Troubleshooting Manual

Troubleshooting Manual
Troubleshooting Manual
Models
1200SJP
1350SJP
3128463
January 10, 2011
?
INTRODUCTION
SECTION A. INTRODUCTION
A.1 HOW TO USE THIS MANUAL
Troubleshooting system problems can be difficult. System wiring and hydraulic diagrams are provided in this book to help
isolate problems.
Follow the flow chart of Figure A-1. Troubleshooting Flowchart on Pg. 3. Only perform calibrations when indicated in procedures 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, disconnected connectors, programming modes, etc. should be removed, re-connected, restored, etc. after completing
the step unless directed otherwise. Some procedures call for swapping components, connections, etc. All instructions to
repair refer to the machine as assembled before the procedure started. Reinstall to proper locations all swapped components, connections before repairing machine.
When a function will not operate with the same speed or power as a machine in good working condition, refer to the topic
which most closely describes the problem.
Conclude each session by rerunning the system test, checking for other problems.
If this method does not identify the problem, contact the factory for assistance.
Start
Using Analyzer,
Run Platform and
Ground System
Tests
“Ground/
Everything OK”
No
Yes
Is Distress
Lamp Blinking?
No
Yes
Plug in Analyzer
and read Help
Message
No
Troubleshoot by
Help Message in
Section 1
Using Analyzer,
find logged Help
Messages
Identify Fault
Repair Machine
Problem
Solved?
Yes
Done
Figure A-1. Troubleshooting Flowchart
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A-3
INTRODUCTION
A.2 VISUAL INSPECTION
Perform a thorough visual and “hands on” inspection before starting any troubleshooting procedure. Also, perform a visual
inspection at every connector, sensor, hose, harness, etc. opened or accessed during the procedure. You can quickly find
the cause of many problems just by looking.
Has the machine been serviced recently? Check that everything has been reconnected properly.
Inspect Hoses for:
• Correct routing
• Pinches and kinks
• Splits, cuts, or breaks.
Inspect Wiring for:
• Contact with sharp edges
• Contact with hot surfaces
• Pinched, burned or chafed insulation
• Proper routing and connections
Check Sensors and Actuators for Damage.
Check Electrical Connectors for:
• Corrosion on pins
• Moisture in the housing or on the contacts
• Bent or damaged pins
• Contacts not properly seated in housing
• Bad wire crimps to terminals
A.3 READING FAULT CODES
Current and logged system fault codes and ADE service flash codes can be read from the analyzer. Refer to 4.2 Using the
Analyzer on Pg. 177. Fault logs are separated by POWER CYCLE messages. In Troubleshooting, you may be asked to see
all of the currently active faults. This simply means all of the faults since the latest power cycle. Scroll through the chronological faults on the analyzer, listing all the faults until the first “POWER CYCLE” message. Troubleshoot each of these items
separately unless instructed otherwise.
ADE service flash codes can also be read from the green LED on the face of the ground module or the system distress lamp
in the platform console, see Figure A-2. Ground Module and Platform Fault (System Distress) Lights on Pg. 4. Use the table
of contents to find possible faults based on the flashed code. Flash codes are the first two digits of Diagnostic Trouble
Codes or DTC’s. There is a unique DTC for each fault that occurs on the machine.
FAULT
CODE
LIGHT
1705744 A
J1
J4
J2
J3
1705745 B
1705171 A
1702938
1705170 A
Figure A-2. Ground Module and Platform Fault (System Distress) Lights
A-4
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INTRODUCTION
A.4 CONNECTOR REFERENCES
Electrical connectors are given a three digit identifier number preceded with “X”. See 2.1 Connector Index on Pg. 137 for a
list.
For Example:
[X004.21] refers to terminal 21 (pin and socket) of connector X004.
[X004.21.soc] refers to the socket side of terminal 21, connector X004.
[X004.21.pin] refers to the pin side of terminal 21, connector X004.
A.5 GROUND REFERENCE
Battery negative [X117] should be used as the ground reference for voltage measurements, unless stated otherwise.
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A-5
INTRODUCTION
A.6 CONTROL MODULE POWER AND COMMUNICATIONS
Always make sure that all of the control models are properly powered. See Figure A-3. Basic Electronic Module Connections
on Pg. 6
1. For Ground Module operation, Terminals [X001.24], and [X008.2] should have a voltage of Vbatt. Terminal [X008.1]
should be grounded.
2. CAN communication wires should have 60 resistance between CAN HI and CAN LO whenever both the Platform
Module and Chassis Module are connected or 120 when one of them are disconnected. Both CAN HI and CAN LO
should be isolated (show very high resistance or overload, OL) from the shield and ground. A CAN termination 120
resistor is located at both ends of the CAN bus. One is embedded in the platform module. The other terminator is jumpered in the chassis module.
X169 Platform
1
2
3
12
16
Vbatt from EMS 1
X160
Gateway Module
X287 X288
X289
IGNITION
J2
BATT +
16 15
22 7 23
A B
E D C
X171
26
28
29
27
120
Analyzer
CAN LO 30
X170
Vbatt from Ground Module X008.4
12 16
X166
32
CAN HI 31
CAN 2 HI
CAN 2 LO
SHIELD
GROUND
IGNITION
CAN 2 LO
CAN 2 HI
CAN LO
CAN HI
10 9 8 7 12 11
X290
V BATT
GND
SHIELD
12
Diagnostic Connector
V BATT
CAN 2 HI
CAN 2 LO
Black
TCU Module
IGNITION
GROUND
Gray
J7 Module
Mode Select from
2
Ground Module X007.14
2
Ground from Ground Module X008.3
1 2 3 X043
120
J8
1
120
Engine
Module
A
B
C
X279
X279
A B C
X270
C BA A
X269
B
C
C BA
A
B
C
B
C
X268
X014
X278 CAN HI
A
6
7
CAN Shield 8
Ignition Power 5
Ground from Ground Module X001.8
9
10
11
12
J4
J5
1
2
3
4
5
Vbatt from EMS
Platform Mode Select
J7
J1
8
28
29
30
31
24
3
14
X083
5 4 3 2 1
X216
30
X229
Ground to Engine Module X240.1
J1
Analyzer Power
Analyzer RS232 Receive
Analyzer RS232 Transmit
Analyzer Ground
Constant Battery (Vbatt)
X008
2
Ground from B- 1
Platform Ground
3
Platform Power 4
5 4 3 2 1
X266
85
X097
Vbatt from Power
Down Relay
X062
Chassis Power
Relay
87
86
Ground Module
CAN HI 13
CAN LO 24
CAN Shield 18
14
C B A X084
A
B
D
E Load Pin
CAN HI
CAN LO
CAN Shield
BLAM Module
X007 X001
1
Ignition Power
X089
X090
Analyzer Power
Analyzer RS232 Receive
Analyzer RS232 Transmit
Analyzer Ground
Analyzer
12
13
J1
CAN LO
4
X091
X240
X086
Chassis
Module
CAN HI 6
X013
2 1 X263
120
Analyzer
2
CAN LO 7
X267
X280
3
Ignition Power
CAN Shield 8
Chassis Power 5
J8
9
CAN Jumper
Battery +
Battery CAN HI
CAN LO
Constant Battery (Vbatt)
Ground 4
CAN 2 HI
CAN 2 LO
Note: BLAM and Chassis Module Analyzer connections for download only
10
X235
Analyzer
Analyzer Power
Analyzer RS232 Receive
Analyzer RS232 Transmit
Analyzer Ground
X233
9
10
11
12
J5
Figure A-3. Basic Electronic Module Connections
A-6
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INTRODUCTION
A.7 CRITICAL SENSORS
Main Boom Angle Sensors
Main Boom Rotary Angle Sensor #1 (Right) [X099]
Main Boom Rotary Angle Sensor #2 (Left) [X100]
Measure the angle of the main boom with respect to the turntable. Power is supplied by the Ground Module so the sensors
can be turned on separately at startup for identification and diagnostic purposes. Once initialized, a constant 12 volts should
be supplied by the Power Down Relay [X011.87] to Main Boom Angle Sensor #1, [X099.1] and Main Angle Sensor #2,
[X100.1]. Each sensor communicates with the BLAM on its own serial bus.
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D ANGLE1: XXX.X
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D ANGLE2: XXX.X
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM ANGLE1: XX.X DEG
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM ANGLE1: XX.X DEG
In transport position approximate typical values are:
MAIN BOOM A/D ANGLE1: -38.0
MAIN BOOM A/D ANGLE2: -38.0
MAIN BOOM ANGLE1: -1.0
MAIN BOOM ANGLE2: -1.0
Main Boom Length Sensor
Main Boom Length Sensor #1 (Top Right) [X093]
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM LENGTH: XXX.X"
ANALYZER  DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D LENGTH: XXXXX
Measures the total stroke of the main boom using a cable potentiometer. The sensor’s analog outputs are read by the BLAM
module. It increases as the boom length increases. The sensor is powered by a 5 volt reference and ground from the BLAM
module. Each sensor should measure 5k  resistance between the A and B pins.
In transport position approximate typical values are:
MAIN BOOM LENGTH: 37.3"
MAIN BOOM A/D LENGTH: 395
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A-7
INTRODUCTION
This Page Left Blank Intentionally
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A-8
SAFETY
SECTION B. TROUBLESHOOTING SAFETY PRECAUTIONS
B.1 GENERAL
B.3 TROUBLESHOOTING SAFETY
This section contains the general safety precautions
which must be observed during troubleshooting of the
aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings
and precautions to avoid possible injury to themselves or
others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe
to operate.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
The specific precautions to be observed during troubleshooting are inserted at the appropriate point in the manual. These precautions are, for the most part, those that
apply when servicing hydraulic and larger machine component parts.
Your safety, and that of others, is the first consideration
when engaging in the troubleshooting of equipment.
Always be conscious of weight. Never attempt to move
heavy parts without the aid of a mechanical device. Do not
allow heavy objects to rest in an unstable position. When
raising a portion of the equipment, ensure that adequate
support is provided.
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER TROUBLESHOOTING,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF
THE OWNER/OPERATOR.
B.2 HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
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FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
• No smoking is mandatory. Never refuel during electrical
storms. Ensure that fuel cap is closed and secure at all
other times.
• Remove all rings, watches and jewelry when performing
any troubleshooting.
• Do not wear long hair unrestrained, or loose-fitting
clothing and neckties which are apt to become caught
on or entangled in equipment.
• Observe and obey all warnings and cautions on
machine and in service and operators manuals.
• Keep oil, grease, water, etc. wiped from standing surfaces and hand holds.
• Use caution when checking a hot, pressurized coolant
system.
• Never work under an elevated boom until boom has
been safely restrained from any movement by blocking
or overhead sling, or boom safety prop has been
engaged.
• A machine that is damaged or malfunctioning should
immediately be tagged and removed from service.
• Repair any machine damage or malfunction before
operating the machine.
• Unless otherwise specified, perform any troubleshooting procedure with the machine parked on a flat level
surface, boom stowed, key switch off and key removed,
park brake applied.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in
their proper place.
• Use only approved, nonflammable cleaning solvents.
1200SJP 1350SJP
B-9
REVISION LOG
April 25, 2008
- Original issue of fault guide for use with P7.2 or above Software and Telematics.
January 10, 2011
- Manual Revised
10
1200SJP 1350SJP
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TABLE OF CONTENTS
TABLE OF CONTENTS
SECTION A - INTRODUCTION
A.1
A.2
A.3
A.4
A.5
A.6
A.7
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Ground Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Control Module Power and Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Critical Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
SECTION B - TROUBLESHOOTING SAFETY PRECAUTIONS
B.1
B.2
B.3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
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001 - EVERYTHING OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
002 - GROUND MODE OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION . . . . . . . . . . . . . . . . . . . . . . 1-15
0011 - FSW OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
0012 - RUNNING AT CREEP - CREEP SWITCH OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . 1-17
0014 - CHASSIS TILT SENSOR OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
0015 - LOAD SENSOR READING UNDER WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . 1-18
0017 - OVER MOMENT - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
0018 - UNDER MOMENT - HYDRAULICS SUSPENDED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . 1-19
0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . 1-19
211 - POWER CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
212 - KEYSWITCH FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
213 - FSW FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
227 - STEER SWITCHES FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2211 - FSW INTERLOCK TRIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . 1-20
2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2215 - D/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2216 - D/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2217 - D/S JOY. CENTER TAP BAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2218 - L/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2219 - L/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2220 - L/S JOY. CENTER TAP BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH. . . . . . . . . . . . . . . . 1-21
2222 - WAITING FOR FSW TO BE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE . . . . . . . . . . . . . . . . . . 1-21
2224 - FOOTSWITCH SELECTED BEFORE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM . . . . . . . . . . . . . . . . . . . 1-21
235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER . . . . . . . . . . . . . . . 1-21
236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH . . . . . . . . . . . . . 1-21
237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH . . . . . . . . . . . . . . . . . . . . . 1-21
259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS . . . . . . . . . . . . . . . . . . . . 1-21
2513 - GENERATOR MOTION CUTOUT ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
2514 - BOOM PREVENTED - DRIVE SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
2515 - DRIVE PREVENTED - BOOM SELECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
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11
TABLE OF CONTENTS (Continued)
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
12
2516 - DRIVE PREVENTED - ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
2521 - JIB SWING PREVENTED - IN 1000# MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED. . . . . . . . . . . . . . . . . . . . .1-22
2523 - BACKUP BLAM COMMUNICATIONS ACTIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL . . . . . .1-22
331 - BRAKE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
332 - BRAKE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
3311 - GROUND ALARM - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3336 - ALTERNATOR/ECM POWER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3338 - ALTERNATOR POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3339 - ALTERNATOR POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3340 - AUX POWER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3341 - AUX POWER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3342 - AUX POWER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . .1-24
3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . .1-24
3349 - ELECTRIC PUMP - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
3350 - ELECTRIC PUMP - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3351 - ELECTRIC PUMP - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3358 - MAIN DUMP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3359 - MAIN DUMP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3360 - MAIN DUMP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3361 - BRAKE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3362 - START SOLENOID - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3363 - START SOLENOID - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3364 - START SOLENOID - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3368 - TWO SPEED VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3369 - TWO SPEED VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
3370 - TWO SPEED VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3371 - GROUND ALARM - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3372 - GROUND ALARM - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3373 - GEN SET/WELDER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3374 - GEN SET/WELDER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3375 - GEN SET/WELDER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3376 - HEAD TAIL LIGHT - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3377 - HEAD TAIL LIGHT - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3378 - HEAD TAIL LIGHT - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3379 - HOUR METER - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3380 - HOUR METER - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
3381 - HOUR METER - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . .1-27
3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . .1-27
3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . .1-27
3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND . . . . . . . . . . . . . . .1-27
1200SJP 1350SJP
3128463
TABLE OF CONTENTS (Continued)
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3128463
3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . .1-27
3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . .1-27
3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-27
3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . .1-27
3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-28
3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . .1-28
33100 - JIB LIFT UP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33101 - JIB LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33102 - JIB LIFT UP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33103 - JIB LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33104 - JIB LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33118 - SWING RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33119 - SWING RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33121 - SWING RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33122 - SWING LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33130 - THROTTLE ACTUATOR - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33131 - THROTTLE ACTUATOR - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33132 - THROTTLE ACTUATOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33133 - PLATFORM CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33134 - PLATFORM CONTROL VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33150 - LIFT PILOT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
33151 - LIFT PILOT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33152 - LIFT PILOT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33153 - LIFT DOWN AUX VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33154 - LIFT DOWN AUX VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUIT. .1-32
33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33181 - MAIN LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
33183 - MAIN LIFT UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33207 - HORN - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33208 - HORN - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33209 - HORN - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33279 - GLOWPLUG - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
33280 - GLOWPLUG - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33281 - GLOWPLUG - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33295 - SWING LEFT VALVE - oPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33306 - SWING LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . .1-34
1200SJP 1350SJP
13
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33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . .1-34
33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . .1-34
33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . .1-34
33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . .1-34
33329 - MAIN LIFT UP VALVE - SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . .1-35
347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . .1-35
348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-35
431 - FUEL SENSOR SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
432 - FUEL SENSOR SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
433 - OIL PRESSURE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
434 - OIL PRESSURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
435 - COOLANT TEMPERATURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
437 - ENGINE TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
438 - HIGH ENGINE TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
439 - AIR FILTER BYPASSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4310 - NO ALTERNATOR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4311 - LOW OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4313 - THROTTLE ACTUATOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4314 - WRONG ENGINE SELECTED - ECM DETECTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4322 - LOSS OF ENGINE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
4323 - SPEED SENSOR READING INVALID SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
445 - BATTERY VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
662 - CANBUS FAILURE - PLATFORM MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
666 - CANBUS FAILURE - ENGINE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
6610 - CANBUS FAILURE - BLAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
6611 - CANBUS FAILURE - CHASSIS MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44
6612 - CANBUS FAILURE - CYLINDER LOAD PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46
6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47
6622 - CANBUS FAILURE - TCU MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-50
6623 - CANBUS FAILURE - GATEWAY MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51
6629 - TELEMATICS CANBUS LOADING TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP . . . . . . .1-52
813 - CHASSIS TILT SENSOR NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
815 - CHASSIS TILT SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
825 - LSS HAS NOT BEEN CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
826 - RUNNING AT CREEP - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . .1-53
828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . .1-53
831 - PLATFORM LEVELING OVERRIDE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
832 - PLATFORM LEVELING OVERRIDE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . .1-53
834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . .1-54
837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . .1-55
8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . .1-55
8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56
8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE . . . . . . . . . .1-56
8315 - PLATFORM LEVELING SENSOR - DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56
8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-57
8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . .1-58
8318 - PLATFORM LEVELING SYSTEM TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
1200SJP 1350SJP
3128463
TABLE OF CONTENTS (Continued)
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3128463
841 - BOOM ANGLE SENSOR DISAGREEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-60
842 - BOOM LENGTH SWITCH FAILED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-61
843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-62
844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE . . . . . . . . . . . . . . . . . . . .1-62
845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-64
846 - BOOM LENGTH SENSOR - OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-65
847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . .1-66
848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . .1-67
849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . . .1-67
8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . .1-69
8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-70
8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-71
8413 - WRONG TELESCOPE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-72
8414 - WRONG LIFT RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73
851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-73
852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
855 - MOMENT PIN - SENSOR FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
857 - NEW MOMENT PIN DETECTED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-74
861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESS. SWITCH DISAGREEMENT1-74
862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . .1-76
863 - AXLE EXTEND VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76
864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . .1-76
865 - AXLE RETRACT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-76
866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT. . . . . . .1-76
867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-77
868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-77
869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-77
8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-77
8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-78
8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-78
8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-79
8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . .1-79
8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . .1-79
8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80
8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80
8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . .1-80
8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . .1-80
8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . .1-80
8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . .1-80
8622 - FRONT RIGHT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-80
8623 - FRONT LEFT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-81
8624 - REAR RIGHT STEER SENSOR - DECOUPLED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-82
8625 - REAR LEFT STEER SENSOR - DECOUPLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-83
8626 - FRONT LEFT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-84
8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . .1-85
8628 - REAR LEFT STEER SENSOR - NOT RESPONDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-86
8629 - REAR RIGHT STEER SENSOR - NOT RESPONDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-87
8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT. . . . . . . . . .1-88
8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . .1-89
8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-90
8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-91
8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . .1-92
8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .1-93
8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . . .1-94
8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-95
8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
998 - EEPROM FAILURE - CHECK ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER .1-96
1200SJP 1350SJP
15
TABLE OF CONTENTS (Continued)
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9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-96
9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-97
9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY. . . . . . . . . . . . . . .1-98
9922 - PLATFORM MODULE FAILURE - HWFS CODE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-98
9923 - GROUND MODULE FAILURE - HWFS CODE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER. . .1-99
9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER. . . . . .1-99
9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . .1-99
9928 - ENVELOPE CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
9929 - MOMENT CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-99
9930 - STEER SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
9931 - BOOM SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
9932 - LIFT CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
9933 - TELESCOPE CRACKPOINTS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
9934 - DRIVE CRACKPOINTS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-100
9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-101
9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102
9937 - LENGTH SENSOR REF VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-102
9938 - LENGTH SENSOR REF VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
9939 - BLAM HIGH RES A/D FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-103
9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104
9944 - CURRENT FEEDBACK GAINS OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-104
9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT. . . . . . . . . . . . . . . . . . .1-104
9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER. . .1-105
33xx - COMMON STB OR OC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-105
33XX - COMMON STG PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-106
SECTION 2 - ELECTRICAL REFERENCE
2.1
2.2
2.3
2.4
2.5
2.6
Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
BLAM Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
Chassis Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
Ground Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
Platform Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
SECTION 3 - HYDRAULIC REFERENCE
SECTION 4 - JLG ANALYZER
4.1
4.2
4.3
4.4
4.5
4.6
4.7
To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-186
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-187
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-187
Machine Orientation When Setting Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199
System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-199
SECTION 5 - CALIBRATIONS
5.1
5.2
5.3
5.4
5.5
16
Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207
Calibrating Steer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-208
Calibrating Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-210
Electronic Platform Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-214
Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-217
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TABLE OF CONTENTS (Continued)
5.6
5.7
5.8
5.9
5.10
Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-221
Calibrating Lift Crack Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-222
Calibrating Telescope Crack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-225
Calibrating the Boom Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-228
Wire Rope Tensioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-240
SECTION 6 - GENERAL ELECTRICAL INFORMATION
6.1
6.2
6.3
6.4
6.5
6.6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-245
Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-245
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-248
Working with AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-249
Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
LIST OF FIGURES
A-1.
A-2.
A-3.
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
3128463
Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Ground Module and Platform Fault (System Distress) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Basic Electronic Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Color Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-111
Platform Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113
Boom Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115
Engine Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117
Main Valve Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119
Ground Control Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121
Chassis Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123
Ground, Engine and BLAM Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-125
Platform Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127
Chassis Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129
Electrical Wiring (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-131
Electrical Wiring (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-133
Telematics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135
Main Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-163
Pumps Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-164
Platform Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-165
Hydraulic Schematic - Pump Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-166
Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-167
Hydraulic Schematic - Platform Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-168
Hydraulic Schematic - Platform Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-169
Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-170
Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-171
Hydraulic Schematic - Traction Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-172
Hydraulic Schematic - Traction Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-173
Hydraulic Schematic - Boom Control - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-174
Hydraulic Schematic - Boom Control - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-175
Ground Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
Platform Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-177
Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-179
Analyzer Flow Chart - Personalities (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . .4-180
Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . .4-181
Analyzer Flow Chart - Calibrations (Software Version 7.X to Present) . . . . . . . . . . . . . . . . . . . . . .4-182
Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3. . . . . . . . . . .4-183
Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3. . . . . . . . . . .4-184
Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3 . . . . . . . . . . .4-185
System Test Flow Chart - Platform Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-201
1200SJP 1350SJP
17
TABLE OF CONTENTS (Continued)
4-11.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
6-17.
18
System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-203
Boom Sensor Calibration Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-228
Boom Sensor Calibration Position 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-232
Boom Sensor Calibration Position 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-233
Boom Sensor Calibration Position 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-234
Boom Sensor Calibration Position 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-235
Boom Sensor Calibration Position 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-235
Boom Sensor Calibration Position 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-236
Boom Sensor Calibration Position 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-237
Boom Sensor Calibration Position 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-238
Boom Sensor Calibration Position 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-239
Wire Rope Tensioning Figure A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-240
Wire Rope Adjustment Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-243
Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-246
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-246
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-247
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-250
Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-250
Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-251
Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-251
Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-252
Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-252
Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-253
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-254
HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-255
1200SJP 1350SJP
3128463
TABLE OF CONTENTS (Continued)
LIST OF TABLES
1-1
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
2-11
2-12
2-13
2-14
2-15
2-16
2-17
2-18
2-19
2-20
2-21
2-22
2-23
2-24
2-25
2-26
2-27
4-1
4-2
4-3
5-1
5-2
3128463
Common Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Limit Switch States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109
Platform Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112
Main Valve Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118
Chassis Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122
Connector Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
X086 (J1) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
X087 (J2) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
X088 (J3) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
X089 (J4) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
X090 (J5) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
X229 (J1) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
X230 (J2) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
X231 (J3) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
X232 (J4) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
X233 (J5) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
X001 (J1) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
X002 (J2) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
X004 (J4) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
X007 (J7) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
X008 (J8) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
X165 (J1) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
X166 (J2) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
X167 (J5) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
X168 (J6) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
X169 (J7) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
X170 (J8) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-188
Machine Personality Settings and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-194
System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-204
Calibrations Listed by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207
Calibrations Listed by Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-207
1200SJP 1350SJP
19
TABLE OF CONTENTS (Continued)
This Page Left Blank Intentionally
20
1200SJP 1350SJP
3128463
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
SECTION 1. DTC DICTIONARY AND SELECTED TROUBLESHOOTING
For a list of Diagnostic Trouble Codes (DTC’s), see the table of contents.
DTC 001 - EVERYTHING OK
Everything OK. The "normal" help message when the analyzer is plugged into the platform. No problem is detected.
DTC 002 - GROUND MODE OK
Ground mode OK. The "normal" help message when the analyzer is plugged into the ground module. No problem is
detected.
DTC 0010 - RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION
Running at cutback - out of transport position. Drive speed is limited to programmed maximum because the vehicle is out of
transport position. Maximum drive speed is set in the Personality of the machine. Transport position is defined as main boom
retracted, and the boom angle less than +15.0 (default) from gravity. Sensor failures can change these conditions. .
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Read faults
Test
Result
Are there any length sensor, boom angle sen- Yes
sor, switch or transport length switch faults? No
Return machine to transport Did fault clear?
position
Corrective Action
Troubleshoot those faults first
Go to step 2
Yes
Troubleshooting Complete
No
Go to step 3
ANALYZER  DIAGNOSDoes it read OUT OF TRANSPORT?
TICS  TRANSPORT DATA
 TRANSPORT MODE
Yes
Go to step 4
No
Reprogram/replace ground module
ANALYZER  DIAGNOSDoes it read STOWED, or can the main boom
TICS  TRANSPORT DATA be lowered to make it read STOWED?
 MAIN LIFT STATUS
Yes
Keep analyzer connected.
Go to step 5
No
Calibrate boom sensors. See 5.9 Calibrating the
Boom Sensors on Pg. 228.
ANALYZER  DIAGNOSDoes it read RETRACTED, or can the main
TICS  TRANSPORT DATA boom be moved within the transport position
 MAIN TELESCOPE STA- envelope to make it read RETRACTED?
TUS
Yes
Normal operation. Troubleshooting complete.
No
Calibrate boom sensors. See 5.9 Calibrating the
Boom Sensors on Pg. 228.
DTC 0011 - FSW OPEN
Footswitch open. A drive or boom function has been selected but the platform footswitch [X152] is open. This could be
caused by operator not depressing the footswitch before utilizing a machine control in the platform.
Note Pretest Instructions
Step 1
Step 2
3128411
Test
Result
Go to ANALYZER  DIAG- Does the analyzer read OPEN? -AND- Does the Yes
NOSTICS  SYSTEM 
analyzer read CLOSED with the footswitch
FOOTSWITCH INPUT PLAT- depressed?
No
FORM
Locate platform passthru 15 pos [X164]. Ground
meter. See Grounding on
Pg. 245 for details. Take the
following reading by backprobing. See Backprobing
on Pg. 245 for details.
Turn on machine. Is there about 12 VDC on
platform passthru terminal 8 [X164.8]?
1200SJP 1350SJP
Corrective Action
If fault is clear, this is normal operation. Otherwise
reprogram/replace the ground module
Go to step 2
Yes
Keep the test setup in same condition.
Go to step 4
No
Go to step 3
1-15
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Ground meter. Take the following measurement by
backprobing.
Test
Turn on machine. Is there about 12 VDC on
platform module J2 terminal 3 [X166.3]?
Locate platform passthru
Turn on machine. Is there about 12 VDC on
[X164]. Ground meter. Take platform passthru terminal 7 [X164.7]?
the following reading by
backprobing.
Disconnect platform
passthru [X164] and platform module J7 [X169]
Result
Yes
Repair/replace harness between platform module J2 terminal 3 [X166.3] and platform passthru
terminal 8 [X164.8]
No
Replace platform module
Yes
Go to step 5
No
Repair/replace footswitch
Is there continuity between platform passthru Yes
pin 7 [X164.7.pin] and platform module J7
No
socket 8 [X169.8.soc]?
Locate platform control box Turn on machine. Is there about 12 VDC on
passthru - 19 pos [X160].
platform control box terminal 6 [X160.6]?
Ground meter. Take the following reading by backprobing.
Corrective Action
Go to step 6
Repair/replace harness between platform
passthru pin 7 [X164.7.pin] and platform module
J7 socket 8 [X169.8.soc]
Yes
Repair/replace footswitch
No
Keep test setup in place.
Go to step 7
Locate platform control box Turn on machine. Depress footswitch. Is there Yes
passthru - 19 pos [X160].
about 12 VDC on platform control box terminal No
Ground meter. Take the fol- 6 [X160.6]?
lowing reading by backprobing.
Go to step 8
Disconnect ground module Turn on machine. Is there about 12 VDC on
J7 [X007]. With a helper or ground module J7 terminal 15 [X007.15]?
an object, hold the footswitch down. Ground the
meter near the main terminal
box. Take the following measurement by backprobing.
Yes
Reprogram/replace platform module and/or
ground module
No
Go to step 9
Disconnect ground module
J7 [X007] and MTB
passthru - 19 pos [X043]
Repair/replace footswitch
Is there continuity between ground module J7 Yes
socket 15 [X007.15.soc] and MTB passthru
pin 6 [X043.6.pin]?
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]
DTC 0012 - RUNNING AT CREEP - CREEP SWITCH OPEN
Running at creep - creep switch open. All function speeds are limited to creep because the creep switch is open. This switch
is part of the hydraulic speed potentiometer operated by a knob on the platform console. The creep indicator will light when
in creep mode or blink in super creep mode. Circumstances that cause the machine to automatically enter creep/super
creep mode include encroachment of the operating envelope limit main boom, platform leveling fault, throttle actuator failure, stowed platform, software version faults, boom sensor failures, hydraulic warm-up mode, and hydraulic or electrical
retrieval mode.
Note Pretest Instructions
Step 1
Step 2
1-16
Rotate function speed control knob fully CCW until it
clicks.
Test
Result
Corrective Action
Are any of the circumstances that cause creep Yes
or super creep mode automatically present? No
Go to step 2
Is creep light on?
Yes
Go to step 7
No
Go to step 3
1200SJP 1350SJP
Clear any condition present
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Test
Watch creep light while turning on machine
from both the platform and the ground. Is
creep light on for the lamp check?
Disconnect hyd speed pot
Is there about 12VDC at hyd speed pot
passthru - 6 pos. [X199].
passthru socket 3 [X199.3.soc]?
Ground meter. See Grounding on Pg. 245 for details.
Turn on machine.
Result
Corrective Action
Yes
Go to step 4
No
Replace LED light panel with light that is bad.
Yes
Keep hyd speed pot passthru - 6 pos. [X199] disconnected.
Go to step 6
No
Keep hyd speed pot passthru - 6 pos. [X199] disconnected.
Go to step 5
Disconnect hyd speed pot
Is there continuity between hyd speed pot
Yes
passthru - 6 pos. [X199] and passthru socket 3 [X199.3.soc] and platform No
platform module J1 [X165] module J1 socket 18 [X165.18.soc]?
Replace platform module
Replace/repair harness between hyd speed pot
passthru socket 3 [X199.3.soc] and platform
module J1 socket 18 [X165.18.soc]
Disconnect hyd speed pot
Is there continuity between hyd speed pot
passthru - 6 pos. [X199] and passthru pin 2 [X199.2.pin] and platform
platform module J1 [X165] 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]
Turn on machine. Rotate
Does creep light turn off?
function speed control knob
CW 1/4 turn to 9 o’clock
position.
Yes
Keep machine in same condition.
Go to step 8
No
Go to step 9
Turn on machine. Rotate
Does fault message clear?
function speed control knob
CW 1/4 turn to 9 o’clock
position.
Yes
Normal operation. Troubleshooting complete.
No
Reprogram/replace ground module
Rotate function speed con- Is there a short between hyd speed pot
trol knob CW 1/4 turn to 9
passthru socket 2 [X199.2.soc] and pin 3
[X199.3.pin]?
o’clock position. Disconnect hyd speed pot passthru
- 6 pos. [X199].
Yes
Repair/replace function speed control and/or
harness to hyd speed pot passthru - 6 pos.
[X199]
No
Go to step 10
Yes
Repair/replace harness between platform module J1 socket 32 [X165.32.soc] and socket 18
[X165.18.soc]
No
Keep hyd speed pot passthru - 6 pos. [X199] disconnected.
Go to step 11
Yes
Repair/replace harness between hyd speed pot
passthru pin 2 [X199.2.pin]
No
Reprogram/replace platform module
Step 10 Disconnect hyd speed pot
Is there a short between platform module J1
passthru - 6 pos. [X199] and socket 32 [X165.32.soc] and socket 18
platform module J1 [X165] [X165.18.soc]?
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]?
DTC 0013 - RUNNING AT CREEP - TILTED AND ABOVE ELEVATION
Running at creep - tilted and above elevation. All boom function speeds are limited to creep because the machine is tilted
and above elevation. The machine is "Tilted" if the chassis is greater than 5.0 in any direction. If Tilt calibration has not been
performed after the ground module or the main terminal box has been removed or replaced the machine will also indicate it
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
is tilted. The machine is "Above Elevation" if the boom is greater than +15.0 (default) from gravity. This resets at 10.0. Sensor failures can change these conditions..
Note Pretest Instructions
Step 1
Return machine to Transport position and level
ground
Step 2
Step 3
Return machine to Transport position and level
ground. ANALYZER 
DIAGNOSTICS  TRANSPORT DATA
Step 4
Test
Result
Is fault still active?
Corrective Action
Yes
Go to step 2
No
Troubleshooting complete
Are there any boom sensor or Chassis tilt sen- Yes
sor faults?
No
Go to step 3
Does MAIN LIFT read STOWED?
Yes
Go to step 4
No
Perform 5.9 Calibrating the Boom Sensors on
Pg. 228
Is the Tilt indicator on?
Troubleshoot those faults
Yes
Perform 5.6 Calibrating Tilt Sensor on Pg. 221
No
Repair/reprogram ground module
DTC 0014 - CHASSIS TILT SENSOR OUT OF RANGE
Chassis tilt sensor out of range. Chassis tilt sensor has indicated a tilt angle greater than 19 for more than 4 seconds.
Note Pretest Instructions
Test
Step 1 Put machine on level surface Did fault clear?
Step 2 Perform Tilt calibration. See Did it calibrate successfully?
5.6 Calibrating Tilt Sensor
on Pg. 221.
Result
Corrective Action
Yes
Normal operation. Troubleshooting complete.
No
Go to step 2
Yes
Troubleshooting complete
No
Replace ground module
DTC 0015 - LOAD SENSOR READING UNDER WEIGHT
Load sensor reading under weight. The load sensor is reading 20% or more under the calibrated zero point. This fault may
occur if the platform is resting on the ground. Not reported during the 2 second power-up.
Note Pretest Instructions
Step 1
Step 2
Test
Safely ensure platform is not Does fault clear?
resting on anything.
Perform 5.9 Calibrating the Does calibration complete successfully?
Boom Sensors on Pg. 228.
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 2
Yes
Troubleshooting complete
No
Troubleshoot according to calibration fault
DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED
Envelope encroached - hydraulics suspended. The system detected a violation of the safe operating area envelope. If platform is stuck in the air call JLG for help.
Note Pretest Instructions
Step 1
Step 2
1-18
Test
Is the platform stuck in the air?
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Did calibration complete successfully?
1200SJP 1350SJP
Result
Corrective Action
Yes
Call JLG for help
No
Go to step 2
Yes
Go to step 3
No
Troubleshoot according to calibration fault
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Calibrate chassis tilt. See
5.6 Calibrating Tilt Sensor
on Pg. 229 for details.
Test
Did calibration complete successfully?
Result
Corrective Action
Yes
Troubleshooting complete
No
Troubleshoot according to calibration fault
DTC 0017 - OVER MOMENT - HYDRAULICS SUSPENDED
Over moment - hydraulics suspended. Notification that the system has detected too much force applied to the moment pin,
and suspended hydraulics to prevent further encroachment. While the boom is in over-moment violation, the system will prevent all jib, lift down, telescope out, drive, steer and swing functions until the over-moment violation clears. All remaining
functions are limited to super creep. The BCS indicators are on continuously. The system will flash the BCS indicators and
sound the platform alarm while the user commands a disallowed function. Use the APU to telescope in or lift up to return the
platform to the ground. See DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.
DTC 0018 - UNDER MOMENT - HYDRAULICS SUSPENDED
Under moment - hydraulics suspended. The system has detected too little force on the moment pin. If the engine is running,
the system suspends all jib, lift up, telescope in, drive, steer and swing functions until the under-moment violation clears. In
APU mode, the system suspends swing functions only, but flashes the BCS lamp and sounds the alarm during any command of the jib, lift up, telescope in or swing functions. If the platform is stuck in the air call JLG for help.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Test
Is the platform stuck in the air?
Return boom to transport
position
Does fault clear and not return repeatedly?
Perform boom sensor calibration
Did calibration complete successfully?
Perform Chassis Tilt calibra- Did calibration complete successfully?
tion
Result
Corrective Action
Yes
Call JLG for help
No
Go to step 2
Yes
Troubleshooting complete
No
Go to step 3
Yes
Go to step 4
No
Troubleshoot according to calibration fault
Yes
Troubleshooting complete
No
Troubleshoot according to calibration fault
DTC 0019 - MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED
Main envelope encroached - hydraulics suspended. Notification that the system has detected a main envelope violation and
suspended hydraulics to prevent further encroachment. Use the APU to telescope in or lift down inside the envelope. See
DTC 0016 - ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 18.
DTC 0020 - TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED
Tower envelope encroached - hydraulics suspended. This fault does not occur on a properly configured 1200/1350 SJP.
Ensure Machine Setup has proper model configured.
DTC 211 - POWER CYCLE
Power cycle. Normal message that appears in DTC stack when power is turned off then on. DTC’s before a power cycle are
active, i.e. they occured after power was turned on.
DTC 212 - KEYSWITCH FAULTY
Keyswitch faulty. Both platform [X007.2] and ground [X007.3] modes are selected simultaneously. This could be due to a
bad keyswitch [X030], wiring, or bad diodes at the power down relay [X011].
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 213 - FSW FAULTY
Footswitch faulty. The two footswitch inputs [X169.8 X007.15] have read the same state for more than one second. These
signals should always be opposite. Check the footswitch and wiring for shorts or open circuits.
DTC 227 - STEER SWITCHES FAULTY
Steer switches faulty. Notification that both left and right steer switch inputs [X168.5 X168.6] are active at the same time. This
could be due to a faulty steer switch [X176] or wiring.
DTC 2211 - FSW INTERLOCK TRIPPED
Footswitch interlock tripped. Notification that the footswitch was closed for seven seconds with no function selected.
Release the footswitch, close the footswitch again, then activate the desired function with seven seconds.
DTC 2212 - DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
Drive locked - joystick moved before footswitch. Notification that drive was selected before and during footswitch signal
[X007.15] closure. Can be reported during power-up sequence. Allow the joystick to return to neutral before activating the
footswitch. This may also indicated a problem with the footswitch wiring.
DTC 2213 - STEER LOCKED - SELECTED BEFORE FOOTSWITCH
Steer locked - selected before footswitch. Notification that one of the platform steer inputs [X168.5 X168.6] was selected
before the footswitch was closed. Steering will be prevented. Close the footswitch before steering. This could also be due to
a faulty steer switch [X176] or wiring.
DTC 2215 - D/S JOY. OUT OF RANGE LOW
Drive/Steer joystick out of range low. The drive joystick input [X168.3] is below the working voltage range.
DTC 2216 - D/S JOY. OUT OF RANGE HIGH
Drive/Steer joystick out of range high. The drive joystick input [X168.3] is above the working voltage range.
DTC 2217 - D/S JOY. CENTER TAP BAD
Drive/Steer joystick center tap bad. The drive joystick center tap input [X168.2] is not reading the correct voltage, +/- 10%
from the reference voltage middle point.
DTC 2218 - L/S JOY. OUT OF RANGE LOW
Lift/Swing joystick out of range low. The lift and/or swing joystick input [X167.3 X167.4] is below the working voltage range.
DTC 2219 - L/S JOY. OUT OF RANGE HIGH
Lift/Swing joystick out of range high. The lift and/or swing joystick input [X167.3 X167.4] is above the working voltage range.
DTC 2220 - L/S JOY. CENTER TAP BAD
Lift/Swing joystick center tap bad. The lift and/or swing joystick center tap inputs [X167.2 X167.5] are not reading the correct
voltage, +/- 10% from the reference voltage middle point.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 2221 - LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH
Lift/swing locked - joystick moved before footswitch. Notification that the platform lift and/or swing joystick was not centered
before the footswitch was closed. Lift and swing will be prevented. Close the footswitch before selecting any function or
moving the joystick. This could also be due to faulty joystick not returning to center.
DTC 2222 - WAITING FOR FSW TO BE OPEN
Waiting for footswitch to be open. Notification that the platform footswitch input [X169.8] was open when the platform mode
was selected. This indicates that the footswitch [X152] was engaged before platform power-on and may be blocked or
stuck. This can also be reported during the power-up sequence. The footswitch or its wiring may be faulty.
DTC 2223 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE
Pump switches locked - selected before footswitch. A platform boom function switch input (lower lift, telescope, platform
level, platform rotate, jib) was selected before key switch or footswitch input [X169.8] closure. The footswitch must be activated before any function. This may be caused by a problem with a switch or its wiring. Run ANALYZER  SYSTEM TEST
from the platform controls to find the specific switch.
DTC 2224 - FOOTSWITCH SELECTED BEFORE START
Footswitch selected before start. Notification that the footswitch was selected before starting the machine. Release the footswitch before starting the machine.
DTC 234 - FUNCTION SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM
Pump switches faulty - check diagnostics/boom. A ground control or platform control boom function switch (lower lift, telescope, platform level, platform rotate, jib, etc.) has both directions selected together. This may be caused by a problem with
a switch or its wiring. Run ANALYZER  SYSTEM TEST from the ground controls and platform controls to find the specific
switch.
DTC 235 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER
Pump switches locked - selected before aux power. A ground function switch input (lower lift, telescope, platform level, platform rotate, jib) was selected before the ground auxiliary power switch input [X004.16]. The auxiliary power (enable) switch
must be activated before the desired function switch. This also may be caused by a problem with a switch or its wiring. Run
ANALYZER  SYSTEM TEST from the ground controls to find the specific switch.
DTC 236 - FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH
Pump switches locked - selected before start switch. A ground control or platform control boom function switch (lower lift,
telescope, platform level, platform rotate, jib, etc.) input was selected before the start switch input [X165.14 X004.4]. The
start switch may only be activated when no function is commanded. This also may be caused by a problem with a switch or
its wiring. Run ANALYZER  SYSTEM TEST from the ground controls and platform controls to find the specific switch.
DTC 237 - START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH
Start switch locked - selected before keyswitch. The start switch input [X004.4] was selected at startup. The engine start
switch [X026] is likely stuck or the wiring is shorted.
DTC 259 - MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS
Model changed - hydraulics suspended - cycle emergency stop switch. Notification that the model number was changed
using the analyzer. The hydraulics will be suspended until the power is cycled.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 2513 - GENERATOR MOTION CUTOUT ACTIVE
Generator motion cutout active. Notification that the generator motion cutout is configured and the machine is in platform
mode with the generator active and a function was engaged. Do not engage functions while the generator is active or
change the machine configuration.
DTC 2514 - BOOM PREVENTED - DRIVE SELECTED
Boom prevented - drive selected. Notification that ANALYZER  MACHINE SETUP  FUNCTION CUTOUT is set to BOOM
CUTOUT and the machine is driving above elevation and a boom function is being attempted. Operate drive and boom separately or change the machine setup.
DTC 2515 - DRIVE PREVENTED - BOOM SELECTED
Drive prevented - boom selected. Notification that drive was selected while a boom function was selected and drive cutout is
configured to prevent simultaneous drive & boom operation.
DTC 2516 - DRIVE PREVENTED - ABOVE ELEVATION
Drive prevented - above elevation. Notification that drive was selected while above elevation and drive cutout is configured to
prevent drive.
DTC 2517 - DRIVE PREVENTED - TILTED & ABOVE ELEVATION
Drive prevented - tilted & above elevation. Notification that drive was selected while tilted and above elevation and tilt is configured to cutout drive.
DTC 2521 - JIB SWING PREVENTED - IN 1000# MODE
Jib swing prevented - in 1000 pound mode. Notification that the machine is in 1000# mode and the jib swing function was
engaged. Swinging the jib is not allowed in 1000# mode.
DTC 2522 - CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED
CAN dongle attached - hydraulics not restricted. Notification the production dongle control tool is connected.
DTC 2523 - BACKUP BLAM COMMUNICATIONS ACTIVE
Backup BLAM communications active. This fault should never occur on properly configured machines. Check model in
MACHINE SETUP.
DTC 2524 - DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL
Disconnect analyzer and cycle EMS to perform boom retrieval. This fault should never occur on properly configured
machines. Check model in MACHINE SETUP.
DTC 331 - BRAKE - SHORT TO BATTERY
Parking brake short to battery. The parking brake output [X001.23] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 113.
DTC 332 - BRAKE - OPEN CIRCUIT
Parking brake open circuit. The parking brake output [X001.23] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
1-22
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DTC 3311 - GROUND ALARM - SHORT TO BATTERY
Ground alarm short to battery. The ground alarm output [X002.27] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.
DTC 3316 - RIGHT FORWARD DRIVE PUMP - SHORT TO GROUND
Right forward drive pump short to ground. The right forward drive pump output [X087.1] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3317 - RIGHT FORWARD DRIVE PUMP - OPEN CIRCUIT
Right forward drive pump open circuit. The right forward drive pump output [X087.1] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 113.
DTC 3318 - RIGHT FORWARD DRIVE PUMP - SHORT TO BATTERY
Right forward drive pump short to battery. The right forward drive pump output [X087.1] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3320 - RIGHT REVERSE DRIVE PUMP - SHORT TO GROUND
Right reverse drive pump short to ground. The right reverse drive pump output [X087.12] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3321 - RIGHT REVERSE DRIVE PUMP - OPEN CIRCUIT
Right reverse drive pump open circuit. The right reverse drive pump output [X087.12] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.
DTC 3322 - RIGHT REVERSE DRIVE PUMP - SHORT TO BATTERY
Right reverse drive pump short to battery. The right reverse drive pump output [X087.12] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3324 - LEFT FORWARD DRIVE PUMP - SHORT TO GROUND
Left forward drive pump short to ground. The left forward drive pump output [X090.1] is shorted to ground. See DTC 33XX COMMON STG PROCEDURE on Pg. 106.
DTC 3325 - LEFT FORWARD DRIVE PUMP - OPEN CIRCUIT
Left forward drive pump open circuit. The left forward drive pump output [X090.1] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.
