read as follows:

When Position 7 Calibrating is complete, the screen willread:


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Press Enter. The screen read:

30. Lift until the function stops (controller will stop at 5degrees above horizontal) for Calibration Position 8.


Press Enter. The screen will read:

31. Telescope to the yellow witness mark (controller willbe close - operator must position the pointer to cen-


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ter line on decal within 0.25" [6 mm]) for CalibrationPosition 9.

When the boom is in the proper position, hit Enter. Thescreen will read:

When Position 9 calibrating is complete, the screen willread:



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32. Telescope in to green witness mark (controller willfind the position - operator must visually verify theposition).

When the boom is in the proper position, the screen willread:


33. After completing all the Boom Sensors Calibrations,hit ESC twice to go back to Calibrations.


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5.10 WIRE ROPE TENSIONING PROCEDURE

With the boom assembly in the fully retracted position andbefore making any adjustments to the wire ropes of theboom assembly, remove any covers necessary to visuallyinspect the threaded fittings, taking note of the amount ofadjustment that is left for both the extend and retract wireropes for the fly and outer mid booms. Also, take note ofthe position of each boom section while the assembly is inthe fully retracted position. Take preliminary measure-ments and compare them to Figure 5-11., Wire Rope Ten-sioning Figure A.

NOTE: The inner mid section is positioned by the hydrauliccylinder. No adjustments will be made to this section.The wire ropes within the assembly control themovement of the outer mid and fly boom sections.

If it is necessary to reposition the outer mid and fly boomsections to achieve the measurements in Figure 5-11.,Wire Rope Tensioning Figure A, sound technician judg-ment should be used to compare the thread adjustment(that is left on the wire rope fittings) to the position of theboom sections. The sections can be repositioned slightlyto achieve a more even adjustment at the wire rope fittingswhen comparing the extend and retract systems.

1. Remove the lock plates and nylon collar locknutsfrom the wire rope fittings.

2. Extend the boom 5 to 6 feet (1.5 to 1.8 m) from fullyretracted position while maintaining a horizontal (+/-5°) position of boom.

3. Using tool P/N 4120043, torque outer mid retractadjuster nuts to 80 ft.lb. (112 Nm), alternatingbetween the two ropes until both maintain therequired torque.

BASE BOOMINNER MID BOOM

NOTE: Boom shown in fully retracted position.

OUTER MID BOOMFLY BOOM

9.5 ± 0.5”241 ± 13 mm

3.5 ± 0.5”90.5 ± 13 mm

8.0 ± 0.5”203 ± 13 mm

Figure 5-11. Wire Rope Tensioning Figure A

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4. Using tool P/N 4120043, torque fly retract adjusternuts to 80 ft.lb. (112 Nm), alternating between thetwo ropes until both maintain the required torque.

5. Retract boom 2 to 3 feet (0.6 to 0.9 m) from exten-sion point reached in Step #2.

NOTE: Ensure the boom is not fully retracted for followingsteps.

6. Using tool P/N 4120043, torque outer mid extendadjuster nuts to 80 ft.lb. (112 Nm), alternatingbetween the two ropes until both maintain therequired torque.

7. Using tool P/N 4120040, torque fly extend adjusternuts to 10 ft.lb. (14 Nm), alternating between the fourropes until all maintain the required torque.

8. Fully retract the boom assembly and verify theexposed boom section dimensions meet the dimen-sion tolerances shown in Figure 5-11., Wire RopeTensioning Figure A.

9. Reinstall nylon collar locknuts to fly extend wire ropefittings. Torque locknuts to 10 ft.lb. (14 Nm).

10. Reinstall lock plates to remaining adjuster nuts.

11. Install all covers and check for proper function ofboom assembly.

DO NOT REPEAT STEPS #2 THROUGH #7 MULTIPLE TIMES TOVERIFY ROPE TENSION. VERIFICATION OF THE ROPE TENSIONSHOULD BE DETERMINED BY PROPER FUNCTION OF THE BOOMASSEMBLY.