DTC 3326 - LEFT FORWARD DRIVE PUMP - SHORT TO BATTERY
Left forward drive pump short to battery. The left forward drive pump output [X090.1] is shorted to battery. See DTC 33xx COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 3328 - LEFT REVERSE DRIVE PUMP - SHORT TO GROUND
Left reverse drive pump short to ground. The left reverse drive pump output [X090.2] is shorted to ground. See DTC 33XX COMMON STG PROCEDURE on Pg. 106.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 3329 - LEFT REVERSE DRIVE PUMP - OPEN CIRCUIT
Left reverse drive pump open circuit. The left reverse drive pump output [X090.2] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.
DTC 3330 - LEFT REVERSE DRIVE PUMP - SHORT TO BATTERY
Left reverse drive pump short to battery. The left reverse drive pump output [X090.2] is shorted to battery. See DTC 33xx COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 3336 - ALTERNATOR/ECM POWER - SHORT TO GROUND
Alternator power short to ground. The alternator power output [X001.10] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 114.
DTC 3338 - ALTERNATOR POWER - OPEN CIRCUIT
Alternator power - open circuit. The alternator power output [X001.10] is shorted to ground. See common OC/STB .
DTC 3339 - ALTERNATOR POWER - SHORT TO BATTERY
Alternator power short to ground. The alternator power output [X001.10] is shorted to ground. See common OC/STB.
DTC 3340 - AUX POWER - SHORT TO GROUND
Auxiliary power short to ground. The auxiliary power output [X001.13] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.
DTC 3341 - AUX POWER - OPEN CIRCUIT
Auxiliary power open circuit. There is an open circuit in the auxiliary power output [X001.13]. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 113.
DTC 3342 - AUX POWER - SHORT TO BATTERY
Auxiliary power short to battery. The auxiliary power output [X001.13] is shorted to battery voltage. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3343 - COLD START ADVANCE SOLENOID - SHORT TO GROUND
Cold start advance solenoid short to ground. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.
DTC 3344 - COLD START ADVANCE SOLENOID - OPEN CIRCUIT
Cold start advance solenoid open circuit. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.
DTC 3345 - COLD START ADVANCE SOLENOID - SHORT TO BATTERY
Cold start advance solenoid short to battery. This fault should never occur on properly configured machines. Reload ground
module software or replace the ground module.
DTC 3349 - ELECTRIC PUMP - SHORT TO GROUND
Electric pump short to ground. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 3350 - ELECTRIC PUMP - OPEN CIRCUIT
Electric pump open circuit. This fault should never occur on properly configured machines. Reload ground module software
or replace the ground module.
DTC 3351 - ELECTRIC PUMP - SHORT TO BATTERY
Electric pump short to battery. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module.
DTC 3358 - MAIN DUMP VALVE - SHORT TO GROUND
Main dump short to ground. The main dump output [X002.13] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 3359 - MAIN DUMP VALVE - OPEN CIRCUIT
Main dump open circuit. The main dump output [X002.13] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on
Pg. 105.
DTC 3360 - MAIN DUMP VALVE - SHORT TO BATTERY
Main dump short to battery. The main dump output [X002.13] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 3361 - BRAKE - SHORT TO GROUND
Parking brake short to ground. The parking brake output [X001.23] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.
DTC 3362 - START SOLENOID - SHORT TO GROUND
Start solenoid short to ground. The engine start solenoid output [X001.11] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 114.
DTC 3363 - START SOLENOID - OPEN CIRCUIT
Start solenoid open circuit. The engine start solenoid output [X001.11] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3364 - START SOLENOID - SHORT TO BATTERY
Start solenoid short to battery. The engine start solenoid output [X001.11] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.
DTC 3368 - TWO SPEED VALVE - SHORT TO GROUND
Two speed short to ground. The two speed valve output [X001.20] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 114.
DTC 3369 - TWO SPEED VALVE - OPEN CIRCUIT
Two speed open circuit. The two speed valve output [X001.20] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 3370 - TWO SPEED VALVE - SHORT TO BATTERY
Two speed short to battery. The two speed valve output [X001.20] is shorted to battery. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 113.
DTC 3371 - GROUND ALARM - SHORT TO GROUND
Ground alarm short to ground. The ground alarm output [X002.27] is shorted to ground. See DTC 33XX - COMMON STG
PROCEDURE on Pg. 106.
DTC 3372 - GROUND ALARM - OPEN CIRCUIT
Ground alarm open circuit. The ground alarm output [X002.27] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 3373 - GEN SET/WELDER - SHORT TO GROUND
Generator set/welder short to ground. The output for the generator [X001.22] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 3374 - GEN SET/WELDER - OPEN CIRCUIT
Generator set/welder open circuit. The output for the generator [X001.22] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 3375 - GEN SET/WELDER - SHORT TO BATTERY
Generator set/welder short to battery. The output for the generator [X001.22] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.
DTC 3376 - HEAD TAIL LIGHT - SHORT TO GROUND
Head tail light short to ground. The head and tail light output [X002.26] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.
DTC 3377 - HEAD TAIL LIGHT - OPEN CIRCUIT
Head tail light open circuit. The head and tail light output [X002.26] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 3378 - HEAD TAIL LIGHT - SHORT TO BATTERY
Head tail light short to battery. The head and tail light output [X002.26] is shorted to battery. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.
DTC 3379 - HOUR METER - SHORT TO GROUND
Hour meter short to ground. The hourmeter output [X004.12] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 3380 - HOUR METER - OPEN CIRCUIT
Hour meter open circuit. The hourmeter output [X004.12] has an open circuit. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
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1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 3381 - HOUR METER - SHORT TO BATTERY
Hour meter short to battery. The hourmeter output [X004.12] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND
Platform up override short to ground. The ground module J2 platform level up override output [X002.5] is shorted to ground.
If there are no open wires, the fault DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND on Pg. 35 should also be
active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3386 - PLATFORM LEVEL UP OVERRIDE VALVE - OPEN CIRCUIT
Platform up override open circuit. The ground module J2 platform level up override output [X002.5] is open. If the open is in
or near the platform up solenoid [X136], the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN
CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY
Platform up override short to battery. The ground module J2 platform level up override output [X002.5] is shorted to battery.
If there are no open wires, the fault DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on
Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND
Platform down override short to ground. The ground module J2 platform level down override output [X002.7] is shorted to
ground. If there are no open wires, the fault DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND on Pg. 35
should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3392 - PLATFORM LEVEL DOWN OVERRIDE VALVE - OPEN CIRCUIT
Platform down override open circuit. The ground module J2 platform level down override output [X002.7] is open. If the open
is in or near the platform down solenoid [X137], the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY
OR OPEN CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO BATTERY
Platform down override short to battery. The ground module J2 platform level down override output [X002.7] is shorted to
battery. If there are no open wires, the fault DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN
CIRCUIT on Pg. 35 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 3394 - PLATFORM ROTATE LEFT VALVE - SHORT TO GROUND
Platform left short to ground. The platform module J7 platform rotate left output [X169.5] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3395 - PLATFORM ROTATE LEFT VALVE - OPEN CIRCUIT
Platform left open circuit. The platform module J7 platform rotate left output [X169.5] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.
DTC 3396 - PLATFORM ROTATE LEFT VALVE - SHORT TO BATTERY
Platform left short to battery. The platform module J7 platform rotate left output [X169.5] is shorted to battery. See DTC 33xx
- COMMON STB OR OC PROCEDURE on Pg. 113.
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1-27
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 3397 - PLATFORM ROTATE RIGHT VALVE - SHORT TO GROUND
Platform right short to ground. The platform module J7 platform rotate right output [X169.6] is shorted to ground. See DTC
33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 3398 - PLATFORM ROTATE RIGHT VALVE - OPEN CIRCUIT
Platform right open circuit. The platform module J7 platform rotate right output [X169.6] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 113.
DTC 3399 - PLATFORM ROTATE RIGHT VALVE - SHORT TO BATTERY
Platform right short to battery. The platform module J7 platform rotate right output [X169.6] is shorted to battery. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 33100 - JIB LIFT UP VALVE - SHORT TO GROUND
Jib up short to ground. The jib up output [X169.25] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on
Pg. 106.
DTC 33101 - JIB LIFT UP VALVE - OPEN CIRCUIT
Jib up open circuit. The jib up output [X169.25] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33102 - JIB LIFT UP VALVE - SHORT TO BATTERY
Jib up short to battery. The jib up output [X169.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33103 - JIB LIFT DOWN VALVE - SHORT TO GROUND
Jib down short to ground. The jib down output [X169.26] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33104 - JIB LIFT DOWN VALVE - OPEN CIRCUIT
Jib down open circuit. The jib down output [X169.26] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
105.
DTC 33105 - JIB LIFT DOWN VALVE - SHORT TO BATTERY
Jib down short to battery. The jib down output [X169.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33118 - SWING RIGHT VALVE - SHORT TO GROUND
Swing right valve short to ground. The swing right valve output [X002.35] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.
DTC 33119 - SWING RIGHT VALVE - OPEN CIRCUIT
Swing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
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1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 33120 - MAIN TELESCOPE IN VALVE - SHORT TO BATTERY
Main telescope in short to battery. The main telescope in output [X002.4] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.
DTC 33121 - SWING RIGHT VALVE - SHORT TO BATTERY
Swing right valve open circuit. The swing right output [X002.35] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33122 - SWING LEFT VALVE - SHORT TO GROUND
Swing right valve short to ground. The swing right valve output [X002.34] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.
DTC 33123 - MAIN TELESCOPE OUT VALVE - SHORT TO BATTERY
Main telescope out short to battery. The main telescope out output [X002.16] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33130 - THROTTLE ACTUATOR - SHORT TO GROUND
Throttle actuator short to ground. This fault should only occur on machines configured with non-ECM engines. The engine
throttle actuator output [X001.1] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 33131 - THROTTLE ACTUATOR - OPEN CIRCUIT
Throttle actuator open circuit. This fault should only occur on machines configured with non-ECM engines. The engine throttle actuator output [X001.1] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 33132 - THROTTLE ACTUATOR - SHORT TO BATTERY
Throttle actuator short to battery. This fault should only occur on machines configured with non-ECM engines. The engine
throttle actuator output [X001.1] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 33133 - PLATFORM CONTROL VALVE - SHORT TO GROUND
Platform control valve short to ground. The platform dump valve output [X002.3] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 33134 - PLATFORM CONTROL VALVE - OPEN CIRCUIT
Platform control valve open circuit. The platform dump valve output [X002.3] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 113.
DTC 33135 - PLATFORM CONTROL VALVE - SHORT TO BATTERY
Platform control valve short to battery. The platform dump valve output [X002.3] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 33150 - LIFT PILOT VALVE - SHORT TO GROUND
Lift Pilot Valve Short to Ground. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
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1200SJP 1350SJP
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 33151 - LIFT PILOT VALVE - OPEN CIRCUIT
Lift Pilot Valve Open Circuit. The lift down auxiliary select valve output, ground module J2 -10 [X002.10], is open. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33152 - LIFT PILOT VALVE - SHORT TO BATTERY
Lift Pilot Valve Short to Battery. The lift down auxiliary select valve output, ground module J2-10 [X002.10], is shorted to battery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33153 - LIFT DOWN AUX VALVE - SHORT TO GROUND
Lift Down Auxiliary Valve Short to Ground. The lift down auxiliary valve output, ground module J2 - 12 [X002.12] is shorted to
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33154 - LIFT DOWN AUX VALVE - OPEN CIRCUIT
Lift Down Auxiliary Valve Open Circuit. The lift down output, ground module J2 - 12 [X002.12], is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33155 - LIFT DOWN AUX VALVE - SHORT TO BATTERY
Lift Down Auxiliary Valve Short to Battery. The lift down auxiliary valve output, ground module J2 - 12 [X002.12], is shorted to
battery + side. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR
OPEN CIRCUIT
Restricted to transport - Axle lockout valve short to battery or open circuit. The control system detected a short to battery or
an open circuit on the PWM output for the Axle Lockout valve.
Note Pretest Instructions
Step 1
Step 2
Test
Result
Is the resistance of the axle lockout valve sole- Yes
noid [X212] about 6.2
No
Disconnect the axle lockout
valve solenoid DIN connector [X212]
Corrective Action
Go to step 2
Replace the axle lockout valve solenoid
Does the voltage between the positive battery Yes
terminal [X116] and terminal 2 of the Axle
No
Lockout valve solenoid DIN connector
[X212.2.soc] measure 12VDC?
Go to step 3
Step 3
Does the voltage between the positive battery Yes
terminal [X116] and terminal 2 of the chassis
module J4 connector [X232.2.pin] measure
12VDC?
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 module J4 connector [X232.2.soc]
Step 4
Does the voltage between the positive battery Yes
terminal [X116] and terminal 4 of the chassis No
module J1 connector [X229.4] measure
12VDC?
Go to step 5
Does the voltage between the positive battery Yes
terminal [X116] and terminal 5 of the chassis
(bottom) swivel connector [X216.5] measure
12VDC?
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
Step 5
No
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1200SJP 1350SJP
Go to step 10
Go to step 4
Replace the chassis module
Go to step 6
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Result
Does the voltage between the positive battery Yes
terminal [X116] and terminal 5 of the Turntable No
(top) Swivel connector [X083.5] measure
12VDC?
Does the voltage between the positive battery Yes
terminal [X116] and any terminal of the 12
No
position MTB ground buss connector [X009]
measure 12VDC?
Does the voltage between the positive battery Yes
terminal [X116] and terminal 3 of the ground
module J8 connector [X008.3] measure
12VDC?
No
Does the voltage between the positive battery Yes
terminal [X116] and terminal 1 of the ground No
module J8 connector [X008.1] measure
12VDC?
Step 10 Disconnect the axle lockout
valve solenoid DIN connector [X212]
Does the voltage on terminal 1 of the axle lock- Yes
out valve solenoid DIN connector
No
[X212.1.soc] measure 12VDC?
Step 11 Remove terminal 8 of the
chassis (bottom) swivel
connector [X216.8]
Does the voltage on terminal 1 of the axle lock- Yes
out valve solenoid DIN connector
[X212.1.soc] measure 12VDC?
Corrective Action
Replace the Collector Ring and swivel harness
Go to step 7
Replace the valve harness
Go to step 8
Repair/Replace the Black wire between terminal
3 of the ground module J8 connector [X008.3]
and the MTB ground buss connector [X009]
Go to step 9
Replace the ground module
Repair/Replace the Black wire from the battery
Go to step 11
Go to step 15
Repair/replace the ORANGE 60-2 wire between
terminal 1 of the axle lockout valve solenoid connector [212.1] and terminal 8 of the chassis (bottom) swivel connector [X216.8]
No
Go to step 12
Step 12 Remove terminal 8 of the
turntable (top) swivel connector [X083.8]
Does the voltage on terminal 1 of the axle lock- Yes
out valve solenoid DIN connector
No
[X212.1.soc] measure 12VDC?
Go to step 13
Step 13 Remove terminal 4 of the 6
position BLAM-Valve harness passthru connector
[X280.4]
Does the voltage on terminal 1 of the axle lock- Yes
out valve solenoid DIN connector
[X212.1.soc] measure 12VDC?
No
Step 14 Remove terminal 3 of the
Does the voltage on terminal 1 of the axle lock- Yes
BLAM module J5 connector out valve solenoid DIN connector
[X090.3]
[X212.1.soc] measure 12VDC?
No
Step 15 Remove terminal 8 of the
chassis (bottom) swivel
connector [X216.8] and disconnect the axle lockout
valve solenoid DIN connector [X212]
Is there continuity between terminal 8 of the
Yes
chassis (bottom) swivel connector
No
[X216.8.pin] and terminal 1 of the axle lockout
valve solenoid DIN connector [X212.1.soc]?
Step 16 Remove terminal 8 of the
Turntable (top) swivel connector [X083.8] and disconnect 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 solenoid DIN connector [X212.1.soc]?
3128411
1200SJP 1350SJP
Replace the collector ring and swivel harness
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]
Go to step 14
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 BLAMValve harness passthru connector [X280.4]
Replace the BLAM module
Go to step 16
Repair/replace the ORANGE 60-2 wire between
terminal 1 of the axle lockout valve solenoid connector [212.1] and terminal 8 of the chassis (bottom) swivel connector [X216.8]
Yes
Go to step 17
No
Replace the Collector Ring and swivel harness
1-31
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 17 Remove terminal 4 of the 6
position BLAM-Valve harness passthru connector
[X280.4] and disconnect the
axle lockout valve solenoid
DIN connector [X212]
Is there continuity between terminal 4 of the 6 Yes
position BLAM-Valve harness passthru con- No
nector [X280.4] and disconnect the axle lockout valve solenoid DIN connector [X212] and
terminal 1 of the axle lockout valve solenoid
DIN connector [X212.1.soc]?
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
Yes
BLAM module J5 connector [X090.3] and ter- No
minal 1 of the axle lockout valve solenoid DIN
connector [X212.1.soc]?
Corrective Action
Go to step 18
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]
Replace the BLAM module
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 BLAMValve harness passthru connector [X280.4]
DTC 33174 - RESTRICTED TO TRANSPORT - BRAKE - SHORT TO BATTERY OR OPEN CIRCUIT
Restricted to transport - parking brake short to battery. The parking brake output [X001.23] is shorted to battery so the boom
cannot go above the transport position. See DTC 331 - BRAKE - SHORT TO BATTERY on Pg. 22.
DTC 33175 - JIB ROTATE LEFT VALVE - OPEN CIRCUIT
Jib left open circuit. The jib swing left output [X169.28] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
105.
DTC 33176 - JIB ROTATE LEFT VALVE - SHORT TO BATTERY
Jib left short to battery. The jib swing left output [X169.28] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33177 - JIB ROTATE LEFT VALVE - SHORT TO GROUND
Jib left short to ground. The jib swing left output [X169.28] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33178 - JIB ROTATE RIGHT VALVE - OPEN CIRCUIT
Jib right open circuit. The jib swing right output [X169.27] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on
Pg. 105.
DTC 33179 - JIB ROTATE RIGHT VALVE - SHORT TO BATTERY
Jib right short to battery. The jib swing right output [X169.27] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 33180 - JIB ROTATE RIGHT VALVE - SHORT TO GROUND
Jib right short to ground. The jib swing right output [X169.27] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33181 - MAIN LIFT UP VALVE - OPEN CIRCUIT
Main cylinder lift up open circuit. The main boom cylinder lift up output [X002-11] is open. See DTC 33xx - COMMON STB
OR OC PROCEDURE on Pg. 105.
1-32
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 33183 - MAIN LIFT UP VALVE - SHORT TO GROUND
Main cylinder lift up valve - short to ground. The main boom cylinder lift up output [X002-11] is shorted to battery (-) terminal/
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33184 - MAIN LIFT DOWN VALVE - OPEN CIRCUIT
Main cylinder lift down open circuit. The main boom cylinder lift down output [X002.22] is open. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.
DTC 33185 - MAIN LIFT DOWN VALVE - SHORT TO GROUND
Main cylinder lift down short to ground. The main boom cylinder lift down output [X002.22] is shorted to battery (-) terminal/
ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33186 - MAIN TELESCOPE OUT VALVE - OPEN CIRCUIT
Main telescope out open circuit. The main telescope out output [X002.16] is open. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 33188 - MAIN TELESCOPE OUT VALVE - SHORT TO GROUND
Main telescope out short to ground. The main telescope out output [X002.16] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33189 - MAIN TELESCOPE IN VALVE - OPEN CIRCUIT
Main telescope in open circuit. The main telescope in output [X002.4] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.f
DTC 33190 - MAIN TELESCOPE IN VALVE - SHORT TO GROUND
Main telescope in short to ground. The main telescope in output [X002.4] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.
DTC 33207 - HORN - OPEN CIRCUIT
Horn open circuit. The ground module horn output [X002.2] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE
on Pg. 105.
DTC 33208 - HORN - SHORT TO BATTERY
Horn short to battery. The ground module horn output [X002.2] is shorted to battery. See DTC 33xx - COMMON STB OR OC
PROCEDURE on Pg. 105.
DTC 33209 - HORN - SHORT TO GROUND
Horn short to ground. The ground module horn output [X002.2] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33279 - GLOWPLUG - OPEN CIRCUIT
Glow plug open circuit. The glow plug / intake heater output [X001.12] is open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
3128411
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1-33
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 33280 - GLOWPLUG - SHORT TO BATTERY
Glow plug short to battery. The glow plug / intake heater output [X001.12] is shorted to battery. See DTC 33xx - COMMON
STB OR OC PROCEDURE on Pg. 105.
DTC 33281 - GLOWPLUG - SHORT TO GROUND
Glow plug short to ground. The glow plug / intake heater output [X001.12] is shorted to ground. See DTC 33XX - COMMON
STG PROCEDURE on Pg. 106.
DTC 33295 - SWING LEFT VALVE - OPEN CIRCUIT
Swing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.
DTC 33306 - SWING LEFT VALVE - SHORT TO BATTERY
Swing left valve open circuit. The swing left valve output [X002.35] is shorted to ground. See DTC 33xx - COMMON STB OR
OC PROCEDURE on Pg. 105.
DTC 33307 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO GROUND
Main cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control flow control output
[X002.9] is open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33308 - MAIN TELESCOPE FLOW CONTROL VALVE - OPEN CIRCUIT
Main cylinder telescope flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33309 - MAIN TELESCOPE FLOW CONTROL VALVE - SHORT TO BATTERY
Main cylinder lift down flow control valve short to ground. The main boom telescope cylinder flow control output [X002.9] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33310 - MAIN LIFT DOWN VALVE - SHORT TO BATTERY
Main cylinder lift down short to battery. The main boom cylinder lift down output [X002.22] is shorted to battery (+) terminal.
See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33311 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO GROUND
Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 106.
DTC 33312 - MAIN LIFT FLOW CONTROL VALVE - OPEN CIRCUIT
Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 33313 - MAIN LIFT FLOW CONTROL VALVE - SHORT TO BATTERY
Main cylinder lift down flow control valve short to ground. The main boom cylinder lift down flow control output [X002.19] is
open. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
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SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 33329 - MAIN LIFT UP VALVE - SHORT TO BATTERY
Main cylinder lift up short to battery. The main boom cylinder lift up output [X002-11] is shorted to battery (+) terminal. See
DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 343 - PLATFORM LEVEL UP VALVE - SHORT TO GROUND
Platform up short to ground. The platform module J7 platform level up output [X169.15] is shorted to ground. If there are no
open wires, the fault DTC 3385 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO GROUND on Pg. 27 should also be
active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 344 - PLATFORM LEVEL UP VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Platform up short to battery or open circuit. The platform module J7 platform level up output [X169.15] is shorted to battery
or open. If there are no open wires, the fault DTC 3387 - PLATFORM LEVEL UP OVERRIDE VALVE - SHORT TO BATTERY on
Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 347 - PLATFORM LEVEL DOWN VALVE - SHORT TO GROUND
Platform down short to ground. The platform module J7 platform level down output [X169.16] is shorted to ground. If there
are no open wires, the fault DTC 3391 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO GROUND on Pg. 27
should also be active. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 348 - PLATFORM LEVEL DOWN VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Platform down short to battery or open circuit. The platform module J7 platform level down output [X169.16] is shorted to
battery or open. If there are no open wires, the fault DTC 3393 - PLATFORM LEVEL DOWN OVERRIDE VALVE - SHORT TO
BATTERY on Pg. 27 should also be active. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 431 - FUEL SENSOR SHORT TO BATTERY
Fuel sensor short to battery. Indicates that the fuel sensor signal [X002.25] may be shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 105.
DTC 432 - FUEL SENSOR SHORT TO GROUND
Fuel sensor short to ground. Indicates that the fuel sensor signal [X002.25] may be shorted to ground. See DTC 33XX COMMON STG PROCEDURE on Pg. 106.
DTC 433 - OIL PRESSURE SHORT TO BATTERY
Oil pressure short to battery. This fault should only occur on machines configured with non-ECM engines. The engine oil
pressure input [X001.15] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 434 - OIL PRESSURE SHORT TO GROUND
Oil pressure short to ground. This fault should only occur on machines configured with non-ECM engines. The engine oil
pressure input [X001.15] is shorted to ground. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 435 - COOLANT TEMPERATURE SHORT TO GROUND
Coolant temperature short to ground. This fault is only active for machines configured with older non-ECM Deutz engines.
The engine coolant temperature input [X001.14] is shorted to ground.
3128411
1200SJP 1350SJP
1-35
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 437 - ENGINE TROUBLE CODE
Engine trouble code. This fault text is followed by the engine’s specific fault code. This code could represent engine faults
like low oil pressure warning, high coolant temperature warning, etc. See Table 1-1. Common Deutz Engine Fault Codes on
Pg. 36 or consult the engine control module manual to interpret the engine specific fault code.
Table 1-1. Common Deutz Engine Fault Codes
Fault Code using
JLG Analyzer
Fault Code using
Deutz SERDIA
190:8
1
100:2
1-36
Fault Description
Troubleshooting
Engine
Troubleshooting
Machine
Cause
Results
Speed sensor
Engine speed sensor failure OR Gap
from sensor tip to
ring gear too large
OR Additional
incorrect impulses
received OR Wiring
to sensor interrupted.
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.
8
Oil Pressure
110:2
9
Coolant temperature
Fault at corresponding sensor
OR wiring connection has a short circuit or open circuit.
The engine will continue operating with
the failure of either
Oil Pressure or
Coolant Temperature sensors. However with a failure of
the sensor, the
associated monitoring function is
de-activated
Check relevant sensor replace if
required. Check relevant wiring and
connections
between sensor
and ECU.
100:1
30
Oil Pressure warning
Engine Oil Pressure Fault message
has fallen below
occurs. Engine may
acceptable value.
also shutdown
depending on JLG
Machine programming
Check engine oil
level. Check oil
pressure sensor
and wiring. Check
engine for other
possible mechanical 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 Programming the engine will
either Shutdown OR
only give a warning
110:0
31
Coolant Temperature warning
Engine Oil Temper- Fault message
ature has exceeded occurs. Engine may
acceptable value.
also shutdown
depending on JLG
Machine programming. Fault will disappear when Oil
Temperature drops
below preset recovery temperature.
Check engine oil
level. Check Oil
temperature sensor and wiring.
Check cooling system for leaks or
contamination, etc.
Depending on
Machine Programming the engine will
either Shutdown OR
only give a warning
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Table 1-1. Common Deutz Engine Fault Codes
Fault Code using
JLG Analyzer
Fault Code using
Deutz SERDIA
702:14
35
Overspeed warning Engine RPM was or
(with thrust mode is above maximum
operation).
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 recovery speed (2810
RPM).
100:1
40
Oil pressure switch Oil pressure below
off
switch-off limit.
Normally this would See Oil Pressure
cause an EmerWarning info
gency stop of the
engine. But EMR is
not programmed to
directly shutdown
the engine in JLG
machines. Only if
the JLG machine is
programmed to
shutdown will this
occur
110:0
41
Coolant temperature switch-off
Oil temperature has Normally this would See Coolant Temexceeded switch off cause an Emerperature Warning
limit
gency stop of the
info
engine. But EMR is
not programmed to
directly shutdown
the engine in JLG
machines. Only if
the JLG machine is
programmed to
shutdown will this
occur
91:11
67
Error Hand Setp1
898:2
68
Loss of CAN bus
input.
743:12
70
743:9
71
CAN interface SAE J Overflow in input
1939
buffer or a transmission cannot be
placed on the bus.
743:14
74
CAN Passive error
3128411
Fault Description
Cause
Results
Troubleshooting
Engine
Troubleshooting
Machine
If condition persists: Check fuel
rack. Check actuator and replace if
required. Check
wiring to actuator.
Check engine
speed sensor, ring
gear teeth, etc.
Check for external
environmental conditions that could
cause engine overspeed condition
Engine will only run Check CAN conat constant speed nection and wiring
Error CAN Setp1
of 1835 RPM
connection entering
engine ECU from
CAN-Bus controller Controller for CAN- Engine will shutbus is faulty. Fault
down or not restart machine. Check
removal despite
OR Engine will only ECU for proper CAN
bus data flow and
reinitializing contin- run at constant
uously not possispeed of 1835 RPM correct programming.
ble.
Open or Short circuit in wiring
Engine will shutdown or not restart
OR engine will only
run at constant
speed of 1835 RPM
1200SJP 1350SJP
Check relevant wiring and connections between
machine and ECU
for open or short
circuit. Check Terminating resistor in
machine wiring
Check CAN connection and wiring
connection entering
engine ECU from
machine.
1-37
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 438 - HIGH ENGINE TEMP
High engine temperature. This fault should only occur on machines configured with non-ECM engines. The engine temperature is above 130°C.
DTC 439 - AIR FILTER BYPASSED
Air filter bypassed. This fault should never occur on properly configured machines. Reload ground module software or
replace the ground module.
DTC 4310 - NO ALTERNATOR OUTPUT
No alternator output. Notification that the engine has been running for 15 seconds or more and the battery voltage is still
below 11.5 volts. This probably indicates a problem with the alternator or its wiring.
DTC 4311 - LOW OIL PRESSURE
Low oil pressure. This fault should only occur on machines configured with non-ECM engines. Notification that the oil pressure input [X001.15] is below 8 PSI and the engine has been running for at least 10 seconds.
DTC 4313 - THROTTLE ACTUATOR FAILURE
Throttle actuator failure. This fault should only occur on machines configured with non-ECM engines. The engine is overspeeding, reading over 3050 RPM. This probably indicates the throttle actuator has failed.
DTC 4314 - WRONG ENGINE SELECTED - ECM DETECTED
Wrong engine selected - ECM present. The machine is configured to be a non-ECM engine, but an ECM signal is detected
on the CAN bus. Change the machine engine configuration.
DTC 4322 - LOSS OF ENGINE SPEED SENSOR
Speed input lost. This fault should only occur on machines configured with non-ECM engines. Notification that there is no
engine speed detected on the engine flywheel speed sensor input [X001.16], but the oil pressure input [X001.15] reads
above 8 PSI for more than 3 seconds.
DTC 4323 - SPEED SENSOR READING INVALID SPEED
Speed sensor reading invalid speed. This fault should only occur on machines configured with non-ECM engines. Notification that the engine flywheel speed sensor input [X001.16] is indicating a speed that greater than 4000 RPM or approximately 8875 Hz.
DTC 441 - BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
Battery too low - system shut down. A warning that the voltage at ground module J8 [X008.2] is below 9 volts. The system
will shut down after about 5 seconds. Remove any corrosion on battery terminals and battery cable terminals. Recharge or
replace battery.
DTC 442 - BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
Battery too high - system shut down. The voltage at ground module J8 [X008.2] is above 18.6 volts. The system will shut
down. Check battery and battery connections or replace battery.
DTC 445 - BATTERY VOLTAGE LOW
Battery voltage is too low. A warning that the voltage at ground module J8 [X008.2] is below 11 volts. Remove any corrosion
on battery terminals and battery cable terminals. Recharge or replace battery. Check battery charging system.
1-38
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 662 - CANBUS FAILURE - PLATFORM MODULE
Platform CAN communications lost. The system cannot communicate with the platform module. This may be due to wiring
problems between platform and ground modules.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Check fault log for other
modules having lost communication
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
Disconnect the platform
module J8 connector
[X170]. Turn machine on in
platform mode
Is there zero VDC between platform module J8 Yes
connector socket 1 [X170.1.soc] and socket No
2 [X170.2.soc]?
Keep machine on. Go to step 5
Step 3
Step 4
Step 5
Step 6
Step 7
Remove any corrosion on
Does battery still exhibit low power?
battery terminals and battery
cable terminals. Run
machine to recharge battery.
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 position platform control box passthru connector
terminal 12 [X160.12] and terminal 16
[X160.16]?
Take the following measure- Turn machine on in platform mode. Is there
ment by backprobing
11VDC or more between MTB pass thru - 19
position connector pin 12 [X043.12.pin] and
pin 16 [X043.16.pin]?
Yes
Replace battery
No
Retry normal vehicle operation
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
Yes
Repair/replace harness between the MTB pass
thru - 19 position connector [X043] and the platform control box passthru - 19 position connector [X160]
No
Go to step 7
Take the following measure- Turn machine on in platform mode. Is there
Yes
ment by backprobing
11VDC or more between ground module J8
connector pin 3 [ X008.3] and pin 4 [X008.4]?
No
Step 8
Disconnect the ground
module J8 connector
[X008]. Turn machine on in
platform mode
Go to step 4
Is there 11VDC or more between ground mod- Yes
ule J8 connector pin 3 [X008.3] and pin 4
[X008.4]?
No
Repair/replace harness between the ground
module J8 connector [X008] and the MTB pass
thru - 19 position connector [X043]
Go to step 8
Repair/replace harness between the ground
module J8 connector [X008] and the MTB pass
thru - 19 position connector [X043]
Replace the ground module
DTC 666 - CANBUS FAILURE - ENGINE CONTROLLER
Engine controller CAN communications lost. The ground module is not receiving CAN messages from the engine controller.
Note Pretest Instructions
Test
Result
Step 1
Is the 6613 - CANBUS FAILURE - EXCESSIVE Yes
CANBUS ERRORS fault active in the fault log?
Step 2
Does the BLAM software version show "??" in Yes
ANALYZER  DIAGNOSTICS  VERSIONS
 B.L.A. MODULE SOFTWARE:?
No
No
3128411
1200SJP 1350SJP
Corrective Action
Troubleshoot DTC 6613 - CANBUS FAILURE EXCESSIVE CANBUS ERRORS on Pg. 55 first
Go to step 2
See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
48
Go to step 3
1-39
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
Step 5
Step 6
Step 7
Test
Result
Disconnect the EMR2 ECU
equipment connector
[X240]. Turn on the
machine.
Does the voltage between EMR2 ECU equip- Yes
ment connector socket 14 [X240.14.soc] and No
socket 1 [X240.1.soc] measure 12VDC?
Backprobe between any terminal of the MTB power bus
connector [X010] and the
ground module J1 connector 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?
Corrective Action
Go to step 5
Go to step 4
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 persists, replace the ground module
Backprobe EMR2 ECU
Does the CAN resistance between EMR2 ECU Yes
equipment connector termi- equipment connector terminal 12 [X240.12] No
nal 12 [X240.12] and termi- and terminal 13 [X240.13] measure 60?
nal 13 [X240.13]
Disconnect the EMR2 ECU
equipment connector
[X240] and the BLAM module J4 connector [X089].
See 6.3 Continuity Measurement Over Long Distances
on Pg. 247.
Is there CAN HI continuity between socket 12 Yes
of the EMR2 ECU equipment connector
No
[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]?
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 Yes
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] No
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]?
Go to step 6
See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
48
Call Deutz dealer
Go to step 7
Replace the valve harness between the BLAM
module J4 connector [X089] and the CAN pass
thru for EMR2 - 3 position connector [X268]
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]
DTC 6610 - CANBUS FAILURE - BLAM
BLAM CAN communications lost. The system cannot communicate with the Boom Length Angle Module (BLAM). This may
be due to wiring problems between the platform and chassis modules. If power is lost to the BLAM, then power will not be
provided to the cylinder load pin and the 6612 - CANBUS FAILURE - CYLINDER LOAD PIN fault will also be active.
Note Pretest Instructions
Step 1
Step 2
Step 3
1-40
Test
Result
Corrective Action
Check the fault log for other
modules having lost communication (6-6 codes)
Is CYLINDER LOAD PIN CAN COMMUNICATIONS LOST fault active?
Yes
Go to step 2
No
Go to 5
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
Yes
Repair wire(s) between Valve Passthru [X280]
and BLAM J1 [X086]
No
Go to step 4
Disconnect Valve Passthru
[X280]
Does the voltage between Valve Passthru
socket 1 [X280.1.soc] and socket 6
[X280.6.soc] measure 12 VDC?
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 4
Step 5
Step 6
Step 7
Step 8
3128411
Test
Disconnect MTB Power Bus Does the voltage between one of the sockets
[X010]
of the MTB Power Bus[X010] and Ground
Module J8 terminal 3 [X008.3] measure 12
VDC?
Disconnect BLAM J1
[X086] connector
Result
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].
Does the resistance between BLAM J1 socket Yes
6 [X086.6.soc] and socket 7 [X086.7.soc]
measure 60? -AND- Is there an open circuit No
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]?
Disconnect BLAM J1
[X086] connector and
Ground Module J7 [X007]
Is there continuity only between the following Yes
points?
• BLAM J1 socket 6 [X086.6.soc] and No
Ground Module J7 socket 13
[X007.13.soc]
• BLAM J1 socket 7 [X086.7.soc] and
Ground Module J7 socket 24
[X007.24.soc]
• BLAM J1 socket 8 [X086.8.soc] and
Ground Module J7 socket 18
[X007.18.soc]
Disconnect CAN 3-Way to
BLAM [X269] and Ground
Module J7 [X008]
Is there continuity only between the following Yes
points?
• CAN 3-Way to BLAM pin A [X269.A.pin] No
and Ground Module J7 socket 13
[X007.13.soc]
• CAN 3-Way to BLAM pin B [X269.B.pin]
and Ground Module J7 socket 24
[X007.24.soc]
• CAN 3-Way to BLAM pin C [X269.C.pin]
and Ground Module J7 socket 18
[X007.18.soc]
Disconnect CAN 3-Way to
BLAM [X269] and CAN
Passthru for EMR2 [X268]
Is there continuity only between the following Yes
points?
No
• CAN 3-Way socket A [X269.A.soc] and
C A N Pa s s t h r u f o r E M R 2 s o c k e t A
[X268.A.soc]
• CAN 3-Way socket B [X269.B.soc] and
C A N Pa s s t h r u f o r E M R 2 s o c k e t B
[X268.B.soc]
• CAN 3-Way socket C [X269.C.soc] and
C A N Pa s s t h r u f o r E M R 2 s o c k e t C
[X268.C.soc]
1200SJP 1350SJP
Corrective Action
Keep BLAM J1 [X086] connector disconnected.
Go to step Figure 6
Go to step 11
Ensure BLAM and Ground Module are running
proper version. Replace BLAM
Keep Ground Module J7 [X007] disconnected.
Go to step 7
Keep CAN 3-Way to BLAM [X269] disconnected.
Go to step 8
Keep BLAM J1 [X086] disconnected.
Go to step 10
Go to step 9
Repair wire(s) between CAN 3-Way to BLAM
[X269] and CAN Passthru for EMR2 [X278]
1-41
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 9
Test
Result
Disconnect CAN Passthru to Is there continuity only between the following Yes
BLAM [X278] and BLAM J1 points?
[X086]
• BLAM J1 socket 6 [X086.6.soc] and CAN No
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]
Corrective Action
Replace CAN 3-way connected to CAN Passthru
to BLAM [X278]
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 Yes
points?
• CAN 3-Way to Ground Module pin A No
[X014.A.pin] and Ground Module J7
socket 13 [X007.13.soc]
• CAN 3-Way to Ground Module pin B
[X014.B.pin] and Ground Module J7
socket 24 [X007.24.soc]
• CAN 3-Way to Ground Module pin C
[X014.C.pin] and Ground Module J7
socket 18 [X007.18.soc]
Replace CAN 3-way connected to CAN 3way - to
Ground Module [X014]
Step 11 Disconnect CAN Passthru
for EMR2 [X268]
Does the resistance between CAN Passthru
Yes
for EMR2 socket A [X268.A.soc] and socket B No
[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]?
Go to step 14
Step 12 Disconnect CAN 3way - to
Platform [X270]
Does the resistance between CAN 3way - to
Yes
Platform socket A [X270.A.soc] and socket B No
[X270.B.soc] measure 120? -AND- Is there
an open circuit between CAN 3way - to Platform socket A [X270.A.soc] and shield socket
C [X270.C.soc]. -AND- Is there an open circuit
between CAN 3way - to Platform socket B
[X270.B.soc] and shield socket C
[X270.C.soc]?
Step 13
Is the software in the BLAM and Ground Mod- Yes
ule the proper version?
No
Step 14 Disconnect CAN Passthru to Does the resistance between CAN Passthru to Yes
Engine Harness [X279]
Engine Harness socket A [X279.A.soc] and
socket B [X279.B.soc] measure 120? AND- Is there an open circuit between CAN
No
Passthru to Engine Harness socket A
[X279.A.soc] and shield socket C
[X279.C.soc]. -AND- Is there an open circuit
between CAN Passthru to Engine Harness
socket B [X279.B.soc] and shield socket C
[X279.C.soc]?
1-42
1200SJP 1350SJP
Repair failed wire(s) between CAN 3way - to
Ground Module [X014]and Ground Module J7
[X008]
Go to step 12
Go to step 13
Go to step 20
Replace BLAM
Load proper software
Repair wire(s) between CAN Passthru to Engine
Harness [X279] CAN T-connector and BLAM J1
[X086]
Go to step 15
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 15 Disconnect Swivel Top con- Does the resistance between Swivel Top con- Yes
nector [X083]
nector pin 1 [X083.1.pin] and pin 2
No
[X083.2.pin] measure 120? -AND- Is there
an open circuit between Swivel Top connector
pin 1 [X083.1.pin] and pin 3 [X083.3.pin]? AND- Is there an open circuit between Swivel
Top connector pin 2 [X083.2.pin] and pin 3
[X083.3.pin]?
Step 16 Disconnect Swivel Chassis
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 connector 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]?
Go to step Figure 16
Repair failed wire(s) and/or slip rings between
Swivel Top connector [X083] and Swivel Chassis
connector [X216]
No
Keep Swivel Chassis connector [X216] disconnected.
Go to step 17.
Step 18 Disconnect Deutz EMR2
Chassis CAN connector
[X084]
Does the resistance between Deutz EMR2
Yes
Chassis CAN connector [X084] pin A
No
[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]? -ANDIs there an open circuit between Deutz EMR2
Chassis CAN connector pin B [X084.B.pin]
and pin C [X084.C.pin]?
Step 19 Disconnect EMR2 ECU
Equipment Connector
[X240] and CAN Passthru to
Engine Harness [X279].
Does the resistance between EMR2 ECU
Yes
Equipment Connector socket 12
[X240.12.soc] and socket 13 [X240.13.pin]
measure 120? -AND- Is there an open cir- No
cuit between the shield and both EMR2 ECU
Equipment Connector socket 12
[X240.12.soc] and socket 13 [X240.13.pin]?
1200SJP 1350SJP
Go to step 18
Yes
Step 17 Disconnect Chassis Module Is there continuity only between the following Yes
J1 [X229] and Swivel Chas- points?
No
sis connector [X216]
• 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]
a nd Ch ass is Module J 1 soc ke t 10
[X229.10.soc]
3128411
Corrective Action
Replace Chassis Module
Repair failed wire(s) between Chassis Module J1
[X229] and Swivel Chassis connector [X216]
Go to step 19
Repair failed wire(s) between Swivel Top connector [X083] and Deutz EMR2 Chassis CAN
connector [X084]
Repair failed wire(s) between EMR2 ECU Equipment Connector [X240] and CAN Passthru to
Engine Harness [X279]
Repair failed wire(s) between EMR2 ECU Equipment Connector [X240] and Deutz EMR2 Chassis
CAN connector [X084]
1-43
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 20 Disconnect Platform Control Does the resistance between Platform Control Yes
Box Passthru [X160]
Box Passthru connector pin 2 [X160.2.pin]
No
and pin 3 [X083.3.pin] measure 120? AND- Is there an open circuit between Platform Control Box Passthru connector pin 1
[X160.1.pin] and pin 2 [X160.2.pin]? -ANDIs there an open circuit between Platform Control Box Passthru connector pin 1
[X160.1.pin] and pin 3 [X160.3.pin]?
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 connector 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]?
Corrective Action
Go to step 21
Keep Platform Control Box Passthru [X160] disconnected.
Go to step 22
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 Is there continuity only between the following Yes
Box Passthru [X160] and
points?
No
Platform Module J7 [X169] • Platform Control Box Passthru pin 1
[X160.1.pin] and Platform Module J7
socket 32 [X169.32.soc]
• Platform Control Box Passthru pin 2
[X160.2.pin] and Platform Module J7
socket 30 [X169.30.soc]
• Platform Control Box Passthru pin 3
[X160.3.pin] and Platform Module J7
socket 31 [X169.31.soc]
Replace Platform Module
Repair failed wire(s) between Platform Control
Box Passthru [X160] and Platform Module J7
[X169]
DTC 6611 - CANBUS FAILURE - CHASSIS MODULE
Chassis CAN communications lost. The system cannot communicate with the chassis module. This may be due to wiring
problems between the chassis and ground module.
Note Pretest Instructions
Step 1
Check fault log for other
modules having lost communication
Step 2
Test
Have most modules lost communications?
Is Chassis Power fuse [X267] blown?
(Located by Aux Power Pump.)
Result
Corrective Action
Yes
See DTC 6613 - CANBUS FAILURE - EXCESSIVE
CANBUS ERRORS on Pg. 55
No
Go to step 2
Yes
Replace with 30A fuse. If it blows again immediately, 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 turning on the machine, go to step 16
No
Go to step 3
Yes
See DTC 6613 - CANBUS FAILURE - EXCESSIVE
CANBUS ERRORS on Pg. 55 fault 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]?
No
Keep machine on. Go to step 4
Step 4
Disconnect the chassis
module J1 connector
[X229]. Turn on machine
Is there zero VDC between chassis module J1 Yes
connector socket 4 [X229.4.soc] and socket No
5 [X229.5.soc]?
Keep machine on. Go to step 6
1-44
1200SJP 1350SJP
Go to step 5
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 5
Step 6
Step 7
Step 8
Step 9
Test
Remove any corrosion on
Does battery still exhibit low power?
battery terminals and battery
cable terminals. Run
machine to recharge battery.
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]?
Result
Corrective Action
Yes
Replace battery
No
Retry normal vehicle operation
Yes
Inspect/repair/replace harness between the
Lower Swivel connector [X216] and the chassis
module J1 connector [X229]
No
Go to 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
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]
No
Keep machine on. Go to 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 Is there about 12 VDC at the Auxiliary Pump
Fuse from the holder [X267] 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 Yes
relay connector socket 86 [X266.86.soc] and No
socket 85 [X266.85.soc]?
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 chassis power relay connector [X266].
No
Go to step 13
Step 13 Perform this test by backprobing. See Backprobing
on Pg. 245.
Is there about 12 VDC between pin 3 of the
Yes
Valve passthru - 6 pos connector [X280.3.pin] No
and Auxiliary Pump B- terminal?
Go to step 14
Step 14
Is there continuity between Chassis Power
Yes
distribution relay socket 85 [X266] and Auxiliary Pump B- terminal [X110]?
Repair/replace the YEL/RED 2-70-4 wire
between the Valve passthru - 6 pos connector terminal 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
3128411
Do the faults 849 - BOOM ANGLE SENSOR #1 Yes
- COMMUNICATIONS FAULT and 8410 BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT both show in the fault log before No
a power cycle?
1200SJP 1350SJP
Replace Chassis Power relay.
Go to step 15
See DTC 849 - BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT on Pg. 75 to troubleshoot the power supply.
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].
1-45
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 16 Disconnect chassis module Is there a short to ground on socket 5 of chas- Yes
J1 connector [X229]
sis module J1 connector [X229.5.soc]?
No
Step 17 Disconnect chassis module Is there a short between the chassis module J1 Yes
J1 connector [X229]
connector pin 4 [X229.4.pin] and pin 5
No
[X229.5.pin]?
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]?
Go to step 18
Leave chassis module disconnected.
Go to step 17
Replace the chassis module
Check the connections at the chassis module J1
connector [X229]
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- Yes
tor pin 4 [X083.4.pin] and pin 5 [X083.5.pin]? No
Step 20 Disconnect the chassis
power relay connector
[X266]
Is there a short between socket 87 of the Chas- Yes
sis Power Relay connector [X266.87.soc]
and socket 85 of the Chassis Power Relay
connector [X266.85.soc] or the negative side No
of the battery [X117]?
Step 21 Disconnect the chassis
power relay connector
[X266]
Corrective Action
Is there a short between socket 30 of the Chas- Yes
sis Power Relay connector [X266.30.soc]
and socket 85 of the Chassis Power Relay
connector [X266.85.soc] or the negative side No
of the battery [X117]?
Repair Swivel harness or replace Swivel
Go to step 20
Repair/replace harness between the chassis
power relay connector [X266] and the Upper
Swivel connector [X083]
Leave the chassis power relay connector disconnected. Go to step 21.
Repair/replace harness between the Chassis
Power Relay [X266] and the Chassis Power Fuse
[X267]
Replace Chassis Power Relay
DTC 6612 - CANBUS FAILURE - CYLINDER LOAD PIN
Cylinder load pin CAN communications lost. The system cannot communicate with the cylinder load pin. This may be due to
wiring problems between the cylinder load pin and BLAM module.
Note Pretest Instructions
Step 1
Test
Result
Is the 6613 - CANBUS FAILURE - EXCESSIVE Yes
CANBUS ERRORS fault active in the fault log?
No
Step 2
Step 3
Step 4
Step 5
1-46
Does the BLAM software version show "??" in Yes
ANALYZER  DIAGNOSTICS  VERSIONS
 B.L.A. MODULE SOFTWARE:?
No
Corrective Action
Troubleshoot DTC 6613 - CANBUS FAILURE EXCESSIVE CANBUS ERRORS on Pg. 55 first
Go to step 2
See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
48
Go to step 3
Disconnect the load pin con- Does the voltage between the load pin connec- Yes
nector [X062]. Turn on the tor socket A [X062.A.soc] and socket B
No
machine
[X062.B.soc] measure 12VDC?
Go to step 4
Backprobe BLAM module J4 Does the voltage between the BLAM module Yes
terminal 1 [X089.1] and ter- J4 connector terminal 1 [X089.1] and terminal No
minal 2 [X089.2]
2 [X089.2] measure 12VDC?
Replace the BLAM module
Backprobe the BLAM module J4 connector
terminal 3 [X089.3],
terminal 4 [X089.4], and
terminal 5 [X089.5]
Does the CAN resistance between the BLAM Yes
module J4 connector terminal 3 [X089.3] and No
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]?
1200SJP 1350SJP
Go to step 5
Replace load pin harness
Go to step 6
See DTC 6610 - CANBUS FAILURE - BLAM on Pg.
48
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Disconnect the load pin connector [X062] and the BLAM
module J4 connector
[X089].
Test
Result
Is there CAN HI continuity between socket D of Yes
the load pin connector [X062.D.soc] and
No
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 module J4 connector [X089.4.soc]?
Corrective Action
Replace the load pin
Replace the load pin harness
DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS
Excessive CAN bus communication errors. More than 500 bus off or more than 500 bus passive conditions have been
detected by the ground module in the current power cycle. This could be due to faulty bus wiring or termination resistors,
capacitance on the bus, or a module not communicating.
Note Pretest Instructions
Step 1
Step 4
Step 5
3128411
Result
Does the CAN resistance between ground
Yes
module J7 connector terminal 13 [X007.13] No
and terminal 24 [X007.24] measure 60 and
open circuit between terminal 13 [X007.13]
and shield [X007.18] and open circuit
between terminal 24 [X007.24] and shield
[X007.18]?
Step 2
Step 3
Test
Does the platform software version show "??" Yes
in ANALYZER  DIAGNOSTICS  VERNo
SIONS  PLATFORM MODULE SOFTWARE:??
For help with this type of test
see 6.3 Continuity Measurement Over Long Distances
on Pg. 247
Is there CAN HI continuity between terminal 31 Yes
of the platform module J7 connector
No
[X169.31] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 30 of the platform
module J7 connector [X169.30] and terminal
24 of the ground module J7 connector
[X007.24]?
Is there CAN HI continuity between terminal 3 Yes
of the platform control box passthru - 19 position connector [X160.3] and terminal 13 of the
ground module J7 connector [X007.13] and
CAN LO continuity between terminal 2 of the
No
platform control box passthru - 19 position
connector [X160.2] and terminal 24 of the
ground module J7 connector [X007.24]?
Is there CAN HI continuity between terminal 3 Yes
of the MTB pass thru - 19 position connector
[X043.3] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 2 of the MTB pass thru No
- 19 position connector [X043.2] and terminal
24 of the ground module J7 connector
[X007.24]?
1200SJP 1350SJP
Corrective Action
Go to step 2
Go to step 17 to examine the CAN termination
Go to step 3
Go to step 8
Go to step 8
Go to step 4
Check the RED, BLACK, and Shield wires
between the platform module J7 connector
[X169] and the platform control box passthru - 19
position connector [X160]
Go to step 5
Check the RED, BLACK, and Shield wires
between the MTB pass thru - 19 position connector [X043] and the platform control box passthru 19 position connector [X160].
Go to step 6
1-47
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Result
Is there CAN HI continuity between terminal A Yes
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 connector [X007.13] and CAN LO continuity
between terminal B of the platform module
No
side of the 3 way CAN connector in the main
terminal box [X270.B] and terminal 24 of the
ground module J7 connector [X007.24]?
Step 7
Is there CAN HI continuity between terminal A Yes
of the 3 way CAN connector [X014.A] and terminal 13 of the ground module J7 connector No
[X007.13] and CAN LO continuity between
terminal B of the 3 way CAN connector
[X014.B] and terminal 24 of the ground module J7 connector [X007.24]?
Does the BLAM software version show "??" in Yes
ANALYZER  DIAGNOSTICS  VERSIONS No
 B.L.A. MODULE SOFTWARE:??
Step 8
Step 9
Test
For help with this type of test
see 6.3 Continuity Measurement Over Long Distances
on Pg. 247
Step 10
Is there CAN HI continuity between terminal 6 Yes
of the BLAM module J1 connector [X086.6]
No
and terminal 13 of the ground module J7 connector [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]?
Is the CYLINDER LOAD PIN CAN COMMUNI- Yes
CATIONS LOST fault active in the fault log?
No
Corrective Action
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]
Go to step 7
Repair/Replace the 3 way CAN connector in the
main terminal box [X014] [X269] [X270]
Repair/Replace the harness between the 3 way
CAN connector in the main terminal box [X014]
and the ground module J7 connector [X007]
Go to step 9
Go to step 10
Go to step 10
Go to DTC 6610 - CANBUS FAILURE - BLAM on
Pg. 48
Go to step 11
Go to step 13
Step 11 For help with this type of test
see 6.3 Continuity Measurement Over Long Distances
on Pg. 247. Disconnect
Load Pin [X062].
Is there CAN HI continuity between Load Pin
Yes
pin 3 [X062.3.pin] and ground module J7 con- No
nector terminal 13 [X007.13]. Also, CAN LO
continuity between Load Pin pin 4
[X062.4.pin] and ground module J7 connector terminal 24 [X007.24]?
Step 12
Is there CAN HI continuity between Load Pin
Yes
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]?
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.
Yes
Go to step 14
No
Go to step 15
Step 13
1-48
Is the 666 - CANBUS FAILURE - ENGINE
CONTROLLER fault active in the fault log?
1200SJP 1350SJP
Go to step 13
Go to step 12
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 14 For help with this type of test
see 6.3 Continuity Measurement Over Long Distances
on Pg. 247
Is there CAN HI continuity between terminal 12 Yes
of the engine module connector [X240.12]
No
and terminal 13 of the ground module J7 connector [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]?
Step 15
Does the Chassis software version show "??" Yes
in ANALYZER  DIAGNOSTICS  VERNo
SIONS  CHASSIS MODULE SOFTWARE:??
Corrective Action
Go to step 15
Check the RED, BLACK, and shield wires
between the engine module connector [X240]
and the ground module J7 connector [X007]
Go to step 16
Go to step 17
Step 16 For help with this type of test
see 6.3 Continuity Measurement Over Long Distances
on Pg. 247
Is there CAN HI continuity between terminal 6 Yes
of the chassis module J1 connector [X229.6]
and terminal 13 of the ground module J7 con- No
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]?
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?
Step 18 Disconnect the chassis
module J1 connector
[X229]
Does the CAN resistance between of the chas- Yes
sis module J1 connector pin 6 [X229.6.pin]
and pin 10 [X229.10.pin] measure 120?
No
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 termination 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
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]
Step 22 Disconnect the BLAM mod- Does the CAN resistance between BLAM
ule J1 connector [X086]
module J1 connector socket 6 [X086.6.soc]
and socket 7 [X086.7.soc] measure 120?
3128411
1200SJP 1350SJP
Check all CAN connections for moisture and bad
connections
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]
Yes
Go to step 18
No
Replace the platform module
Leave the chassis module disconnected and go
to step 19
Replace the chassis module
1-49
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 6622 - CANBUS FAILURE - TCU MODULE
CAN bus failure - Telematics Communications Unit Module. The TCU cannot comunicate with ground module. Machine
Setup indicates that the Telematics system is installed, but there was no comunication from the gateway module for 30 seconds.
Note Pretest Instructions
Step 1
Step 2
Step 3
Read active DTC’s
Read active DTC’s
Test
Result
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
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 - EXCESSIVE CANBUS ERRORS on Pg. 55 or the respective DTC on other device first.
No
Go to step 3.
Is 6623 - CANBUS FAILURE - GATEWAY MOD- Yes
ULE?
No
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Disconnect Telematics
Communications Unit
[X290]. Turn on machine.
Is there 12 VDC between Telematics Commu- Yes
nication Unit connector socket 15
[X290.15.soc] and scoket 16 [X290.16.soc]? No
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 CommunicaYes
tion Unit connector socket 23 [X290.23.soc]? No
Go to DTC 6623 - CANBUS FAILURE - GATEWAY
MODULE on Pg. 59.
Go to step 4.
Keep connector disconnected.
Go to step 5.
Repair wire(s) between Telematics Communication Unit connector socket 15 [X290.15.soc]and
battery bus connector [X097] -AND- between
socket 16 [X290.16.soc] and ground bus connector [X098].
Go to step 7
Go to step 6
Remove Telematics ComIs there 12VDC on the contact closest to the
munication Unit fuse [X295] MTB EMS?
from holder. Do not turn on
unit. Ground meter.
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.
Disconnect telematics com- Is there 60 Ohms between telematics communication unit connector munication unit connector socket 7
[X290].
[X290.7.soc] and socket 22 [X290.22.soc]?
Yes
Go to step8
No
Keep connector disconnected.
Go to step 10
Disconnect gateway module gray connecor [X287].
Is there 60 Ohms between gateway module
black connector socket ?
Yes
Go to step 9
No
Repair wire(s) between Telematics Communication unit black connector and Gateway CAN 3way
connector X291.
Disconnect gateway module black connector [X288]
and TCU CAN 3way to TCU
[X293].
Gateway module black connector socket 3
Yes
[X288.3.soc] should have continuity to TCU
CAN 3way to TCU pin C [X293.C.pin]? -AND- No
Pin C [X293.C.pin] should be open to both pin
A [X293.A.pin] and pin B [X293.B.pin] .
Are measurements correct?
Step 10 Disconnect telematics
Is there 120 Ohms between telematics comcommunication unit conmunication unit connector socket 7
nector [X290] and TCU CAN [X290.7.soc] and socket 22 [X290.22.soc]?
3way to harness [X294].
1-50
Corrective Action
1200SJP 1350SJP
Reprogram/replace telematics communication
unit [X290].
Repair wire as needed.
Yes
Keep TCU CAN 3 way to harness [X294] disconnected. Go to step 12
No
Keep telematics communication unit connector
[X290] disconnected. Go to step 11
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Corrective Action
Step 11 Disconnect telematics
communication unit connector [X290] and TCU CAN
3way to TCU [X293].
Is there continuity between telematics communication 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 Gateway CAN 3 way to Harness
connector [X292].
There should be continuity be tween TCU CAN Yes
3 way to harness connector socket A
No
[X294.A.soc] to Gateway CAN 3 way to Harness socket A [X292.A.soc] and open to the
other terminals. Check terminals B and C the
same way.
Are measurements correct?
Go to step 13
Step 13 Disconnect gateway module gray [X287] and black
[X288] connectors. Also,
disconnect Gateway CAN 3
way to Gateway [X291].
There should be continuity be tween Gateway Yes
CAN 3 way to gateway connector socket A
[X291.A.soc] to gateway module gray conNo
nector socket 8 [X287.8.soc] and open to the
other terminals. There should be continuity be
tween Gateway CAN 3 way to Gateway connector 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?
Repair/replace Gateway CAN 3 way to Gateway
[X291]
Repair bad wire(s)
Repair bad wire(s)
DTC 6623 - CANBUS FAILURE - GATEWAY MODULE
CAN bus failure - Gateway Module. Telematics gateway module cannot comunicate with ground module. Machine Setup
indicates Telematics system is installed, but there was no comunication from the gateway module for 30 seconds.
Note Pretest Instructions
Step 1
Step 2
Step 3
3128411
Read active faults
Test
Is the fault DTC 6613 - CANBUS FAILURE EXCESSIVE CANBUS ERRORS or other fault
on a CAN device that is not an option active?
Result
Yes
Go to DTC 6613 - CANBUS FAILURE - EXCESSIVE CANBUS ERRORS on Pg. 55 or the respective fault on other device first.
No
Go to step 3.
Disconnect gateway module gray connector [X287].
Turn on machine.
Is there 12 VDC between socket 12
Yes
[X287.12.soc] and socket 11 [X287.11.soc]?
Disconnect gateway module gray connector [X287].
Is there 60 Ohms between socket 9
[X287.9.soc] and socket 10 [X287.10.soc]?
1200SJP 1350SJP
Corrective Action
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].
Yes
Reprogram/replace gateway module
No
Go to step 4
1-51
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 4
Disconnect gateway module gray connector [X287]
and the two connectors on
the same harness, T-ed in at
the CAN passthru to Engine
Hns [X279].
Test
Is there continuity between gateway module
gray connector socket 10 [X287.10.soc]and
both "A" terminals at the connectors disconnected 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].
Result
Corrective Action
Yes
Go to DTC 6610 - CANBUS FAILURE - BLAM on
Pg. 48.
No
Repair wire(s) without continuity.
DTC 6629 - TELEMATICS CANBUS LOADING TOO HIGH
The Telematics Gateway Module has detected CAN message traffic levels that are too high. Communications between the
machine and the telematics system are restricted. This DTC will stay active at least until a power cycle.
Note Pretest Instructions
Step 1
Step 2
Test
Are there any other CAN bus DTC’s?
Cycle power.
Did DTC clear?
Result
Corrective Action
Yes
Troubleshoot those first.
No
Go to Step 2
Yes
Troubleshooting complete
No
Call JLG
DTC 681 - REMOTE CONTRACT MANAGEMENT OVERRIDE - ALL FUNCTIONS IN CREEP
The control system has received a command to disable the machine from the Telematics control center. This condition
remains in effect until the enable command is received from the Telematics control center. Call the control center to send the
enable signal.
DTC 813 - CHASSIS TILT SENSOR NOT CALIBRATED
Chassis tilt sensor not calibrated. Notification that the chassis tilt sensor calibration information has been lost. Machine will
indicate that it is tilted at all times. Perform tilt calibration. See 5.6 Calibrating Tilt Sensor on Pg. 221.
DTC 815 - CHASSIS TILT SENSOR DISAGREEMENT
Chassis tilt sensor disagreement. Reserved for future use. Should not occur on current machine.
Note Pretest Instructions
Step 1
Step 2
Go to ANALYZER 
MACHINE SETUP
Test
Result
Are parameters and configuration set properly Yes
in Machine Setup?
No
Reprogram ground module. Does fault clear?
Corrective Action
Go to Step 2 .
Reprogram/replace ground module
Yes
Troubleshooting complete
No
Reprogram/replace ground module
DTC 825 - LSS HAS NOT BEEN CALIBRATED
Load sensor not calibrated. The load sense system (LSS) sensors require calibration. See the calibration procedure in the
LSS manual for more details.
DTC 826 - RUNNING AT CREEP - PLATFORM OVERLOADED
Running at creep - platform overloaded. Reported when the platform is overloaded, causing the machine to be in creep
mode. Only displayed when the load sensor machine configuration is set to WARN ONLY.
1-52
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 827 - DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED
Drive & boom prevented - platform overloaded. Only applies to machines configured with platform load sensing. Drive and
boom functions will be prevented while the platform is overloaded.
DTC 828 - LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED
Lift up & telescope out prevented - platform overloaded. Notification that the machine is configured with load system cutouts, the platform is overloaded, and lift up or tele out is selected. Lift up and telescope out are prevented while the platform
is overloaded.
DTC 831 - PLATFORM LEVELING OVERRIDE ON
Platform leveling override on. This fault only applies to service access levels. Notification that the user has forced platform
leveling on.
DTC 832 - PLATFORM LEVELING OVERRIDE OFF
Platform leveling override off. This fault only applies to service access levels. Notification that the user has forced platform
leveling off.
DTC 833 - PLATFORM LEVEL UP CRACKPOINT - NOT CALIBRATED
Platform leveling crackpoint up not calibrated. The control system detected there was no stored calibration data for the platform leveling up 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 platform
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 up crackpoint calibration, see 5.5 Calibrating Platform Level on Pg. 217
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
3128411
Run a system test
Test
Are there any platform leveling sensor faults?
Result
Corrective Action
Yes
Troubleshoot those faults first.
No
Go to step 2
Complete a level up crackpoint calibration, see Yes
5.5 Calibrating Platform Level on Pg. 217. Did No
it complete successfully?
Troubleshooting complete
Go to step 3
Install a high pressure gauge Activate level up to end of stroke. Does gauge
on port M1 of the platform
read or adjust to about 2500 psi?
valve. Start engine.
Yes
Go to step 4
No
Keep machine in same condition.
Go to step 5.
Remove hose from platform Start engine. Activate level down. Does presvalve port L2. - Cap port L2. sure on gauge read about 2500 psi?
Install a high pressure gauge
on end of hose.
Yes
Repair/replace level circuit check valve
No
Repair/replace level cylinder holding valve.
Install a high pressure gauge Activate level down to end of stroke. Does
on port MP of the platform
gauge read about 3400psi?
valve. Start engine.
Yes
Go to step 8
No
Go to step 6
Install a high pressure gauge Activate level down to end of stroke. Does
on port MP of the main valve. gauge read about 3400psi?
Start engine.
Yes
Unclog/repair/replace pressure filter at the platform and/or hose from main valve port P3 to platform valve port P.
No
Keep machine in same condition.
Go to step 7.
1200SJP 1350SJP
1-53
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Step 8
Step 9
Test
Result
Corrective Action
Install a high pressure gauge Activate level down to end of stroke. Adjust
Yes
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3Start engine.
2. Pumps Layout on Pg. 164 for location. Can
it be adjusted to proper pressure?
No
Inspect/repair/replace hydraulics between main
valve and platform valve, including filter at platform valve.
Start engine.
Yes
Go to step 10
No
Go to step 9
Yes
Clean/repair/replace platform dump valve [X135]
cartridge.
No
Replace platform dump solenoid [X135]
Turn off machine. Disconnect platform dump solenoid [X135].
Step 10
Do the other platform functions operate?
Does the platform dump solenoid [X135]
measure about 6.4 ?
In the platform valve, swap cartridge common Yes
to level up solenoid [X136] and level down
solenoid [X135] with the cartridge common to
rotate right [X138] and rotate left [X139]. Does No
the crackpoint calibrate?
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 pressure of the platform level down relief for
2500psi. See Figure 3-3. Platform Valve Layout on Pg. 165 for location. Does gauge read
the proper pressure?
Repair/replace function pump and/or high pressure relief
Repair/replace cartridge that was originally
installed common to level up solenoid [X136] and
level down solenoid [X135]
Go to step 11
Yes
Repair/replace platform level cylinder
No
Repair/replace platform level up relief
DTC 834 - PLATFORM LEVEL DOWN CRACKPOINT - NOT CALIBRATED
Platform leveling crackpoint down not calibrated. The control system detected there was no stored calibration data for the
platform leveling down valve current crackpoint. This could be due to installing a new ground module that has not yet been
calibrated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic platform leveling will be disabled. Platform leveling can still be performed manually, but the PLATFORM LEVELING SYSTEM
TIMEOUT fault will still be enabled. Complete a level down crackpoint calibration, see 5.5 Calibrating Platform Level on Pg.
217
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
1-54
Run a system test
Test
Are there any platform leveling sensor faults?
Result
Corrective Action
Yes
Troubleshoot those faults first.
No
Go to step 2
Complete a level down crackpoint calibration, Yes
see 5.5 Calibrating Platform Level on Pg. 217. No
Did it complete successfully?
Go to step 3
Troubleshooting complete
Install a high pressure gauge Activate level down to end of stroke. Does
on port M2 of the platform
gauge read or adjust to about 1500 psi?
valve. Start engine.
Yes
Go to step 4
No
Keep machine in same condition.
Go to step Step 5 .
Remove hose from platform Start engine. Activate level down. Does presvalve port L1. - Cap port L1. sure on gauge read about 1500 psi?
Install a high pressure gauge
on end of hose.
Yes
Repair/replace level circuit check valve
No
Repair/replace level cylinder holding valve.
Install a high pressure gauge Activate level down to end of stroke. Does
on port MP of the platform
gauge read about 3400psi?
valve. Start engine.
Yes
Go to step 8
No
Go to step 6
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Install a high pressure gauge Activate level down to end of stroke. Does
on port MP of the main valve. gauge read about 3400psi?
Start engine.
Result
Corrective Action
Yes
Unclog/repair/replace pressure filter at the platform and/or hose from main valve port P3 to platform valve port P.
No
Keep machine in same condition.
Go to step 7.
Install a high pressure gauge Activate level down to end of stroke. Adjust
Yes
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3start engine.
2. Pumps Layout on Pg. 164 for location. Can
it be adjusted to proper pressure?
No
Inspect/repair/replace hydraulics between main
valve and platform valve, including filter at platform valve.
Start engine.
Yes
Go to step 10
No
Go to step 9
Yes
Clean/repair/replace platform dump valve [X135]
cartridge.
No
Replace platform dump solenoid [X135]
Turn off machine. Disconnect platform dump solenoid [X135].
Step 10
Step 11 Cap platform valve port L2
and its hose. Install a high
pressure gauge in port M2.
Start engine.
Do the other platform functions operate?
Does the platform dump solenoid [X135]
measure about 6.4 ?
In the platform valve, swap cartridge common Yes
to level up solenoid [X136] and level down
solenoid [X135] with the cartridge common to
rotate right [X138] and rotate left [X139]. Does No
the crackpoint calibrate?
Operate level down to end of stroke. Adjust
pressure of the platform level down relief for
1500psi. See Figure 3-3. Platform Valve Layout on Pg. 165 for location. Does gauge read
the proper pressure?
Repair/replace function pump and/or high pressure relief
Repair/replace cartridge that was originally
installed common to level up solenoid [X136] and
level down solenoid [X135]
Go to step 11
Yes
Repair/replace platform level cylinder
No
Repair/replace platform level down relief
DTC 837 - PLATFORM LEVEL SENSOR #1 - SHORT TO BATTERY
Platform leveling sensor 1 short to battery. The platform module J1 right platform level sensor communication terminal
[X016.25] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 838 - PLATFORM LEVEL SENSOR #1 - SHORT TO GROUND OR OPEN CIRCUIT
Platform leveling sensor 1 short to ground or open circuit. The platform module J1 right platform level sensor communication
terminal [X016.25] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 8311 - PLATFORM LEVEL SENSOR #2 - SHORT TO BATTERY
Platform leveling sensor 2 short to battery. The platform module J1 left platform level sensor communication terminal
[X016.26] is shorted to battery. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8312 - PLATFORM LEVEL SENSOR #2 - SHORT TO GROUND OR OPEN CIRCUIT
Platform leveling sensor 2 short to ground or open circuit. The platform module J1 left platform level sensor communication
terminal [X016.26] is shorted to ground or open. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
3128411
1200SJP 1350SJP
1-55
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 8313 - PLATFORM LEVEL SENSOR #1 - REFERENCE VOLTAGE OUT OF RANGE
Platform leveling tilt reference 1 out of range. Platform J7, terminal 11 [X169.11] is reading outside of the expected range of
4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is
present only in software before version P7.0.
Note Pretest Instructions
Step 1
Cycle power
Step 2
Test
Is fault still present?
Result
Corrective Action
Yes
Go to step 2
No
Troubleshooting complete
Inspect harness and at platform module J7. Is Yes
there a wire or short to terminal 11 [X169.11]? No
Repair/replace harness
Reprogram/replace platform module
DTC 8314 - PLATFORM LEVEL SENSOR #2 - REFERENCE VOLTAGE OUT OF RANGE
Platform leveling tilt reference 2 out of range. Platform J7, terminal 12 [X169.12] is reading outside of the expected range of
4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is
present only in software before version P7.0.
Note Pretest Instructions
Step 1
Cycle power
Step 2
Test
Is fault still present?
Result
Corrective Action
Yes
Go to step 2
No
Troubleshooting complete
Inspect harness and at platform module J7. Is Yes
there a wire or short to terminal 12 [X169.12]? No
Repair/replace harness
Reprogram/replace platform module
DTC 8315 - PLATFORM LEVELING SENSOR - DISAGREEMENT
Platform leveling tilt sensors disagree. The platform leveling tilt readings from platform tilt sensor #1 and #2 both appear to
be good, but their measurements are not within 5.0° of each other. This value is programmable. A power cycle is required.
Note Pretest Instructions
Step 1
Are there any other platform leveling faults?
Step 4
1-56
Result
Corrective Action
Yes
Troubleshoot them first
No
Go to step 2
Are both sensors mounted properly and
securely?
Yes
Go to step 3
No
Repair as needed
Disconnect platform level
sensor #1 (Right) [X150]
Turn on machine. Does the PLATFORM LEVELING TILT SENSOR 1 COMMUNICATIONS
LOST fault appear?
Yes
Go to step 4
No
Wires to wrong sensor. Swap harness connections and ensure they attach to the correct sensor.
Perform 5.5 Calibrating
Platform Level on Pg. 217.
(There is also helpful information in section 5.4 Electronic Platform Leveling on
Pg. 214.)
Does it calibrate successfully? -AND- Does
fault clear?
Yes
Troubleshooting complete
No
Replace both platform level sensors, #1 [X148]
and #2 [X150]
Step 2
Step 3
Test
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 8316 - PLATFORM LEVEL SENSOR #1 - COMMUNICATIONS LOST
Platform leveling tilt sensor 1 communications lost. The control system lost serial communications with platform tilt angle
sensor #1 (right). A power cycle is required.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Result
Is harness from platform level sensor 1 [X150] Yes
plugged into the platform level passthru 1
No
[X162]? Also, are those connections in good
condition?
Check the faults.
Is the fault PLATFORM LEVELING TILT SENSOR 2 COMMUNICATIONS LOST active?
Corrective Action
Go to step 2
Correct wiring
Yes
Go to step 9
No
Go to step 3
Yes
Replace original platform level sensor 1 (RIGHT)
[X150]
No
Go to step 4
Disconnect platform level
sensor 1 [X150]. Turn on
machine.
Measure voltage between platform level sen- Yes
sor 1 pin1[X150.1.pin] and pin 3
No
[X150.3.pin]. Does it measure about 12VDC?
Go to step 5
Disconnect platform level
sensor 1 [X150] and platform module J1
Is there continuity between platform level sen- Yes
sor 1 pin 2 [X150.2.pin] and platform module No
J1 socket 25 [X165.25.soc]?
Plug platform level sensor 2 Does the PLATFORM LEVELING TILT SEN(left) [X148] into connector SOR 1 COMMUNICATIONS LOST fault clear?
for platform level sensor 1
(right) [X150]
Disconnect platform level
Is there continuity between platform level
passthru 1 [X162] and plat- passthru 1 pin 2 [X162.2.pin] and platform
form module J1 [X165]
module J1 socket 25 [X165.25.soc]?
Disconnect platform module Turn on machine. Measure voltage between
J2 [X166]. Ground meter.
platform module J2 pin 32 [X166.32] and
See Grounding on Pg. 245 ground. Does it measure about 12VDC?
for details.
Disconnect platform level
passthru 1 [X162]. Turn on
machine.
Go to step 7
Replace platform level sensor 1 [X150]
Go to step 6
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]
Yes
Go to step 8
No
Replace platform module
Measure voltage between platform level
Yes
passthru 1 pin 1 [X162.1.pin] and pin 3
[X162.3.pin]. Does it measure about 12VDC?
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 J7
[X169] and/or J1 [X165]
Take the following measure- Is there about 12 VDC between platform mod- Yes
ment by backprobing. See ule J2 terminal 32 [X166.32] and platform
No
Backprobing on Pg. 245 for module J7 terminal 21 [X169.21]?
details.
Step 10 Turn on machine.
3128411
Test
Measure voltage between platform level sensor 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?
1200SJP 1350SJP
Go to step 10
Replace platform module
Yes
Go to step 12
No
Go to step 11
1-57
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Corrective Action
Step 11 Turn on machine. Disconnect platform level passthru
1 [X162] and platform level
passthru 2 [X163]
Measure voltage between platform level
Yes
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]
No
and pin 3 [X163.3.pin]. Do they measure
about 12 VDC?
Repair/replace harness between the platform
level sensor and platform level passthru connector that did not have the proper voltage.
Step 12 Disconnect platform level
passthru 1 [X162] and platform level passthru 2
[X163]. Ground meter.
Is there continuity between platform level
Yes
passthru 1 pin 3 [X162.3.pin] and ground?
No
Also, is there continuity between platform level
passthru 2 pin 3 [X163.3.pin] and ground?
Go to step 13
Step 13 Disconnect platform level
sensor 1 [X150] and platform level sensor 2 [X148].
Ground meter.
Is there continuity between platform level sen- Yes
sor 1 pin 3 [X150.3.pin] and ground. Also, is No
there continuity between platform level sensor
2 pin 3 [X148.3.pin] and ground.
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.
Repair/replace harness between platform module J7 [X169] and the connectors platform level
passthru 1 [X162] and platform level passthru 2
[X163].
Replace both platform level sensors
Repair/replace harness(es) that did not have continuity.
DTC 8317 - PLATFORM LEVEL SENSOR #2 - COMMUNICATIONS LOST
Platform leveling tilt sensor 2 communications lost. The control system lost serial communications with platform tilt angle
sensor #2 (Left).
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
1-58
Test
Result
Is harness from platform level sensor 2 [X148] Yes
plugged into the platform level passthru 2
No
[X163]? Also, are those connections in good
condition?
Check the faults.
Is the fault PLATFORM LEVELING TILT SENSOR 1 COMMUNICATIONS LOST active?
Corrective Action
Go to step 2
Correct wiring
Yes
Go to step 9
No
Go to step 3
Yes
Replace original platform level sensor 2 (left)
[X148]
No
Go to step 4
Disconnect platform level
sensor 2 (left) [X148]. Turn
on machine.
Measure voltage between platform level sen- Yes
sor 2 pin1[X148.1.pin] and pin 3
No
[X148.3.pin]. Does it measure about 12VDC?
Go to step 5
Disconnect platform level
sensor 2 (left) [X148] and
platform module J1
Is there continuity between platform level sen- Yes
sor 1 pin 2 [X148.2.pin] and platform module No
J1 socket 26 [X165.26.soc]?
Plug platform level sensor 1 Does the PLATFORM LEVELING TILT SEN(right) [X150] into connec- SOR 2 COMMUNICATIONS LOST fault clear?
tor for platform level sensor
2 (left) [X148]
Disconnect platform level
Is there continuity between platform level
passthru 2 [X163] and plat- passthru 2 pin 5 [X163.5.pin] and platform
form module J1 [X165]
module J1 socket 26 [X165.26.soc]?
Disconnect platform module Turn on machine. Measure voltage between
J2 [X166]. Ground meter.
platform module J2 pin 32 [X166.32] and
See Grounding on Pg. 245 ground. Does it measure about 12VDC?
for details.
1200SJP 1350SJP
Go to step 7
Replace platform level sensor 2 (left) [X148]
Go to step 6
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]
Yes
Go to step 8
No
Replace platform module
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 8
Step 9
Disconnect platform level
passthru 1 [X162]. Turn on
machine.
Test
Result
Measure voltage between platform level
Yes
passthru 1 pin 1 [X162.1.pin] and pin 3
[X162.3.pin]. Does it measure about 12VDC?
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 J7
[X169] and/or J1 [X165]
Take the following measure- Is there about 12 VDC between platform mod- Yes
ment by backprobing. See ule J2 terminal 32 [X166.32] and platform
No
Backprobing on Pg. 245 for module J7 terminal 21 [X169.21]?
details.
Step 10 Turn on machine.
Corrective Action
Go to step 10
Replace platform module
Measure voltage between platform level sensor 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. Disconnect 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 connector 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 platform 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 module 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 platform level sensor 2 [X148].
Ground meter.
Is there continuity between platform level sen- Yes
sor 1 pin 3 [X150.3.pin] and ground.
No
-AND- Is there continuity between platform
level sensor 2 pin 3 [X148.3.pin] and ground.
Replace both platform level sensors
Repair/replace harness(es) that did not have continuity.
DTC 8318 - PLATFORM LEVELING SYSTEM TIMEOUT
Platform leveling system time-out. The control system detected the platform tilt angle was not within 5.0° of the setpoint for at
least 2 seconds while out of transport or for at least 15 seconds while in the transport position. These values are programable. This fault can happen when driving too fast over abrupt terrain changes because the platform leveling system cannot
respond fast enough. Platform operations will be disabled.
Note Pretest Instructions
Step 1
Step 2
Step 3
3128411
Examine active faults
Test
Are there any other platform leveling faults?
Result
Corrective Action
Yes
Troubleshoot those first
No
Go to 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
Are the mounting blocks for both sensors
properly assembled? -AND- Is the hardware
tight?
Yes
Go to step 4
No
Repair as needed
1200SJP 1350SJP
1-59
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 4
Disconnect platform level
sensor #1 (Right) connector [X150]
Step 5
Step 6
Step 7
Step 8
Step 9
Test
Result
Is the fault PLATFORM LEVELING TILT SENSOR 1 COMMUNICATIONS LOST now an
active fault?
Yes
Go to step 5
No
Connections are swapped. Make proper harness
connections to sensors.
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
Yes
Go to step 10
No
Go to step 7
Do the other platform functions operate?
Install a high pressure gauge Activate level down to end of stroke. Does
on port MP of the platform
gauge read about 3400psi?
valve. Start engine.
Yes
Go to step 9
No
Go to step 8
Install a high pressure gauge Activate level down to end of stroke. Adjust
Yes
on port MP of the main valve. high pressure relief to 3400psi. See Figure 3Start engine.
2. Pumps Layout on Pg. 164 for location. Can
it be adjusted to proper pressure?
No
Turn off machine. Disconnect platform dump solenoid [X135].
Step 10 Turn off machine. Disconnect platform level UP
[X136] and level DOWN
[X137].
Corrective Action
Does the platform dump solenoid [X135]
measure about 6.4 ?
Do both solenoids measure 10.1?
Step 11 Take cartridge from platform Does problem clear or move?
level valve [X136] [X137]
and swap it with the one in
the jib swing valve [X140]
[X141]
Step 12 Install a high pressure gauge Activate level down to end of stroke. Does
on ports M1 and M2 of the pressure measure or adjust to about 1500
platform valve. Start engine. psi? Also, activate level up to end of stroke.
Does pressure measure or adjust to about
2500 psi?
Inspect/repair/replace hydraulics between main
valve and platform valve, including filter at platform valve.
Repair/replace function pump and/or high pressure relief
Yes
Clean/repair/replace platform dump valve [X135]
cartridge.
No
Replace platform dump solenoid [X135]
Yes
Go to step 11
No
Replace platform level valve coil [X136] [X137]
Yes
Replace cartridge originally in the platform level
valve [X136] [X137].
No
Go to step 12
Yes
Repair/replace 75psi check valve and/or level
cylinder assembly
No
Repair/replace relief valve that does not produce
proper pressure.
DTC 841 - BOOM ANGLE SENSOR DISAGREEMENT
The control system detected a difference in angle measurements from the Boom Angle Sensors of greater than 2.5 for
longer than 2 seconds.
Note Pretest Instructions
Step 1
Step 2
1-60
Test
Connect Analyzer. Read
Are there another Boom Angle Sensor faults?
active faults. (Logged faults
before power cycle.)
Put boom in transport position. Navigate to ANALYZER
 ACCESS LEVEL 1 
DIAGNOSTICS  ENVELOPE
Result
Yes
Troubleshoot those first.
No
Go to step 2
Do the readings on the machine approximately Yes
agree with the following?
• MAIN LIFT 1 ANGLE A/D: -38.7
No
• MAIN LIFT 2 ANGLE A/D: -38.9
• MAIN LIFT 1 ANGLE: -1.1
• MAIN LIFT 2 ANGLE: -1.0
1200SJP 1350SJP
Corrective Action
Keep ANALYZER connected.
Go to step 4
Go to step 3
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
Step 5
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228.
Test
Do sensors calibrate successfully?
Is the fault BOOM ANGLE SENSOR 2# COMTurn off vehicle. Disconnect MUNICATIONS FAULT active?
Boom Angle Sensor 1. Connect Analyzer. Turn on vehicle.
Observe MAIN LIFT 1 ANGLE A/D value while
Navigate to ANALYZER 
slowly raising and lowering boom. The value
ACCESS LEVEL 1  DIAG- should change smoothly and consistently
NOSTICS  ENVELOPE.
without jumping or stopping. Does it?
Repeat for sensor MAIN LIFT 2 ANGLE A/D.
Result
Corrective Action
Yes
Troubleshooting complete
No
Troubleshoot according to calibration fault
Yes
Sensor wires are swapped. Connect harnesses
to proper sensors.
No
Go to step 5
Yes
Repeat test several times. If no bad behavior is
observed calibrate and go to step.3
No
Replace sensor that exhibits bad behavior.
DTC 842 - BOOM LENGTH SWITCH FAILED
Boom Length Switch Failed. Both Boom Length (Transport) Limit Switches show same state, when they should be reading
opposite.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
3128411
Test
Result
Is Boom Length Limit Switch [X281] jammed, Yes
obstructed, loose or mounted incorrectly?
No
Also, is the switch prevented from properly
contacting the boom?
Corrective Action
Repair as needed
Go to step 2
Disconnect Boom Transport Check continuity between Boom Transport
Yes
Switch Passthru [X017]
Switch Passthru socket 1 [X017.1.soc] and
both socket 2 [X017.2.soc] and socket 6
[X017.6.soc]. One measurement should have No
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?
Leave Boom Transport Switch Passthru [X017]
disconnected.
Go to step 3
Disconnect Boom Transport Is there continuity between all of the followSwitch Passthru [X017] and ing? Boom Transport Switch Passthru pin 1
Ground Module J7 [X007]
[X017.1.pin] to Ground Module J7 pin socket
29 [X007.29.pin];
[X017.2.pin] to [X007.11.soc]; and
[X017.6.pin] to [X007.35.soc]
Yes
Replace Ground Module
No
Repair/Replace wire that did not have continuity.
Disconnect Boom Transport
Switch Passthru [X017] and
gain access wires inside
Boom Length Limit Switch
[X281]
Is there continuity between all of the followYes
ing? Boom Transport Switch Passthru socket No
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]
1200SJP 1350SJP
Leave Boom Transport Switch Passthru [X017]
disconnected.
Go to step 4
Replace Boom Transport Switch [X281]
Repair/Replace wire that did not have continuity.
1-61
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 843 - BOOM LENGTH SWITCH/SENSOR DISAGREEMENT
Boom Length Switch/Sensor Disagreement. The control system did not detect a change in the boom length switch at the
calibrated point. This could be a problem with the Boom Length Sensor or Boom Length Limit Switch, or the boom sensor
calibration.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Is Boom Length Limit Switch [X281] jammed, Yes
obstructed, loose or mounted incorrectly?
No
Step 2
Is the Boom Length Sensor [X273] jammed,
obstructed, loose, have cable stuck or
mounted incorrectly?
Yes
Repair as needed
No
Goo to step 3
Is there a Boom Length Sensor or Boom
Length Limit Switch fault present?
Yes
Troubleshoot those first
No
Go to step 4
Step 3
Check active faults (before
first power cycle)
Step 4
Calibrate boom sensors. See 5.9 Calibrating Yes
the Boom Sensors on Pg. 228. Does machine No
calibrate without faults?
Repair as needed
Go to step 2
Troubleshooting complete
Troubleshoot in accordance with calibration
fault.
DTC 844 - BOOM LENGTH SENSOR NOT DETECTING LENGTH CHANGE
Boom Length Sensor Not Detecting Length Change. The control system has not detected a minimum change in length while
the user commanded telescope. The minimum change is 0.3" over 3 seconds when command is at least 45%. This fault
check is enabled when the boom is greater than 5 inches from the maximum or minimum mechanical length. An EMS cycle
is required.
Note Pretest Instructions
Step 1
Step 2
Result
Have swing, lift, telescope, and platform func- Yes
tions stopped operating?
No
Check active faults. (Fault
log before power cycle.)
Step 3
Are there any other Boom Length sensor
faults?
Extend boom completely
Corrective Action
Go to step 17
Go to step 2
Yes
Troubleshoot those first
No
Go to step 3
Examine the electrical connections at the
Yes
boom length sensor [X273], Boom Length
No
Sensor Passthru [X272] and BLAM module J3
connector [X088]. Are there any loose connections, moisture or corrosion?
Step 4
Step 5
Test
Clean or replace any bad connections
Go to 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.
Apply lubricant to wear pad tracks on booms.
Move boom in and out completely. Does fault
clear?
Yes
Troubleshooting complete
No
Go to step 6
Yes
Keep test setup in place.
Go to step 7
No
Go to step 8
Step 6
Raise and extend boom.
Plug main valve port 8.
Does boom retract without command?
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
1-62
Torque boom wire ropes per procedure. See
Yes
5.10 Wire Rope Tensioning Procedure on Pg. No
240. Does fault clear?
1200SJP 1350SJP
Troubleshooting complete
Go to step 9
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 9
Test
Result
Connect a 5000 psi presAdjust the low pressure relief on the function Yes
sure gauge to MP port on the pump until gauge reads 400 psi. See Figure 3main valve manifold
2. Pumps Layout on Pg. 164 for location. Can No
adjustment be made to correct pressure?
Corrective Action
Keep gauge installed. Make note of results.
Go to step 10.
Replace function pump compensating valve.
Step 10 Connect a 5000 psi pressure 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 pressure gauge to M8 on the
main valve manifold. Cap
the hose and port on port 8.
Activate telescope out. Does pressure read or Yes
adjust to 3000 psi? See Figure 3-1. Main Valve
Layout on Pg. 163 for location of extend pres- No
sure adjustment.
Make note of results.
Go to step 13
Step 13 Connect a 5000 psi pressure gauge to M7 on the
main valve manifold. Cap
the hose and port on port 7.
Activate telescope in. Does pressure read or Yes
adjust to 3200psi? See Figure 3-1. Main Valve
Layout on Pg. 163 for location of retract pres- No
sure adjustment.
Make note of results
Go to step 14
Make note of results
Go 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 pressure.
No
Go to step 15
Step 15
Did both M7 and M8 pressures fail to adjust to Yes
pressures above
No
Go to step 16
Step 16 Swap Tele proportional
valve [X072] cartridge with
the Lift proportional [X286]
cartridge.
Does fault move?
Step 17 Disconnect main dump
[X074]
Make note of results.
Go to step 13
Go to step 6
Yes
Replace cartridge originally in Tele proportional
valve [X072]
No
Go to step 17
Measure resistance. Is coil resistance about 5 Yes
Ohms?
No
Go to step 18
Replace main dump coil.
Step 18 On main valve, cap port B
Activate telescope in. Does pressure read or
and P2 (to aux pump). Install adjust to 3400 psi with high pressure relief?
5000psi gauge on MP port
and.
Yes
Keep test setup in place.
Go to step 19
No
Go to step 20
Step 19 Remove cap from port B and Activate telescope in. Does pressure read or
restore connection.
adjust to 3400psi with high pressure relief?
Yes
Repack/reseal swivel
No
Replace check valve in aux pump.
Step 20 Replace main dump cartridge.
Yes
Troubleshooting complete
No
Replace function pump compensating valve.
3128411
Does fault clear?
1200SJP 1350SJP
1-63
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 845 - BOOM LENGTH SENSOR - OUT OF RANGE HIGH
Boom Length Sensor Out of Range High. The control system reads a boom length greater than 1480.9" for the 1350 or
1294.4" for the 1200. This could be caused by a mechanical problem with the sensor or cable, the sensor ground wire being
broken, or a sensor failure.
Note Pretest Instructions
Step 1
Test
Corrective Action
Yes
Go to step 2
No
Repair as needed
Disconnect boom length
sensor [X273]
Does the boom length sensor connector
Yes
[X273] have moisture, damage or corrosion? No
Repair as needed
Turn on machine. Disconnect 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. Disconnect 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. Disconnect 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 2
Step 3
Step 6
Is the boom length sensor [X273] securely
mounted to the machine and is cable free to
move?
Result
Keep boom length sensor [X273] disconnected.
Go to step 3
Unclip sensor cable from
boom. Observe resistance
between boom length sensor pin A [X273.A.pin] and
pin C [X273.C.pin].
Have second person slowly walk cable out
Yes
and back completely. The sensor cable
No
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?
Disconnect boom length
sensor [X273] and BLAM
module J3 connector
[X088].
Is there a short between the Blue wire in boom Yes
length sensor socket C [X273.C.soc] and red
wire in socket A [X273.A.soc] -OR- between No
boom length sensor socket C [X273.C.soc]
and battery positive [X116]?
Disconnect boom length
sensor [X273] and boom
length sensor passthru
[X272]
Is there a short between the Blue wire in boom Yes
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]
No
and battery positive [X116]?
Repair short or replace harness between boom
length sensor [X273] and boom length sensor
passthru [X272]
Disconnect boom length
sensor [X273] and BLAM
module J3 connector
[X088]
Is there continuity between boom length sen- Yes
sor socket C [X273.C.soc] and BLAM module No
J3 socket 8 [X088.8.soc]?