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BOOM SECTION REPOSITIONING EXAMPLE:If the outer mid boom section is still extended outside ofthe tolerance as shown in Figure 5-11., Wire Rope Ten-sioning Figure A while the boom assembly is fullyretracted, it will be necessary to loosen the outer midextend wire rope fittings. After loosening the outer midextend wire rope fittings, extend the boom assembly 5 to 6feet (1.5 to 1.8 m) from the fully retracted position andrepeat the tensioning steps for the outer mid retract ropes.Steps #5 & #6 should then be repeated. Once thosesteps are complete, fully retract the boom assembly andverify that the exposed boom section dimensions meetthe dimension tolerances of Figure 5-11., Wire Rope Ten-sioning Figure A.

This same method can be applied to repositioning the flyboom section by substituting the correct steps for the flyboom wire ropes. This is also applicable if either of thesections is positioned too far in, in the retracted position.The technician should begin the repositioning procedurewith the boom partially extended, slightly loosen theretract wire ropes, and partially retract the boom.

NOTE: Ensure that the boom is not fully retracted.

At this point, the correct steps should be followed to ten-sion the extend wire ropes for that section. Once thosesteps are complete, the steps required to tension theretract wire ropes should then be performed.

NOTE: Any repositioning of the outer mid boom section willalso effect the position of the fly boom section, as theouter mid is used to control the movement of the fly.The best practice is to correctly position the outermid boom before repositioning the fly boom.

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1. 2" Socket2. 3/4” Socket3. Retaining Bolt

Figure 5-12. Wire Rope Adjustment Tools

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SECTION 6. GENERAL ELECTRICAL INFORMATION

6.1 GENERAL

This section contains schematics to be used for locating and correcting most of the operating problems which may develop.If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, tech-nically qualified guidance should be obtained before proceeding with any maintenance.

6.2 MULTIMETER BASICS

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

Grounding

"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touchit to a good ground. A good ground will be a short circuit to the battery negative terminal or known good ground such as theplatform grounding bolt. Check this with a multimeter on continuity measurement or resistance. If the meter lead won’t reacha good ground "walk" the meter back to one, finding shorts along the way.

Backprobing

To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the backof the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specificallydesigned for this technique. Whenever possible insert probes into the side of the connector such that the test also checksboth terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sidesof a connector terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are stillattached to the contact and contacts are seated in the connector.

Min/Max

Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions whilealone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from thesolenoid and meter, is held down.

Polarity

Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.Check what reading is expected, the location of the signal and that the leads are connected to the device under test cor-rectly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the otherport goes to the positive side of the signal.

Scale

M = Mega = 1,000,000 * (Displayed Number)

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

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

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

Example: 1.2 k = 1200

Example: 50 mA = 0.05 A

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Voltage Measurement Resistance Measurement

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

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

• Use firm contact with meter leads

• 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 testingresistance

• Disconnect component from circuit before testing

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


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6.3 CONTINUITY MEASUREMENT OVER LONG DISTANCES

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

Requirements:

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

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

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

• Meter that can measure resistance or continuity.

Continuity Measurement Current Measurement

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

• Some meters require a separate button press toenable audible continuity testing

• Circuit power must be turned OFF before testing con-tinuity

• Disconnect component from circuit before testing


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

• Set up the meter for the expected current range

• Be sure to connect the meter leads to the correctjacks for the current range you have selected

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


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ProcedureTest multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate mea-surement.

Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reachof the jumper.

1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not com-pletely isolated disconnect battery terminals also, as a precaution.

2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,repair the shorted wires or replace the harness.

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

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

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

6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the lengthincreases and as the diameter decreases.

One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem thethird wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.

6.4 SWITCHES

Basic checkThe following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switchis functioning properly when there is continuity between the correct terminals or contacts only when selected.

1. De-energize the circuit.

2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.

3. Access the terminals to the switch.

4. If the switch has two terminals:

a. Measure resistance across the terminals.

b. Change the switch position.

c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read anopen. If the meter was reading open it should read short.

5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals willbe connected. The test is similar to testing a switch with two terminals.

a. Place one meter lead on the common contact and the other on a different contact in the same circuit.

b. Cycle through all positions of the switch. The meter should read short only when the switch connects the twoterminals and open otherwise.

c. If the switch has more than one common contact repeat the process for that circuit.

Limit SwitchesLimit switches are used to control movement or indicate position. Mechanical limit switches are just like manually oper-ated switches except that the moving object operates the switch. These switches can be tested the same way as a stan-dard switch by manually operating the sensing arm.