Go to step 11
Step 10 Disconnect boom length
sensor [X273] and boom
length sensor passthru
[X272]
Is there continuity between boom length sen- Yes
sor passthru socket 3 [X272.3.soc] and boom
length sensor socket C [X273.C.soc]?
No
Step 7
Step 8
Step 9
1-64
1200SJP 1350SJP
Go to step 7
Replace boom length sensor [X273]
Keep boom length sensor [X273] disconnected.
Go to step 8
Leave boom length sensor [X273] and BLAM
module J3 [X088] disconnected.
Go to step 9
Repair short or replace harness between boom
length sensor [X272] and BLAM J3 [X088]
Go to step 10
Repair or replace harness between BLAM J3
[X088] and boom length sensor [X273]
Repair/replace harness between boom length
sensor [X093] and BLAM module J3 connector
[X088].
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Step 11 Disconnect boom length
sensor [X273] and BLAM
module J3 connector
[X088]
Is there continuity between boom length sen- Yes
sor socket B [X273.B.soc] and BLAM module
J3 connector socket 9 [X088.9.soc]?
No
Step 12 Disconnect boom length
sensor [X273] and boom
length sensor
passthru[X272]
Is there continuity between boom length sensor socket B [X273.B.soc] and boom length
sensor passthru socket 2 [X272.2.soc]?
Step 13 Turn on machine. Disconnect boom length sensor
[X273]
Does the fault become inactive -AND- the fault Yes
BOOM LENGTH SENSOR ONE VALUE OUT OF No
RANGE LOW appear?
Corrective Action
Leave boom length sensor [X273] disconnected.
Go to step 13
Go to step 12
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]
Replace boom length sensor [X273]
Reprogram/replace BLAM
DTC 846 - BOOM LENGTH SENSOR - OUT OF RANGE LOW
Boom Length Sensor Out of Range Low. The control system reads a boom length less than 443.0" for the 1350 or 394.9" for
the 1200. This could be caused by a mechanical problem with the sensor or cable, a disconnected or broken sensor cable
clip, the sensor power and/or signal wire being broken, or sensor failure.
Note Pretest Instructions
Step 1
Test
Result
Corrective Action
Is the boom length sensor [X273] securely
Yes
mounted to the machine, is cable free to move No
and is it connected correctly?
Go to step 2
Disconnect boom length
sensor [X273]
Does the boom length sensor connector
Yes
[X273] have moisture, damage or corrosion? No
Repair as needed
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]. Is there about 5VDC between BLAM J3 pin 7
Turn on machine.
[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 2
Step 3
Step 6
Step 7
3128411
Unclip sensor cable from
boom. Observe resistance
between boom length sensor pin A [X273.A.pin] and
pin C [X273.C.pin].
Have second person slowly walk cable out
Yes
and back completely. The sensor cable
No
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?
Disconnect boom length
Is there a short between boom length sensor
sensor [X273] and BLAM J3 socket C [X273.C.soc] or BLAM J3 socket 8
[X088]
[X088.8.soc] to battery negative [X117]?
1200SJP 1350SJP
Repair as needed
Keep boom length sensor [X273] disconnected
and machine on. Go to step 3
Go to step 7
Replace boom length sensor [X273]
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
1-65
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 8
Step 9
Test
Result
Corrective Action
Is there continuity between boom length senDisconnect boom length
sensor [X273] and BLAM J3 sor socket C [X273.C.soc] and BLAM J3
socket 8 [X088.8.soc]?
[X088]
Yes
Go to step 10
No
Go to step 9
Disconnect boom length
sensor [X273] and boom
length sensor passthru
[X272]
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 continuity between boom length sensor socket C [X273.C.soc] and boom length
sensor passthru socket 3 [X272.3.soc]?
Step 10 Disconnect boom length
Is there a short between boom length sensor
sensor [X273] and BLAM J3 socket C [X273.C.soc] and socket B
[X088]
[X273.B.soc]?
Yes
Go to step 11
No
Reprogram/replace BLAM
Step 11 Disconnect boom length
Is there a short between boom length sensor
sensor passthru [X272] and socket C [X273.C.soc] and socket B
boom length sensor [X273] [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]
DTC 847 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE HIGH
Boom Length Sensor Value Out of Range High. The control system detected the boom length sensor input voltage is above
acceptable range.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
1-66
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 2
Yes
Leave all optional power sources de-energized.
Go to step 3.
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.
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Does fault clear?
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Re-energize one source and re-check faults.
Does fault re-appear?
Disconnect BLAM J3
[X088]. Turn on machine.
Is there between 5.5 V and 4.5 volts measured Yes
between the following points on
No
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]?
Go to step 5
Disconnect BLAM J3
[X088]. Disconnect battery
(+) terminal [X116]
Is there a short between the battery (+) termi- Yes
nal [X116] and any of the following: BLAM J3,
socket 1 [X088.1.soc], socket 4
No
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?
Troubleshoot BLAM J3 [X088] harness wire with
short
1200SJP 1350SJP
Replace BLAM
Reprogram/replace BLAM
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 848 - BOOM LENGTH SENSOR - VALUE OUT OF RANGE LOW
Boom Length Sensor Value Out of Range Low. The control system detected the boom length sensor input voltage is below
acceptable range.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 2
Disconnect BLAM J3
[X088] and Boom Length
Sensor [X273].
Is there continuity measured between BLAM Yes
J3 [X088] and Boom Length Sensor [X273] at No
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]?
Go to step 3
Disconnect BLAM J3
[X088]. Turn on machine.
Is there between 4.5 V and 5.5 V measured
Yes
between all of the following points on
No
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]?
Go to step 4
Unclip sensor cable from
boom. Observe resistance
between Boom Length Sensor pin A [X273.A. pin] and
pin C [X273.C.pin]
Have a second person slowly walk the cable Yes
out and back completely. The sensor extends No
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?
Reprogram BLAM and calibrate boom sensors
Repair Harness
Replace BLAM
Replace Boom Length Sensor
DTC 849 - BOOM ANGLE SENSOR #1 - COMMUNICATIONS FAULT
Boom angle sensor #1 communications fault. The control system lost serial communications with #1 angle sensor (Operator’s right side).
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
3128411
Test
Result
Are there loose or damaged connections at the Yes
#1 boom angle sensor connector [X099]?
Corrective Action
Repair any loose or damaged wires or connectors
No
Go to step 2
Does the fault log show BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT before a
power cycle?
Yes
Go to step 4
No
Go to step 3
Turn on machine. DisconIs there 12VDC on #1 boom angle sensor
nect #1 boom angle sensor connector socket 1 [X099.1.soc] and socket
connector [X099]
3 [X099.3.soc]?
Yes
Leave connector disconnected. Go to step 8.
No
Go to step 4
Turn on machine. BackIs there 12VDC between 12-pin V-Batt+ bus Yes
probe between the 12-pin
connector[X097] and 12-pin ground bus conground bus connector
nector [X098]?
[X098] and 12-pin V-Batt+
No
bus connector [X097] by the
BLAM. (See 6.2 Multimeter
Basics on Pg. 245 for details
on backprobing.)
1200SJP 1350SJP
Repair/replace 12-pin V-Batt+ bus connector
[X097] and/or 12-pin ground bus connector
[X098].
Leave machine on. Go to step 5.
1-67
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 5
Step 6
Step 7
Step 8
Step 9
Test
Result
Turn on machine. Discon- Is there 12VDC between 6-pin Deutsch pin 2
nect 6-pin Deutsch connec- [X280.2.pin] and pin 5 [X280.5.pin]?
tor [X280].
Yes
Go to step 11
No
Leave 6-pin Deutsch connector [X280] diconnected. Go to 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] disconnected. 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]
Disconnect 6-pin Deutsch
connector [X280] and
ground control module J8
[X008]
Is there continuity between 6-pin Deutsch
Yes
connector pin 5 [X280.5.pin] and ground control module J8 socket 3 [X008.3.soc]?
Ensure both contacts of the 6-pin Deutsch connector 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]
Plug the #2 boom angle
Does the BOOM ANGLE SENSOR #2 COMsensor connector [X100]
MUNICATIONS FAULT appear?
into the #1 sensor and the
boom angle sensor #1 connector [X099] into the #2
sensor. Read faults.
Yes
Replace sensor #1
No
Leave the #1 boom angle sensor [X099] disconnected.
Go to step 9
Disconnect #1 boom angle Is there continuity between #1 boom angle
sensor connector [X099]
sensor pin 2 [X099.2.pin] and BLAM J2
socket 8 [X087.8.soc]?
and BLAM J2 [X087]
Yes
Go to step 11
No
Leave the #1 boom angle sensor [X099] disconnected.
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 Connectors on Pg. 119 for location).
Is there continuity between #1 boom angle
Yes
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 No
correctly?
Step 11 Disconnect the #1 boom
Is there 12VDC between the #1 boom angle
angle sensor passthru - 4
sensor passthru socket 1 [X095.1.soc] and
position [X095]. Turn on the socket 3 [X095.3.soc]?
machine.
1200SJP 1350SJP
Repair/replace harness between boom angle
sensor 1 pass through [X095] and BLAM J2
[X087]
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]
Yes
Leave the connector disconnected and machine
on. Go to step 13.
No
Go to step 12
Step 12 Disconnect battery busbar - Is there 12VDC between ANY of the sockets in Yes
12 pos. [X097] and ground battery busbar [X097] and ANY of the sockets
busbar - 12 pos. [X098]
in ground busbar [X098]? This measurement
may also be taken by backprobing the connector without disconnecting it. (See Backprobing on Pg. 245.)
No
1-68
Corrective Action
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].
Repair/replace harness and or connectors
between battery busbar - 12 pos. [X097] and 6pin Deutsch connector socket 2 [X280.2.soc]
and/or the ground busbar - 12 pos. [X098] and 6pin Deutsch connector socket 5 [X280.5.soc]
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 13 Disconnect the #1 boom
angle sensor [X099]. Turn
on the machine.
Test
Is there 12VDC between the #1 boom angle
sensor harness connector closest to the sensor socket 1 [X099.1.soc] and socket 3
[X099.3.soc]?
Step 14 Disconnect the #1 boom
Is there continuity between #1 boom angle
angle sensor [X099] and the sensor socket 2 [X099.2.soc] and the BLAM
BLAM connector J2 [X087] connector J2 socket 8 [X087.8.soc]? Also,
are the contacts free from damage?
Result
Corrective Action
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]
Yes
Reprogram/replace the BLAM
No
Repair/replace harness and/or contacts as
needed
DTC 8410 - BOOM ANGLE SENSOR #2 - COMMUNICATIONS FAULT
Boom angle sensor #2 communications fault. The control system lost serial communications with #2 boom angle sensor
(Operator’s left side).
Note Pretest Instructions
Step 1
Step 4
Step 5
Step 6
Step 7
3128411
Result
Are there loose or damaged connections at the Yes
#2 boom angle sensor connector [X100]?
Corrective Action
Repair any loose or damaged wires or connectors
No
Go to step 2
Does the fault log show BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT before a
power cycle?
Yes
Go to step 4
No
Go to step 3
Turn on machine. DisconIs there 12VDC on #2 boom angle sensor
nect #2 boom angle sensor connector socket 1 [X100.1.soc] and socket
connector [X100]
3 [X100.3.soc]?
Yes
Leave connector disconnected. Go to step 8.
No
Go to step 4
Step 2
Step 3
Test
Turn on machine. BackIs there 12VDC between 12-pin V-Batt+ bus Yes
probe between the 12-pin
connector[X097] and 12-pin ground bus conground bus connector
nector [X098]?
[X098] and 12-pin V-Batt+
No
bus connector [X097] by the
BLAM. (See Backprobing
on Pg. 245 for details on
backprobing.)
Repair/replace 12-pin V-Batt+ bus connector
[X097] and/or 12-pin ground bus connector
[X098].
Leave machine on. Go to step 5.
Turn on machine. Discon- Is there 12VDC between 6-pin Deutsch pin 2
nect 6-pin Deutsch connec- [X280.2.pin] and pin 5 [X280.5.pin]?
tor [X280].
Yes
Go to step 11
No
Leave 6-pin Deutsch connector [X280] diconnected. Go to step 6.
Disconnect 6-pin Deutsch
connector [X280] and
Power Down Relay [X011]
Yes
Leave 6-pin Deutsch connector [X280] disconnected.
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]
Yes
Ensure both contacts of the 6-pin Deutsch connector 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]
Disconnect 6-pin Deutsch
connector [X280] and
ground control module J8
[X008]
Is there a short between 6-pin Deutsch connector pin 2 [X280.2.pin] and Power Down
Relay socket 87 [X011.87.soc]?
Is there a short between 6-pin Deutsch connector pin 2 [X280.2.pin] and ground control
module J8 socket 3 [X008.3.soc]?
1200SJP 1350SJP
1-69
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 8
Test
Result
Corrective Action
Plug the #1 boom angle
Does the BOOM ANGLE SENSOR #1 COMsensor connector [X099]
MUNICATIONS FAULT appear?
into the #2 sensor and the
#2 boom angle sensor connector [X100] into the #1
sensor. Read faults.
Yes
Replace sensor #2
No
Go to step 9
Disconnect #2 boom angle Is there continuity between #2 boom angle
sensor connector [X100]
sensor pin 2 [X100.2.pin] and BLAM J2
and BLAM J2 [X087]
socket 9 [X087.9.soc]?
Yes
Go to step 11
No
Leave the #2 boom angle sensor [X100] disconnected. Go to step 10.
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 sensor 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
Is there 12VDC between the #2 boom angle
angle sensor passthru - 4
sensor passthru socket 1 [X096.1.soc] and
position [X096]. Turn on the socket 3 [X096.3.soc]?
machine.
Yes
Leave the connector disconnected and machine
on. Go to step 13
No
Go to step 12
Step 9
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).
Step 12 Disconnect battery busbar - Is there 12VDC ANY of the sockets in battery Yes
12 pos. [X097] and ground busbar [X097] and ANY of the sockets in
busbar - 12 pos. [X098]
ground busbar [X098]? This measurement
may also be taken by backprobing the connector without disconnecting it. (See Backprobing on Pg. 245.)
No
Step 13 Disconnect the #2 boom
angle sensor [X100]. Turn
on the machine.
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].
Repair/replace harness and or connectors
between battery busbar - 12 pos. [X097] and 6pin Deutsch connector socket 2 [X280.2.soc]
and/or the ground Busbar - 12 pos. [X098] and 6pin Deutsch connector socket 5 [X280.5.soc]
Is there 12VDC between the #2 boom angle
sensor harness connector closest to the sensor 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
Is there continuity between #2 boom angle
angle sensor [X100] and the sensor socket 2 [X100.2.soc] and the BLAM
BLAM connector J2 [X087] 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
DTC 8411 - BOOM ANGLE SENSOR #1 - INVALID ANGLE
Angle sensor number 1 invalid angle. Boom angle sensor 1 (right) is reading over +80 degrees or less than -25 degrees.
Note Pretest Instructions
Step 1
Step 2
Check fault log for active
faults.
Test
Is BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT present?
Result
Yes
Troubleshoot that fault first
No
Go to step 2
Is sensor mounted correctly and undamaged? Yes
Go to step 3
No
1-70
Corrective Action
1200SJP 1350SJP
Repair as needed
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Disconnect Boom Angle
Sensor #1 (Right) [X099].
Test
Result
Does BOOM ANGLE SENSOR #2 COMMUNI- Yes
CATIONS FAULT appear?
Corrective Action
Sensor connections between sensor #1 [X099]
and #2 [X100] are swapped. Restore proper
connections.
No
Go to step 4
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
Disconnect Boom Angle
Turn on the machine. Is there about 12 VDC
Sensor #1 Passthru [X095] 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]
Disconnect Boom Angle
Sensor #1 (Right) [X099]
and Boom Angle Sensor #1
Passthrough [X095]
Is there continuity between Boom Angle Sensor #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]
Disconnect Boom Angle
Is there continuity between Boom Angle SenSensor #1 Passthru [X095] sor #1 Passthru socket 2 [X095.2.soc] and
and BLAM J2 [X087]
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]
Put boom in transport position. Go to ANALYZER 
DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D
ANGLE #1.
Yes
Calibrate boom sensors. See 5.9 Calibrating the
Boom Sensors on Pg. 228.
No
Replace Boom Angle Sensor #1 (Right) [X099]
Disconnect Boom Angle
Sensor #1 (Right) [X099].
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?
DTC 8412 - BOOM ANGLE SENSOR #2 - INVALID ANGLE
Angle sensor number 2 invalid angle. Boom Angle sensor 2 (left) is reading over +80 degrees or less than -25 degrees.
Note Pretest Instructions
Step 1
Check fault log for active
faults.
Step 2
Test
Is BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT present?
Result
Yes
Step 4
3128411
Disconnect Boom Angle
Sensor #2 (Left) [X100].
Disconnect Boom Angle
Sensor #2 (Left) [X100].
Troubleshoot that fault first
No
Go to step 2
Is sensor mounted correctly and undamaged? Yes
Go to step 3
No
Step 3
Corrective Action
Does BOOM ANGLE SENSOR #1 COMMUNI- Yes
CATIONS FAULT appear?
Turn on the machine. Is there about 12 VDC
between Boom Angle Sensor #2 socket1
[X100.1.soc] and socket 3 [X100.2.soc]?
1200SJP 1350SJP
Repair as needed
Sensor connections between sensor #1 [X099]
and #2 [X100] are swapped. Restore proper
connections.
No
Go to step 4
Yes
Keep sensor disconnected.
Go to step 6
No
Go to step 5
1-71
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 5
Step 6
Step 7
Step 8
Test
Result
Corrective Action
Disconnect Boom Angle
Turn on the machine. Is there about 12 VDC
Sensor #2 Passthru [X096] 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].
Disconnect Boom Angle
Sensor #2 (Left) [X100]
and Boom Angle Sensor #2
Passthrough [X096]
Is there continuity between Boom Angle Sensor #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]
Disconnect Boom Angle
Is there continuity between Boom Angle SenSensor #2 Passthru [X096] sor #2 Passthru socket 2 [X096.2.soc] and
and BLAM J2 [X087]
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]
Put boom in transport position. Go to ANALYZER 
DIAGNOSTICS  ENVELOPE  MAIN BOOM A/D
ANGLE #2.
Yes
Calibrate boom sensors. See 5.9 Calibrating the
Boom Sensors on Pg. 228.
No
Replace boom Angle Sensor #2 (Left) [X100]
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?
DTC 8413 - WRONG TELESCOPE RESPONSE
Wrong telescope response. Boom telescope movement contrary to user command. This could be caused by a hydraulic
problem preventing the boom from telescoping in the direction commanded.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 6
1-72
Result
Are there any faults for the Boom Length Sen- Yes
sor [X273], Boom Length Limit Switch
No
[X281], Main Tele In[X073] or Main Tele Out
[X071]?
Raise and extend boom.
Extend boom completely
Step 4
Step 5
Test
Corrective Action
Troubleshoot those faults first
Go to step 2
Operate main boom telescope IN and OUT. Is
the response correct?
Yes
Go to step 3
No
Go to step 6
Apply lubricant to wear pad tracks on booms.
Move boom in and out completely. Does fault
clear?
Yes
Troubleshooting complete
No
Go to step 4
Torque boom wire ropes. See 5.10 Wire Rope Yes
Tensioning Procedure on Pg. 240. Does fault No
clear?
Go to step 5
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228.
Also, calibrate telescope
crack points. See 5.8 Calibrating Telescope Crack
point on Pg. 225.
Does calibration complete successfully?
Yes
Troubleshooting complete
No
Repair according to calibration fault
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
1200SJP 1350SJP
Troubleshooting complete
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Result
Does the hosing between the main valve Yes
main tele section and main tele cylinder match No
the schematic in Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 on Pg.
174?
Corrective Action
Repair/replace main tele cylinder holding valve
Correct hosing as needed
DTC 8414 - WRONG LIFT RESPONSE
Wrong lift response. Boom lift movement contrary to user command. This could be caused by a hydraulic problem preventing the boom from lifting in the direction commanded.
Note Pretest Instructions
Step 1
Step 2
Step 3
Raise and extend boom.
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.
Step 4
Test
Result
Are there any faults for the Boom Angle Sensors [X099] & [X100], or Main lift UP [X276]
and Main lift Down [X277]?
Yes
Troubleshoot them first
No
Go to step 2
Operate main boom lift UP and DOWN. Is the
response correct?
Yes
Go to step 3
No
Go to step 4
Do both calibrations complete successfully?
Yes
Troubleshooting complete
No
Repair according to calibration fault
Yes
Go to step 5
No
Harnesses for main lift up [X276] and main lift
down [X277] are swapped. Correct them.
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
Does the hosing between the main valve main lift valves and main lift cylinder match the No
schematic in Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 on Pg.
174?
Step 5
Corrective Action
Repair/replace main tele cylinder holding valve
Correct hosing as needed
DTC 851 - MOMENT PIN - HORIZONTAL FORCE OUT OF RANGE
Moment pin - horizontal force out of range. The control system has detected that the force applied to the horizontal axis of
the moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is
required.
Note Pretest Instructions
Step 1
3128411
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Result
Does fault still occur? -OR- Does pin fail to cal- Yes
ibrate?
No
1200SJP 1350SJP
Corrective Action
Replace moment pin
Troubleshooting complete
1-73
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 852 - MOMENT PIN - VERTICAL FORCE OUT OF RANGE
Moment pin - vertical force out of range. The control system has detected that the force applied to the vertical axis of the
moment pin is beyond acceptable limits. Moment pin calibration is erased. Recalibration of the boom sensors is required.
Note Pretest Instructions
Step 1
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Result
Does fault still occur? -OR- Does pin fail to cal- Yes
ibrate?
No
Corrective Action
Replace moment pin
Troubleshooting complete
DTC 855 - MOMENT PIN - SENSOR FAULT
Moment pin sensor fault. The control system has detected a fault in the moment pin.
Note Pretest Instructions
Step 1
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Does fault still occur?
Result
Corrective Action
Yes
Replace moment pin
No
Troubleshooting complete
DTC 857 - NEW MOMENT PIN DETECTED FAULT
New moment pin detected fault. The moment pin detected by the system is different from the one used to calibrate machine.
Note Pretest Instructions
Step 1
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Does fault still occur?
Result
Corrective Action
Yes
Replace moment pin
No
Troubleshooting complete
DTC 861 - RESTRICTED TO TRANSPORT - OSCILLATING AXLE PRESSURE SWITCH
DISAGREEMENT
Restricted to transport - Oscillating axle pressure switch disagreement. The control system detected hydraulic pressure at
the oscillating axle lockout pressure switch while the oscillating axle lockout valve solenoid was not being energized or did
not detect pressure while the solenoid was energized. These fault conditions were detected for at least 5 seconds. This fault
is ignored if the engine speed is under 1200 RPM. Only when driving in transport position should the oscillating axle lockout
valve solenoid be energized, closing the oscillating axle lockout pressure switch and unlocking the oscillating axle cylinders.
When out of transport position, drive/steer, main lift up, and main telescope out are prevented. This fault will be active until
an EMS cycle, the engine will be stopped if out of transport and pressure is indicated with this fault, and engine starting will
be prevented while out of transport and pressure is indicated by this switch.
Note Pretest Instructions
Step 1
Step 2
1-74
Test
Result
Is the primary fault, 33173 - RESTRICTED TO Yes
TRANSPORT - AXLE LOCKOUT VALVE No
SHORT TO BATTERY OR OPEN CIRCUIT
present in the fault log?
With the machine idling, does ANALYZER 
DIAGNOSTICS  SYSTEM  OSCILATING
AXLE PRES. SW. read CLOSED?
1200SJP 1350SJP
Corrective Action
Troubleshoot any primary faults first
Go to step 2
Yes
Go to step 14
No
Go to step 3
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
While drive is activated in the transport position does ANALYZER  DIAGNOSTICS 
SYSTEM  OSCILATING AXLE PRES. SW.
read CLOSED?
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Test
Result
Yes
Go to step 4
No
Go to step 5
While drive is activated in the elevated position Yes
does ANALYZER  DIAGNOSTICS  SYSTEM  OSCILATING AXLE PRES. SW. read
No
OPEN?
Tee in a 1000 psi pressure
gauge next to the pressure
switch on the traction control valve manifold
Step 12
3128411
Perform drive calibration. See 5.3 Calibrating
Drive on Pg. 210.
Check the fault log. Troubleshoot any 3-3 codes
in the fault log first
While drive is activated in the transport position does the gauge read above 200 psi?
Yes
Go to step 11
No
Go to step 6
Connect a 1000 psi presWith the machine idling, can the pressure be
sure gauge to the MP port on adjusted with the adjacent charge relief valve
the traction control valve
so that the gauge reads 500psi?
manifold
Yes
Replace the axle lockout valve cartridge
No
Go to step 7
Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes
four drive hoses at the top of has been warmed up. Does the gauge read
the swivel (ports 3, 4, 5, and about 500psi?
No
6). Tee a gauge in with the
hoses at the charge (pressure) filter (on engine side).
Plug open lines.
Tee a gauge in with the
Start engine and let it idle. Ensure hydraulic oil Yes
hoses at the charge filter.
has been warmed up. Does the gauge read
No
Disconnect the front drive
about 500psi?
pump charge pressure lines
(ports Fa and Fe). A jumper
hose between the fittings on
the pump is required to prevent pump damage.
Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes
four drive hoses at the bot- has been warmed up. Does the gauge read
tom of the swivel (ports 3, 4, about 500psi?
No
5, and 6). Tee a gauge in with
the hoses at the charge filter.
Plug open lines.
Step 10 Disconnect hoses to tracStart engine and let it idle. Ensure hydraulic oil Yes
tion valve ports A3, A4, A5, has been warmed up. Does the gauge read
No
A6, B3, B4, B5, and B6.
about 500psi?
Plug/cap open lines and
ports. Tee a gauge in with
the hoses at the charge filter.
Step 11
Corrective Action
Does the voltage at the axle lockout pressure
switch connector YEL/RED 2-1-7 wire
[X213.1.soc] measure 12VDC?
Shut down, and reassemble, but keep gauge
installed. Go to step 8.
Repair/replace right side drive pump
Repair/replace left side drive pump.
Shut down, and reassemble, but keep gauge
installed. Go to step 10.
Repair seals in swivel.
Repair drive motor leakage or replace.
Repair/replace traction valve.
Yes
Go to step 12
No
Check YEL/RED 2-1-7 wire for breaks between
the axle lockout pressure switch [X213] and terminal 1 of the Chassis module J4 connector
[X232.1]
While drive is activated in the transport posi- Yes
tion, does the voltage at the axle lockout pres- No
sure switch connector ORN/RED 49-107 wire
[X213.3] measure 12VDC?
1200SJP 1350SJP
Reassemble, but keep gauge installed. Go to step
9.
Go to step 13
Replace the axle lockout pressure switch
1-75
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 13
Step 14 Plumb a 1000 psi pressure
gauge to the pressure
switch port on the traction
control valve manifold
Test
Result
While drive is activated in the transport posi- Yes
tion, does the voltage at terminal 7 of the chas- No
sis module J2 connector ORN/RED 49-107
wire [X230.7.soc] measure 12VDC?
Corrective Action
Replace the chassis module
Check ORN/RED 49-107 wire for breaks between
the axle lockout pressure switch [X213] and terminal 7 of the Chassis module J2 connector
[X230.7]
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
With the machine idling, does the gauge read
valve solenoid from the
any pressure?
valve. Tee in a 1000 psi
pressure gauge next to the
pressure switch on the traction control valve manifold
Yes
Replace the axle lockout valve cartridge
No
Go to DTC 33173 - RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
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 With the machine idling, does ANALYZER 
chassis module J2 connec- DIAGNOSTICS  SYSTEM  OSCILATING
tor [X230.7.soc]
AXLE PRES. SW. read CLOSED?
Yes
Replace the chassis module
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 connector [X230.7]
Step 16 Disconnect the axle lockout
pressure switch DIN connector [X213]
DTC 862 - AXLE EXTEND VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Axle extend short to battery or open circuit. The control system detected a short to battery or open circuit on the axle extension valve output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC
33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 863 - AXLE EXTEND VALVE - SHORT TO GROUND
Axle extend short to ground. The control system detected a short to ground on the axle extension valves output [X230.11]
controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 864 - AXLE RETRACT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Axle retract short to battery or open circuit. The control system detected a short to battery or open circuit on the axle retract
valves output [X230.12] controlling the front axles retract solenoid [X209] and the rear axles retract solenoid [X221]. See
DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 865 - AXLE RETRACT VALVE - SHORT TO GROUND
Axle retract short to ground. The control system detected a short to ground on the axle retract valves output [X230.12] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 866 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right front steer right valve output [X233.1]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg.
113.
1-76
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 867 - RIGHT FRONT STEER RIGHT VALVE - SHORT TO GROUND
Right front steer right short to ground. The control system detected a short to ground on the chassis module right front steer
right valve output [X233.1]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 868 - RIGHT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right front steer left valve output [X233.2]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 869 - RIGHT FRONT STEER LEFT VALVE - SHORT TO GROUND
Right front steer left short to ground. The control system detected a short to ground on the chassis module right front steer
left valve output [X233.2]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 8610 - LEFT FRONT STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module left front steer left valve output [X233.3].
Note Pretest Instructions
Step 1
Step 2
Connect analyzer and read
fault log
Step 5
Step 6
Step 7
Step 8
3128411
Does fault log shows other steer STB or OC
faults.
Result
Go to step 2
No
Go to step 4
Is there a bad connection at chassis module J5 Yes
connector [X233] or the left front steer right
No
solenoid connector [X207]?
Disconnect the left front
Is the solenoid resistance about 4.9 ?
steer right solenoid connector [X207]. Measure the
solenoid resistance.
Corrective Action
Yes
Disconnect chassis module Check for an open between chassis module J1 Yes
J1 [X230] and battery nega- [X229] socket 4 [X229.4.soc] and the negative terminal [X117]
tive battery terminal
No
Step 3
Step 4
Test
Leave negative battery terminal disconnected. Go
to step 8
Go to step 3
Re-connect connector
Go to step 4
Yes
Go to step 5
No
Replace solenoid
Disconnect the left front
steer right solenoid connector [X207] and chassis
module J5 [X233].
Are all contacts good and is there continuity
Yes
between left front steer right solenoid connector [X207] YELLOW wire and Chassis module No
J5 socket 4 [X233.4.soc]?
Leave solenoid connector and chassis module J5
disconnected. Go to 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 positive battery terminal [X116]?
Yes
Repair/Replace harness
No
Go to 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 connectors?
Yes
Repair/Replace harness
No
Repair/Replace connector as needed.
Yes
Leave negative battery terminal disconnected. Go
to step 10
No
Leave negative battery terminal disconnected. Go
to step 9
Disconnect Upper Swivel
Is there an open between socket 5
connector [X083] and nega- [X083.5.soc] and battery negative terminal
tive battery terminal [X117]. [X117]?
1200SJP 1350SJP
Repair/Replace harness
1-77
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 9
Test
Result
Disconnect negative battery Is there an open between negative battery ter- Yes
terminal [X117] and Lower minal [X117] and Lower Swivel connector pin No
Swivel connector [X216].
5 [X216.5.pin]?
Step 10 Disconnect negative battery Is there an open between Auxiliary Power
terminal [X117]
Pump negative terminal and the negative battery terminal [X117].
Corrective Action
Replace swivel
Repair/replace harness to Chassis module.
Yes
Repair/replace harness between Auxiliary Power
Pump negative terminal and negative battery terminal.
No
Repair/replace harness between Upper Swivel
connector and Auxiliary Power Pump negative
connector.
DTC 8611 - LEFT FRONT STEER RIGHT VALVE - SHORT TO GROUND
Left front steer right short to ground. The control system detected a short to ground on the chassis module left front steer
right valve output [X233.3].
Note Pretest Instructions
Step 1
Step 2
Test
Disconnect the left front
Is the solenoid about 4.9 ?
steer right solenoid connector [X207]
Disconnect the left front
steer right solenoid connector [X207], the chassis
module J5 connector and
the and the Lower Swivel
connector [X216].
Result
Corrective Action
Yes
Leave the left front steer right solenoid connector
[X207] disconnected. Go to step
No
Replace solenoid
Is there a short between the left front steer right Yes
solenoid connector [X207] YELLOW 10-1
No
wire and the Lower Swivel connector socket 5
[X216.5.soc]?
Repair/Replace harness
Check for loose, bent or corroded contacts or
moisture in the connectors. Repair/Replace connector as needed.
DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module left front steer left valve output [X233.4].
Note Pretest Instructions
Step 1
Step 2
Connect analyzer and read
fault log
Step 5
1-78
Does fault log shows other steer STB or OC
faults.
Result
Go to step 2
No
Go to step 4
Is there a bad connection at chassis module J5 Yes
connector [X233] or the left front steer left
No
solenoid connector [X210]?
Disconnect the left front
Is the solenoid resistance about 4.9 ?
steer left solenoid connector
[X210]. Measure the solenoid resistance.
Disconnect the left front
steer left solenoid connector
[X210] and chassis module
J5 [X233].
Leave negative battery terminal disconnected. Go
to step 8
Go to step 3
Re-connect connector
Go to step 4
Yes
Go to step 5
No
Replace solenoid
Are all contacts good and is there continuity
Yes
between left front steer left solenoid connector
yellow wire and Chassis module J5 socket 4 No
[X233.4.soc]?
1200SJP 1350SJP
Corrective Action
Yes
Disconnect chassis module Check for an open between chassis module J1 Yes
J1 [X230] and battery nega- [X229] socket 4 [X229.4.soc] and the negative terminal [X117]
tive battery terminal
No
Step 3
Step 4
Test
Leave solenoid connector and chassis module J5
disconnected. Go to step 6
Repair/Replace harness
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Disconnect positive battery
terminal [X116], left front
steer left solenoid [X210]
and chassis module J5
[X233].
Test
Result
Corrective Action
Is there a short between left front steer left
solenoid [X210] YELLOW 9-1 wire and positive battery terminal [X116]?
Yes
Repair/Replace harness
No
Go to step 7
Check black ground wire
Are there loose, bent, broken or corroded
between terminal 5 of the
wires or contacts or moisture in the connecbottom (chassis) swivel
tors?
connector [X216.5.soc] and
the left front steer left solenoid connector [X210]
Yes
Repair/Replace harness
No
Repair/Replace connector as needed.
Disconnect Upper Swivel
Is there an open between socket 5
connector [X083] and nega- [X083.5.soc] and battery negative terminal
tive battery terminal [X117]. [X117]?
Yes
Leave negative battery terminal disconnected. Go
to step 10
No
Leave negative battery terminal disconnected. Go
to step 9
Disconnect negative battery Is there an open between negative battery ter- Yes
terminal [X117] and Lower minal [X117] and Lower Swivel connector pin No
Swivel connector [X216].
5 [X216.5.pin]?
Step 10 Disconnect negative battery Is there an open between Auxiliary Power
terminal [X117]
Pump negative terminal and the negative battery terminal [X117].
Replace swivel
Repair/replace harness to Chassis module.
Yes
Repair/replace harness between Auxiliary Power
Pump negative terminal and negative battery terminal.
No
Repair/replace harness between Upper Swivel
connector and Auxiliary Power Pump negative
connector.
DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND
Left front steer left short to ground. The control system detected a short to ground on the chassis module left front steer left
valve output [X233.4].
Note Pretest Instructions
Step 1
Step 2
Test
Result
Corrective Action
Disconnect the left front
Is the solenoid about 4.9 ?
steer left solenoid connector
[X210].
Yes
Leave the left front steer left solenoid [X210]disconnected. Go to step 2
No
Replace the solenoid
Disconnect chassis module
connector J5 [X233] left
front steer left solenoid connector [X210] and the Lower
Swivel connector [X216]
Yes
Repair/Replace harness
No
Check for loose, bent or corroded contacts or
moisture in the connectors. Repair/Replace connector as needed.
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]?
DTC 8614 - RIGHT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right rear steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right rear steer right valve output [233.5]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8615 - RIGHT REAR STEER RIGHT VALVE - SHORT TO GROUND
Right rear steer right short to ground. The control system detected a short to ground on the chassis module right rear steer
right valve output [233.5]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
3128411
1200SJP 1350SJP
1-79
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 8616 - RIGHT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Right rear steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the
chassis module right rear steer left valve output [233.6]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8617 - RIGHT REAR STEER LEFT VALVE - SHORT TO GROUND
Right rear steer left short to ground. The control system detected a short to ground on the chassis module right rear steer left
valve output [233.6]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 8618 - LEFT REAR STEER RIGHT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left rear steer right short to battery or open circuit. the control system detected a short to battery or open circuit on the chassis module left rear steer right valve output [X233.7]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8619 - LEFT REAR STEER RIGHT VALVE - SHORT TO GROUND
Left rear steer right short to ground. The control system detected a short to ground on the chassis module left rear steer right
valve output [X233.7]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 8620 - LEFT REAR STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT
Left rear steer left short to battery or open circuit. the control system detected a short to battery or open circuit on the chassis
module left rear steer left valve output [X233.8]. See DTC 33xx - COMMON STB OR OC PROCEDURE on Pg. 113.
DTC 8621 - LEFT REAR STEER LEFT VALVE - SHORT TO GROUND
Left rear steer left short to ground. The control system detected a short to ground on the chassis module left rear steer left
valve output [X233.8]. See DTC 33XX - COMMON STG PROCEDURE on Pg. 114.
DTC 8622 - FRONT RIGHT STEER SENSOR - DECOUPLED
Front right wheel steering sensor decoupled. The control system detected the front right steer angle sensor value was below
the mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or
the sensor may be faulty.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Check faults
Is the fault FRONT RIGHT WHEEL BLOCKED
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?
Yes
Repair as needed
No
Go to step 3
Is the front right wheel sensor [X200] in tact
Yes
and properly installed? This includes checking No
that the sensor pin will turn the sensor and the
sensor is properly tensioned.
Go to step 4
Step 3
Step 4
Step 5
1-80
Extend axles. Go to ANALYZER  DIAGNOSTICS 
DRIVE R FRONT WHEEL
ANGL
Monitor value while operating steering. Steer Yes
fully to the left, then fully to the right. Does the No
displayed angle ever climb above ±42.11?
-OR- Does the value pause, jump or act erratically?
Swap front right wheel sensor [X200] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor fault?
No
1200SJP 1350SJP
Reinstall and recheck
Repair/replace sensor and mounting as needed
Go to step 5
Replace sensor originally at the front right wheel.
Go to step 6
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Test
Calibrate steering. Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 7
Step 7
Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes
sensor [X200]
right wheel sensor socket A [X200.A.soc] and
socket C [X200.C.soc]?
No
Step 8
Disconnect front right wheel Is there continuity between front left wheel
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis
module J3 [X231]
module J3 socket 2 [X231.2.soc]?
Yes
Reprogram/replace ground module
No
Keep front right wheel sensor [X200] disconnected.
Go to step 9
Disconnect front right wheel Is there continuity between front right wheel
sensor [X200] and front
sensor socket B [X200.B.soc] and front right
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]?
[X201]
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]
Is there 5VDC between front right steer
Yes
passthru socket 1 [X201.1.soc] and socket 3
[X201.3.soc]?
Repair/replace harness between front right steer
passthru [X201] and front right wheel sensor
[X200]
Step 9
Step 10 Disconnect front right steer
passthru - 4 pos. [X201].
Turn on machine.
No
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
1 [X231.1.pin] and pin 3 [X231.3.pin]?
No
Keep sensor disconnected.
Go to step 8.
Go to step 10
Go to step 11
Repair/Replace harness between front right steer
passthru [X201] and chassis module J3 [X231]
Replace chassis module
DTC 8623 - FRONT LEFT STEER SENSOR - DECOUPLED
Front left wheel steering sensor not sensing movement. The control system detected the front left steer angle sensor value
was below the mechanical minimum angle while the steer sensor is attached to the wheel. The mechanical limitations on the
maximum steering angle depend on the axle extension. When fully retracted, the steering will be mechanically limited to
about 25°. As the axle is extended, the mechanical limit will increase to about 45°, however the control system will maintain a
25° limit until the axle is fully extended, when the control system allows the full 45° of steering. The sensor may be mounted
improperly or the sensor may be faulty.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Check faults
Is the fault FRONT LEFT WHEEL BLOCKED
present?
Yes
Troubleshoot that first
No
2
Step 2
Disconnect front left steer
sensor [X203]
Do the connectors have any loose, damaged,
corroded contacts or moisture inside?
Yes
Repair as needed
No
Go to step 3
Is the front left wheel sensor X203] in tact and Yes
properly installed? This includes checking that No
the sensor pin will turn the sensor and the sensor is properly tensioned.
Go to step 4
Step 3
Step 4
Step 5
3128411
Extend axles. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L FRONT WHEEL
ANGL
Monitor value while operating steering. Steer Yes
fully to the left, then fully to the right. Does the No
displayed angle ever climb above ±42.11?
-OR- Does the value pause, jump or act erratically?
Swap front left wheel sensor Check faults. Does the new location now have Yes
[X203] with a sensor that
a wheel sensor fault?
No
doesn’t have a fault.
1200SJP 1350SJP
Reinstall and recheck
Repair/replace sensor and mounting as needed
Go to step 5
Replace sensor originally at the front left wheel.
Go to step 6
1-81
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Test
Calibrate steering. Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 7
Step 7
Disconnect front left wheel
sensor [X203]
Turn on machine. Is there 5VDC between front Yes
left wheel sensor socket A [X203.A.soc] and
socket C [X203.C.soc]?
No
Step 8
Disconnect front left wheel
sensor [X203] and chassis
module J3 [X231]
Is there continuity between front left wheel
sensor socket B [X203.B.soc] and chassis
module J3 socket 5 [X231.5.soc]?
Yes
Reprogram/replace ground module
No
Keep front left wheel sensor [X203] disconnected.
Go to 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 9
Step 10 Disconnect front left steer
passthru - 4 pos. [X202].
Turn on machine.
Is there 5VDC between front left steer passthru Yes
socket 1 [X202.1.soc] and socket 3
[X202.3.soc]?
No
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
4 [X231.4.pin] and pin 6 [X231.6.pin]?
No
Keep sensor disconnected.
Go to step 8.
Go to step 10
Repair/replace harness between front left steer
passthru [X202] and front left wheel sensor
[X203]
Go to step 11
Repair/Replace harness between front left steer
passthru [X202] and chassis module J3 [X231]
Replace chassis module
DTC 8624 - REAR RIGHT STEER SENSOR - DECOUPLED
Rear right wheel sensor decoupled. The control system detected the rear right steer angle sensor value was below the
mechanical minimum angle while the steer sensor is attached to the wheel. The sensor may be mounted improperly or the
sensor may be faulty.
Note Pretest Instructions
Step 1
Step 2
Check faults
Disconnect rear right steer
sensor [X239]
Step 3
Step 4
Step 5
Step 6
1-82
Test
Result
Corrective Action
Is the fault REAR RIGHT WHEEL BLOCKED
present?
Yes
Troubleshoot that first
No
2
Do the connectors have any loose, damaged,
corroded contacts or moisture inside?
Yes
Repair as needed
No
Go to step 3
Is the rear right wheel sensor [X239] in tact
Yes
and properly installed? This includes checking No
that the sensor pin will turn the sensor and the
sensor is properly tensioned.
Extend axles. Go to ANALYZER  DIAGNOSTICS 
DRIVE  R REAR WHEEL
ANGL
Monitor value while operating steering. Steer Yes
fully to the left, then fully to the right. Does the No
displayed angle ever climb above ±42.11?
-OR- Does the value pause, jump or act erratically?
Swap rear right wheel sensor [X239] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor fault?
No
Calibrate steering. Does fault clear?
1200SJP 1350SJP
Go to step 4
Reinstall and recheck
Repair/replace sensor and mounting as needed
Go to step 5
Replace sensor originally at the rear right wheel.
Go to step 6
Yes
Troubleshooting complete
No
Go to step 7
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Step 8
Step 9
Disconnect rear right wheel
sensor [X239]
Disconnect rear right wheel
sensor [X239] and chassis
module J3 [X231]
Test
Turn on machine. Is there 5VDC between rear Yes
right wheel sensor socket A [X239.A.soc] and
socket C [X239.C.soc]?
No
Is there continuity between rear right wheel
sensor socket B [X239.B.soc] and chassis
module J3 socket 8 [X231.8.soc]?
Disconnect rear right wheel Is there continuity between rear right wheel
sensor [X239] and rear right sensor socket B [X239.B.soc] and rear right
steer passthru - 4 pos.
steer passthru pin 2 [X236.2.pin]?
[X236]
Step 10 Disconnect rear left steer
passthru - 4 pos. [X237].
Turn on machine.
Result
Corrective Action
Keep sensor disconnected.
Go to step 8.
Go to step 10
Yes
Reprogram/replace ground module
No
Keep rear right wheel sensor [X239] disconnected.
Go to step 9
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]
Is there 5VDC between rear right steer
Yes
passthru socket 1 [X236.1.soc] and socket 3
[X236.3.soc]?
No
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
10 [X231.10.pin] and pin 12 [X231.12.pin]?
No
Repair/replace harness between rear left steer
passthru [X237] and rear left wheel sensor
[X238]
Go to step 11
Repair/Replace harness between rear right steer
passthru [X236] and chassis module J3 [X231]
Replace chassis module
DTC 8625 - REAR LEFT STEER SENSOR - DECOUPLED
Rear left wheel sensor decoupled. The control system detected the rear left steer angle sensor value was below the 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
Step 1
Step 2
Check faults
Disconnect rear left steer
sensor [X238]
Step 3
Step 4
Step 5
Step 6
3128411
Extend axles. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L REAR WHEEL
ANGL
Test
Result
Corrective Action
Is the fault REAR LEFT WHEEL BLOCKED
present?
Yes
Troubleshoot that first
No
2
Do the connectors have any loose, damaged,
corroded contacts or moisture inside?
Yes
Repair as needed
No
Go to step 3
Is the rear left wheel sensor [X238] in tact and Yes
properly installed? This includes checking that No
the sensor pin will turn the sensor and the sensor is properly tensioned.
Go to step 4
Monitor value while operating steering. Steer Yes
fully to the left, then fully to the right. Does the No
displayed angle ever climb above ±42.11?
-OR- Does the value pause, jump or act erratically?
Swap rear left wheel sensor Check faults. Does the new location now have Yes
[X238] with a sensor that
a wheel sensor fault?
No
doesn’t have a fault.
Calibrate steering. Does fault clear?
1200SJP 1350SJP
Reinstall and recheck
Repair/replace sensor and mounting as needed
Go to step 5
Replace sensor originally at the rear left wheel.
Go to step 6
Yes
Troubleshooting complete
No
Go to step 7
1-83
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Step 8
Step 9
Disconnect rear left wheel
sensor [X238]
Test
Turn on machine. Is there 5VDC between rear
left wheel sensor socket A [X238.A.soc] and
socket C [X238.C.soc]?
Result
Corrective Action
Yes
Keep sensor disconnected.
Go to step 8.
No
Go to step 10
Disconnect rear left wheel
sensor [X238] and chassis
module J3 [X231]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and chassis mod- No
ule J3 socket 11 [X231.11.soc]?
Keep rear left wheel sensor [X238] disconnected.
Go to step 9
Disconnect rear left wheel
sensor [X238] and rear left
steer passthru - 4 pos.
[X237]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]?
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]
Step 10 Disconnect rear left steer
passthru - 4 pos. [X237].
Turn on machine.
Is there 5VDC between rear left steer passthru Yes
socket 1 [X237.1.soc] and socket 3
[X237.3.soc]?
No
Step 11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
10 [X231.10.pin] and pin 12 [X231.12.pin]?
No
Reprogram/replace ground module
Repair/replace harness between rear left steer
passthru [X237] and rear left wheel sensor
[X238]
Go to step 11
Repair/Replace harness between rear left steer
passthru [X237] and chassis module J3 [X231]
Replace chassis module
DTC 8626 - FRONT LEFT STEER SENSOR - NOT RESPONDING
Front left wheel steering sensor not sensing movement. The control system is unable to steer the front left wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front left steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.
Note Pretest Instructions
Step 1
Is the front left wheel kept from moving?
Step 2
Step 3
Step 4
Step 5
1-84
Test
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
Note that glow plug’s large
power draw can aggravate
existing problems with
power distribution wiring
and low battery power. Frequent starting can drain battery when preheating.
Result
Yes
Free the wheel from any obstructions
No
Go to step 2
Yes
If a primary fault is found, troubleshoot it before
this fault
No
Go to step 3
When engine coolant temperature is below
Yes
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 No
30 seconds after starting engine?
Watch the angle sensor
Steer completely left, pause, then completely Yes
value on ANALYZER 
right, pause. Does the value continuously and
ACCESS LEVEL 1  CALI- smoothly change while steering?
BRATIONS  STEER 
No
CALIBRATE? Press Enter to
view raw value FRONT LT
STEER VALUE = XX. Do not
press Enter.
If the wheel will not steer in either direction,
check the steer valve for a stuck spool.
1200SJP 1350SJP
Corrective Action
Examine the battery condition and contacts
within the Chassis power distribution wiring.
Repair/replace as needed.
Go to step 4
ESC out of calibrate mode. Cycle E-stop switch to
clear failed calibration message.
Go to step 5
Repair/Replace the sensor and calibrate.
Yes
Repair/Replace the valve
No
Go to step 6
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Are there any bent, damaged, or seized steering components?
Ensure proper pressure with
ANALYZER  ACCESS
LEVEL 1  CALIBRATIONS
 STEER  FRONT LT
STEER VALUE = XX.
Result
Yes
Repair/Replace the component
No
Go to step 7
Install a 3000 psi gauge or higher on Front
Yes
Steer Axle valve port MS1 and MS2 Adjust
No
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 calibrate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Install a low pressure gauge Is condition clear?
(1000 psi) on main manifold
MP1 and adjust to 450 psi ±
10% on load sense
Swap valve section with the Does condition follow valve section to other
one on the other side of
side of machine?
machine.
Corrective Action
Troubleshooting complete
Do not remove gauges.
Go to step 8
Yes
Troubleshooting complete
No
Do not remove gauges.
Go to step 9
Yes
Repair/replace valve section
No
Repair/replace front left steer cylinder and/or
hoses.
DTC 8627 - FRONT RIGHT STEER SENSOR - NOT RESPONDING
Front right wheel steering sensor not sensing movement. The control system is unable to steer the front right wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front right steer angle
sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor.
Note Pretest Instructions
Test
Result
Step 1
Is the front right wheel kept from moving?
Step 2
Check the fault log for primary faults, RT FNT Yes
STEER LT STB OR OC, RT FNT STEER LT STG,
RT FNT STEER RT STB OR OC, RT FNT STEER No
RT STG, or any sensor value too high or too
low
Step 3
Step 4
Step 5
3128411
Note that glow plug’s large
power draw can aggravate
existing problems with
power distribution wiring
and low battery power. Frequent starting can drain battery when preheating.
Yes
Free the wheel from any obstructions
No
Go to step 2
When engine coolant temperature is below
Yes
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 No
30 seconds after starting engine?
Watch the angle sensor
Steer completely left, pause, then completely Yes
value on ANALYZER 
right, pause. Does the value continuously and
ACCESS LEVEL 1  CALI- smoothly change while steering?
No
BRATIONS  STEER 
CALIBRATE? Press Enter
then right arrow to view
FRONT RT STEER VALUE =
XX Do not press Enter.
If the wheel will not steer in either direction,
check the steer valve for a stuck spool.
1200SJP 1350SJP
Corrective Action
If a primary fault is found, troubleshoot it before
this fault
Go to step 3
Examine the battery condition and contacts
within the Chassis power distribution wiring.
Repair/replace as needed.
Go to step 4
ESC out of calibrate mode. Cycle E-stop switch to
clear failed calibration message. Go to step 5
Repair/Replace the sensor and calibrate.
Yes
Repair/Replace the valve
No
Go to step 6
1-85
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Are there any bent, damaged, or seized steering components?
Ensure proper pressure with
ANALYZER  ACCESS
LEVEL 1  CALIBRATIONS
 STEER  FRONT RT
STEER VALUE = XX.
Result
Yes
Repair/Replace the component
No
Go to step 7
Install a 3000 psi gauge or higher on Front
Yes
Steer Axle valve port MS3 and MS4 Adjust
No
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 calibrate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Install a low pressure gauge Is condition clear?
(1000 psi) on main manifold
MP1 and adjust to 450 psi ±
10% on load sense
Swap valve section with the Does condition follow valve section to other
one on the other side of
side of machine?
machine.
Corrective Action
Troubleshooting complete
Do not remove gauges. Go to step 8
Yes
Troubleshooting complete
No
Do not remove gauges. Go to step 9
Yes
Repair/replace valve section
No
Repair/replace front left steer cylinder and/or
hoses.
DTC 8628 - REAR LEFT STEER SENSOR - NOT RESPONDING
Rear left wheel steering sensor not sensing movement. The control system is unable to steer the rear left wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear left steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.
Note Pretest Instructions
Test
Result
Step 1
Is the rear left wheel kept from moving?
Step 2
Check the fault log for primary faults, LT REAR Yes
STEER LT STB OR OC, LT REAR STEER LT
STG, LT REAR STEER RT STB OR OC, LT
No
REAR STEER RT STG, or any steer angle sensor fault
Step 3
Step 4
Step 5
1-86
Yes
Free the wheel from any obstructions
No
Go to step 2
Note that glow plug’s large
power draw can aggravate
existing problems with
power distribution wiring
and low battery power. Frequent starting can drain battery when preheating.
When engine coolant temperature is below
Yes
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 No
30 seconds after starting engine?
Watch the angle sensor
value on ANALYZER 
ACCESS LEVEL 1  CALIBRATIONS  STEER 
CALIBRATE? Press Enter to
view raw value REAR LT
STEER VALUE = XX Do not
press Enter.
Steer completely left, pause, then completely Yes
right, pause. Does the value continuously and
smoothly change while steering?
If the wheel will not steer in either direction,
check the steer valve for a stuck spool.
1200SJP 1350SJP
Corrective Action
If a primary fault is found, troubleshoot it before
this fault
Go to step 3
Examine the battery condition and contacts
within the Chassis power distribution wiring.
Repair/replace as needed.
Go to step 4
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.
Yes
Repair/Replace the valve
No
Go to step 6
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Are there any bent, damaged, or seized steering components?
Ensure proper pressure with
ANALYZER  ACCESS
LEVEL 1  CALIBRATIONS
 STEER  REAR LT
STEER VALUE = XX.
Result
Yes
Repair/Replace the component
No
Go to step 7
Install a 3000 psi gauge or higher on Rear
Yes
Steer Axle valve port MS1 and MS2 Adjust
No
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 calibrate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Install a low pressure gauge Is condition clear?
(1000 psi) on main manifold
MP1 and adjust to 450 psi ±
10% on load sense
Swap valve section with the Does condition follow valve section to other
one on the other side of
side of machine?
machine.
Corrective Action
Troubleshooting complete
Do not remove gauges.
Go to step 8
Yes
Troubleshooting complete
No
Do not remove gauges.
Go to step 9
Yes
Repair/replace valve section
No
Repair/replace rear left steer cylinder and/or
hoses.
DTC 8629 - REAR RIGHT STEER SENSOR - NOT RESPONDING
Rear right wheel steering sensor not sensing movement. The control system is unable to steer the rear right wheel. Steering
was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear right steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor.
Note Pretest Instructions
Test
Result
Step 1
Is the right rear wheel kept from moving?
Step 2
Check the fault log for primary faults, RT REAR Yes
STEER LT STB OR OC, RT REAR STEER LT
STG, RT REAR STEER RT STB OR OC, RT
No
REAR STEER RT STG, or any steer angle sensor fault
Step 3
Step 4
Step 5
3128411
Yes
Free the wheel from any obstructions
No
Go to step 2
Note that glow plug’s large
power draw can aggravate
existing problems with
power distribution wiring
and low battery power. Frequent starting can drain battery when preheating.
When engine coolant temperature is below
Yes
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 No
30 seconds after starting engine?
Watch the angle sensor
value on ANALYZER 
ACCESS LEVEL 1  CALIBRATIONS  STEER 
CALIBRATE? Press Enter to
view raw value REAR RT
STEER VALUE = XX Do not
press Enter.
Steer completely left, pause, then completely Yes
right, pause. Does the value continuously and
smoothly change while steering?
If the wheel will not steer in either direction,
check the steer valve for a stuck spool.
1200SJP 1350SJP
Corrective Action
If a primary fault is found, troubleshoot it before
this fault
Go to step 3
Examine the battery condition and contacts
within the Chassis power distribution wiring.
Repair/replace as needed.
Go to step 4
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.
Yes
Repair/Replace the valve
No
Go to step 6
1-87
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 6
Step 7
Step 8
Step 9
Test
Are there any bent, damaged, or seized steering components?
Ensure proper pressure with
ANALYZER  ACCESS
LEVEL 1  CALIBRATIONS
 STEER  REAR RT
STEER VALUE = XX.
Result
Yes
Repair/Replace the component
No
Go to step 7
Install a 3000 psi gauge or higher on Rear
Yes
Steer Axle valve port MS1 and MS2 Adjust
No
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 calibrate mode. Cycle E-stop switch to clear failed
calibration message. Is condition clear?
Install a low pressure gauge Is condition clear?
(1000 psi) on main manifold
MP1 and adjust to 450 psi ±
10% on load sense
Swap valve section with the Does condition follow valve section to other
one on the other side of
side of machine?
machine.
Corrective Action
Troubleshooting complete
Do not remove gauges.
Go to step 8
Yes
Troubleshooting complete
No
Do not remove gauges.
Go to step 9
Yes
Repair/replace valve section
No
Repair/replace front left steer cylinder and/or
hoses.
DTC 8630 - FRONT RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Front right wheel sensor short to ground or open circuit. The control system detected the front right steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
1-88
Test
Is the front right steer angle sensor [X200]
installed and connected properly?
Result
Corrective Action
Yes
Go to step 2
No
Repair as needed
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  R FRONT WHEEL
ANGL.
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap front right wheel sensor [X200] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor out of range low fault?
No
Go to step 4
Calibrate steering. Does fault clear?
Yes
Troubleshooting complete
No
Go to step 5
Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes
sensor [X200]
right wheel sensor socket A [X200.A.soc] and
socket C [X200.C.soc]?
No
Disconnect front right wheel Is there continuity between front right wheel
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis
module J3 [X231]
module J3 socket 2 [X231.2.soc]?
1200SJP 1350SJP
Go to step 3
Go to 5
Replace sensor originally at the front right wheel.
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep front right wheel sensor [X200] disconnected.
Go to step 7
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Disconnect front right wheel Is there continuity between front right wheel
sensor [X200] and front
sensor socket B [X200.B.soc] and front right
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]?
[X201]
Result
Corrective Action
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 left steer
passthru pin 2 [X201.2.pin]
Is there 5VDC between front right steer
Yes
passthru socket 1 [X201.1.soc] and socket 3
[X202.3.soc]?
Repair/replace harness between front right steer
passthru [X201] and front right wheel sensor
[X200]
Step 8
Disconnect front right steer
passthru - 4 pos. [X201].
Turn on machine.
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
1 [X231.1.pin] and pin 3 [X231.3.pin]?
No
No
Go to step 9
Repair/Replace harness between front right steer
passthru [X201] and chassis module J3 [X231]
Replace chassis module
DTC 8631 - FRONT RIGHT STEER SENSOR - SHORT TO BATTERY
Front right wheel sensor short to battery. The control system detected the front right steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
3128411
Test
Is the front right steer angle sensor [X200]
installed and connected properly?
Result
Yes
No
Corrective Action
Go to step 2
Repair as needed
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  R FRONT WHEEL
ANGL.
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap front right wheel sensor [X200] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor out of range high fault?
No
Go to step 4
Calibrate steering. Does fault clear?
Yes
Troubleshooting complete
No
Go to step 5
Disconnect front right wheel Turn on machine. Is there 5VDC between front Yes
sensor [X200]
right wheel sensor socket A [X200.A.soc] and
socket C [X200.C.soc]?
No
Disconnect front right wheel Is there continuity between front right wheel
sensor [X200] and chassis sensor socket B [X200.B.soc] and chassis
module J3 [X231]
module J3 socket 2 [X231.2.soc]?
1200SJP 1350SJP
Go to step 3
Go to step 5
Replace sensor originally at the front right wheel.
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep front right wheel sensor [X200] disconnected.
Go to step 7
1-89
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Disconnect front right wheel Is there continuity between front right wheel
sensor [X200] and front
sensor socket B [X200.B.soc] and front right
right steer passthru - 4 pos. steer passthru pin 2 [X201.2.pin]?
[X201]
Result
Corrective Action
Yes
Repair harness between front right steer passthru
socket 2 [X202.2.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]
Is there 5VDC between front right steer
Yes
passthru socket 1 [X201.1.soc] and socket 3
[X201.3.soc]?
Repair/replace harness between front right steer
passthru [X201] and front right wheel sensor
[X201]
Step 8
Disconnect front right steer
passthru - 4 pos. [X201].
Turn on machine.
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
1 [X231.1.pin] and pin 3 [X231.3.pin]?
No
No
Go to step 9
Repair/Replace harness between front right steer
passthru [X201] and chassis module J3 [X231]
Replace chassis module
DTC 8632 - FRONT LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Front left wheel sensor short to ground or open circuit. The control system detected the front left steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the front left steer angle sensor [X203]
installed and connected properly?
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L FRONT WHEEL
ANGL.
Step 6
1-90
Result
Yes
No
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap front left wheel sensor Check faults. Does the new location now have Yes
[X203] with a sensor that
a wheel sensor out of range low fault?
No
doesn’t have a fault.
Step 4
Step 5
Test
Calibrate steering. Does fault clear?
Disconnect front left wheel
sensor [X203]
Disconnect front left wheel
sensor [X203] and chassis
module J3 [X231]
1200SJP 1350SJP
Go to step 2
Repair as needed
Go to step 3
Go to step 5
Replace sensor originally at the front left wheel.
Go to step 4
Yes
Troubleshooting complete
No
Go to step 5
Turn on machine. Is there 5VDC between front Yes
left wheel sensor socket A [X203.A.soc] and
socket C [X203.C.soc]?
No
Is there continuity between front left wheel
sensor socket B [X203.B.soc] and chassis
module J3 socket 5 [X231.5.soc]?
Corrective Action
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep front left wheel sensor [X203] disconnected.
Go to step 7
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Result
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]?
Step 8
Disconnect front left steer
passthru - 4 pos. [X202].
Turn on machine.
Is there 5VDC between front left steer passthru Yes
socket 1 [X202.1.soc] and socket 3
[X202.3.soc]?
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
4 [X231.4.pin] and pin 6 [X231.6.pin]?
Corrective Action
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]
No
No
Repair/replace harness between front left steer
passthru [X202] and front left wheel sensor
[X203]
Go to step 9
Repair/Replace harness between front left steer
passthru [X202] and chassis module J3 [X231]
Replace chassis module
DTC 8633 - FRONT LEFT STEER SENSOR - SHORT TO BATTERY
Front left wheel sensor shorted to battery. The control system detected the front left steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the front left steer angle sensor [X203]
installed and connected properly?
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L FRONT WHEEL
ANGL.
Step 6
3128411
Result
Yes
No
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap front left wheel sensor Check faults. Does the new location now have Yes
[X203] with a sensor that
a wheel sensor out of range high fault?
No
doesn’t have a fault.
Step 4
Step 5
Test
Calibrate steering. Does fault clear?
Disconnect front left wheel
sensor [X203]
Disconnect front left wheel
sensor [X203] and chassis
module J3 [X231]
1200SJP 1350SJP
Go to step 2
Repair as needed
Go to step 3
Go to step 5
Replace sensor originally at the front left wheel.
Go to step 4
Yes
Troubleshooting complete
No
Go to step 5
Turn on machine. Is there 5VDC between front Yes
left wheel sensor socket A [X203.A.soc] and
socket C [X203.C.soc]?
No
Is there continuity between front left wheel
sensor socket B [X203.B.soc] and chassis
module J3 socket 5 [X231.5.soc]?
Corrective Action
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep front left wheel sensor [X203] disconnected.
Go to step 7
1-91
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Result
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]?
Step 8
Disconnect front left steer
passthru - 4 pos. [X202].
Turn on machine.
Is there 5VDC between front left steer passthru Yes
socket 1 [X202.1.soc] and socket 3
[X202.3.soc]?
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
4 [X231.4.pin] and pin 6 [X231.6.pin]?
Corrective Action
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]
No
No
Repair/replace harness between front left steer
passthru [X202] and front left wheel sensor
[X203]
Go to step 9
Repair/Replace harness between front left steer
passthru [X202] and chassis module J3 [X231]
Replace chassis module
DTC 8634 - REAR RIGHT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Rear right wheel sensor short to ground or open circuit. The control system detected the rear right steer angle sensor value
was below the electrical minimum. This may be due to an open circuit or a poor connection.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the rear right steer angle sensor [X239]
installed and connected properly?
Step 6
1-92
Result
Yes
No
Corrective Action
Go to step 2
Repair as needed
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  R REAR WHEEL
ANGL.
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap rear right wheel sensor [X239] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor out of range low fault?
No
Go to step 4
Calibrate steering. Does fault clear?
Yes
Troubleshooting complete
No
Go to step 5
Step 4
Step 5
Test
Disconnect rear right wheel
sensor [X239]
Disconnect rear right wheel
sensor [X239] and chassis
module J3 [X231]
Turn on machine. Is there 5VDC between rear Yes
right wheel sensor socket A [X239.A.soc] and
socket C [X239.C.soc]?
No
Is there continuity between rear right wheel
sensor socket B [X239.B.soc] and chassis
module J3 socket 8 [X231.8.soc]?
1200SJP 1350SJP
Go to step 3
Go to step 5
Replace sensor originally at the rear right wheel.
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep rear right wheel sensor [X239] disconnected.
Go to step 7
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Disconnect rear right wheel Is there continuity between rear right wheel
sensor [X239] and rear right sensor socket B [X239.B.soc] and rear right
steer passthru - 4 pos.
steer passthru pin 2 [X236.2.pin]?
[X236]
Result
Corrective Action
Yes
Repair harness between rear right steer passthru
socket 2 [X2.236.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 8
Disconnect rear right steer
passthru - 4 pos. [X236].
Turn on machine.
Is there 5VDC between rear right steer
Yes
passthru socket 1 [X236.1.soc] and socket 3
[X236.3.soc]?
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
7 [X231.10.pin] and pin 9 [X231.9.pin]?
No
No
Repair/replace harness between rear right steer
passthru [X236] and rear right wheel sensor
[X239]
Go to step 9
Repair/Replace harness between rear right steer
passthru [X236] and chassis module J3 [X231]
Replace chassis module
DTC 8635 - REAR RIGHT STEER SENSOR - SHORT TO BATTERY
Rear right wheel sensor short to battery. The control system detected the rear right steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the rear right steer angle sensor [X239]
installed and connected properly?
Step 6
3128411
Result
Yes
No
Corrective Action
Go to step 2
Repair as needed
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  R REAR WHEEL
ANGL.
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap rear right wheel sensor [X239] with a sensor
that doesn’t have a fault.
Check faults. Does the new location now have Yes
a wheel sensor out of range high fault?
No
Go to step 4
Calibrate steering. Does fault clear?
Yes
Troubleshooting complete
No
Go to step 5
Step 4
Step 5
Test
Disconnect rear right wheel
sensor [X239]
Disconnect rear right wheel
sensor [X239] and chassis
module J3 [X231]
Turn on machine. Is there 5VDC between rear Yes
right wheel sensor socket A [X239.A.soc] and
socket C [X239.C.soc]?
No
Is there continuity between rear right wheel
sensor socket B [X239.B.soc] and chassis
module J3 socket 8 [X231.8.soc]?
1200SJP 1350SJP
Go to step 3
Go to step 5
Replace sensor originally at the rear right wheel.
Keep sensor disconnected.
Go to step 6.
Go to step 8
Yes
Reprogram/replace ground module
No
Keep rear right wheel sensor [X239] disconnected.
Go to step 7
1-93
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 7
Test
Result
Disconnect rear right wheel
sensor [X239] and rear left
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]?
Step 8
Disconnect rear right steer
passthru - 4 pos. [X236].
Turn on machine.
Is there 5VDC between rear right steer
Yes
passthru socket 1 [X237.1.soc] and socket 3
[X236.3.soc]?
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
7 [X231.7.pin] and pin 9 [X231.9.pin]?
Corrective Action
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]
No
No
Repair/replace harness between rear right steer
passthru [X236] and rear right wheel sensor
[X239]
Go to step 9
Repair/Replace harness between rear right steer
passthru [X236] and chassis module J3 [X231]
Replace chassis module
DTC 8636 - REAR LEFT STEER SENSOR - SHORT TO GROUND OR OPEN CIRCUIT
Rear left wheel sensor short to ground or open circuit. The control system detected the rear left steer angle sensor value was
below the electrical minimum. This may be due to an open circuit or a poor connection.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the rear left steer angle sensor [X238]
installed and connected properly?
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L REAR WHEEL
ANGL.
Step 6
Step 7
1-94
Result
Yes
No
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Swap rear left wheel sensor Check faults. Does the new location now have Yes
[X238] with a sensor that
a wheel sensor out of range low fault?
No
doesn’t have a fault.
Step 4
Step 5
Test
Calibrate steering. Does fault clear?
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]?
Corrective Action
Go to step 2
Repair as needed
Go to step 3
Go to step 5
Replace sensor originally at the front left wheel.
Go to step 4
Yes
Troubleshooting complete
No
Go to step 5
Yes
Keep sensor disconnected.
Go to step 6.
No
Go to step 8
Disconnect rear left wheel
sensor [X238] and chassis
module J3 [X231]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and chassis mod- No
ule J3 socket 11 [X231.11.soc]?
Keep rear left wheel sensor [X238] disconnected.
Go to step 7
Disconnect rear left wheel
sensor [X238] and rear left
steer passthru - 4 pos.
[X237]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]?
Repair harness between rear left steer passthru
socket 2 [X2.237.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]
1200SJP 1350SJP
Reprogram/replace ground module
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 8
Disconnect rear left steer
passthru - 4 pos. [X237].
Turn on machine.
Test
Result
Is there 5VDC between rear left steer passthru Yes
socket 1 [X237.1.soc] and socket 3
[X237.3.soc]?
No
Step 9
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
10 [X231.10.pin] and pin 12 [X231.12.pin]?
No
Corrective Action
Repair/replace harness between rear left steer
passthru [X237] and rear left wheel sensor
[X237]
Go to step 9
Repair/Replace harness between rear left steer
passthru [X237] and chassis module J3 [X231]
Replace chassis module
DTC 8637 - REAR LEFT STEER SENSOR - SHORT TO BATTERY
Rear left wheel sensor short to battery. The control system detected the rear left steer angle sensor value was above the
electrical maximum. This may be due to a short to battery or a wiring problem.
Note Pretest Instructions
Step 1
Step 2
Step 3
Is the rear left steer angle sensor [X238]
installed and connected properly?
Extend axles. Enable crab
steering mode. Go to ANALYZER  DIAGNOSTICS 
DRIVE  L REAR WHEEL
ANGL.
Step 6
Step 7
Step 8
Result
Disconnect rear left wheel
sensor [X238]
Go to step 2
No
Repair as needed
Observe angle while operating steering. Steer Yes
fully to the left. Check all wheel angles. They
No
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?
Go to step 3
Go to step 5
Replace sensor originally at the rear left wheel.
Go to step 4
Calibrate steering. Does fault clear?
Yes
Troubleshooting complete
No
Go to step 5
Turn on machine. Is there 5VDC between rear
left wheel sensor socket A [X238.A.soc] and
socket C [X238.C.soc]?
Yes
Keep sensor disconnected.
Go to step 6.
No
Go to step 8
Disconnect rear left wheel
sensor [X238] and chassis
module J3 [X231]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and chassis mod- No
ule J3 socket 11 [X231.11.soc]?
Keep rear left wheel sensor [X238] disconnected.
Go to step 7
Disconnect rear left wheel
sensor [X238] and rear left
steer passthru - 4 pos.
[X237]
Is there continuity between rear left wheel sen- Yes
sor socket B [X238.B.soc] and rear left steer
passthru pin 2 [X237.2.pin]?
Repair harness between rear left steer passthru
socket 2 [X237.2.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]
Disconnect rear left steer
passthru - 4 pos. [X237].
Turn on machine.
Is there 5VDC between rear left steer passthru Yes
socket 1 [X237.1.soc] and socket 3
[X237.3.soc]?
No
3128411
Corrective Action
Yes
Swap rear left wheel sensor Check faults. Does the new location now have Yes
[X238] with a sensor that
a wheel sensor out of range high fault?
No
doesn’t have a fault.
Step 4
Step 5
Test
1200SJP 1350SJP
Reprogram/replace ground module
Repair/replace harness between rear left steer
passthru [X237] and rear left wheel sensor
[X238]
Go to step 9
1-95
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 9
Test
Result
Disconnect chassis module Is there 5VDC between chassis module J3 pin Yes
J3. Turn on machine.
10 [X231.10.pin] and pin 12 [X231.12.pin]?
No
Corrective Action
Repair/Replace harness between rear left steer
passthru [X237] and chassis module J3 [X231]
Replace chassis module
DTC 8651 - ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT
Engine shutdown - axle lockout valve fault. The control system detected a short to battery or open circuit on the axle lockout
valve and detects pressure on the pressure switch and the boom is out of transport position. Engine starting will be prevented while this fault is active. Use auxiliary power to lower the boom to transport. See DTC 33173 - RESTRICTED TO
TRANSPORT - AXLE LOCKOUT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 30.
DTC 998 - EEPROM FAILURE - CHECK ALL SETTINGS
EEPROM failure - check all settings. A critical failure occurred with the EEPROM. Personalities, machine configuration digits,
etc. may be reset to default values and should be checked. A power cycle is required. This can occur if new software that
adds a personality or other configurations, is downloaded to the machine.
Note Pretest Instructions
Step 1
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Reprogram/replace ground module
DTC 9910 - FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER
Functions locked out - platform module software version improper. Notification that the functions have been locked out
because the major version of the platform module software does not match the major version of the ground module software. Load the same version of software in the platform and ground modules.
DTC 9914 - PLATFORM MODULE SOFTWARE UPDATE REQUIRED
Platform module software update required. The platform module software is a different major version than the ground module. Load new platform module software.
DTC 9915 - CHASSIS TILT SENSOR NOT GAIN CALIBRATED
Chassis tilt sensor not gain calibrated. Chassis tilt sensor calibration information has been lost. Machine will indicate that it is
tilted at all times. This calibration data is programmed into the ground module during its manufacture, not in the field.
Note Pretest Instructions
Step 1
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Replace ground module
DTC 9916 - CHASSIS TILT SENSOR GAIN OUT OF RANGE
Chassis tilt sensor gain out of range. Chassis tilt sensor calibration information has been corrupted. This calibration data is
programmed into the ground module during its manufacture, not in the field.
Note Pretest Instructions
Step 1
1-96
Cycle power
Test
Does fault clear?
1200SJP 1350SJP
Result
Corrective Action
Yes
Troubleshooting complete
No
Replace ground module
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 9917 - HIGH RESOLUTION A2D FAILURE - INTERRUPT LOST
High resolution analog to digital failure-interrupt lost. This fault should only occur with software versions prior to 7.0. There is
an internal problem with the platform module.
DTC 9918 - HIGH RESOLUTION A2D FAILURE - REINIT LIMIT
High resolution analog to digital failure - reinit limit. This fault should only occur with software versions prior to 7.0. There is
an internal problem with the platform module.
DTC 9919 - GROUND SENSOR REF VOLTAGE OUT OF RANGE
Ground sensor reference voltage out of range. The ground module 7VDC reference voltage is out of acceptable range. This
reference voltage is unused at this time. Possible causes of this fault include bad supply circuit in the module, or wires mistakenly connected to the following pins on ground module J7 [X007]: J7-5, J7-16, J7-26, or J7-27.
Note Pretest Instructions
Step 1
Test
Result
Are there any wires present in any of the folYes
lowing terminals: ground module J7 terminal 5
[X007.5], terminal 16 [X007.16], terminal 26
[X007.26], or terminal 27 [X007.27]?
No
Step 2 Use backprobing for following measurement. See
Backprobing on Pg. 245 for
details.
Is there 6.6VDC - 7.5VDC at the following ter- Yes
minals: ground module J7 terminal 5
No
[X007.5], terminal 16 [X007.16], terminal 26
[X007.26], or terminal 27 [X007.27]?
Corrective Action
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.
Go to step 2
Reprogram/replace the ground module
Replace the ground module
DTC 9920 - PLATFORM SENSOR REF VOLTAGE OUT OF RANGE
Platform sensor reference voltage out of range. The platform module 7VDC reference voltage is out of acceptable range.
This supply is used for the lift, swing, drive and pump controls.
Note Pretest Instructions
Test
Step 1 Disconnect platform module Is there about 2.5k between platform modJ5 [X167]
ule J5 socket 1 [X167.1.soc] and J5 socket 7
[X167.7.soc]?
Result
Corrective Action
Yes
Keep connector disconnected.
Go to step 2.
No
Repair/replace Lift & Swing joystick assembly
and/or wiring
Step 2 Disconnect platform module Is there 6.6V - 7.5V between platform module Yes
J5 [X167] and J6 [X168]
J5 pin 1 [X167.1.pin] and J5 pin 7
and hyd speed pot passthru [X167.7.pin]?
No
- 6 pos [X199]. Turn on
machine.
Keep J5 [X167] disconnected.
Go to step 3.
Step 3 Disconnect platform module Is there a short between platform module J5
J5 [X167]. Ground multime- socket 1 [X167.1.soc] and ground?
ter. See Grounding on Pg.
245 for details.
Yes
Repair/replace harness affecting Lift & Swing
joystick wiring.
No
Go to step 4
Step 4 Disconnect platform module Turn on machine. Is there about 12 VDC
J5 [X167]. Ground multime- between platform module J5 socket 1
ter. See Grounding on Pg.
[X167.1.soc] and ground?
245 for details.
Yes
Short to battery. Repair/replace harness affecting
the Lift & Swing joystick wiring.
No
Go to step 5
Step 5 Disconnect platform module Is there about 5k between platform module
J6 [X168]
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
Go to step 12
1-97
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Corrective Action
Step 6 Disconnect platform module Is there a short between platform module J6
J6 [X168]. Ground multime- socket 1 [X168.1.soc] and ground?
ter. See Grounding on Pg.
245 for details.
Yes
Short to ground. Repair/replace harness affecting
Drive joystick assembly.
No
Go to step 7
Step 7 Disconnect platform module Turn on machine. Is there about 12 VDC
J6 [X168]. Ground multime- between platform module J6 socket 1
ter. See Grounding on Pg.
[X168.1.soc] and ground?
245 for details.
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]
Step 9 Disconnect hyd speed pot
passthru - 6 pos. [X199].
Step 10 Disconnect hyd speed pot
passthru [X199] and platform module J1 [X165].
Measure resistance between hyd speed pot
Yes
passthru socket 4 [X199.4.soc] and socket 5
[X199.5.soc]. Is there a short or open?
No
Measure resistance from hyd speed pot
passthru pin 4 [X199.4.pin] and pin 5
[X199.5.pin]. Is there a short?
Measure resistance from platform module J1
socket 13 [X165.13.soc] and socket 34
[X165.34.soc]. Is there a short?
Keep hyd speed pot passthru [X199] disconnected.
Go to step 10
No
Keep hyd speed pot passthru [X199] disconnected.
Go to step 11
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
Measure resistance between hyd speed pot
Yes
passthru socket 3 [X199.3.soc] and socket 4 No
[X199.4.soc]. Is there a short?
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?
Measure resistance between hyd speed pot
passthru pin 3[X199.3.pin] and pin 4
[X199.4.pin]. Is there a short?
Keep hyd speed pot passthru [X199] disconnected.
Go to step 9
Yes
Step 11 Disconnect hyd speed pot
passthru [X199]
Step 13 Disconnect hyd speed pot
passthru [X199] and platform module J1 [X165]
Repair/replace hyd speed pot passthru [X199]
and or Speed Controller [X192]
Repair/replace Speed Controller [X192]
Keep hyd speed pot passthru [X199] disconnected.
Go to step 12
Yes
Keep hyd speed pot passthru [X199] disconnected.
Go to step 13.
No
Reprogram/replace platform module
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.
DTC 9921 - GROUND MODULE FAILURE - HIGH SIDE DRIVER CUTOUT FAULTY
Ground module failure: high side driver cutout faulty. There is an internal problem with the ground module.
DTC 9922 - PLATFORM MODULE FAILURE - HWFS CODE 1
Platform module failure: hardware fail-safe code 1. Platform module V(low) FET has failed. A power cycle is required.
Note Pretest Instructions
Step 1
1-98
Cycle power
Test
Does fault clear?
1200SJP 1350SJP
Result
Corrective Action
Yes
Troubleshooting complete
No
Replace platform module
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 9923 - GROUND MODULE FAILURE - HWFS CODE 1
Ground module failure: hardware fail-safe code 1. The ground module V(low) FET has failed. A power cycle is required.
Note Pretest Instructions
Step 1
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Replace ground module
DTC 9925 - FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER
Functions locked out - chassis module software version improper. Notification that the functions have been locked out
because the major version of the chassis module software does not match the major version of the ground module software.
Load the same version of software in the chassis and ground modules.
DTC 9926 - FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER
Functions locked out - BLAM module software version improper. Notification that the functions have been locked out
because the major version of the BLAM module software does not match the major version of the ground module software.
Load the same version of software in the BLAM and ground modules.
DTC 9927 - GROUND MODULE CONSTANT DATA UPDATE REQUIRED
Ground module constant data update required. The ground module has old constant data that is not compatible with the
current ground module software. The ground module constant data must be updated to a newer version. A power cycle is
required.
Note Pretest Instructions
Step 1
Cycle power
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Reprogram/replace ground module
DTC 9928 - ENVELOPE CONTROL DISABLED
Envelope control disabled. The user has forced envelope control off with the analyzer from access level 0. This can happen
if calibration procedure is not followed properly.
Note Pretest Instructions
Step 1
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Did fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Reprogram/replace ground module
DTC 9929 - MOMENT CONTROL DISABLED
Moment control disabled. The user has forced envelope control off with the analyzer from access level 0.
Note Pretest Instructions
Step 1
Step 2
3128411
Cycle power
Calibrate boom sensors.
See 5.9 Calibrating the
Boom Sensors on Pg. 228
for details.
Test
Does fault still occur?
Does fault still occur?
1200SJP 1350SJP
Result
Corrective Action
Yes
Go to step 2
No
Troubleshooting complete
Yes
Replace ground module
No
Troubleshooting complete
1-99
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 9930 - STEER SENSORS NOT CALIBRATED
Steer sensors not calibrated. The steering sensors require calibration. This fault can happen if calibration is incorrect or a
new chassis module has been installed and steering calibration is not done. See 5.2 Calibrating Steer on Pg. 208 for instructions 5.2 Calibrating Steer on Pg. 208.
DTC 9931 - BOOM SENSORS NOT CALIBRATED
Boom sensors not calibrated. The Boom sensors require calibration. See 5.1 Calibration Instructions on Pg. 207, Table 5-2.
Calibrations Listed by Service Action on Pg. 207 and 5.9 Calibrating the Boom Sensors on Pg. 228 for more details. The
machine will be in electrical retrieval mode until in transport position. Then, controlled angle, auto main lift, and main lift up
will be disabled.
Note Pretest Instructions
Step 1
Step 2
Read active faults
Perform boom sensor calibration.
Test
Result
Are there any boom sensor faults?
Does machine calibrate successfully?
Corrective Action
Yes
Troubleshoot those faults first
No
Go to step 2
Yes
Troubleshooting complete
No
Troubleshoot in accordance with calibration fault
DTC 9932 - LIFT CRACKPOINTS NOT CALIBRATED
Lift crackpoints not calibrated. The lift valves require a calibration that has not yet been performed. See 5.7 Calibrating Lift
Crack Point on Pg. 222 for instructions.
DTC 9933 - TELESCOPE CRACKPOINTS NOT CALIBRATED
The telescope valves require a calibration that has not yet been performed. See 5.8 Calibrating Telescope Crack point on Pg. 225 for
instructions.
DTC 9934 - DRIVE CRACKPOINTS NOT CALIBRATED
Drive crackpoints not calibrated. The drive valves require a calibration that has not been performed.
Note Pretest Instructions
Step 1
Test
Are there any Drive faults?
Result
Corrective Action
Yes
Troubleshoot those first
No
Go to step 2
Step 2 Perform dive calibration.
Did calibration complete successfully?
See 5.3 Calibrating Drive on
Pg. 210.
Yes
Troubleshooting complete
No
Go to step 3
Step 3
Yes
Troubleshoot all calibration faults
No
Go to step 4
While drive is activated in the transport position does the gauge read about 500 psi?
Yes
Replace the ground module
No
Go to step 5
Step 5 Connect a 1000 psi presWith the machine idling, can the pressure be
sure gauge to the MP port on adjusted with the adjacent charge relief valve
the traction control valve
so that the gauge reads 500psi?
manifold
Yes
Replace the axle lockout valve cartridge
No
Go to step 6
Step 4 Tee in a 1000 psi pressure
gauge next to the pressure
switch on the traction control valve manifold
1-100
Were there any calibration faults?
1200SJP 1350SJP
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Test
Result
Corrective Action
Step 6 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes
four drive hoses at the top of has been warmed up. Does the gauge read
the swivel (ports 3, 4, 5, and about 500psi?
No
6). Tee in a gauge with the
hoses at the charge (pressure) filter (on engine side).
Plug open lines.
Reassemble, but keep gauge installed.
Go to step 8.
Step 7 Tee in a gauge with the
Start engine and let it idle. Ensure hydraulic oil Yes
hoses at the charge filter.
has been warmed up. Does the gauge read
No
Disconnect the front drive
about 500psi?
pump charge pressure lines
(ports Fa and Fe). A jumper
hose between the fittings on
the pump is required to prevent pump damage.
Repair/replace right side drive pump
Step 8 Disconnect, plug and cap all Start engine and let it idle. Ensure hydraulic oil Yes
four drive hoses at the bot- has been warmed up. Does the gauge read
tom of the swivel (ports 3, 4, about 500psi?
5, and 6). Tee in a gauge with
No
the hoses at the charge filter.
Plug open lines.
Step 9 Disconnect hoses to tracStart engine and let it idle. Ensure hydraulic oil Yes
tion valve ports A3, A4, A5, has been warmed up. Does the gauge read
A6, B3, B4, B5, and B6.
about 500psi?
No
Plug/cap open lines and
ports. Tee a gauge in with
the hoses at the charge filter.
Shut down, and reassemble, but keep gauge
installed.
Go to step 7.
Repair/replace left side drive pump.
Shut down, and reassemble, but keep gauge
installed.
Go to step 9.
Repair seals in swivel.
Repair drive motor leakage or replace drive
motor.
Repair/replace traction valve.
DTC 9935 - BLAM SENSOR SUPPLY OUT OF RANGE HIGH
BLAM sensor supply out of range high. BLAM sensor power supply voltage for the boom angle sensors is above the
expected range. A power cycle is required.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
3128411
Cycle power
Test
Does fault clear?
Result
Yes
Troubleshooting complete
No
Go to step 2
Yes
Leave all optional power sources de-energized.
Go to step 3.
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.
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Does fault clear?
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Re-energize one source and re-check faults.
Does fault re-appear?
Disconnect BLAM J3
[X088]. Turn on machine.
Is there between 5.5 V and 4.5 volts measured Yes
between the following points on
No
BLAM J3?
pin 1 [X088.8.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin]
1200SJP 1350SJP
Corrective Action
Go to step 5
Replace BLAM
1-101
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 5
Disconnect BLAM J3
[X088]. Disconnect battery
(+) terminal [X116]
Test
Result
Is there a short between the battery (+) termi- Yes
nal [X116] and any of the following: BLAM J3,
socket 1 [X088.1.soc], socket 4
No
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?
Corrective Action
Troubleshoot BLAM J3 [X088] harness wire with
short
Reprogram/replace BLAM
DTC 9936 - BLAM SENSOR SUPPLY OUT OF RANGE LOW
BLAM sensor supply out of range low. BLAM sensor power supply voltage for the boom angle sensors is below the expected
range. A power cycle is required.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Cycle power
Does fault clear?
Step 2
Disconnect BLAM J3
[X088]. Turn on machine.
Disconnect BLAM J3
[X088]. Disconnect battery
( - ) terminal [X117]
Is there a short between the battery ( - ) termi- Yes
nal [X117] and any of the following: chassis
module J3, socket 1 [X088.1.soc], socket 4 No
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?
Troubleshoot BLAM J3 [X088] harness wire with
short
Step 3
Yes
Troubleshooting complete
No
Go to step 2
Is there between 5.5 V and 4.5 volts measured Yes
between the following points on
No
BLAM J3?
pin 1 [X088.8.pin] to pin 3 [X088.3.pin];
pin 4 [X088.4.pin] to pin 6 [X088.6.pin];
Go to step 3
Replace BLAM
Reprogram/replace BLAM
DTC 9937 - LENGTH SENSOR REF VOLTAGE HIGH
Length sensor reference voltage high. Supply voltage for the boom length sensors is above 5.5VDC. A power cycle is
required.
Note Pretest Instructions
Test
Result
Corrective Action
Step 1
Cycle power
Did fault clear?
Yes
No
Go to step 2
Step 2
Disconnect all on-board and Did fault clear?
off-board optional power
systems such as 110VAC
and welders to keep them
from energizing
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- Yes
sured between all of the following points on
No
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]?
Go to step 4
Step 3
Step 4
1-102
Disconnect BLAM J3
[X088]. Turn on machine.
Disconnect BLAM J3
Is there a short between the battery (+) termi- Yes
[X088] and battery + termi- nal [X116] and any of the following: BLAM J3
socket 1 [X088.1.soc], socket 4
nal [X116].
No
[X088.4.soc], socket 7 [X088.7.soc], or
socket 10 [X088.10.soc]?
1200SJP 1350SJP
Troubleshooting complete
Replace BLAM
Troubleshoot BLAM J3 [X088] harness wire(s)
with short
Reprogram/replace BLAM
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 9938 - LENGTH SENSOR REF VOLTAGE LOW
Length sensor reference voltage low. Supply voltage for the boom length sensors is below 4.5VDC. A power cycle is
required.
Note Pretest Instructions
Step 1
Step 2
Step 3
Cycle power
Test
Did fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 3
Disconnect BLAM J3
[X088]. Turn on machine.
Is there between 5.5 VDC and 4.5 VDC mea- Yes
sured between the following points on
No
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]?
Go to step 4
Disconnect BLAM J3
[X088]. Ground meter. See
Grounding on Pg. 245 for
details.
Is there a short between ground and any of the Yes
following: BLAM J3 socket 1 [X088.1.soc],
socket 4 [X088.4.soc], socket 7
No
[X088.7.soc], or socket 10 [X088.10.soc]?
Troubleshoot BLAM J3 [X088] harness wire(s)
with short
Replace BLAM
Reprogram/replace BLAM
DTC 9939 - BLAM HIGH RES A/D FAILURE
BLAM high resolution analog to digital converter failure. A BLAM internal circuit to measure sensor output had a failure. A
power cycle is required.
Note Pretest Instructions
Step 1
Cycle power. Check faults.
Test
Does fault continue to occur after cycling
power?
Result
Corrective Action
Yes
Replace BLAM
No
Troubleshooting complete
DTC 9940 - CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH
Chassis sensor supply out of range high. The supply voltage for steer angle sensors is above the expected range. A power
cycle is required.
Note Pretest Instructions
Step 1
Step 2
Step 3
Step 4
3128411
Cycle power
Test
Does fault clear?
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Does fault clear?
Ensure all optional power
sources are de-energized,
including welding and offboard power.
Re-energize one source and re-check faults.
Does fault re-appear?
Result
Yes
Troubleshooting complete
No
Go to step 2
Yes
Leave all optional power sources de-energized.
Go to step 3.
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.
Disconnect chassis module Is there between 5.5 V and 4.5 volts measured Yes
J3 [X231]. Turn on machine. between all of the following points on
No
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]?
1200SJP 1350SJP
Corrective Action
Go to step 5
Replace chassis module
1-103
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 5
Test
Result
Disconnect chassis module Is there a short between the battery (+) termi- Yes
J3 [X231]. Disconnect bat- nal [X116] and any of the following: chassis
tery (+) terminal [X116]
module J3, socket 1 [X231.1.soc], socket 4 No
[X231.4.soc], socket 7 [X231.7.soc], or
socket 10 [X231.10.soc]?
Corrective Action
Troubleshoot chassis module J3 [X231] harness
wire with short
Reprogram/replace chassis module
DTC 9941 - CHASSIS SENSOR SUPPLY OUT OF RANGE LOW
Chassis sensor supply out of range low. The supply voltage for chassis steer angle sensors is below the expected range. A
power cycle is required.
Note Pretest Instructions
Step 1
Cycle power
Step 2
Step 3
Test
Does fault clear?
Result
Corrective Action
Yes
Troubleshooting complete
No
Go to step 2
Disconnect chassis module Is there between 5.5 V and 4.5 volts measured Yes
J3 [X231]. Turn on machine. between the following points on
No
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]?
Go to step 3
Disconnect chassis module Is there a short between the battery(-) terminal Yes
J3 [X231]. Disconnect bat- [X117] and any of the following: chassis modtery - terminal [X117]
ule J3, socket 1 [X231.1.soc], socket 4
No
[X231.4.soc], socket 7 [X231.7.soc], or
socket 10 [X231.10.soc]?