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Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductiveproximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They donot require contact, and must be energized to actuate. These types of switches can be used to detect boom or platformposition, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To findthe sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switchas follows:

1. Remove prox switch from its mount.

2. Reconnect harness if it was disconnected for step a, and turn on machine.

3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. Seevehicle or control system documentation on how to do this.

4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrousmetal physically similar to it. The switch state in the control system diagnostics should change.

5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between theswitch and object sensed.

Automatic Switches

If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switchto test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be ener-gized to actuate.

1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.

2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to dothis.

3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for exam-ple. The state indicated in the control system should change.

Switch Wiring - Low Side, High Side

When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch iscalled a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative sideof the power source and the load, it is a "low side" switch. The switch provides the ground to the load.

A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping currentflow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the batterynegative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. Thiscould mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture ofpower or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can mea-sure the voltage at both power terminals with respect to battery ground. The difference between those two measure-ments is the voltage applied to the load.

6.5 WORKING WITH AMP CONNECTORS

Applying Silicone Dielectric Compound To Amp ConnectorsSilicone Dielectric Compound must be used on the AMP connections for the following reasons:

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

• To prevent electrical malfunction caused by low level conductivity between pins when wet.

Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.

1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male andfemale pins on the inside of the connector after the mating of the housing to the header. This is easily achieved byusing a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside

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the header. When assembling the housing to the header, it is possible that the housing will become air locked, thuspreventing the housing latch from engaging.

2. Open one of the unused wire seals to allow the trapped air inside the housing to escape.

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

Figure 6-5. AMP Connector

AssemblyCheck to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Pro-ceed as follows:

Figure 6-6. Connector Assembly (1 of 4)

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1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. ConnectorAssembly (2 of 4)).

2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Fig-ure 6-7. Connector Assembly (2 of 4)).

3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the lock-ing latches by squeezing them inward (See Figure 6-8. Connector Assembly (3 of 4)).

4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)).



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Disassembly

1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.

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

3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact isremoved.

Figure 6-10. Connector Disassembly

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

Wedge Lock

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

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Service - Voltage Reading

DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.

It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. Thispractice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. Theresulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifiesthe effectiveness of the connector seals and could result in system failure.

Figure 6-11. Connector Installation

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6.6 WORKING WITH DEUTSCH CONNECTORS

DT/DTP Series Assembly

Figure 6-12. DT/DTP Contact Installation

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

2. Hold connector with rear grommet facing you.

3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked inplace.

4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedge-lock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.

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

DT/DTP Series Disassembly

Figure 6-13. DT/DTP Contact Removal

1. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.

2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving itaway from the contact with a screwdriver.

3. Hold the rear seal in place, as removing the contact may displace the seal.

HD30/HDP20 Series Assembly

Figure 6-14. HD/HDP Contact Installation

1. Grasp contact about 25mm behind the contact crimp barrel.

2. Hold connector with rear grommet facing you.

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

Figure 6-15. HD/HDP Locking Contacts Into Position

NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing

HD30/HDP20 Series Disassembly

Figure 6-16. HD/HDP Contact Removal

1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.

2. Slide tool along into the insert cavity until it engages contact and resistance is felt.

3. Pull contact-wire assembly out of connector.

Figure 6-17. HD/HDP Unlocking Contacts

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

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Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0) 161 654 1000

+44 (0) 161 654 1001

JLG France SASZ.I. de Baulieu47400 Fauillet

France

+33 (0) 5 53 88 31 70

+33 (0) 5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0) 421 69 350 20

+49 (0) 421 69 350 45

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

Oshkosh-JLG Singapore Technology Equipment Pte Ltd.29 Tuas Ave 4Jurong Industrial Estate639379 - Singapore

+65-6591-9030

+65-6591-9031

JLG PolskaUI. Krolewska00-060 WarsawaPoland

+48 (0) 914 320 245

+48 (0) 914 358 200

JLG Industries (Scotland)Wright Business Centre1 Lonmay RoadQueenslie, Glasgow G33 4ELScotland

+44 (0) 141 781 6700

+44 (0) 141 773 1907

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0) 850 659 500

+46 (0) 850 659 534

www.jlg.com

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