Replace chassis module
Troubleshoot chassis module J3 [X231] harness
wire with short
Reprogram/replace chassis module
DTC 9944 - CURRENT FEEDBACK GAINS OUT OF RANGE
Current feedback gains out of range. Reserved for future use. Should not occur on current machine..
Note Pretest Instructions
Test
Step 1
Go to ANALYZER 
MACHINE SETUP
Step 2
Reprogram ground module. Does fault clear?
Are parameters set properly in Machine
Setup?
Result
Corrective Action
Yes
Go to step 2
No
Reprogram/replace ground module
Yes
Troubleshooting complete
No
Reprogram/replace ground module
DTC 9945 - CURRENT FEEDBACK CALIBRATION CHECKSUM INCORRECT
Current feedback calibration checksum incorrect. Reserved for future use. Should not occur on current machine..
Note Pretest Instructions
Step 1
Step 2
1-104
Go to ANALYZER 
MACHINE SETUP
Test
Result
Are parameters and configuration set properly Yes
in Machine Setup?
No
Reprogram ground module. Does fault clear?
1200SJP 1350SJP
Corrective Action
Go to step 2
Reprogram/replace ground module
Yes
Troubleshooting complete
No
Reprogram/replace ground module
3128411
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
DTC 9979 - FUNCTIONS LOCKED OUT - GROUND MODULE SOFTWARE VERSION IMPROPER
Functions locked out - ground module software version improper. All functions are locked out because ground module software version is improper for machine configuration...
Note Pretest Instructions
Step 1
Step 2
Test
Is machine fitted with telematics equipment?
Go to ANALYZER 
MACHINE SETUP.
Is model is correct?
Result
Corrective Action
Yes
Go to step 2.
No
Go to ANALYZER  MACHINE SETUP.
Set TELEMATICS to NO.
Yes
Reprogram ground module with proper software.
No
Set correct model.
DTC 33XX - COMMON STB OR OC PROCEDURE
Common short to battery or open circuit procedure. A module input or output pin has been shorted to battery or the circuit
has an open in it. All driver faults are detected in a similar manner. Open circuit faults are detected when the analog feedback
reads too high and the output is commanded off. Short to battery is detected when the analog feedback reads Vbat and the
output is commanded off. See the fault description for the component or module pin identification. Frequently, this is due to
a failed component shorting to battery voltage. This procedure applies to a number of faults, so it leaves the determination of
specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine
schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For
example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some
components are effectively a separate module, such as the main boom angle sensors. When opening any electrical connection, inspect the connectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several examples are given starting at DTC 8612 - LEFT FRONT STEER LEFT VALVE - SHORT TO BATTERY OR OPEN CIRCUIT on Pg.
86.
Note Pretest Instructions
Step 1
Step 2
Step 3
3128411
Test
Are other STB/OC faults in the fault log?
Find component on schematic and on the machine.
Result
Yes
Check for an open at a point in circuit common to
this fault and the others.
No
Go to step 2
Is the component good? Check the compoPass
nent resistance. Resistances of coils are given Fail
in Section 2. Electrical Reference on Pg. 109.
Other loads or sensors should be neither short
nor open. Some values are given on the schematics. For details on what some switch positions mean see Table 2-1. Limit Switch States
on Pg. 109. Also, inspect the connector for
pins that are damaged, loose pushed out, etc.
Find component power con- Is the component power good? Turn on
tacts.
machine and check the harness connector
contacts for power. Not all components are
powered by 12VDC.
1200SJP 1350SJP
Corrective Action
Go to step 3
Repair as needed
Pass
Go to step 4
Fail
Follow power connections back to source checking 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
1-105
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 4
Test
Result
Is the signal wire good? Check the signal wire Pass
between the component and the signal input/ Fail
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 harness sections that may have a problem by disconnecting connectors as needed. Be sure to
check for pins that are damaged, loose or
pushed out of the connector, etc.
Step 5
Are the other wires good? Check wire from the Pass
component in question ground connection to
the nearest major component. It should have
continuity to the module, swivel or bus conFail
nector in accordance with the schematic.
Corrective Action
Go to step 5
Repair as needed
Recheck measurements or try troubleshooting a
different fault. If the component and wiring are
good, reprogram/replace the associated module.
Repair as needed
DTC 33XX - COMMON STG PROCEDURE
Common short to ground procedure. A module input or output pin has been shorted to ground. All driver faults are detected
in a similar manner. Short to ground is detected when the analog feedback reads low and the output is commanded on. See
the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting
ground. This procedure applies to a number of faults so it leaves the determination of specific troubleshooting steps to the
technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power
for a particular component does not necessarily come directly from the battery. For example, the platform module power and
ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate
module, such as the main boom angle sensors and PVG valves. When opening any electrical connection, inspect the connectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several examples are given starting at DTC 8613 - LEFT FRONT STEER LEFT VALVE - SHORT TO GROUND on Pg. 87.
Note Pretest Instructions
Step 1
Step 2
1-106
Find component on schematic and on the machine.
Test
Result
Is the component good? Check the compoPass
nent resistance. Resistances of coils are given Fail
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.
Find component power con- Is the component power good? Turn on
tacts.
machine and check the harness connector
contacts for power. Not all components are
powered by 12VDC.
1200SJP 1350SJP
Corrective Action
Go to step 3
Repair as needed
Pass
Go to step 4
Fail
Follow power connections back to source checking 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
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
Note Pretest Instructions
Step 3
Step 4
3128411
Test
Result
Corrective Action
Is the signal wire good? Check the signal wire Pass
between the component and the signal input/ Fail
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 harness sections that may have a problem by disconnecting connectors as needed. Be sure to
include checking for pins that are damaged,
loose or pushed out of the connector.
Go to step 4
Are the other wires good? If it does not go to
Pass
ground, check other wire from the component
in question connection to the nearest major
component. It should have continuity to the
Fail
module, swivel, bus or other connector in
accordance with the schematic.
Recheck measurements or try troubleshooting a
different fault. If the component and wiring are
good, reprogram/replace the associated module.
1200SJP 1350SJP
Repair as needed
Repair as needed
1-107
SECTION 1 - DTC DICTIONARY AND SELECTED TROUBLESHOOTING
This Page Left Blank Intentionally
1-108
1200SJP 1350SJP
3128411
SECTION 2 - ELECTRICAL REFERENCE
SECTION 2. ELECTRICAL REFERENCE
Limit Switch States
Connector
Switch
X146
X147
X204
X205
X213
X216
X225
X226
X281
Jib Stow
Jib Center
RF Axle Extension
LF Axle Extension
Osc Axle Lockout Pressure
Drive Orientation
LR Axle Extension
RR Axle Extension
Transport Limit Switch
X282
Broken Cable Proximity Switch
3128463
Table 2-1. Limit Switch States
Normally Open or
Reference State
Closed
NC
Open = Stowed (Jib > 70° Right)
NC
Open = Jib Centered ±5°
NC
Closed = Extended
NC
Closed = Extended
NO
Closed = Pressure > 200psi
NO
Open = Normal Orientation
NC
Closed = Extended
NC
Closed = Extended
NC & NO
NC (White to Black) = Closed -AND- NO (White to Red) = Open
= Transport position
NO
Closed (Black to Blue = 12 V) = Cable in tact
1200SJP 1350SJP
2-109
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-110
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Color Key
Figure 2-1. Color Key
3128463
1200SJP 1350SJP
2-111
SECTION 2 - ELECTRICAL REFERENCE
Platform Area Solenoids
Connector
2-112
1200SJP 1350SJP
Table 2-2. Platform Area Solenoids
Nominal Resistance
Function
(Ohms)
X135
Platform Dump
6.4
X136
Level Up
10.1
X137
Level Down
10.1
X138
Rotate Right
10.1
X139
Rotate Left
10.1
X140
Jig Swing Right
10.1
X141
Jib Swing Left
10.1
X142
Jib Up
10.1
X143
Jib Down
10.1
3128463
SECTION 2 - ELECTRICAL REFERENCE
Platform Area Connectors
X198
17
X196
18
X195
19
X194
20
X193
21 X190 X191
X182 X183
22
X179 X285 X177
1
23
2
X175
3
X174
4
1. Power/Emergency Stop
2. Engine Start / Aux Power
3. Capacity Select
4. Drive Orientation Override
5. Drive/Steer
6. Main Boom Telescope
7. Lights
8. Jib Lift
9. Soft Touch Override
10. Jib Swing
11. Tower Boom Lift (1250 Only)
1705744 A
J1
J4
J2
J3
1702565 A
1705745 B
1702938
1705171 A
16
X197
15
X192
14
X189
13
X188
12
11
X187 X186
10
X185
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Soft Touch Indicator
Platform Rotate
Jib Stow Override
Function Speed Control
Main Lift / Swing
Drive Speed / Torque Select
Steer Select
Platform Level Override
Axle Extend / Retract
Horn
Indicator Panel
Boom Control Select
1705170 A
9
X184
8
X180
7
X181
6
X178
5
X176
VALVE
ROTATED
FOR
CLARITY
X154
X153
PLATFORM DUMP
X135
LEVEL UP
X155
X136
LEVEL DOWN
X137
ROTATE RIGHT
X138
JIB SWING
RIGHT
ROTATE LEFT
X140
X139
JIB SWING
LEFT
X152
JIB UP
X141
X142
JIB DOWN
X143
PLATFORM CONTROL AREA
Figure 2-2. Platform Area Connectors
3128463
1200SJP 1350SJP
2-113
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-114
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Boom Area Connectors
PLATFORM LEVEL
SENSOR LEFT
BOOM LENGTH
LIMIT SWITCH
X281
LOAD SENSING PIN
(VIEW ROTATED. CONNECTOR
ON VALVE SIDE.)
X089
X150
X148
CABLE BREAK
PROXIMITY
SWITCH
X062
X282
PLATFORM LEVEL
SENSOR RIGHT
X146
TAILLIGHT
X104
X147
JIB
POSITION
SWITCH
JIB
STOW
SWITCH
(FAR SIDE)
TAILLIGHT
X105
(NEAR SIDE)
BOOM LENGTH
SENSOR
BOOM
ANGLE
SENSOR
#2 LEFT
X099
X100
BOOM
ANGLE
SENSOR
#1 RIGHT
X273
BOOM AREA
Figure 2-3. Boom Area Connectors
3128463
1200SJP 1350SJP
2-115
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-116
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Engine Area Connectors
X241
X240
X103
X084
X113
STARTER
7500W
GENERATOR
X120 RIGHT DRIVE FWD
X118 RIGHT DRIVE REV
X121 LEFT DRIVE FWD
X119 LEFT DRIVE REV
THESE VIEWS SHOWN FOR CLARITY
X250
X251
ENGINE SIDE AREA
Figure 2-4. Engine Area Connectors
3128463
1200SJP 1350SJP
2-117
SECTION 2 - ELECTRICAL REFERENCE
Main Valve Area Solenoids
Table 2-3. Main Valve Area Solenoids
Nominal Resistance
Connector
Function
(Ohms)
2-118
1200SJP 1350SJP
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
3128463
SECTION 2 - ELECTRICAL REFERENCE
Main Valve Area Connectors
X057
LOCATION
APPROXIMATE
B.L.A.M.
X102
BATTERY
BUSSBAR
GROUND
BUSSBAR
X097
X098
BOOM ANGLE
SENSOR
1 PASSTHRU
(4 POS.)
BOOM ANGLE
SENSOR
2 PASSTHRU
(4 POS.)
X095
X096
BLAM PUMP
PASSTHRU
(6 POS.)
BOOM LENGTH
SENSOR PASSTHRU
(6 POS.)
X106
X272
VALVE PASSTHRU
(6 POS.)
X280
X278 CAN to BLAM
VIEW ROTATED
FOR CLARITY
X268 CAN to MTB
MAIN LIFT
DOWN
X277
X279 CAN to Engine
X088
J3
J5
MAIN TELE
RETRACT
X071
X073
MAIN
LIFT UP
X070
X276
SWING
RIGHT
X069
LIFT DOWN
AUXILIARY
J1
J4
X090
MAIN TELE
EXTEND
SWING
LEFT
J2
X086
X074
X275
MAIN TELE
PROPORTIONAL
X089
X072
X087
X263
X091
MAIN
DUMP
X110
LIFT DOWN
AUX SELECT
X274
MAIN
LIFT FLOW
CONTROL
X286
X116
ANALYZER
CONNECTION
X107
X117
X083
MAIN VALVE AREA
Figure 2-5. Main Valve Area Connectors
3128463
1200SJP 1350SJP
2-119
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-120
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Ground Control Connectors
X017
X007
X008
X001
X271
X010
X043
X002
X004
X003
X012
X011
X024
X025
X023
X022
X021
X029
X026
X020
X028
X030
X014 CAN to Ground Module
X269 CAN to BLAM
3128463
X018
GROUND CONTROL BOX AREA
X270 CAN to Platform
Figure 2-6. Ground Control Connectors
1200SJP 1350SJP
2-121
SECTION 2 - ELECTRICAL REFERENCE
Chassis Area Solenoids
Connector
2-122
1200SJP 1350SJP
Table 2-4. Chassis Area Solenoids
Nominal Resistance
Function
(Ohms)
X206
Front Axles Extend
4.9
X207
Front Left Steer Right
4.9
X208
Front Right Steer Right
4.9
X209
Front Axles Retract
4.9
X210
Front Left Steer Left
4.9
X211
Front Right Steer Left
4.9
X212
Axle Lockout Solenoid
6.2
X214
2 Speed Solenoid
6.2
X215
Brake Release Solenoid
6.3
X219
Rear Right Steer Left
4.9
X220
Rear Left Steer left
4.9
X221
Rear Axles Retract
4.9
X222
Rear Right Steer Right
4.9
X223
Rear Left Steer Right
4.9
X224
Rear Axles Extend
4.9
3128463
SECTION 2 - ELECTRICAL REFERENCE
Chassis Area Connectors
X231
X233
J3
CHASSIS MODULE
J1
J4
J5 J2
X229
X232
X230
X238
REAR LEFT
STEER ANGLE
FRONT LEFT
STEER ANGLE
ANALYZER
CONNECTION
X203
X235
X239
X225
REAR LEFT
AXLE SWITCH
REAR RIGHT
STEER ANGLE
X083
AXLE LIMIT
SWITCHES
(REAR)
FRONT RIGHT
STEER ANGLE
X226
REAR REAR
AXLE SWITCH
AXLE
LOCKOUT
X221
X212
X216
REAR
STEER
VALVE
RETRACT
X200
X220
X219
AXLE LIMIT
SWITCHES
(FRONT)
X204
X214
FRONT REAR
AXLE SWITCH
FRONT
STEER
VALVE
X224 EXTEND
X223 REAR LEFT
STEER RIGHT
REAR RIGHT
STEER LEFT
AXLE SWITCH
2 SPEED
AXLE
LOCKOUT
PRESSURE
SWITCH
X213
REAR LEFT
STEER LEFT
X205 FRONT LEFT
X222
REAR RIGHT
STEER RIGHT
RETRACT
X215
X206 EXTEND
X209
X207 FRONT LEFT
FRONT LEFT
STEER LEFT X210
BRAKE
RELEASE
TRACTION CONTROL VALVE
STEER RIGHT
FRONT RIGHT
FRONT RIGHT
STEER LEFT X211
X208 STEER RIGHT
VALVES TURNED FOR CLARITY
CHASSIS AREA
Figure 2-7. Chassis Area Connectors
3128463
1200SJP 1350SJP
2-123
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-124
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Ground, Engine and BLAM Schematic
DRAWING NUMBER
8
7
6
4
5
2
3
1
REV.
1870214
B
14 GA. FUSE LINK
18
BLACK (12)
X030
13
MTB
B1
2
YEL/RED 2-5
EMS
YEL/RED 2-4 (12)
4
10
H
YEL/RED 2-2 (12)
1
YEL/RED 2-30
3
X029
STARTER
X027
DEUTZ ENGINE
MOTOR
YEL/RED 2-1 (12)
RED 1-2(10)
B2
SOL.
H
30 AMP
STARTER
YEL/RED 2-30-4
X113
MOTOR
YEL/RED 2-1-1(12)
BLACK (16)
87a
85
YEL/RED 2-1-3 (12)
30
CHARGE
BLACK
AIR
WHT/YEL 48-1
4
AUX POWER/ENABLE
X026
X022
16
BLUE 27-2
19
BLUE 28-2
TAN 3-2
8
23
UP
MAIN LIFT
DOWN
X020
SWING
X018
X023
JIB SWING
TAN 4-2
LEFT
WHITE 21-2
WHITE 58-2
RIGHT
LEFT
13
WHITE 60-2
9
4
X002
35
J2
(GRAY)
34
19
20
22
25
2-40
BLACK (10)
X035
OIL PRESSURE
YEL/RED 2-40-9
TEMPERATURE
X036
NO CHARGE
X033
GLOW PLUGS
OUT
LIFT DOWN AUX. SELECT
X274
LIFT DOWN AUX.
X275
28
15
UP
TAN 3-3
35
WHITE 22-3
RIGHT
34
WHITE 21-3
LEFT
19
TAN 55-20
30
26
ORN/RED 49-103
TEST
AXLES SET
X032
TAN 4-3
WHT/YEL 39-1-1
1
ORN/RED 49-100
14
X031
500# CAP
RED/YEL 54-2-1
2
X037
1000# CAP
RED/YEL 54-3-1
27
+5Vref(ADC4)
21
ADC4
20
GND (ADC4)
1
14
ActorOut
2
15
ActorOut
3
17
RackMeasCom
4
19
RackMeasSignal
5
18
RackMeasRef
X277
X069
SWING
X070
X063
BLU/ORN 52-10
HEAD/TAIL
ALARM
J3
LIGHTS
87
86
BLU/ORN 52-12
87a
BLACK 0-1
B
ORN/RED 49-199
L
ORN/RED 49-198
K
YEL/RED 2-1-98
A
GREEN
X088
BOOM LENGTH ANGLE MODULE
ORN/RED
FUEL SENSOR (SIGNAL)
BLACK
SENSOR (GROUND)
7
8
9
WHT/YEL 48-9
12
10
YEL/RED 2-80
1
ORN/RED 49-110
3
BLACK
BRN/BLK
12
A
BLUE
C
2
BLACK
B
4
BRN/BLK
E
X106
J5
5
18
X279
2
19
27
4
A
2
SHIELD
4
J1
(WHITE)
16
21
X283, X284
17
PROX. SWITCH
4
1
3
31
22
10
16
25
WHITE
21
1
2
RED
6
ORN/RED 49-64
ORN/RED 49-65
3
2
1
A
A
RED(18)
BLACK
SHIELD
B
B
C
C
C
B
RED
BLACK
SHIELD
CAN HI
13
CAN LO
24
18
A
X119
ORANGE 7-2
RIGHT REVERSE DRIVE PUMP X118
4
ORANGE 7-3
RIGHT FORWARD DRIVE PUMP X120
3
ANALYZER GROUND
4
ANALYZER POWER
RED
1
ANALYZER RECEIVE
WHITE
ANALYZER TRANSMIT
3
ANALYZER GROUND
4
2
X091
D
2
4
ORANGE 60-1
V-BAT +
X097
J2
BLACK X087
12
ORANGE 7-2
11
ORANGE 7-3
9
BLU/ORN 52-5
YEL/RED 2-82
1
ORANGE
1
ORN/RED 49-112
2
YELLOW
2
WHITE
ANGLE SENSOR
BLACK
3
BLACK
3
BLACK
SERIAL OUTPUT
BRN/BLK
4
BRN/BLK
13
GND -
BLACK (14)
5
X271
X098
8
#2 LEFT SIDE BOOM
YEL/RED 2-81
1
RED
1
ORN/RED 49-111
2
BLUE
2
WHITE
ANGLE SENSOR
BLACK
3
BLACK
3
BLACK
SERIAL OUTPUT
4
BRN/BLK
BRN/BLK
GRAY
J4
BLACK 5 (16)
BRN/ORN 53-3
87
86
4
8 4
5
6
7
2
1
X083
1
RED
A
BLACK
B
3
GREEN
D
4
WHITE
E
5
SHIELD
X062
X267
X110
AUXILIARY POWER
RELAY
PUMP MOTOR
8
B+
M
30 AMP
SLIP RING CONNECTOR TO CHASSIS
9
LIFT
CYL. PIN
CHASSIS POWER
DISTRIBUTION
30
3
X108
X116
B
6
5
8
7
13
28
14
X269
2500W
BLU/ORN 52-6 (12)
87
86
3
87a
85
30
GENERATOR
12 VDC
BATTERY
X127
GENERATOR
10
V REF
C
X099
X095
X266
87a
85
#1 RIGHT SIDE BOOM
RED
2
X089
2
J7
(BLACK)
RED
12
19
X007
X100
X096
YEL/RED 2-70-3 (14)
YEL/RED 2-70-4 (14)
33
35
CAN SHIELD
LEFT REVERSE DRIVE PUMP
3
GREEN
BLACK/SHIELD
32
25
B
ANALYZER TRANSMIT
35
11
7
ANALYZER RECEIVE
WHITE
34
29
X014
X270
GREEN
17
22
BLACK
LEFT FORWARD DRIVE PUMP X121
ORANGE 8-3
ORANGE 8-2
3
27
20
YEL/RED 2-60
3
5
4
1
20
33
19
X017
12
BLACK (16)
23
34
14
13
11
12
YEL/RED 2-70-2 (14)
3
32
16
X281
BOOM LENGTH LIMIT SWITCH
10
9
X278
15
19
22
3
9
7
8
1
2
BLACK
5
1
CAN SHIELD
X013
YEL/RED 2-61
BROWN
BLUE
ANALYZER POWER
BLACK/SHIELD
2
ORANGE 8-2
CAN LO
6
14
7
ORN/RED 49-88
X268
RED
ORANGE 8-3
X280
12
4
X282
C
28
29
30
31
23
BLACK
BROKEN CABLE
SHIELD
10
30
YEL/RED 2-40-10
BLACK
C
YEL/RED 2-70-5
TEST SWITCH
26
9
BOOM CONTROL SYSTEM
B
C
X001
14
ORN/RED 49-102
B
BLACK
RED (18)
MTB MODE OUTPUT
YEL/RED 2-30-1
11
1
2
12
6
CAN HI
9
15
3
5
2
ORANGE 55-47
YEL/RED 2-30
6
X086
1
RED
A
BLACK (14)
FOOTSWITCH
MTB MODE SELECT
YEL/RED 2-21
6
C
A
RED
2
D
B
YEL/RED 20-70-1
YELLOW
YEL/RED 2-2-1
24
BROWN
GRAY
J1
5
4
STRING POT
23
X010
6
1
BOOM LENGTH SENSOR
X272
X084
YEL/RED 2-70-4
YEL/RED 2-3-2
C
3
J8
BLACK
CAN SHIELD
MTB EMS TO PLATFORM
YEL/RED 2-1-2(12)
12
3
BLACK (18)
BLACK (12)
16
X008
2
GND TO PLATFORM
ORANGE 55-45
MTB EMS input
B
PLUG
X273
RED
X090
A
DIANOSTICS
5
8
1
DEUTZ
X242
6
BRN/WHT 47-12
WHT/YEL 48-3
3
INTAKE HEATERS
CAN HI
2
X101
11
31
G
CAN LO
1
85
28
BLACK
D+
WHT/YEL 48-10 (10)
CAN SHIELD
X286
24
ORN/RED 49-101
GND FROM BATTERY
REGULATOR
SENSING AND
SWITCHING
CIRCUITS
WHT/YEL 48-11 (10)
sol.
X111
23
CONTROL
HAVE INTAKE HEATERS OR
F
BLACK (18)
BLACK
6
14
ALTERNATOR
NOTE: ENGINE WILL ONLY
GLOW PLUGS NOT BOTH.
YEL/RED 2-1-99
RED (18)
29
25
13
X240
X241
X276
MAIN LIFT
LIFT FLOW CONTROL
18
BOOM SYSTEM
X039
22
2
30
13
OVERLOAD
24
1
12
X071
DOWN
27
26
PLATFORM
X038
MAIN TELE.
11
22
MOMENT CONTROL
X040
E
IN
BROWN 14-3
29
BRN/WHT 47-6-1
X126
BROWN 13-3
BRN/WHT 47-5-1
BRN/WHT 47-8-1
ACTUATOR
TAN 55-22
14
ADC2
4
3
X073
TAN 55-21
20
+5Vref(ADC2)
11
EMR
10
32
WHT/YEL 48-6
X072
16
12
ENGINE HIGH
X034
X074
TELE. FLOW CONTROL
12
BRN/WHT 47-8
HOURMETER
ENGINE LOW
MAIN DUMP
BROWN 55-10
33
11
X028
RED/WHT 50-1
1
X004
J4 (BLUE)
33
WHITE 22-2
RIGHT
PINK 25-3-1
PRESSURE
X257
RED (18)
F
BRN/ORN 53-2
UP
DOWN
JIB
RED/WHT 50-2-1
PINK 26-3-1
5
25
X125
IN HEAD GLOW PLUG
BATTERY CABLE (1 GA.)
START SWITCH
3
7
GRD (ACD2)
ADC5(TEMP1)
10
DEUTZ ENGINE
5
CAN LO
17
PINK 26-2
UP
DOWN
ENGINE OIL
CAN HI
6
PINK 25-2
LEVEL
YEL/RED 2-6-2
CAN SHIELD
GRAY 23-2
ROTATE
X025
HORN GND
HORN OUTPUT
BLU/ORN 52-2
BLACK (18)
LEFT
X024
17
2
4
GRD (SPEED)
sol.
BLACK
RIGHT
18
RED 1-1 (12)
30
YEL/RED 2-70 (14)
7
BROWN 14-2
GRAY 24-2
OUT
23
2
3
24
BROWN 13-2
IN
MAIN TELE
X021
1
X256
PRESSURE
X017
12
LINK
X112
WHT/YEL 48-9
TO BATTERY NEG.
1
CAMSHAFT
BLACK
GROUND CONTROL MODULE
X122
STATOR
RED 1-1(10)
86
2
SPEED
13
2
B+
FUSIBLE
1
ADC7(TEMP3)
BRN/WHT 47-8
POWER DOWN
RELAY
X011
9
48-12(12)
ENGINE
SPEED
87
RECTIFER
GRD(TempAll)
8
1
WHT/YEL 48-13 (8)
5
G
2
X124
TEMPERATURE
WHT/YEL
COOLANT
X012
WHT/YEL 48-3
IGN. ON
RELAY
86
85
30
MTB TO EMR2 ENGINE CONTROL
87
87a
YEL/RED 2-4-1
7
EMR2 ENGINE CONTROL TO ENGINE
YEL/RED 2-3-1
4
9
14 GA. FUSE LINK
RED 1-3 (12)
11
X117
X248
7500 W GENERATOR
1
BLU/ORN 52-6
5
V BAT
YEL/RED 2-20
BLACK
12
RED
BLACK
SHEILD
87
86
5 AMP
B
X109
GENERATOR
A
CONTROL
C
BOX
BRN/WHT 47-20
87a
X246
85
30
A
A
RED
BLACK (14)
87
86
87a
X247
85
30
RED
8
7
6
4
5
3
2
1
Figure 2-8. Ground, Engine and BLAM Electrical Schematic
3128463
1200SJP 1350SJP
2-125
SECTION 2 - ELECTRICAL REFERENCE
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2-126
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Pleatform Schematic
DRAWING NUMBER
8
7
6
4
5
3
2
1
REV.
1870214
B
X144
ORN/RED 49-10
14
YEL/RED 2-11
13
ORN/RED 49-12
H
JIB STOW LIMIT SWITCH X146
2
ORN/RED 49-12
YEL/RED 2-11-1
1
YEL/RED 2-11-2
1
YEL/RED 2-11
21
JIB INLINE LIMIT SWITCH X147
BROWN(18)
7
9
RED/BLK
5
BLUE(18)
TO MTB
2
ORN/RED 49-11
H
X145
YEL/RED 2-12-1
PLATFORM WORK LIGHTS
YEL/RED 2-12-2
X153
RED
BLACK
V REF.
17
7
G
IN
BROWN 13-1
5
OUT
BROWN 14-1
6
7
X188
ROTATE
RIGHT
LEFT
GRAY 24-1
GRAY 23-1
8
X195
LEVEL
UP
DOWN
PINK 25-1
9
PINK 26-1
10
BLUE 27-1
11
JIB
UP
DOWN
X180
BLUE 28-1
X192
POTENTIOMETER
WIPER
GND
CREEP
3
RED/WHT 55-30
6
RED/WHT 55-31
35
5
BLACK
13
2
ORN/RED 49-11
32
33
X175
CAPACITY
17
20
YEL/RED 2-37
RED/YEL 54-1
21
ORN/RED 49-120
22
X177
RET
YEL/WHT 44-1
BLACK
PINK 25-3-1
YELLOW
2
BLACK
3
WHITE
MOUNTED ON LEFT
BLACK
SIDE OF BOOM
RED/WHT 50-2-3
RED/WHT 50-2-3
5
PLATFORM DUMP
PINK 25-3-3
7
PINK 25-3-3
PINK 26-3-2
PINK 26-3-3
6
PINK 26-3-3
J1
(WHITE)
5
GRAY 23-3
8
GRAY 23-3
LEFT
6
GRAY 24-3
9
GRAY 24-3
RIGHT
24
BLUE 27-3
10
26
BLUE 28-3
11
BLUE 28-3
WHITE 60-3
19
WHITE 60-3
RIGHT
28
WHITE 59-3
20
WHITE 59-3
LEFT
29
BLACK
12
BLACK
BRN/ORN 53-1
15
31
WHT/YEL 48-5
28
30
ORN 55-46
27
32
YEL/RED
2-5
YEL/RED
X138
2-2(12)
31
3
ORN/RED 49-40
29
1
X181
BLU/ORN 52-12
30
8
X142
35
23
3
BRN/WHT 47-3
24
2
BRN/WHT 47-2
24
1
BRN/WHT 47-1
5
JIB SWING
X141
RED (18)
BLACK (18)
output
EMS PTF TO MTB
ORN/RED 49-70
ORN/RED 49-15
1
FOOTSWITCH/ENABLE
J2
X191
2
YEL/RED 2-21
7
3
BRN/WHT 47-13
21
6
BLACK
18
BOOM CONTROL SYSTEM
ORN/RED 49-1000
19
2
WHT/YEL 39-1
14
3
ORANGE 55-51
30
1
AXLE SET
BLACK (18)
2
1
4
SHIELD
1
ORN (18)
4
ALARM
8
6
YELLOW (18)
6
11
BLU/BLK
11
E
FOOTSWITCH
GREEN
WHITE
X152
X172
3
1
GENERATOR
BLU/ORN 52-4
X155
14
HOLE PLUG (12)
17
HOLE PLUG (18)
17
19
HOLE PLUG (18)
19
BLACK (12)
16
BLACK (12)
16
YEL/RED 2-1-2 (12)
12
RED (12)
12
14
2
D
J8
(BLACK)
9
RED (18)
2
BLACK
X166
5
CREEP
BLACK
7
16
4
D
3
3
YEL/RED 2-30-1
22
ORN/RED 49-42
YEL/RED 2-3-1
GND MODE
25
X187 SOFT TOUCH
F
X140
CAN LO
ORN/RED 49-69
23
10
2-3(16)
X143
CAN HI
BLU/ORN 52-4
BRN/WHT 47-4
13
ORN(12)
YEL/RED
JIB
DOWN
CAN SHIELD
ORN/RED 49-4
22
ORN/BLK(18)
10
X139
UP
BLUE 27-3
13
PTF EMS
BLU/ORN 52-1
32
X179
X137
ROTATE
27
25
J7
(BLACK)
EMS
LEVEL
DOWN
X169
23
BLACK
G
PLATFORM
X135
X136
UP
PINK 25-3-2
AUX POWER
4
SWITCH
BLACK(10)
GREEN(10)
BLU/ORN 52-3
FUEL GAGE
X190
MTB
2
20 AMP C.B.
16
9
1/4
1
BRN/BLK (18)
15
18
1/2
BLU/ORN 52-11
RED
YEL/RED 2-16-2
J1
15
X057
1
ORANGE
X165
20
3/4
YEL/BLK(18)
RED/WHT 50-2-1
SOFT TOUCH OVERIDE
6
15
BASKET LEVEL SENSOR #2
X148
14
19
FULL
STROBE LIGHT
BRN/BLK (18)
13
2
HEAD/TAIL LIGHTS
RED
X154
WHITE(10)
PINK 26-3-1
12
14
HORN
SIDE OF BOOM
RED
10
11
WHT/YEL 48-1
TWO SPEED
MOUNTED ON RIGHT
BLACK
6
ORN/RED 49-81
START SWITCH
X193
E
YEL/WHT 43-1
ENGINE SPEED
X198
X184
EXT
AXLE SET
X194
8
18
19
1000#
BOOM CONTROL SELECT
X285
WHITE
3
BRAIDED SHIELD
16
YELLOW 55-17
15
2
BLACK
5
34
3
500#
BLUE
3
4
35
2
4
BLACK (12)
BLK/WHT (12)
SELECT
18
YELLOW 55-16
CRAB STEER
COORDINATED STEER
2
X163
4
1
X196
1
34
YEL/RED 2-10
F
RED
BLU/ORN 52-11
33
4
ORN/RED 49-68
1
BRAIDED SHIELD
12
X199
Ref.V
PUMP
21
18
BASKET LEVEL SENSOR #1
X150
X162
25
26
19
MAIN TELE
X178
8
ORN/RED 49-80
ORN/RED 49-63
J2
(GRAY)
GND FROM GND MODULE
1
GND EMS
2
X170
J3
DRIVE ORIENTATION
X182
4
RED/YEL 54-3-1
BROKEN CABLE
5
ORN/RED 49-101
10
SYSTEM DISTRESS
6
BRN/WHT 47-12
8
453KG/1000# CAPACITY
13
RED/YEL 54-3
SWING
C
C
5K
8
AUTO LEVEL SYSTEM
BRN/WHT 47-10
1
GENERATOR ON
2
BLU/ORN 52-4-1
15
3
ORN/RED 49-100
11
4
RED/YEL 54-2
12
TILT
5
ORN/RED 49-3
6
GLOW PLUG
6
WHT/YEL 48-6
17
X167
X197
5
1
J4
OVERLOAD
X183
226KG/500# CAPACITY
6
20
J5
(WHITE)
4
2
LIFT
X160
12= 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX
5K
3
12= 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOXX161
7
12
= 19 POSITION DEUTSCH CONNECTOR TO MAIN TERMINAL/GROUND BOXX043
= TERMINAL STRIP IN PLATFORM BOX
33
BLU/ORN 52-3
1
B
ANALYZER POWER
RED
ORN/RED 49-92
11
2
ANALYZER RECEIVE
GREEN
10
ORN/RED 49-91
28
3
ANALYZER TRANSMIT
WHITE
9
ORN/RED 49-90
29
ANALYZER GROUND
BLACK/SHIELD
8
ORN/RED 49-89
27
14
X168
6
J6
(BLACK)
4
26
RIGHT
STEER
X176
B
2
1
DRIVE
3
YEL/RED 2-36
7
WHITE 59-1
2
YEL/RED 2-10-14
34
LEFT
X185
X164
LEFT
5
4
X171
= 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.)
8
31
X173
JIB SWING
RIGHT
X174
DRIVE ORIENTATION OVERIDE
WHITE 60-1
1
ORANGE 55-50
4
YEL/RED 2-16
3
YEL/RED 2-16-1
X189
JIB STOW
V BAT.
WHITE 59-60
YEL/RED 2-16-3
6
A
SOFT TOUCH LIMIT SWITCHS
8
5
8
YEL/RED 2-16-2
BLACK
WHITE
7
A
5
ORN/RED 49-67
4
BLACK
6
WHITE
5
4
3
2
1
Figure 2-9. Platform Electrical Schematic
3128463
1200SJP 1350SJP
2-127
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-128
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Chassis Electric Schematic
DRAWING NUMBER
8
7
6
5
4
3
2
1
1870214
REV.
B
X083
H
H
DRIVE ORIENTATION
ORANGE 55-45
ORANGE 60-2
RED
X204
LEFT FRONT AXLE
RIGHT FRONT AXLE
EXTEND LIMIT SWITCH
EXTEND LIMIT SWITCH
BLK
3
J2 BLACK
12
1
BLACK
2
3
OSC. AXLE
X205
2
4
11
YEL/RED 2-1-7
X213
WHT
BLK
WHT
YEL/RED 2-1-3
OSC. AXLE
LOCK-OUT
VALVE
LOCK-OUT
PRESSURE
4
SWITCH
5
ORN/RED 49-105
6
ORN/RED 49-106
7
ORN/RED 49-107
WHT
BLK
WHT
LEFT REAR AXLE
X225
YEL/RED 2-1-2
5
X226
ORN/RED
6
ORN/RED
7
X212
RIGHT REAR AXLE
EXTEND LIMIT SWITCH
G
X232
ORN/RED 49-104
BLK
J4 GRAY
ORANGE 55-47
10
1
G
BLK
BLK 14GA
9
BLK
8
YEL/RED
7
VIOLET
6
X216
ORN/RED 49-106
ORANGE (16)
5
YEL/BLK 14G
YELLOW (16)
4
BLK 14GA
RED 14GA
3
BLK
SHIELD
2
BLK
1
SHIELD
RED
SWITCH
EXTEND LIMIT SWITCH
8
X230
F
F
8
1
9
X214
10
YEL/WHT 39-2
FRONT AXLE EXTEND
X206
X224
2
SPD
VALVE
X215
2
BRAKE
VALVE
3
6 PIN
BUSS
4
CONNECTOR
5
X227
6
E
11
YEL/WHT 39-2-43-1
YEL/WHT 43-1
REAR AXLE EXTEND
12
YEL/WHT 40-2-44-1
YEL/WHT 44-1
REAR AXLE RETRACT X221
YEL/WHT 40-2
FRONT AXLE RETRACT X209
E
X200
1
RED
2
WHT
3
BLK
1
RED
A
2
BLUE
B
3
BLK
C
4
BRN/BLK
1
RED
A
2
BLUE
B
X201
BLK
D
C
J5 RUST
2
YEL 9-2
3
YEL 10-1
LEFT FRONT STEER RIGHT
X207
4
YEL 9-1
LEFT FRONT STEER LEFT
X210
RIGHT FRONT STEER LEFT
X211
J3 GREEN
RIGHT FRONT STEER RIGHT X208
YEL/RED 2-1-1 (14GA)
YEL 10-2
BLK 14GA
1
4
BRN/BLK
RED
RIGHT FRONT
STEER SENSOR
D
X203
X202
5
WHT
6
BLK
BLK
7
BRN/BLK
RED
3
BLK
4
BRN/BLK
1
RED
A
2
BLUE
B
3
BLK
C
4
BRN/BLK
1
RED
A
2
BLUE
B
3
BLK
C
4
BRN/BLK
LEFT FRONT
STEER SENSOR
C
X239
X236
5
YEL 12-2
6
YEL 11-2
RIGHT REAR STEER RIGHT
RIGHT REAR STEER LEFT
X222
X219
8
WHT
9
BLK
C
BLK
X233
7
YEL 12-1
LEFT REAR STEER RIGHT
10
X223
BRN/BLK
RED
X238
X237
WHT
12
BLK
4
5
6
7
8
YEL/RED 2-1-6
GRN
11
SHIELD
10
BLK
RED
YEL/RED 2-1-5
9
X220
LEFT REAR STEER LEFT
RED
YEL 11-1
BLACK
B
8
RIGHT REAR
STEER SENSOR
11
WHT
12
BLK
BLK
BRN/BLK
LEFT REAR
STEER SENSOR
B
1
2
3
J1 GRAY
4
3
2
1
9
10
11
12
X229
X235
A
A
8
7
6
5
4
3
2
1
Figure 2-10. Chassis Electrical Schematic
3128463
1200SJP 1350SJP
2-129
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-130
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Electrical Wiring Sheet 1
X158
X159
X142
PLATFORM
FLOODLIGHTS
X141 X139
X138
X143 X140
X137
2500W
GENERATOR
X156
PLATFORM
CONTROL
VALVE
X160
X161
X162
X163
X144
X146
X175
X176
X145
X148
X177
X285
X178
X179
X181
X180
X182
X183
X184
X185
X168
X167
X187
X188
X189
X190
X191
X192
X193
X199
X194
X195
X196
DUAL CAPACITY
JIB POSITION
SWITCH
GENERATOR
CONTROL BOX
X147
Platform Level
Sensor (Left)
X258
AIR FILTER
PRESSURE
SWITCH
X241
X169
J1
J7
X165
THROTTLE
ACTUATOR X126
X150
FOOTSWITCH
X125
J2
J8
X152
X170
X153
X154
PLATFORM
WORK LIGHTS
X155
X172
X281
X197
X198
X282
GENERATOR
SWITCH
TRANSPORT
LIMIT
SWITCH
BROKEN
CABLE
PROXIMITY
SWITCH
BOOM
ANGLE
SENSOR
#1 (RIGHT)
X040 X035
X034
X036 X271
X013
X033 X039
X010
X038
X001
X032
X031
GROUND
CONTROL
BOX
X099
X062
BOOM
ANGLE
SENSOR
#2 (LEFT)
X008
X087
X029
X086
X123
OIL
PRESSURE
SWITCH
TO CHASSIS
POWER RELAY
SWIVEL
J5
J4
X088
X276
J1 J3
X272
X069
X074
X071
CHASSIS
POWER
DISTRIBUTION
RELAY
X267 X266
X279
X097
X064
X104
X102
X268
X072
HORN
TAILLIGHTS
FUEL
LEVEL
SENSOR
X110
GLOW
PLUG
RELAY
X111
MAIN
CONTROL
VALVE
X107
ALARM
X105
X073
X278
X277
X106
X043
X028
X030
X280
X063
X101
X103
X275
X070
X098
HEADLIGHTS
LIGHTS
RELAY
X020
X022
X018
J2
X089
X095
J4
J3 J2
X021
X026
HYDRAULIC
PUMPS
X121
B.L.A.M.
MODULE
X090
X278
X007
X269
X014
X057
X283
X027
X120
X124
TEMP
SWITCH
X119
X274
J7
X023
X025
X257
X083
X096
J1
X024
X118
ANALYZER
CONNECTION
X091
X273
J8
X037
LIFT
CYLINDER
PIVOT
PIN
X084
BOOM
LENGTH
SENSOR
STROBE
LIGHT
DIAGNOSTIC
ANALYZER
X173
X244
ALTERNATOR
X100
PLATFORM
CONTROL
BOX
ENGINE
SPEED
SENSOR
X122
X245
X171
X164
ENGINE
HARNESS
(DEUTZ)
CHARGE
ENGINE CONTROL
PRESSURE
(DEUTZ EMR2)
X256
X240
OIL
PRESSURE
STARTER
X112
X243
X166
J5 J6
X134
X265
X264
X252
X255
Platform Level
Sensor (Right)
X251
X247
7500W
GENERATOR
7500W
RELAYS
SKYPOWER
GENERATOR
X246
X248
X113
7500W
GENERATOR
PLATFORM
BOX
X250
X249
7500W
GENERATOR
CONTROL BOX
X253
X254
JIB STOW
SWITCH
X132
X130
X128
X127
GENERATOR
RELAY
X157
X174
X129
X133
X108
AUX
POWER
RELAY
X109
X242
X002
X011
X012
X004 X017 X270
Figure 2-11. Electrical Wiring (Sheet 1 of 2)
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1200SJP 1350SJP
2-131
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-132
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Electrical Wiring Sheet 2
STEER
ANGLE
SENSOR
STEER
ANGLE
SENSOR
X200
X239
X226
AXLE
LIMIT
SWITCH
X204
AXLE
POWER
TRACK
AXLE
LIMIT
SWITCH
AXLE
POWER
TRACK
DIAGNOSTIC
CONNECTION
TO ANALYZER
SWIVEL
X227
X228
X235
X206
X207
X219
X208
X220
X221
CHASSIS
MODULE
X201
TRACTION
VALVE
X230
STEER
VALVE
STEER
VALVE
X212
FRONT
X236
X214
X233
X232
J2 J5
J4
X216
REAR
J1 J3
X229
X237
X231
X202
X209
X210
X211
X213
X215
X222
X223
X224
AXLE
POWER
TRACK
AXLE
POWER
TRACK
X225
AXLE
LIMIT
SWITCH
AXLE
LIMIT
SWITCH
X205
BATTERY CABLE CONNECTIONS
X116
X117
X110
AUX PUMP
X108
X238
+
X203
STARTER
STEER
ANGLE
SENSOR
Figure 2-12. Electrical Wiring (Sheet 2 of 2)
3128463
1200SJP 1350SJP
X113
START RELAY
AUX
POWER
RELAY
STEER
ANGLE
SENSOR
X112
2-133
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-134
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
Telematics System
GATEWAY
MODULE
X289
GATEWAY MODULE
X287
(GRAY) X287
B
A
16 15 23
CAN HI
CAN LO
E
IGNITION
D
BATTERY +
GROUND
C
7 22
RED
1-100-1
RED
1-100-2
BLK
GROUND
RED
YEL/RED
2-100-1
X098
BLK
BLACK
BLK
RED
MTB GROUND BUS
BATTERY +
3
CAN SHIELD
CAN
SHIELD
7
CAN HI
CAN 2 HI
CAN 2 LO
8
TELEMATICS
COMMUNICATION
UNIT
X290
CAN LO
B-
10 9
(BLACK)
X288
12 11
B+
CAN 1 HI
ANTENNA
CAN 1 LO
X291, X292
TELEMATICS
DIAGNOSTIC
CONNECTOR
X289
YEL/RED
2-100-2
MTB BATTERY BUS
X097
10 A
X291
TELEMATICS
COMMUNICATION UNIT
A
BLK
RED
X289 TELEMATICS
DIAGNOSTIC CONNECTOR
120
Ohms
B
A
A
B
B
C
A
A
B
B
C
C
C
C
TO ENGINE
CAN HARNESS
X279
X295
X293
X029 GROUND E-STOP
SWITCH BATTERY SIDE
RED
BLK
SHIELD
X292
TO MTB CAN
HARNESS
X279
10 A
X296
A
B
C
A
A
B
B
C
C
120
Ohms
X294
1001102417
A
X290
CELLULAR CABLE
GPS CABLE
Figure 2-13. Telematics System
3128463
1200SJP 1350SJP
2-135
SECTION 2 - ELECTRICAL REFERENCE
This Page Left Blank Intentionally
2-136
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
2.1 CONNECTOR INDEX
Table 2-5. Connector Index
End1
Connector
Description
X001
Ground J1, White/Natural - 35 Position
X002
X004
X007
Ground J2, Gray - 35 Position
Ground J4, Blue - 35 Position
Ground J7, Black - 35 Position
X008
X009
X010
X011
X012
X013
X014
Ground J8 - 4 Position
MTB Ground Bus - 12 Position
MTB Power Bus - 6 Position
Power Down Relay
Ignition On Relay
Ground Analyzer - 4 Position
CAN 3way - to Ground Module, Green
X015
X016
X017
X018
X019
X020
X021
X022
X023
X024
X025
X026
X027
X028
X029
X030
X031
X032
X033
X034
X035
X036
X037
X038
X039
X040
X042
X043
X044
X045
X046
3128463
End2
Schematic
Drawings
--
2-8. (6D)
2-6.
----
2-8. (6F)
2-8. (7F)
2-8. (7C)
2-6.
2-6.
2-6.
-----AMP04P
--
2-8. (7E)
2-6.
2-8. (5E)
2-8. (5G)
2-8. (4H)
2-8. (5D)
2-8. (7B)
2-6.
2-6.
2-6.
2-8. (7C)
2-8. (7F)
2-6.
2-6.
2-8. (7F)
2-8. (7G)
2-8. (7F)
2-8. (7F)
2-8. (7G)
2-8. (7G)
2-8. (7G)
2-8. (4H)
2-8. (7F)
2-8. (4H)
2-8. (5H)
2-8. (7E)
2-8. (7E)
2-8. (7E)
2-8. (7E)
2-8. (7F)
2-8. (7E)
2-8. (7E)
2-8. (7E)
2-8. (7E)
2-8. (7E)
2-6.
2-6.
2-6.
2-6.
2-6.
2-6.
2-6.
RS232 passthru
Ground Panel Relay
Boom Transport Switch Pass thru
Ground Swing Switch
Ground Tower Lift Switch
Ground Main Lift Switch
Ground Main Tele Switch
Ground Jib Lift Switch
Ground Jib Swing Switch
Ground Rotate Switch
Ground Level Switch
Ground Start Switch
Fuseholder with Cover
Ground Hourmeter
Ground EMS Switch
Ground Key Switch
500 Capacity Light
Axle Lock Light
Glow Plugs Light
High Engine Temperature Light
Oil Pressure Light
Battery Voltage Light
1000 Capacity Light
Platform Overload (Euro) Light
Envelope Light (BCS)
Test Light
MTB pass thru - 21 Position
MTB pass thru - 19 Position
AMP352P (Neutral)
AMP354P (Gray)
AMP355P (Blue)
AMP351P
(Black)
MMF04P
DT12BP
DT06AP
--AMP04R
DT03P032BP
(Blue)
DT08AP
-AMP06P
E06P
E06P
E06P
E06P
E06P
E06P
E06P
E06P
E06P
----PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
PACKARD2LR
DHD21R
DHD19R
DT08AR
-AMP06R
-----------------------DHD21P
DHD19P
Turntable pass thru - 21 Position
Turntable pass thru - 19 Position
Dual Capacity Switch Passthru - 3 Position
DHD21R
DHD19R
DT03P
DHD21P
DHD19P
DT03R
1200SJP 1350SJP
2-8. (8)
2-9. (1)
2-6.
2-6.
2-6.
2-6.
2-6.
2-137
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
X047
X048
X049
X050
X051
X052
X053
X054
X055
X056
X057
X058
X059
X060
X061
X062
X063
X064
X065
Main Boom Transport Switch Passthru - 3 Position
Main Rotary Angle Sensor Right - 5 Position
Main Rotary Angle Sensor Left - 5 Position
Boom Sensor Passthru - 19 Position
Main Boom Angle Switch
Dual Capacity Switch #1
Dual Capacity Switch #2
Main Boom Transport Switch #1
Main Boom Transport Switch #2
Tower Boom Transport Switch
Strobe Light
BLAM passthru - 12 Position
RS232 Backup passthru
Load Pin Pass Thru - 8 Position (Gray)
Filter Module
Load Pin panel - 6 Position
Alarm Connector
Fuel Level Sensor - 2 Position
Main Lift PVG - 4 Position (Black)
X066
Tower Lift PVG - 4 Position (Black)
X067
Tower Tele PVG - 4 Position (Black)
X068
X069
X070
X071
X072
X073
X074
X075
X076
X077
X078
X079
X080
X081
X082
X083
X084
X086
X087
X088
X089
X090
2-138
End2
DT03P
--DHD19P
-------DT12AP
-DT08AP
------
PVG Enable Solenoid
Swing Right Solenoid
Swing Left Solenoid
Main Tele Extend Solenoid
Main Tele Proportional Solenoid
Main Tele Retract Solenoid
Main Dump Solenoid
Tower Lift Pilot Solenoid
Tower Tele Pilot Solenoid
Main Lift Pilot Solenoid
Hyd Oil Temp Switch - 2 Position
Pressure Switch
Tower Lift Enable Solenoid
Tower Tele Enable Solenoid
Main Lift Enable Solenoid
Swivel - 12 Position (Black)
DT03R
PHEONIX5P
PHEONIX5P
DHD19R
DTM04P
-----AMP02R
DT12AR
DT03R
DT08AR
-ANL06P
AMP02P
PACKARD2P
AMPPVG4P
(Black)
AMPPVG4P
(Black)
AMPPVG4P
(Black)
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DT02P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DT12BP
Deutz EMR2 Chassis CAN - 3 Position
BLAM J1 - 12 Position (Gray)
BLAM J2 - 12 Position (Black)
BLAM J3 - 12 Position
BLAM J4 - 8 Position
BLAM J5 - 12 Position (Green)
DT03R
DT12AP
DT12BP
DT12CP
DT08AP
DT12DP
DT03P
------
1200SJP 1350SJP
Schematic
Drawings
2-9. (1G)
2-8. (2C)
2-8. (6E)
2-3.
-------------------
2-8. (6F)
2-8. (6F)
2-8. (6F)
2-8. (6F)
2-8. (6F)
2-8. (6G)
2-8. (5B)
2-10. (5H)
2-8. (4E)
2-8. (4D)
2-8. (3C)
2-8. (4E)
2-8. (3C)
2-8. (3E)
2-5.,2-7.
2-4.
2-5.
2-5.
2-5.
2-5.
2-5.
3128463
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
X091
X092
X093
X094
X095
X096
X097
X098
X099
X100
X101
X102
X103
X104
X105
X106
X107
X108
X109
X110
X111
X112
X113
X116
X117
X118
X119
X120
X121
X122
X123
X124
X125
X126
X127
X128
X129
X130
X131
X132
X133
X134
X135
X136
X137
X138
X139
Blam Analyzer - 4 Position
Tower Lift Cyl Angle Sensor - 3 Position
Boom Length Sensor 1(Top) - 3 Position
Tower Boom Length Sensor 2 (Bottom) - 3 Position
Boom Angle Sensor1 Passthrough - 4 Position (Gray)
Boom Angle Sensor2 Passthrough - 4 Position (Gray)
12 Pos Batt Busbar
12 Pos Ground Busbar
Boom Angle Sensor #1 (Right)
Boom Angle Sensor #2 (Left)
Lights Relay
Headlight
Headlight
Taillight
Taillight
BLAM Pump Passthru
Horn
Aux Power Relay
Power Relay Fuse
Aux Pump
Glow Plug Relay
Start Relay
Starter
Battery Positive
Battery Negative
Right Side Drive Reverse Solenoid
Left Side Drive Reverse Solenoid
Right Side Drive Forward Solenoid
Left Side Drive Forward Solenoid
Engine Speed Sensor - 2 Position
Engine Oil Pressure Switch
Engine Coolant Temp Switch
Engine Alternator
Engine Throttle Actuator
Generator Relay
Generator Connector
Generator Control Box
Generator Extension
Generator Extension
Generator Outlet
Generator
Worklight passthru - 3 Position
Platform Dump Solenoid
Platform Level Up Solenoid
Platform Level Down Solenoid
Platform Rotate Right Solenoid
Platform Rotate Left Solenoid
3128463
AMP04R
DT03P
DT03P
DT03P
DT04R
DT04P
DT12BP
DT12BP
DTM03P
DTM03P
-----DT06R
---------DIN43650P
DIN43650P
DIN43650P
DIN43650P
AMPJT826008P
---DIN43650P
-------PACKARD3P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
1200SJP 1350SJP
End2
Schematic
Drawings
-DT03R
DT03R
DT03R
DT04P
DT04R
--DTM03R
DTM03R
-------------------------------PACKARD3R
------
2-8. (2D)
2-5.
2-8. (2C)
2-8. (2C)
2-8. (3C)
2-8. (3C)
2-8. (2C)
2-8. (2C)
2-8. (6E)
2-5.
2-5.
2-5.
2-5.
2-3.
2-3.
2-8. (2E)
2-8. (2B)
2-8. (4B)
2-8. (2B)
2-8. (2G)
2-8. (2G)
2-8. (2H)
2-8. (1B)
2-8. (1B)
2-8. (2E)
2-8. (2E)
2-8. (2E)
2-8. (2D)
2-8. (4H)
2-5.
2-4.
2-3.
2-3.
2-5.
2-5.
2-5.
2-4.
2-5.
2-5.
2-4.
2-4.
2-4.
2-4.
2-8. (4H)
2-8. (1H)
2-8. (4F)
2-8. (5B)
2-9. (4F)
2-9. (4F)
2-9. (4F)
2-9. (4F)
2-9. (4F)
2-2.
2-2.
2-2.
2-2.
2-2.
2-139
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
End2
Schematic
Drawings
X140
X141
X142
X143
X144
X145
X146
X147
X148
X150
X152
X153
X154
X155
X156
X157
X158
X159
X160
X161
X162
X163
X164
Platform Jib Swing Right
Platform Jib Swing Left
Platform Jib Up
Platform Jib Down
Jib Stow Pass Thru - 2 Position
Jib Limit Switch Pass Thru - 2 Position
Jib Stow Switch
Jib Position Switch
Platform Level Sensor 2 (Left)
Platform Level Sensor 1 (Right)
Footswitch
Platform Worklight
Platform Worklight
Generator Switch
Floodlights passthru - 3 Position
Platform Floodlights component
Floodlight passthru - 2 Position
Floodlight passthru - 2 Position
Platform Control Box Passthrough - HD34-24-19-PE
Platform Valve passthru - Deutsch 21 Pin
Platform Level Passthru #1
Platform Level Passthru #2
Platform passthru - Amp 15 Position
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DT02R
DT02P
--DTM03R
DTM03R
----PACKARD3P
-AMP02P
AMP02P
DHD19R
DHD1821R
PHEONIX7P
PHEONIX7P
AMP15R
--------DTM03P
DTM03P
----PACKARD3R
-AMP02R
AMP02R
DHD19P
DHD1821P
--AMP15P
2-9. (4F)
2-9. (4F)
2-9. (4F)
2-9. (4F)
2-9. (5H)
2-9. (5H)
2-9. (4H)
2-9. (4H)
2-9. (4G)
2-9. (4G)
2-9. (3E)
2-9. (2H)
2-9. (2G)
2-9. (5E)
2-2.
2-2.
2-2.
2-2.
X165
Platform J1 Connector - 35 Position (Natural)
--
X166
X167
X168
X169
Platform J2 Connector - 35 Position (Blue)
Platform J5 Connector, Male - 8 Position
Platform J6 Connector, Female - 8 Position
Platform J7 Connector - 35 Position (Black)
-----
2-9. (7D)
2-9. (6C)
2-9. (6B)
2-9. (6F)
X170
X171
X172
X173
X174
X175
X176
X177
X178
X179
X180
X181
X182
X183
X184
X185
Platform J8 Connector, Male - 2 Position
Platform Diagnostics Connector
Platform Alarm
Platform Analyzer Pass Thru
Drive Orientation Override Switch - 6 Position
Platform Capacity Select Switch - 6 Position
Controller Harness/Circuit Board Assembly (Drive and Steer)
Platform Engine Start/ Aux Power Switch - 6 Position
Platform Boom Telescope Switch - 6 Position
Platform EMS Switch
Platform Jib Lift Switch - 6 Position
Platform Lights Switch
Platform LED J4 - 6 Position
Platform LED J3 - 6 Position
Platform Soft Touch Override Switch
Platform Jib Swing Switch - 6 Position
AMP352P (Neutral)
AMP355P (Blue)
AMP08NP
AMP08BP
AMP351P
(Black)
MMF02P
AMP04R
MMF02P
AMP15R
E06P
E06P
-E06P
E06P
-E06P
-AMP06P
AMP06P
-E06P
2-9. (2)
2-9. (5F)
2-9. (5G)
2-9. (5G)
2-9. (A7,A6,
E5,5D,3E,7F)
2-9. (7F)
---AMP15P
-------------
2-9. (6D)
2-9. (8B)
2-9. (5E)
2-9. (7B)
2-9. (7A)
2-9. (7F)
2-9. (6B)
2-9. (7E)
2-9. (7G)
2-9. (2F)
2-9. (7G)
2-9. (7E)
2-9. (8C)
2-9. (8C)
2-9. (7E)
2-9. (7B)
2-140
1200SJP 1350SJP
2-3.
2-3.
2-3.
2-3.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
3128463
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
X186
X187
X188
X189
X190
X191
X192
X193
X194
X195
X196
X197
X198
X199
X200
X201
X202
X203
X204
X205
X206
X207
X208
X209
X210
X211
X212
X213
X214
X215
X216
X219
X220
X221
X222
X223
X224
X225
X226
X227
X228
X229
X230
X231
X232
X233
X235
Platform Tower Boom Lift Switch - 6 Position
Platform Soft Touch Indicator
Platform Rotate Switch - 6 Position
Platform Jib Stow Override
Platform LED J1 - 6 Position
Platform LED J2 - 6 Position
Speed Control Harness
Platform Horn Switch
Platform Axle Extent/Retract Switch - 6 Position
Platform Level Override Switch - 6 Position
Platform Steer Select Switch - 6 Position
Controller Harness Assembly (Lift and Swing)
Platform Drive Speed / Torque Select Switch - 6 Position
Hyd Speed Pot passthru - 6 Position
Front Right Steer Angle Sensor - 3 Position
Front Right Steer Passthrough Connector, Gray - 4 Position
Front Left Steer Passthrough Connector, Gray - 4 Position
Front Left Steer Angle Sensor - 3 Position
Front Right Axle Limit Switch
Front Left Axle Limit Switch
Front Axles Extend Solenoid
Left Front Steer Right Solenoid
Right Front Steer Right Solenoid
Front Axles Retract Solenoid
Left Front Steer Left Solenoid
Right Front Steer Left Solenoid
Axle Lockout Solenoid
Axle Lockout Pressure Switch
2spd Solenoid
Brake Release Solenoid
Swivel Chassis Connector - 12 Position
Right Rear Steer Left Solenoid
Left Rear Steer Left Solenoid
Rear Axles Retract Solenoid
Right Rear Steer Right Solenoid
Left Rear Steer Right Solenoid
Rear Axles Extend Solenoid
Left Rear Axle Limit Switch
Right Rear Axle Limit Switch
Ground Bus - 6 Position
Deleted in Newer revisions - 2 Position
Chassis Module J1 Connector, Gray - 12 Position
Chassis Module J2 Connector, Black - 12 Position
Chassis Module J3 Connector, Green - 12 Position
Chassis Module J4 Connector, Gray - 8 Position
Chassis Moduel J5 Connector, Brown - 12 Position
Chassis Module Diagnostics Connector
3128463
E06P
-E06P
-AMP06P
AMP06P
--E06P
E06P
E06P
-E06P
AMP06P
DT03P
DT04P
DT04P
DT03P
--DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DT12BR
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
--DT06AP
DT02P
DT12AP
DT12BP
DT12CP
DT08AP
DT12DP
AMP04R
1200SJP 1350SJP
End2
--------------DT03R
DT04R
DT04R
DT03R
------------DT12BP
-----------------
Schematic
2-9. (7D)
2-9. (7G)
2-9. (7A)
2-9. (D8)
2-9. (D8)
2-9. (7G)
2-9. (7E)
2-9. (7F)
2-9. (7G)
2-9. (7F)
2-9. (5C)
2-9. (7E)
2-9. (7G)
2-10. (2D)
2-10. (2D)
2-10. (2D)
2-10. (2D)
2-10. (6G)
2-10. (7G)
2-10. (7E)
2-10. (7D)
2-10. (7D)
2-10. (7E)
2-10. (7C)
2-10. (7D)
2-10. (4G)
2-10. (2G)
2-10. (4F)
2-10. (4F)
2-10. (5G)
2-10. (7C)
2-10. (7C)
2-10. (7E)
2-10. (7C)
2-10. (7C)
2-10. (7E)
2-10. (7F)
2-10. (6F)
2-10. (3F)
2-10. (5B)
2-10. (8G)
2-10. (1G)
2-10. (8D)
2-10. (7A)
Drawings
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-2.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-7.
2-141
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
X236
X237
X238
X239
X240
X241
X242
X243
X244
X245
X246
X247
X248
X249
X250
X251
X252
X253
X254
X255
X256
X257
X258
X259
Rear Right Steer Passthrough Connector, Gray - 4 Position
Rear Left Steer Passthrough Connector, Gray - 4 Position
Rear Left Steer Angle Sensor - 3 Position
Rear Right Steer Angle Sensor - 3 Position
EMR2 ECU Equipment Connector
EMR2 ECU Engine Connector
EMR2 Engine Diagnostics Connector
EMR2 Capped 12 position Plug
EMR2 16 position sensor passthru
EMR2 12 position passthru
Skypower Relay
Skypower Relay
Skypower Control Box
Skypower Control Box
Skypower Generator
Skypower Generator
Skypower Distribution Box
Skypower Outlet
Skypower Outlet
Skypower Outlet
EMR2 charge air pressure - 4 position
EMR2 engine oil pressure
EMR2 air filter pressure switch
Main Lift PVG unused (Gray)
X260
Tower Lift PVG unused (Gray)
X261
Tower Tele PVG unused (Gray)
X262
X263
X264
X265
X266
X267
X268
X269
Load Pin CAN Pass thru - 3 position
Chassis Power - 2 position
Generator Platform Box Pass Thru
Generator Platform Box Pass Thru
Chassis Power Relay
Chassis Power Fuse
CAN pass thru for EMR2 - 3 position
CAN 3way - to BLAM, Blue
X270
CAN 3way - to Platform, Blue
X271
X272
X273
X274
X275
X276
X277
MTB Ground Bus - 6 Position
Boom Length Sensor Passthru
Boom Length Sensor
Lift Down Auxiliary Select
Lift Down Auxiliary
Main Lift Up
Main Lift Down
2-142
DT04P
DT04P
DT03P
DT03P
AMP25RP
AMP25LP
ITTC12P
DEUTZ12ENGR
DEUTZ16P
DEUTZ12R
----------DEUTZE
-DEUTZG
AMPPVG4GP
(Gray)
AMPPVG4GP
(Gray)
AMPPVG4GP
(Gray)
DT03P
DT02P
--BOSCH05P
-DT03P
DT03P032BP
(Blue)
DT03P032BP
(Blue)
DT06AP
DT06R
DT03P
DIN43650P
DIN43650P
DIN43650P
DIN43650P
1200SJP 1350SJP
End2
Schematic
DT04R
-DT03R
DT03R
----DEUTZ16R
DEUTZ12P
---------------
2-10. (2C)
2-10. (2C)
2-10. (2C)
2-10. (2C)
2-8. (3G)
2-8. (3G)
2-8. (2F)
Drawings
2-7.
2-4.
2-4.
2-4.
2-8. (5A)
2-8. (5A)
2-8. (5A)
2-4.
2-4.
2-8. (4G)
2-8. (4G)
--DT03R
DT02R
----DT03R
--
2-8. (4B)
2-8. (4B)
2-8. (5D)
2-8. (7B)
2-5.
2-6.
--
2-8. (8B)
2-6.
-DT06AP
DT03R
-----
2-8. (6C)
2-8. (3E)
2-8. (3E)
2-8. (6F)
2-8. (6F)
2-8. (6F)
2-8. (6F)
2-6.
2-5.
2-3.
2-5.
2-5.
2-5.
2-5.
3128463
SECTION 2 - ELECTRICAL REFERENCE
Table 2-5. Connector Index
End1
Connector
Description
X278
CAN passthru to BLAM - 3 position (Green)
X279
CAN passthru to Engine Hns - 3 position (Green)
X280
X281
X282
X283
X284
X285
X286
X287
X288
X289
X290
X291
Valve passthru
Transport Limit Switch
Broken Cable Proximity Switch
Boom Control System Test Switch
Boom Control System Test Switch
Boom Control Select
Main Lift Flow Control
Gateway Module (Gray)
Gateway Module (Black)
Telematics Diagnostic Connector
Telematics Communication Unit (TCU)
Gateway CAN 3-way to Gateway
X292
Gateway CAN 3-way to Harness
X293
TCU CAN 3-way to TCU
X294
TCU CAN 3-way to Harness
X295
X296
TCU Fuse
Telematics Diagnostic Connetor Fuse
3128463
DT03P032BP
(Blue)
DT03P032GP
(Green)
DT06AP
----E06P
DIN43650P
DTM12AP
DTM12BP
DHD1939R
AMP23P
DT03P032OP
(Orange)
DT03P032OP
(Orange)
DT03P032OP
(Orange)
DT03P032OP
(Orange)
---
1200SJP 1350SJP
End2
Schematic
--
2-8. (4D)
Drawings
--
2-8. (5D)
DT06R
------------
2-8. (5D,5C)
2-8. (8C)
2-8. (8C)
2-8. (8D)
2-8. (8D)
2-9. (7F)
2-8. (6F)
2-13.
2-13.
2-13.
2-13.
2-13.
2-2.
2-5.
2-13.
2-13.
2-13.
2-13.
2-13.
--
2-13.
2-13.
--
2-13.
2-13.
--
2-13.
2-13.
---
2-13.
2-13.
2-13.
2-13.
2-5.
2-3.
2-3.
2-143
SECTION 2 - ELECTRICAL REFERENCE
2.2 BLAM MODULE CONNECTOR PINOUTS
Table 2-6. X086 (J1) BLAM Module Pinout
Function
Type
Range (V)
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Not Used
Not Used
Not Used
Ground
V Bat
CAN HI
CAN LO
CAN Shield
CAN Termination Connection
CAN Termination Connection
Not Used
Not Used
Not Used
Not Used
-Not Used
Not Used
Not Used
Not Used
Boom Angle 1 (Right)
Boom Angle 2 (Left)
Not Used
Right Drive Pump Forward
Right Drive Pump Reverse
Input
Input
-----Input/Output
Input/Output
-Output
Output
-------Comm
Comm
-PWM
PWM
Pin
1
2
3
4
5
6
7
8
Pin
1
2
3
4
5
6
7
8
9
10
11
12
V Bat
Ground
CAN HI
CAN LO
CAN Shield
Not Used
Not Used
Not Used
Battery
Ground
Input/Output
Input/Output
Ground
----
Vbatt
0VDC
Comm
Comm
0VDC
----
Table 2-10. X090 (J5) BLAM Module Pinout
Function
Type
Range (V)
Left Drive Pump Forward
Left Drive Pump Reverse
Oscillating Axles
Not Used
Not Used
Not Used
Not Used
Not Used
Analyzer Power
RS232 Receive
RS232 Transmit
Ground
Output
Output
Output
-----Other Voltage
Input/Output
Input/Output
Ground
PWM
PWM
PWM
-----Vbatt
Comm
Comm
0VDC
Table 2-8. X088 (J3) BLAM Module Pinout
Function
Type
Range (V)
Pin
1
2
3
4
5
6
7
8
9
10
11
12
---0VDC
Vbatt
Comm
Comm
0VDC
Comm
Comm
---
Table 2-7. X087 (J2) BLAM Module Pinout
Function
Type
Range (V)
Pin
1
2
3
4
5
6
7
8
9
10
11
12
---Ground
Battery
Input/Output
Input/Output
Ground
Input/Output
Input/Output
---
Table 2-9. X089 (J4) BLAM Module Pinout
Function
Type
Range (V)
Reference Voltage
Reference Voltage From J3-1
Not Used
Not Used
Not Used
Not Used
Reference Voltage
Boom Length Sensor
Ground
Not Used
Not Used
Not Used
2-144
Other Voltage
Analog Input
----Other Voltage
Analog Input
Ground
----
5VDC
5VDC
----5VDC
5VDC
0VDC
----
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
2.3 CHASSIS MODULE CONNECTOR PINOUTS
Pin
1
2
3
4
5
6
7
8
9
Table 2-11. X229 (J1) Chassis Module Pinout
Function
Type
Range (V)
11
12
Not Used
Not Used
Not Used
Main Ground
Main Ignition
CAN HI
CAN LOW
CAN Shield
CAN Terminator (Connected to
J1-10)
CAN Terminator (Connected to
J1-9)
Ignition
Not used
Pin
Table 2-12. X230 (J2) Chassis Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
Not Used
Not Used
Ground
Front Axle Extend Limit Switches
Rear Axle Extend Limit Switches
Drive Orientation Switch
Axle Lockout Pressure Switch
Not Used
Not Used
Not Used
Axle Extend
Axle Retract
Pin
Table 2-13. X231 (J3) Chassis Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
Reference Voltage
Front Right Steer Angle Sensor
Ground
Reference Voltage
Front Left Steer Angle Sensor
Ground
Reference Voltage
Rear Right Steer Angle Sensor
Ground
Reference Voltage
Rear Left Steer Angle Sensor
Ground
10
3128463
---Ground
Vbatt
Input/Output
Input/Output
Input/Output
Input/Output
---0VDC
Vbatt
Comm
Comm
0VDC
Comm
Input/Output
Comm
Vbatt
--
Vbatt
--
--Ground
Input
Input
Input
Input
---Output
Output
Other Voltage
Analog Input
Ground
Other Voltage
Analog Input
Ground
Other Voltage
Analog Input
Ground
Other Voltage
Analog Input
Ground
--0VDC
Vbatt
Vbatt
Vbatt
Vbatt
---Vbatt
Vbatt
Table 2-14. X232 (J4) Chassis Module Pinout
Pin
Function
Type
Range (V)
1
2
3
4
5
6
7
8
Axle Lockout Pressure Switch
Power
Axle Lockout Solenoid
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Vbatt
Ground
-------
Vbatt
0VDC
-------
Table 2-15. X233 (J5) Chassis Module Pinout
Pin
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
Right Front Steer Right Solenoid
Right Front Steer Left Solenoid
Left Front Steer Right Solenoid
Left Front Steer Left Solenoid
Right Rear Steer Right Solenoid
Right Rear Steer Left Solenoid
Left Rear Steer Right Solenoid
Left Rear Steer Left Solenoid
Analyzer Power
Analyzer RS-232 Receive
Analyzer RS-232 Transmit
Analyzer Ground
Output
Outupt
Output
Output
Output
Output
Output
Output
Vbatt
Input
Output
Ground
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Comm
Comm
0VDC
5VDC
0 - 5VDC
0VDC
5VDC
0 - 5VDC
0VDC
5VDC
0 - 5VDC
0VDC
5VDC
0 - 5VDC
0VDC
1200SJP 1350SJP
2-145
SECTION 2 - ELECTRICAL REFERENCE
2.4 GROUND MODULE CONNECTOR PINOUTS
Pin
Table 2-16. X001 (J1) Ground Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Not Used
Not Used
Not Used
Not Used
Ground
Not Used
Not Used
Ground
Not Used
Ignition On Relay
Start Solenoid (Diesel Only)
Glow Plug (Diesel Only Option)
Auxiliary Power
Not Used
Not Used
Not Used
Not Used
Not Used
Ground
Two Speed
Not Used
Generator/Welder (Option)
Parking Brake
Constant Battery
Not Used
Not Used
Not Used
Analyzer Power
Analyzer RS-232 Receive
Analyzer RS-232 Transmit
Analyzer Ground
Not Used
Not Used
Not Used
Not Used
Pin
Table 2-17. X002 (J2) Ground Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
Not Used
Horn
Platform Control Valve
Main Telescope In
Basket Level Up Override
Ground
Basket Level Down Override
Not Used
2-146
----Ground
-Output
Ground
-Output
Output
Output
Output
-----Ground
Output
-Output
Output
Battery
---Other Voltage
Input
Output
Ground
-----
-Output
Output
Output
Output
Ground
Output
--
----0VDC
--0VDC
-Vbatt
Vbatt
Vbatt
Vbatt
-----0VDC
Vbatt
-Vbatt
Vbatt
Vbatt
---9.5VDC
Comm
Comm
0VDC
-----
-Vbatt
Vbatt
Vbatt
Vbatt
0VDC
Vbatt
--
Pin
Table 2-17. X002 (J2) Ground Module Pinout
Function
Type
Range (V)
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Main Telescope Flow Control
Lift Down Auxiliary Select
Main Lift Up
Lift Down Auxiliary
Main Dump
Ground
Not Used
Main Telescope Out
Ground
Not Used
Lift Flow Control
Not Used
Not Used
Main Lift Down
Not Used
Not Used
Fuel Sensor
Head/Tail Light
Alarm
Not Used
Ground
Ground
Not Used
Not Used
Not Used
Swing Left
Swing Right
Pin
Table 2-18. X004 (J4) Ground Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Axles Set Lamp
500# Capacity Lamp
Boom Control System Lamp
Start Switch
Basket Level Down Switch
Basket Rotate Left Switch
Upper Telescope In Switch
Jib Down Switch
Jib Left Switch
Not Used
Not Used
Hour Meter
Moment Control Test Lamp
Platform Overload Lamp
Glow Plugs
Auxiliary Power / Enable
1200SJP 1350SJP
Output
Output
Output
Output
Output
Ground
-Output
Ground
-Output
--Output
--Input
Output
Output
-Ground
Ground
---Output
Output
Output
Output
Output
Input
Input
Input
Input
Input
Input
--Output
Output
Output
Output
Input
PWM
Vbatt
PWM
Vbatt
Vbatt
0VDC
-Vbatt
Vbatt
-PWM
--Vbatt
--Vbatt
Vbatt
Vbatt
-0VDC
0VDC
---PWM
PWM
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
--Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
3128463
SECTION 2 - ELECTRICAL REFERENCE
Pin
Table 2-18. X004 (J4) Ground Module Pinout
Function
Type
Range (V)
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Basket Level Up Switch
Basket Rotate Right Switch
Jib Up Switch
Jib Right Switch
Not Used
Not Used
Boom Lift Up Switch
V Bat
V Bat
No Charge Lamp
1000# Capacity Lamp
Engine High Temperature Lamp
Engine Low Oil Pressure Lamp
Boom Telescope Out Switch
Ground
Not Used
Main Boom Lift Down
Swing Left Switch
Swing Right Switch
Pin
Table 2-19. X007 (J7) Ground Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Platform EMS
Platform Mode
Ground Mode
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Boom Length Limit Closed
Broken Cable Prox Switch
CAN Hi
Ground Mode Out to Platform
Footswitch Engage
Not Used
Not Used
CAN Shield
Ground
Not Used
Boom Control System Test
Switch
Not Used
Ground Control Enable
CAN Lo
3128463
Input
Input
Input
Input
--Input
Battery
Battery
Output
Output
Output
Output
Input
Ground
-Input
Input
Input
Vbatt
Vbatt
Vbatt
Vbatt
--Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
0VDC
-Vbatt
Vbatt
Vbatt
Input
Input
Input
-------Input
Input
Input/Output
Input
Input
--Ground
Ground
-Input
Vbatt
Vbatt
Vbatt
-------Vbatt
Vbatt
Comm
Vbatt
Vbatt
--0VDC
0VDC
-Vbatt
-Input
Input/Output
-Vbatt
Comm
Pin
Table 2-19. X007 (J7) Ground Module Pinout
Function
Type
Range (V)
25
26
27
28
29
30
31
32
33
34
35
Not Used
Not Used
Not Used
Not Used
V Bat
Not Used
Not Used
V Bat
Not Used
Not Used
Boom Length Limit Switch Open
Pin
Table 2-20. X008 (J8) Ground Module Pinout
Function
Type
Range (V)
1
2
3
4
Ground from Battery
Ground EMS
Ground to Platform
Ground EMS Out to Platform
1200SJP 1350SJP
----Battery
--Battery
--Input
Ground
Output
Ground
Output
----Vbatt
--Vbatt
--Vbatt
0VDC
Vbatt
0VDC
Vbatt
2-147
SECTION 2 - ELECTRICAL REFERENCE
2.5 PLATFORM MODULE CONNECTOR PINOUTS
Table 2-21. X165 (J1) Platform Module Pinout
Pin
Function
Type
Range (V)
Table 2-22. X166 (J2) Platform Module Pinout
Pin
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
6
7
8
9
10
11
12
13
14
15
16
17
18
19
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Not Used
Not Used
Not Used
Not Used
Main Telescope In Switch
Main Telescope Out Switch
Basket Rotate Right Switch
Basket Rotate Left Switch
Basket Level Up Switch
Basket Level Down Switch
Jib Up Switch
Jib Down Switch
Pump Potentiometer Return
Start Switch
Auxiliary Switch
Crab Steer Select Switch
Coordinated Steer Select Switch
Switch Input Battery
Inline Limit Switch
LSS Platform Overload
500/1000 # Capacity Select
Switch
Boom Control Select Switch
Axle Extend Switch
Axle Retract Switch
Serial Tilt Sensor Input 1
Serial Tilt Sensor input 2
Two Speed Switch
Engine Speed Switch
Soft Touch Override Switch
Head/Tail Light Switch
Horn Switch
Creep Switch
Not Used
Pump Potentiometer Ref. Voltage
Pump Potentiometer
----Input
Input
Input
Input
Input
Input
Input
Input
Ground
Input
Input
Input
Input
Output
Input
Input
Input
----Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
0VDC
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Input
Input
Input
Input/Output
Input/Output
Input
Input
Input
Input
Input
Input
-Other Voltage
Vbatt
Vbatt
Vbatt
Comm
Comm
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
-7VDC
Input
7 VDC
Table 2-22. X166 (J2) Platform Module Pinout
Pin
Function
Type
Range (V)
1
2
3
4
5
Jib Right Switch
Jib Left Switch
Switch Input Battery
Drive Orientation Override
Switch
Basket Stow Switch
2-148
Input
Input
Vbatt
Input
Vbatt
Vbatt
Vbatt
Vbatt
Input
Vbatt
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
Tilt Lamp
Enable Lamp
System Distress/Fault Lamp
Creep Lamp
Broken Cable Lamp
Overload Lamp
500# Capacity Lamp
1000# Capacity Lamp
Axle Set Lamp
Generator On Lamp
Soft Touch Lamp
Glow Plug Lamp
Lamp Return
Boom Control System Warning
Lamp
Auto Leveling System Lamp
Not Used
Fuel 1/4 Full Lamp
Fuel 3/4 Full Lamp
Fuel 1/2 Full Lamp
Fuel Lamp Return
Analyzer PWR
Analyzer Ground
Analyzer RS232 Receive
Analyzer RS232 Transmit
Drive Orientation Lamp
Not Used
Battery
Battery
Switch Input Battery
Fuel Full Lamp
Pin
Table 2-23. X167 (J5) Platform Module Pinout
Function
Type
Range (V)
1
2
3
4
5
6
7
8
Swing & Lift Joystick Supply
Lift Center Tap
Lift Signal
Swing Signal
Swing Center Tap
Not Used
Ground
Not Used
1200SJP 1350SJP
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Ground
Output
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
0VDC
Vbatt
Output
-Output
Output
Output
Output
Vbatt
Ground
Input/Output
Input/Output
Output
-Vbatt
Vbatt
Vbatt
Output
Vbatt
-Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
0VDC
Comm
Comm
Vbatt
-Vbatt
Vbatt
Vbatt
Vbatt
Vref
Input
Input
Input
Input
-Ground
--
7VDC
7VDC
7VDC
7VDC
7VDC
-0VDC
--
3128463
SECTION 2 - ELECTRICAL REFERENCE
Pin
1
2
3
4
5
6
7
8
Table 2-24. X168 (J6) Platform Module Pinout
Function
Type
Range (V)
Steer & Drive Joystick Supply
Drive Center Tap
Drive Signal
Not Used
Steer Left Switch
Steer Right Switch
Ground
Not Used
Vref
Input
Input
-Input
Input
Ground
--
7VDC
7VDC
7VDC
-7VDC
7VDC
0VDC
--
Pin
1
2
Table 2-26. X170 (J8) Platform Module Pinout
Function
Type
Range (V)
Ground from Ground Module
Ground EMS
Ground
Ground
0VDC
0VDC
Table 2-25. X169 (J7) Platform Module Pinout
Pin
Function
Type
Range (V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
GND Mode Switch
Platform EMS Switch
Platform EMS to GND Module
Not Used
Rotate Left Coil
Rotate Right Coil
Not Used
Footswitch Disengage
Generator On
Not used
Not Used
Not Used
Not Used
Not Used
Basket Level Up Coil
Basket Level Down Coil
Jib Block Limit Switch
Soft Touch Limit Switch
Platform Alarm
Platform Alarm Return
Primary Tilt Sensor Ground
Not used
Not used
Not used
Jib Up Coil
Jib Down Coil
Jib Right Coil
Jib Left Coil
Digital Output Return
CAN LO
CAN HI
CAN Shield
Secondary Tilt Sensor Ground
Not Used
Not Used
3128463
Input
Input
Input
-Output
Output
-Input
Input
-----Output
Output
Input
Input
Output
Ground
Ground
---Output
Output
Output
Output
Ground
Input/Output
Input/Output
Ground
Ground
---
Vbatt
Vbatt
Vbatt
-PWM
PWM
-Vbatt
Vbatt
-----PWM
PWM
Vbatt
Vbatt
Vbatt
0VDC
0VDC
---PWM
PWM
PWM
PWM
0VDC
Comm
Comm
0VDC
0VDC
---
1200SJP 1350SJP
2-149
SECTION 2 - ELECTRICAL REFERENCE
2.6 CONNECTOR LOADING DIAGRAMS
ID
AMP02P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Amp 2 position plug
2
1
AMP02R
Amp 2 position receptacle
2
1
AMPJT82600
8P
Amp 2 position plug
2
1
AMP04P
Amp 4 position plug
4
3
2
1
AMP04R
Amp 4 position receptacle
4
3
1
AMP06P
Amp 6 position plug
32 1
654
AMP06R
Amp 6 position receptacle
1 2 3
45 6
2-150
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
Description
AMP08BP
Amp 8 position black
plug
AMP08NP
Amp 8 position natural
plug
AMP15P
Table 2-27. Connector Loading Diagrams
Diagram
Amp 15 position plug
1
3
6
8
2
3
6
9
12
15
1
4
7
10
13
14
AMP15R
Amp 15 position receptacle
2
3
6
9
12
15
1
4
7
10
13
14
AMP25LP
Amp Rectangular 25
position plug with key for
left
13 12 11 10 9 8
7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14
AMP25RP
Amp Rectangular 25
position plug with key for
right
14 15 16 17 18 19 20 21 22 23 24 25
1 2
AMPPVG4P
(Black)
AMPPVG4GP
(Gray)
3128463
3 4
5
6 7 8 9 10 11 12 13
Amp PVG Valve 4 position plug
4
3
2
1
1200SJP 1350SJP
2-151
SECTION 2 - ELECTRICAL REFERENCE
ID
AMP14P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Ampseal 14 position
1
10
5
AMP
14
Socket Rear Insert
AMP23P
Ampseal 23 position
1
8
16
23
Socket Rear Insert
AMP351P
(Black)
AMP352P
(Neutral)
AMP354P
(Gray)
AMP355P
(Blue)
Ampseal 35 position
AN350P
Anderson Power Connector
ANL06P
Amphenol 6 Position
Sealed Plug
12
1
24
AMP
35
Socket Rear Insert
2-152
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
Description
BOSCH05P
Bosch Relay Sealed Plug
DEUTZ12ENG
R
Deutz Supplied 12 position receptacle
Table 2-27. Connector Loading Diagrams
Diagram
2 3
1
4
9
12
10 11
DEUTZ12P
Deutz Supplied 12 position plug
3 2
4
1
12
9
11 10
DEUTZ12R
Deutz Supplied 12 position receptacle
2 3
1
4
9
12
10 11
DEUTZ16P
Deutz Supplied 16 position plug
2 3
4
8
12
16
1
5
9
13
1415
3128463
1200SJP 1350SJP
2-153
SECTION 2 - ELECTRICAL REFERENCE
ID
DEUTZ16R
Description
Table 2-27. Connector Loading Diagrams
Diagram
Deutz Supplied 16 position receptacle
3 2
4
8
12
16
1
5
9
13
15 14
DEUTZE
Deutz Supplied 4 position charge air pressure
sensor Plug
DEUTZG
Deutz Supplied 2 position air filter pressure
switch Receptacle
DIN43650P
Din 43650 4 position
plug
3
2
1
4
DHD1939R
2-154
Deutsch 9 position HD
series J1939. Receptacle
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
DHD14P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Deutsch 14 position HD
series alum. Plug
Rear View
DHD14R
Deutsch 14 position HD
series alum. Receptacle
Rear View
DHD19P
Deutsch 19 position HD
series alum. Plug
DHD19R
Deutsch 19 position HD
series alum. Receptacle
DHD1821P
Deutsch 21 position HD
series alum. Plug
3128463
1200SJP 1350SJP
2-155
SECTION 2 - ELECTRICAL REFERENCE
ID
Description
DHD1821R
Deutsch 21 position HD
series alum. Receptacle
DHD21P
Deutsch 21 position HD
series alum. Plug
DHD21R
Deutsch 21 position HD
series alum. Receptacle
DHTP31R
(receptacle)
DHTP31P
(plug)
Deutsch HDP 31 position
Table 2-27. Connector Loading Diagrams
Diagram
31
30
20
8
19
29
28
21
9
2
18
7
17
10
3
1
6
16
27
12
13
14
26
23
4
5
15
22
11
25
24
Socket Rear Insert
DT02P
Deutsch 2 position DT
series plug
1
DT02R
Deutsch 2 position DT
series receptacle
2
2-156
2
1200SJP 1350SJP
1
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
DT03P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Deutsch 3 position DT
series plug
A
B
C
DT03R
Deutsch 3 position DT
series receptacle
A
B
C
DT03P032GP
(Green)
DT03P032BP
(Blue)
DT03P032OP
(Orange)
Deutsch 3 position DT
series plug with overmold adaptor
DT04P
Deutsch 4 position DT
series plug
DT04R
Deutsch 4 position DT
series receptacle
DT06AP
Deutsch 6 position DT
series plug
DT06EP032R
Deutsch 6 position bus
receptacle
DT06R
Deutsch 6 position DT
series receptacle
3128463
B
B
A
A
C
C
1200SJP 1350SJP
2-157
SECTION 2 - ELECTRICAL REFERENCE
ID
Description
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
Table 2-27. Connector Loading Diagrams
Diagram
1
2
3
4
5
6
12
11
10
9
8
7
DT12AR
DT12BP
Deutsch 12 position DT
series receptacle with A
keys
7
8
9
10
11
12
Deutsch 12 position DT
series plug with B keys
1
2
3
4
5
6
12
11
10
9
8
7
DT12BR
2-158
6
5
4
3
2
1
Deutsch 12 position DT
series receptacle with B
keys
7
8
9
10
11
12
1200SJP 1350SJP
6
5
4
3
2
1
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
DT12CP
Description
Table 2-27. Connector Loading Diagrams
Diagram
Deutsch 12 position DT
series plug with C keys
1
2
3
4
5
6
12
11
10
9
8
7
DT12DP
Deutsch 12 position DT
series plug with D keys
1
2
3
4
5
6
12
11
10
9
8
7
DT12PBR
DTM03P
Deutsch 12 position bus
receptacle
7
8
9
10
11
12
6
5
4
3
2
1
Deutsch 3 position DTM
series mini plug
3 2 1
DTM03R
Deutsch 3 position DTM
series mini receptacle
12 3
DTM04P
DTM04R
DTM12AP
Deutsch 4 position DTM
series mini plug
1
2
1
2
4
3
Deutsch 4 position DTM
series mini receptacle
Deutsch 12 position DT
series mini plug with A
key
7
6
3128463
4
3
8
5
9
4
10 11 12
3
2
1
1200SJP 1350SJP
2-159
SECTION 2 - ELECTRICAL REFERENCE
ID
DTM12BP
Description
Deutsch 12 position DT
series mini plug with B
key
Table 2-27. Connector Loading Diagrams
Diagram
7
6
DTP02P
8
5
9
4
10 11 12
3
2
1
Deutsch 2 position DTP
series plug
2
1
DTP02R
Deutsch 2 position DTP
series receptacle
2
E06P
1
Eaton Toggle Switch
ITTC12P
ITT Cannon 12 position
plug
MMF02P
Molex 2 position plug
MMF04P
Molex 4 position plug
2
1
4
2
5
3
6
1
4
3
2
1
2-160
1200SJP 1350SJP
3128463
SECTION 2 - ELECTRICAL REFERENCE
ID
MMF08P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Molex Mini Fit 8 position
plug
Rear View
MMF10P
Molex Mini Fit 10 position plug
6
7
8
9
10
1
2
3
4
5
MMF12P
Molex Mini Fit 12 position plug
7
8
1
MMF24P
1
3128463
2
10
3
11
4
12
5
6
Molex Mini Fit 24 position plug
13
PHEONIX5P
9
2
14
3
15
4
16
17
5
6
18
7
19
8
20
9
21
22
10
23
24
11
12
Pheonix 5 position M-12
Plug
1200SJP 1350SJP
2-161
SECTION 2 - ELECTRICAL REFERENCE
ID
PHEONIX7P
Description
Table 2-27. Connector Loading Diagrams
Diagram
Pheonix 7 position M-12
Plug
PACKARD2LR Packard Light Receptacle
PACKARD2P
Packard 2 position plug
A
PACKARD3P
Packard 3 position
receptacle
PACKARD3R
Packard 3 position
receptacle
B
C BA
SUM02N
Sumitomo 2 position
natural
SUM06N
Sumitomo 6 position
natural
1
4
5
1200SJP 1350SJP
1
2
6
2-162
2
3
3128463
SECTION 3 - HYDRAULIC REFERENCE
SECTION 3. HYDRAULIC REFERENCE
M5
MS
M8
TELE OUT
RELIEF
TELE IN
ADJ
RELIEF
ADJ
M7
M4
LIFT UP
LIFT
RELIEF
DOWN
ADJ
RELIEF
ADJ
SWING
RELIEF
ADJ
MP
MAIN VALVE
Figure 3-1. Main Valve Layout
3128463
1200SJP 1350SJP
3-163
SECTION 3 - HYDRAULIC REFERENCE
PUMPS
VIEW ROTATED
RIGHT SIDE DRIVE PUMP
LEFT SIDE DRIVE PUMP
FUNCTION PUMP
LOW PRESS
RELIEF ADJ.
HIGH PRESS
RELIEF ADJ.
Figure 3-2. Pumps Layout
3-164
1200SJP 1350SJP
3128463
SECTION 3 - HYDRAULIC REFERENCE
Platform Valve Layout
P
L2
MP
L1
M1
R2
R1
M2
S2
S1
M3
2.0 GPM
T
75 PSI
CHECK
VALVE
J2
J1
PLATFORM LEVEL
UP RELIEF ADJUST
0.2 GPM
PLATFORM LEVEL
DOWN RELIEF
ADJUST
0.3 GPM
JIB UP/DOWN
2.0 GPM
JIB UP/DOWN
RELIEF ADJUST
JIB UP/DOWN
SHUTTLE
VALVE
10 MICRON
FILTER
BASKET SUPPORT
Figure 3-3. Platform Valve Layout
3128463
1200SJP 1350SJP
3-165
SECTION 3 - HYDRAULIC REFERENCE
Pump Circuit Schematic
SWIVEL PORT
#5
b
a
Ps
(Fe) B
G (Fa)
Ma
5000 PSI
THROTTLE
POSITION
1.7in
3
.37in
3
5000 PSI
1.2mm
Mb
R
T - #1
T1
T2
X1
"OPTION"
OIL COOLER
#1 - T
P - #2
#2 - P
B1 - #5
#5 - B1
B2 - #4
#4 - B2
A2 - #3
#3 - A2
A1 - #6
#6 - A1
S
X2
A
SWIVEL PORT
#6
PUMP CIRCUIT.
1200SJP, 1350SJP, 1250AJP
CD - #7
#7 - CD
2792771 C
SWIVEL
Figure 3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2
3-166
1200SJP 1350SJP
3128463
SECTION 3 - HYDRAULIC REFERENCE
SWIVEL PORT
#4
"P1"
SHT. #1
"LS"
SHT. #1
X
SET AT
300
PSI
a
b
(Fe) B
G (Fa)
Ps
SET AT
3400
PSI
Ma
5000 PSI
1.7in
B
3
.37in
3
2.74in
3
5000 PSI
550 PSI
S
L1
L
Mb
R
T1
T2
X1
X2
S
SWIVEL PORT
#7
SWIVEL PORT
#1
A
SWIVEL PORT
#3
RESERVOIR
"T3"
SHT. #1
2792771 C
Figure 3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2
3128463
1200SJP 1350SJP
3-167
SECTION 3 - HYDRAULIC REFERENCE
Platform Control Schematic
LEVEL CYLINDER
1200SJP-1350SJP
Bore: 5.00" 19.63 sq. in.
Rod: 2.00" 3.14 sq. in.
Annulus: 16.49 sq. in.
Cyl. Area Ratio: 1.19:1
Stroke: 13.375"
PLATFORM ROTATOR
Displacement: 14 c.i.r.
C1
C2
V1
M1
1500 PSI
L1
L2
M2
V2
R1
R2
(1200SJP-1350SJP)
1
2500 PSI
(1200SJP-1350SJP)
2
1
2
2
4
S1
S2
3
2
75 PSI
2
1
4
3
1
S2
1
1
2
S1
2
0.2 GPM
1
T
"T2"
SHT. #1
2
2.0 GPM
3
1
MP
1
10 MICRON ABS
B10 >= 1000
IN
P
2
OUT
100 PSI
BYPASS
"P3"
SHT. #1
PLATFORM CONTROL
1200SJP,1350SJP,1250AJP
2792771 C
Figure 3-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2
3-168
1200SJP 1350SJP
3128463
SECTION 3 - HYDRAULIC REFERENCE
JIB CYLINDER
JIB SWING ROTATOR
Bore: 3.00" 7.06 sq. in.
Rod: 1.50" 1.76 sq. in.
Annulus: 5.3 sq. in.
Cyl. Area Ratio: 1.33:1
Stroke: 23.5"
Displacement: 74.2 cu. in. for 244 degrees
Displacement: 54.7 cu. in. for 180 degrees
C1
C2
V1
V2
.047
S1
S2
M3
J1
J2
2
1
2750 PSI
3
1
2
2
4
S2
S1
3
4
3
1
S2
1
2
2
0.3 GPM
2
S1
2.0 GPM
1
1
PLATFORM CONTROL
1200SJP,1350SJP,1250AJP
2792771 C
Figure 3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2
3128463
1200SJP 1350SJP
3-169
SECTION 3 - HYDRAULIC REFERENCE
Axle Steer Control Schematic
T
LEFT
P
2
SWIVEL PORT
#1
RIGHT SIDE
2000 PSI
b
MS4
1
S4
S3
RIGHT
B
T
A
P
P3
TRACTION CONTROL
(PAGE 5)
1
MS3
a
2600 PSI
REAR STEER
2
2
RIGHT
2000 PSI
b
LEFT SIDE
MS2
1
S2
S1
LEFT
B
T
A
P
1
MS1
a
2600 PSI
RIGHT SIDE
2
V2
MA4
2
2500 PSI
b
V1
REAR AXLE
V1
A4
1
A2
B
T
A1
A
P
1
A3
LEFT SIDE
a
MA3
2500 PSI
2
AXLE
STEER
V2
2792771 C
AXLE EXTENSION CYLINDERS
STEERING CYLINDERS
BORE: 3.50" 9.62 SQ. IN.
ROD: 2.00" 3.14 SQ. IN.
ANNULUS: 6.48 SQ. IN.
CYL. AREA RATIO: 1.48:1
STROKE: 27.125"
BORE: 4.00" 12.56 SQ. IN.
ROD: 1.75" 2.40 SQ. IN.
ANNULUS: 10.16 SQ. IN.
CYL. AREA RATIO: 1.23:1
STROKE: 9.25"
Figure 3-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2
3-170
1200SJP 1350SJP
3128463
SECTION 3 - HYDRAULIC REFERENCE
V2
T
2
LEFT SIDE
P
MA3
2500 PSI
a
P4
TRACTION CONTROL
(PAGE5)
A3
1
P
A
A1
T
B
A2
V1
FRONT AXLE
1
A4
V1
RIGHT SIDE
b
2500 PSI
MA4
2
V2
2
2600 PSI
a
MS1
A
T
B
S1
LEFT SIDE
P
LEFT
1
S2
1
MS2
b
RIGHT
2000 PSI
2
FRONT STEER
2
2600 PSI
a
S3
A
T
B
RIGHT SIDE
P
RIGHT
MS3
1
S4
1
MS4
b
LEFT
2000 PSI
2
AXLE
2792771 C
Figure 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2
3128463
1200SJP 1350SJP
3-171
SECTION 3 - HYDRAULIC REFERENCE
Traction Control Schematic
SEE SHT #4 AXLE
STEER CONTROL
SWIVEL PORT
#2
SWIVEL PORT
#2
P2
PLANETARY GEAR
REDUCTION
88.2 : 1 RATIO
LEFT
P1
A3
4
P3
3
2
3
P4
Br
L1
L
G
2.74 CU. IN. MAX
1.0 CU. IN. MIN
G1
1
2
1
A
4
B3
B
.025 DIA.
ORIFICE
REAR
3
.047
Speed
Two Shift
2
TS
1
2
1
2
1
2
1
2
MBR
2
1
BR
LOP
2
3
MLOP
A
Brake
Release
3
.047
1
AXLE LOCKOUT
B
4
A5
2.74 CU. IN. MAX
1.0 CU. IN. MIN
L
L1
Br
2
G1
G
3
B2
PLANETARY GEAR
REDUCTION
88.2 : 1 RATIO
RIGHT
B5
2792771 C
SWIVEL PORT
#4
B1
SWIVEL PORT
#5
A1
SWIVEL PORT
#6
TRACTION CONTROL
Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2
3-172
1200SJP 1350SJP
3128463
OSC. AXLE L.O. CYL.
PLANETARY GEAR
REDUCTION
88.2 : 1 RATIO
LEFT
SECTION 3 - HYDRAULIC REFERENCE
A4
Br
L1
L
B4
G
2.74 CU. IN. MAX
1.0 CU. IN. MIN
G1
A
FRONT
2
B
4
"OPTION"
3
AXLE LOCK OUT CYLINDERS
1
A
B
2.74 CU. IN. MAX
1.0 CU. IN. MIN
L
L1
Br
2
SET AT 500 PSI
MP
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"
A6
G1
G
D
SWIVEL PORT
#3
SWIVEL PORT
#1
OSC. AXLE L.O. CYL.
RIGHT
A2
PLANETARY GEAR
REDUCTION
88.2 : 1 RATIO
B6
TRACTION CONTROL
SWIVEL PORT
#7
2792771 C
Figure 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2
3128463
1200SJP 1350SJP
3-173
SECTION 3 - HYDRAULIC REFERENCE
Boom Control Schematic
SWINGDRIVE
SWING
BearingtoPinionRatio:103:20
GearboxRatio:54.58:1
MotorDisc.:6.00c.i.r.
A
LIFTCYLINDER
Bore:9.00"63.61sq.in.
Rod:4.00"12.56sq.in.
Annulus:51.05sq.in.
Cyl.AreaRatio:1.24:1
Stroke:62.125"
BOOMCONTROL
B
1200SJP/1350SJP
2792771C
M1
1
2
3
MS
1500PSI
1
2
3
1
2
1500PSI
1
EMERGENCY
LOWER
2
A
B
P
T
2
b
a
RESERVOIR
SHT.#2
3
SWING
1
LIFTDOWN
AUXSELECT
T3
GR
FROMGRPORT
OFGENERATOR
P2
MAIN
DUMP
B
P
M
S
AUX.PUMP
TOGRPORT
OFMAINVALVE
W
GENERATOR RETURN OIL
SWIVEL PORT
#2
LS
GR
1
T1
FROM
"LS" PORT OF
MAIN VALVE
2
2
LS
LS1
1
W
"X"
SHT.#2
2
2
1
3
TO "X" PORT OF
FUNCTION PUMP
SHT.#2
P
A
TO RESERVOIR
MP
G
L
"OPTION"
GENERATOR CONTROL
B
Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2
3-174
1200SJP 1350SJP
3128463
SECTION 3 - HYDRAULIC REFERENCE
LIFT
TELESCOPE
TELESCOPE CYLINDER
Bore:5.00"19.63sq.in.
Rod:4.00"12.56sq.in.
Annulus:7.07sq.in.
Cyl.AreaRatio:2.77:1
Stroke:344.625"
5GPM
V2
4
M4
5
M5
6
V1
M7
7
M8
8
75PSI
2750PSI
3200PSI
3000PSI
1
1
1
2
2
2
LIFT
A
B
a
A
B
P
T
b
P
a
T
b
2
2
TELESCOPE
LIFT DOWN
AUXILIARY
1
2
1
T2
15PSI
1
"T"
SHT.#3
2
1
5PSI
P3
MP3
2
75PSI
"P"
SHT.#3
1
P1
"B"
SHT.#2
2792771C
Figure 3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2
3128463
1200SJP 1350SJP
3-175
SECTION 3 - HYDRAULIC REFERENCE
This Page Left Blank Intentionally
3-176
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
SECTION 4. JLG ANALYZER
4.1 TO CONNECT THE JLG CONTROL SYSTEM
ANALYZER
1. Connect the cable supplied with the analyzer, to the
controller module located in the platform box or at
the controller module in the ground control box and
connect the remaining end of the cable to the analyzer.
4.2 USING THE ANALYZER
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
NOTE: The cable has a four pin connector at each end of
the cable; the cable cannot be connected backwards.
2. Power up the Control System by turning the key to
the platform or ground position and pulling both
emergency stop buttons on.
HELP:
PRESS ENTER
Figure 4-1. Ground Analyzer Connection Point
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC.; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
The top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
Figure 4-2. Platform Analyzer Connection Point
3128463
If you press ENTER, at the HELP: PRESS ENTER display,
and a fault is present, the analyzer display will scroll the
fault across the screen. If there was no fault detected, the
display will read: HELP: EVERYTHING OK. If powered up
at the ground station, the display will read: GROUND OK.
1200SJP 1350SJP
4-177
SECTION 4 - JLG ANALYZER
If ENTER is pressed again, the display moves to the following display:
LOGGED HELP
1: POWER CYCLE (0/0)
At this point, the analyzer will display the last fault the system has seen, if any are present. You may scroll through
the fault logs to view what the last 25 faults were. Use the
right and left arrow keys to scroll through the fault logs. To
return to the beginning, press ESC. two times. POWER
CYCLE (0/0) indicates a power up.
When a top level menu is selected, a new set of menu
items may be offered: for example:
DRIVE
BOOM
SYSTEM
DATALOG
VERSIONS
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
menu. In some cases, such as DRIVE, the next level is the
parameter or information to be changed. Refer to the flow
chart for what menus are available within the top level
menus. You may only view the personality settings for
selected menus while in access level 2. Remember, you
may always cancel a selected menu item by pressing the
ESC. key.
4-178
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
Figure 4-3. Analyzer Flow Chart
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
3128463
1200SJP 1350SJP
4-179
4-180
TO:
MACHINE SETUP
MENU:
PERSONALITIES
FROM:
ACCESS LEVEL 1
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%
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%
MAIN LIFT:
CREEP DOWN X%
DRIVE:
CREEP MAX X%
PLATFORM ROTATE:
ACCEL X.XS
MAIN LIFT:
MAX DOWN X%
DRIVE:
ELEV. MAX X%
PLATFORM LEVEL:
ACCEL X.XS
MAIN LIFT:
MIN DOWN X%
DRIVE:
MAX REVERSE X%
1200SJP 1350SJP
JIB LIFT:
MAX DOWN X%
JIB LIFT:
MIN DOWN X%
JIB LIFT:
MAX UP X%
JIB LIFT:
MIN UP X%
JIB LIFT:
DECEL X.XS
JIB LIFT:
ACCEL X.XS
TOWER LIFT:
MAX DOWN X%
TOWER LIFT:
MIN DOWN X%
TOWER LIFT:
MAX UP X%
TOWER LIFT:
MIN UP X%
JIB LIFT:
MAX RIGHT X%
JIB LIFT:
MIN RIGHT X%
JIB LIFT:
MAX LEFT X%
JIB LIFT:
MIN LEFT X%
JIB LIFT:
DECEL X.XS
JIB LIFT:
ACCEL X.XS
GROUND MODE:
JIB (L/R): XXX%
GROUND MODE:
JIB (U/D): XXX%
GROUND MODE:
TOWER DOWN: XXX%
GROUND MODE:
TOWER UP: XXX%
GROUND MODE:
TOWER TELE: XXX%
GROUND MODE:
MAIN TELE: XXX%
GROUND MODE:
PLT ROTATE: XXX%
GROUND MODE:
PLT LEVEL: XXX%
GROUND MODE:
SWING: XXX%
GROUND MODE:
MAIN DOWN: XXX%
GROUND MODE:
MAIN UP: XXX%
TOWER TELESCOPE:
MAX OUT X%
TOWER TELESCOPE:
MIN OUT X%
TOWER TELESCOPE:
MAX IN X%
TOWER TELESCOPE:
MIN IN X%
TOWER TELESCOPE:
DECEL X.XS
TOWER TELESCOPE:
ACCEL X.XS
PERSONALITIES:
TOWER TELESCOPE
GEN SET/WELDER:
ENGINE 1800 RPM
PERSONALITIES:
GEN SET/WELDER
MAIN TELESCOPE:
MAX OUT X%
MAIN TELESCOPE:
MIN OUT X%
MAIN TELESCOPE:
MAX IN X%
MAIN TELESCOPE:
MIN IN X%
MAIN TELESCOPE:
DECEL X.XS
MAIN TELESCOPE:
ACCEL X.XS
PERSONALITIES:
MAIN TELESCOPE
PERSONALITIES:
GROUND MODE
TOWER LIFT:
DECEL
MEDIUM
TOWER LIFT:
ACCEL X.XS
PERSONALITIES:
TOWER LIFT
PERSONALITIES:
JIB SWING
SWING:
CREEP RIGHT X%
SWING:
MAX RIGHT X%
SWING:
MIN RIGHT X%
SWING:
CREEP LEFT X%
SWING:
MAX LEFT X%
SWING:
MIN LEFT X%
SWING:
DECEL X.XS
SWING:
ACCEL X.XS
PERSONALITIES:
SWING
PERSONALITIES:
JIB LIFT
MAIN LIFT:
CREEP UP X%
DRIVE:
MIN REVERSE X%
PERSONALITIES:
PLATFORM ROTATE
MAIN LIFT:
MAX UP X%
DRIVE:
MAX FORWARD X%
PERSONALITIES:
PLATFORM LEVEL
MAIN LIFT:
MIN UP X%
DRIVE:
MIN FORWARD X%
MAIN LIFT:
ACCEL X.XS
MAIN LIFT:
DECEL X.XS
STEER:
MAX SPEED X%
DRIVE:
ACCEL X.XS
PERSONALITIES:
MAIN LIFT
DRIVE:
DECEL X.XS
PERSONALITIES:
STEER
PERSONALITIES:
DRIVE
SECTION 4 - JLG ANALYZER
Figure 4-4. Analyzer Flow Chart - Personalities (Software Version 7.X to Present)
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
3128463
3128463
TO:
CALIBRATIONS
MENU:
MACHINE SETUP
FROM:
PERSONALITIES
1200SJP 1350SJP
SOFT
TILT: TOUCH:
2=4 DEG
YES
TILT:
3=3 DEG
TILT:
4=4 DEG PLUS CUT
TILT:
5=3 DEG PLUS CUT
OSCILLATING
AXLE: YES
OSCILLATING
AXLE: NO
CHASSIS TILT:
4 DEGREES
CHASSIS TILT:
3 DEGREES
CHASSIS TILT:
4 DEGREES + CUT
CHASSIS TILT:
3 DEGREES + CUT
GROUND ALARM:
NO
GROUND ALARM:
DRIVE
GROUND ALARM:
MOTION
GROUND ALARM:
DESCENT
SOFT TOUCH:
TILT:
1=5 DEG
NO
CHASSIS TILT:
5 DEGREES
ENVELOPE HEIGHT:
1250A: 80' MAX
ENVELOPE HEIGHT:
1250A: 100' MAX
TEMP DISPLAY:
FAHRENHEIT
TEMP DISPLAY:
CELSIUS
GEN SET/WELDER:
HYDRAULIC DRIVE
GEN SET/WELDER:
BELT DRIVE
GEN SET/WELDER:
NO
MARKET:
JAPAN
ENVELOPE HEIGHT:
1200S: 110' MAX
ENVELOPE HEIGHT:
1250A: 125' MAX
MARKET:
AUSTRALIA
MARKET:
CSA
ENVELOPE HEIGHT:
1200S: 120' MAX
ENVELOPE HEIGHT:
1350S: 120' MAX
MODEL NUMBER:
1350S
MARKET:
ANSI EXPORT
MARKET:
CE
ENVELOPE HEIGHT:
1350S: 125' MAX
MODEL NUMBER:
1250A
MARKET:
ANSI USA
ENVELOPE HEIGHT:
1350S: 110' MAX
ENVELOPE HEIGHT:
1350S: 135' MAX
MODEL NUMBER:
1200S
GEN SET CUTOUT:
MOTION CUTOUT
GEN SET CUTOUT:
MOTION ENABLED
ENGINE:
DEUTZ ECM
ENGINE:
DEUTZ F4 TIER2
ENGINE:
DEUTZ F4 TIER1
H & T LIGHTS:
YES
H & T LIGHTS:
NO
GLOW PLUG:
IN-CYLINDER*
GLOW PLUG:
AIR INTAKE
GLOW PLUG:
NO GLOW PLUGS
LOAD SYSTEM:
SPECIAL 1
LOAD SYSTEM:
CUTOUT ALL
LOAD SYSTEM:
CUTOUT PLATFORM
LOAD SYSTEM:
WARN ONLY
FUNCTION CUTOUT:
DRIVE CUT E&T
FUNCTION CUTOUT:
DRIVE CUTOUT
FUNCTION CUTOUT:
BOOM CUTOUT
FUNCTION CUTOUT:
NO
ENGINE SHUTDOWN:
DISABLED
STARTER LOCKOUT:
ENABLED
LOAD SYSTEM:
NO
ENGINE SHUTDOWN:
ENABLED
STARTER LOCKOUT:
DISABLED
SECTION 4 - JLG ANALYZER
Figure 4-5. Analyzer Flow Chart - Machine Setup (Software Version 7.X to Present)
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
4-181
4-182
MENU:
CALIBRATIONS
FROM:
MACHINE SETUP
CALIBRATIONS:
BOOM SENSORS
POSITION 1:
CHECK SYSTEM?
POSITION 1:
CHECK SYSTEM?
CALIBRATE
DRIVE?
CALIBRATE
STEER?
CALIBRATIONS:
TILT SENSOR
CALIBRATIONS:
DRIVE
CALIBRATIONS:
STEER
1200SJP 1350SJP
DEUTZ SETUP:
SETUP 4
DEUTZ SETUP:
SETUP 3
DEUTZ SETUP:
SETUP 2
DEUTZ SETUP:
SETUP 1
CALIBRATIONS:
DEUTZ SETUP:
CALIBRATE
BOOM VALVES?
CALIBRATIONS:
BOOM VALVES
CALIBRATIONS:
NONE AVAILABLE
CALIBRATE LEVEL
UP CRACKPOINT?
CALIBRATIONS:
LEVEL UP CRKPT
CALIBRATE LEVEL
DOWN CRACKPOINT?
CALIBRATIONS:
LEVEL DOWN CRKPT
CALIBRATE MAIN
LIFT CRACKPOINT?
CALIBRATIONS:
MAIN LIFT CRKPT
CALIBRATE MAIN
TELE CRACKPOINT?
CALIBRATIONS:
MAIN TELE CRKPT
SECTION 4 - JLG ANALYZER
Figure 4-6. Analyzer Flow Chart - Calibrations (Software Version 7.X to Present)
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
3128463
3128463
TO:
SYSTEM TEST
MENU:
DIAGNOSTICS
FROM:
HELP:PRESS ENTER
1200SJP 1350SJP
JOYSTICK SWING:
LEFT
XXX%
LIFT OUTPUT:
MAIN UP
XXX%
SWING OUTPUT:
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
JIB SWING:
LEFT
PLATFORM CONTROL
VALVE: OFF
FUNCTION SPEED:
PUMP POT XXX%
CREEP
SWITCH: CLOSED
CREEP MODE:
OFF
JOYSTICK STEER:
LEFT
XXX%
DRIVE OUTPUT:
FORWARD
XXX%
STEER OUTPUT:
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
DRIVE MODE:
MID ENGINE
L FRONT WHEEL
ANGLE: XX.X
R FRONT WHEEL
ANGLE: XX.X
L REAR WHEEL
ANGLE: XX.X
DRV. ORIENTATION
OVERRIDE: OPEN
DRV. ORIENTATION
SWITCH: CLOSED
R REAR WHEEL
ANGLE: XX.X
JOYSTICK LIFT:
MAIN UP
XXX%
JOYSTICK DRIVE:
FORWARD
XXX%
XXX%
XXX%
DIAGNOSTICS:
BOOM FUNCTIONS
DIAGNOSTICS:
DRIVE
ENGINE SPEED
TARGET: XXXX RPM
ENGINE SPEED
ACTUAL: XXXX RPM
STARTER
CRANK TIME: XX S
FUEL LEVEL
SENSOR: OK
AMBIENT
TEMPERATURE:XXXC
ENGINE OIL
PRESSURE:XXXXPSI
COOLANT
TEMPERATURE:XXXC
BATTERY VOLTAGE:
XX.XV
START SEQUENCE:
NOT ACTIVE
DIAGNOSTICS:
ENGINE
AUXILIARY POWER
SWITCH: OPEN
CHASSIS TILT
Y-AXIS: X.X
CHASSIS TILT
X-AXIS: X.X
CHASSIS TILT:
XX.X DEGREES
CREEP MODE:
OFF
CREEP
SWITCH: CLOSED
CABLE BREAK
SWITCH: CLOSED
TRANSPORT MODE:
OUT OF TRANSPORT
FOOTSWITCH INPUT
PLATFORM: CLOSED
FOOTSWITCH INPUT
GROUND: OPEN
STATION CONTROL:
GROUND
GROUND SELECT
KEYSWITCH: OPEN
PLATFORM SELECT
KEYSWITCH:CLOSED
AMBIENT
TEMPERATURE:XXXC
PLATFORM MODULE
BATTERY: XX.XV
GROUND MODULE
BATTERY: XX.XV
DIAGNOSTICS:
SYSTEM
MAIN LIFT PILOT
PRES. SW.: OPEN
HYDRAULIC OIL:
WARM UP NOT DONE
HYDRAULIC OIL
TEMP. SW.: OPEN
OSCILATING AXLE
PRES. SW.: OPEN
PLATFORM TILT2
RAW: XXXX
PLATFORM TILT1
RAW: XXXX
PLATFORM TILT2
ANGLE: XX.X DEG
PLATFORM TILT1
ANGLE: XX.X DEG
LIGHTS
SWITCH: OPEN
GENSET/WELDER
SWITCH: OPEN
SOFT TOUCH
OVERRIDE: OPEN
SOFT TOUCH LIMIT
SWITCH: OPEN
HORN
SWITCH: OPEN
TO:
SHEET 2
SECTION 4 - JLG ANALYZER
Figure 4-7. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 1 of 3
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
4-183
FROM:
SHEET 1
4-184
MAIN BOOM A/D
ANGLE2: XXX.X
BOOM CONTROL:
AUTOMATIC
MODE SW: OPEN
MAIN ENVELOPE
STATUS: NOMINAL
MAIN ENVELOPE
LOW: NOMINAL
TOWER ENVELOPE
STATUS: NOMINAL
MAIN BOOM ANGLE
ZONE: 4
MAIN BOOM LENGTH
ZONE: A
MAIN LIFT
STATUS: ELEVATED
MAIN TELESCOPE
STATUS:RETRACTED
PLATFORM
STOWED: NO
AXLE STATUS:
EXTENDED
JIB STOWED LIMIT
SWITCH: CLOSED
AXLE INPUT SW.:
EXTEND
CLOSED
JIB STOWED LIMIT
OVERRIDE: OPEN
MAIN BOOM A/D
ANGLE1: XXX.X
HYD. RETRIEVAL:
NOT ACTIVE
TOWER TELESCOPE
STATUS:RETRACTED
MAIN BOOM A/D
LENGTH: XXXXX
MAIN BOOM
ANGLE2: XX.X DEG
MAIN BOOM
ANGLE1: XX.X DEG
ELEC. RETRIEVAL:
NOT ACTIVE
TOWER LIFT
STATUS: STOWED
MAIN BOOM
LENGTH: XXX.X"
DIAGNOSTICS:
ENVELOPE
BCS STATUS:
NORMAL
DIAGNOSTICS:
BCS
TRANSPORT MODE:
OUT OF TRANSPORT
DIAGNOSTICS:
TRANSPORT DATA
TOWER LENGTH 2
A/D: XXXXX
TOWER ANGLE 1
A/D: XX.X
TOWER ANGLE 2
A/D: XX.X
MAIN LIFT ANGLE
SWITCH NC: OPEN
MAIN LIFT ANGLE
SWITCH NO:CLOSED
MAIN LIFT ANGLE
STATUS:TRANSPORT
1200SJP 1350SJP
MAIN LIFT 1 RAW
ANGLE: XXX.X
MAIN LIFT 2
ANGLE A/D: XXXXX
MAIN LIFT 1
ANGLE A/D: XXXXX
TOWER CYLINDER
ANGLE A/D: XXXXX
TOWER LENGTH 1
A/D: XXXXX
MAIN ANGLE H TO
GRAVITY: XXX.X
TOWER TELESCOPE
STATUS:RETRACTED
TOWER LIFT ANGLE
SWITCH: OPEN
MAIN ANGLE L TO
GRAVITY: XXX.X
MAIN ANGLE 2 TO
TOWER: XX.X
MAIN ANGLE 1 TO
TOWER: XX.X
TOWER CYLINDER
ANGLE: XX.X
TOWER ANGLE 2
SENSOR: XX.X
TOWER ANGLE 1
SENSOR: XX.X
TOWER LENGTH 2
SENSOR: X.X"
TOWER LENGTH 1
SENSOR: X.X"
DIAGNOSTICS:
BOOM SENSORS
TOWER TELESCOPE
SWITCH NO:CLOSED
TOWER TELESCOPE
SWITCH NC: OPEN
DUAL CAPACITY
LENGTH ZONE: A/B
DUAL CAPACITY
SWITCH NO:CLOSED
DUAL CAPACITY
SWITCH NC: OPEN
MAIN BOOM LENGTH
ZONE: A/D
MAIN BOOM LENGTH
SWITCH NO:CLOSED
MAIN BOOM LENGTH
SWITCH NC: OPEN
DIAGNOSTICS:
BOOM SWITCHES
MAIN TRIP POINT
ANGLE: XXX.X
MAIN ANGLE 2
HIGH CAL: XXXXXX
MAIN ANGLE 1
HIGH CAL: XXXXXX
MAIN ANGLE 2
LOW CAL: XXXXXX
MAIN ANGLE 1
LOW CAL: XXXXXX
TOWER CYLINDER
HIGH CAL: XXXXXX
TOWER CYLINDER
LOW CAL: XXXXXX
TOWER ANGLE 2
HIGH CAL: XXX.X
TOWER ANGLE 1
HIGH CAL: XXX.X
TOWER ANGLE 2
LOW CAL: XXX.X
TOWER ANGLE 1
LOW CAL: XXX.X
TOWER TRIP POINT
LENGTH: XXXX.X"
TOWER EXTENDED
LENGTH 2: XXXXXX
TOWER EXTENDED
LENGTH 1: XXXXXX
TOWER RETRACTED
LENGTH 2: XXXXXX
TOWER RETRACTED
LENGTH 1: XXXXXX
MAIN LIFT 2 RAW
ANGLE: XXX.X
LOAD PIN Y-AXIS
RAW VALUE: XXX
LOAD PIN X-AXIS
RAW VALUE: XXX
LOAD PIN Y-AXIS
VALUE: XXX
LOAD PIN X-AXIS
VALUE: XXX
LOAD PIN ERROR
FLAGS: 0X0000
LOAD PIN MOMENT
CAL POINT: XXXXX
LOAD PIN V-FORCE
CAL: XXXXX
LOAD PIN ANGLE
CAL POINT: XXX.X
LOAD PIN V-FORCE
RAW: XXXXXXXX
LOAD PIN ANGLE
RAW: XXX.X
LOAD PIN RATIO
RAW: XX.XXX
LOAD PIN MOMENT
RAW: XXXXX
LOAD PIN VECTOR
FORCE: XXXXXX
LOAD PIN ANGLE
VALUE: XXX.X
LOAD PIN RATIO
VALUE: XX.XXX
LOAD PIN MOMENT
VALUE: XXXX
DIAGNOSTICS:
LOAD PIN
TO:
SHEET 3
SECTION 4 - JLG ANALYZER
Figure 4-8. Analyzer Flow Chart - Diagnostics (Software Version 7.X to Present) - Sheet 2 of 3
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
3128463
FROM:
SHEET 2
3128463
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
SKY GLAZIER
INSTALLED: NO
SKY BRIGHT
INSTALLED: NO
PIPE RACKS
INSTALLED: NO
CAMERA MOUNT
INSTALLED: NO
RIGHT REVERSE
DRIVE CAL: XXXX
LEFT REVERSE
DRIVE CAL: XXXX
SKY CUTTER
INSTALLED: NO
PLATFORM LOAD
STATE: OK
GREEN WITNESS
CAL: XXXXXXXX
CAN STATISTICS
MSG ERROR: XXXX
RIGHT FORWARD
DRIVE CAL: XXXX
L REAR STEER
CAL: XXXXX
JIB IN-LINE
SWITCH: OPEN
YELLOW WITNESS
CAL: XXXXXXXX
CAN STATISTICS
PASSIVE XXXXX
LEFT FORWARD
DRIVE CAL: XXXX
SKY WELDER
INSTALLED: NO
DUAL CAPACITY
LENGTH ZONE: A/B
UNDER MOMENT CAL
POINT: X
CAN STATISTICS
BUS OFF X
PLATFORM DOWN
CAL: X
R FRONT STEER
CAL: XXXXX
DUAL CAPACITY
SWITCH NO:CLOSED
UNDER MOMENT
XXXXXXXX LB*IN
CAN STATISTICS
TX/SEC: X
PLATFORM UP
CAL: X
LOAD PIN ERROR
FLAGS: 0X0000
DUAL CAPACITY
SWITCH NC: OPEN
OVER MOMENT
XXXXXXXX LB*IN
CAN STATISTICS
RX/SEC: X
DIAGNOSTICS:
CALIBRATION DATA
L FRONT STEER
CAL: XXXXX
PLATFORM
CAPACITY:1000 LB
ACTUAL MOMENT
XXXXXXXX LB*IN
DIAGNOSTICS:
CAN STATISTICS
LOAD PIN RATIO
VALUE: XX.XXX
DIAGNOSTICS:
LOAD
DIAGNOSTICS:
MOMENT
LENGTH SWITCH
CAL: XXXXX
YELLOW WITNESS
MARK CAL: X
DATALOG:
ERASE RENTAL?
DATALOG:
RENTAL XH XM
DATALOG:
MAX VOLTS XX.XV
DATALOG:
MIN TEMP XXC
DATALOG:
MAX TEMP XXC
LENGTH EXTENDED
CAL: XXXXX
DATALOG:
SWING XH XM
MAIN ANGLE 2
HI CAL: X
DATALOG:
TELE XH XM
DATALOG:
LIFT XH XM
MAIN ANGLE 2
LO CAL: X
LENGTH RETRACTED
CAL: XXXXX
DATALOG:
DRIVE XH XM
DATALOG:
ENGINE XH XM
MAIN ANGLE 1
HI CAL: X
MAIN ANGLE 1
LO CAL: X
DATALOG:
ON XXH XXM
DIAGNOSTICS:
DATALOG
1200SJP 1350SJP
VERSIONS:
ANALYZER
V6.3
MAIN ANGLE 2
REV X.X
MAIN ANGLE 2
S/N: XXXXXX
MAIN ANGLE 1
REV X.X
MAIN ANGLE 1
S/N: XXXXXX
CYLINDER PIN
S/N: XXXXXX
CYLINDER PIN
SOFTWARE: RX.XX
B.L.A. MODULE
SOFTWARE: P7.X
CHASSIS MODULE
SOFTWARE: P7.X
PLATFORM MODULE
S/N: XXXXXX
PLATFORM MODULE
HARDWARE: REV 2
PLATFORM MODULE
SOFTWARE: P7.X
GROUND MODULE
S/N: XXXXXX
GROUND MODULE
HARDWARE: REV 4
GROUND MODULE
CNST DATA: P7.X
GROUND MODULE
SOFTWARE: P7.X
DIAGNOSTICS:
VERSIONS
SECTION 4 - JLG ANALYZER
Figure 4-9. Analyzer Flow Chart - Diagnostics(Software Version 7.X to Present) - Sheet 3 of 3
NOTE: The layout shown includes all possible 1200/1250/1350 Analyzer screens. Please note that some screens may not be
available depending upon machine configuration.
4-185
SECTION 4 - JLG ANALYZER
4.3 CHANGING THE ACCESS LEVEL OF THE
HAND HELD ANALYZER
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most settings
which cannot be changed until you enter a password to
advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level,
the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu. For example:
Once the correct password is displayed, press ENTER.
The access level should display the following, if the password was entered correctly:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings.
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 33271.
Continue using the arrow keys until all the remaining digits
of the password is shown.
4-186
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
4.4 ADJUSTING PARAMETERS USING THE
HAND HELD ANALYZER
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
4.5 MACHINE SETUP
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
GROUND ALARM:
2 = LIFT DOWN
PERSONALITIES:
DRIVE ACCEL 1.0s
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular personality. If the value does not change when pressing the
up and down arrows, check the access level to ensure
you are at access level 1.
The effect of the machine digit value is displayed along
with its value. The above display would be selected if the
machine was equipped with a ground alarm and you
wanted it to sound when lifting down. There are certain
settings allowed to install optional features or select the
machine model.
When selection the machine model to match the size of
the machine, the personality settings will all default to the
factory recommended setting.
NOTE: Refer to Table 4-2. Machine Personality Settings and
Speeds on Pg. 202 in this manual for the recommended factory settings.
NOTE: Password 33271 will give you access to level 1,
which will permit you to change all machine personality settings.
There is a setting that JLG strongly recommends that you
do not change. This setting is so noted below:
ELEVATION CUTBACK
CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
3128463
1200SJP 1350SJP
4-187
SECTION 4 - JLG ANALYZER
Table 4-1. Machine Configuration Programming Information
Configuration Digit
Number
Description
Default
Number
NOTE: The machine configuration must be completed before any personality settings can be changed. Changing
the personality settings first and then changing the model number of the machine configuration will cause
the personality settings to return to default
MODEL NUMBER:
1
ENVELOPE HEIGHT:
2
1
1200S
1
2
1250A
3
1350S
1
1350S: 135' MAX
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
5
NOTE: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial
default setting.
MARKET:
3
ENGINE:
4
4-188
0
ANSI USA
0
1
ANSI EXPORT
2
CSA
3
CE
4
AUSTRALIA
5
JAPAN
1
DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1)
2
DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2)
3
DEUTZ ECM: Engine Control Module
1200SJP 1350SJP
3
3128463
SECTION 4 - JLG ANALYZER
Table 4-1. Machine Configuration Programming Information
Configuration Digit
GLOW PLUG:
5
Number
Description
0
NO GLOW PLUGS: No glow plugs installed.
1
AIR INTAKE: Glow plugs installed in the air intake on the manifold.
2
IN-CYLINDER: Glow plugs installed in each cylinder.
0
DISABLED: Automatic pre-glow time determined by ambient air temperature;
engine start can be attempted at any time during pre-glow.
1
ENABLED: Automatic pre-glow time determined by ambient air temperature; engine
start is NOT permitted until pre-glow is finished.
ENGINE SHUTDOWN:
7
0
DISABLED: No engine shutdown.
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.
2
4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 4 degrees and above elevation; also reduces drive speed to creep.
3
3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted
more than 3 degrees and above elevation; also reduces drive speed to creep.
4
4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep
when tilted more than 4 degrees and above elevation; also disallows tower lift up,
tower telescope out, drive, main telescope out and main lift up.
5
3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep
when tilted more than 3 degrees and above elevation; also disallows tower lift up,
tower telescope out, drive, main telescope out and main lift up.
STARTER LOCKOUT:
6
Default
Number
2
0
1
1
NOTE: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform
alarm when the machine is also above elevation.
SOFT TOUCH:
9
3128463
0
NO: No soft touch system installed.
1
YES: Soft touch system installed.
1200SJP 1350SJP
0
4-189
SECTION 4 - JLG ANALYZER
Table 4-1. Machine Configuration Programming Information
Configuration Digit
GEN SET/WELDER:
10
GEN SET CUTOUT:
11*
Number
Description
0
NO: No generator installed.
1
BELT DRIVE: Belt driven setup.
2
HYDRAULIC DRIVE: Hydraulic driven setup.
0
MOTION ENABLED: Motion enabled when generator is ON.
1
MOTION CUTOUT: Motion cutout in platform mode only.
Default
Number
1
0
* Only visible if Gen Set / Welder Menu selection is not 0.
H & T LIGHTS:
12
0
NO: No head and tail lights installed.
1
YES: Head and tail lights installed.
LOAD SYSTEM:
13*
0
NO: No load sensor installed.
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), platform 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).
0
0
* Only visible under certain market selections.
* Certain market selections will limit load system options or alter default setting.
4-190
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
Table 4-1. Machine Configuration Programming Information
Configuration Digit
FUNCTION CUTOUT:
14*
Number
Description
0
NO: No drive cutout.
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.
Default
Number
0
* 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.
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).
0
* Certain market selections will alter default setting.
OSCILLATING AXLE:
16
0
NO: No oscillating axle system installed.
1
YES: Oscillating axle system installed.
TEMPERATURE:
17*
0
CELSIUS: Celsius unit selection.
1
FAHRENHEIT: Fahrenheit unit selection.
1
1
* Certain market selections will alter default setting.
4150364-15
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1200SJP 1350SJP
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SECTION 4 - JLG ANALYZER
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.
HEAD & TAIL LIGHTS
GEN SET CUTOUT
GEN SET / WELDER
SOFT TOUCH
TILT
ENGINE SHUTDOWN
GLOW PLUGS
ENGINE
MARKET
ENVELOPE HEIGHT
MODEL NUMBER
1200SJP
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
4-192
TEMPERATURE
OSCILLATING AXLE
GROUND ALARM
LOAD SYSTEM
FUNCTION CUTOUT
1200SJP
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
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined
numbers indicate the default when the option is factory installed.
HEAD & TAIL LIGHTS
GEN SET CUTOUT
GEN SET / WELDER
SOFT TOUCH
TILT
ENGINE SHUTDOWN
GLOW PLUGS
ENGINE
MARKET
ENVELOPE HEIGHT
MODEL NUMBER
1350SJP
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
3128463
TEMPERATURE
OSCILLATING AXLE
GROUND ALARM
LOAD SYSTEM
FUNCTION CUTOUT
1350SJP
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
1200SJP 1350SJP
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SECTION 4 - JLG ANALYZER
NOTE: Machine personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum
machine performance.
Stop watch should start when the function is activated. Not with the controller or switch.
Unless noted, function speeds should be measured from platform.
Platform speed knob must be at full speed (fully clockwise).
All test should be done with the oil temp above 100° F (38° C).
Table 4-2. Machine Personality Settings and Speeds
SUBMENU
(DISPLAYED ON
ANALYZER 1ST
LINE)
PARAMETER
(DISPLAYED ON ANALYZER
2ND LINE)
DESCRIPTION
DEFAULT
VALUES
RANGE
1200
1350
TIME RANGE (SEC)
(SEE 4.6 Machine
Orientation When
Setting Speeds
WHEN SETTING
SPEEDS)
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
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
ELEV. MAX XX%
Displays/adjusts maximum drive
0 to 50%
speed
NOTE: used when elevation cutout
switches are limiting maximum speed
CREEP MAX XX%
Displays/adjusts maximum drive
speed
NOTE: used when creep switch on
pump pot is active
MAX SPEED XXX%
Displays/adjusts maximum steer
speed.
36-38
36-38
100
36-38
36-38
25
25
93-104
93-104
0 to 50%
35
35
79-87
79-87
0 to 100%
100
100
STEER:
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SECTION 4 - JLG ANALYZER
Table 4-2. Machine Personality Settings and Speeds
SUBMENU
(DISPLAYED ON
ANALYZER 1ST
LINE)
PARAMETER
(DISPLAYED ON ANALYZER
2ND LINE)
DESCRIPTION
DEFAULT
VALUES
RANGE
1200
1350
TIME RANGE (SEC)
(SEE 4.6 Machine
Orientation When
Setting Speeds
WHEN SETTING
SPEEDS)
1200S
1350S
MAIN LIFT:
ACCEL X.Xs
Displays/adjusts main lift acceleration 0.1 to 5.0 sec
1.0
1.0
DECEL X.Xs
Displays/adjusts main lift deceleration 0.1 to 3.0 sec
1.0
1.0
MIN UP XX%
Displays/adjusts minimum main lift
up speed
0 to 60%
20
20
MAX UP XX%
Displays/adjusts maximum main lift
up speed
0 to 100%
50
50
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
CREEP UP XX%
Displays/adjusts maximum main lift
up speed
NOTE: used when creep switch on
pump pot is active
0 to 65%
50
50
CREEP DOWN XX%
Displays/adjusts maximum main lift
down speed
NOTE: used when creep switch on
pump pot is active
0 to 75%
45
45
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 0 to 100%
speed
65
65
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
CREEP LEFT XX%
Displays/adjusts maximum swing left 0 to 65%
speed
NOTE: used when creep switch on
pump pot is active
50
50
CREEP RIGHT XX%
Displays/adjusts maximum swing
right speed
NOTE: used when creep switch on
pump pot is active
50
50
75-100
75-100
85-110
85-110
115-125
115-125
115-125
115-125
SWING:
3128463
1200SJP 1350SJP
0 to 65%
4-195
SECTION 4 - JLG ANALYZER
Table 4-2. Machine Personality Settings and Speeds
SUBMENU
(DISPLAYED ON
ANALYZER 1ST
LINE)
PARAMETER
(DISPLAYED ON ANALYZER
2ND LINE)
DESCRIPTION
DEFAULT
VALUES
RANGE
1200
1350
TIME RANGE (SEC)
(SEE 4.6 Machine
Orientation When
Setting Speeds
WHEN SETTING
SPEEDS)
1200S
1350S
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- 0 to 65%
scope in speed. Same as Creep speed
15
15
MAX IN XXX%
Displays/adjusts maximum main tele- 0 to 100%
scope in speed
65
65
MIN OUT XX%
Displays/adjusts minimum main tele- 0 to 65%
scope out speed. Same as Creep
speed
15
15
MAX OUT XXX%
Displays/adjusts maximum main tele- 0 to 100%
scope out speed
60
60
ACCEL X.Xs
Displays/adjusts basket level acceler- 0.1 to 5.0 sec
ation
1.5
1.5
DECEL X.Xs
Displays/adjusts basket level deceler- 0.1 to 3.0 sec
ation
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
ACCEL X.Xs
Displays/adjusts basket rotate acceleration
0.1 to 5.0 sec
1.0
1.0
DECEL X.Xs
Displays/adjusts basket rotate deceleration
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
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
58-68
65-75
45-55
50-60
24-30
(180)
24-30
(180)
24-30
(180)
24-30
(180)
BASKET LEVEL:
BASKET ROTATE:
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1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
Table 4-2. Machine Personality Settings and Speeds
SUBMENU
(DISPLAYED ON
ANALYZER 1ST
LINE)
PARAMETER
(DISPLAYED ON ANALYZER
2ND LINE)
DESCRIPTION
DEFAULT
VALUES
RANGE
1200
1350
TIME RANGE (SEC)
(SEE 4.6 Machine
Orientation When
Setting Speeds
WHEN SETTING
SPEEDS)
1200S
1350S
JIB LIFT:
ACCEL X.Xs
0.1 to 5.0 sec
1.5
1.5
DECEL X.Xs
Displays/adjusts jib lift deceleration
0.1 to 3.0 sec
1.0
1.0
MIN UP XX%
Displays/adjusts minimum jib up
speed. Same as Creep speed
0 to 65%
40
40
MAX UP XXX%
Displays/adjusts maximum jib up
speed
0 to 100%
65
65
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
ACCEL X.Xs
Displays/adjusts jib swing acceleration
0.1 to 5.0 sec
1.5
1.5
DECEL X.Xs
Displays/adjusts jib swing deceleration
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
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
30-36
30-36
30-36
30-36
60-68
(180)
60-68
(180)
60-68
(180)
60-68
(180)
JIB SWING:
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1200SJP 1350SJP
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SECTION 4 - JLG ANALYZER
Table 4-2. Machine Personality Settings and Speeds
SUBMENU
(DISPLAYED ON
ANALYZER 1ST
LINE)
PARAMETER
(DISPLAYED ON ANALYZER
2ND LINE)
DESCRIPTION
DEFAULT
VALUES
RANGE
1200
1350
TIME RANGE (SEC)
(SEE 4.6 Machine
Orientation When
Setting Speeds
WHEN SETTING
SPEEDS)
1200S
1350S
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 0 to 100%
speed
60
60
TOWER TELE XXX%
Displays/adjusts fixed tower telescope speed
Not displayed if TOWER TELE=NO
0 to 100%
100
100
T. LIFT UP XXX%
Displays/adjusts fixed tower lift up
speed
Not displayed if TOWER LIFT=NO
0 to 100%
100
100
T. LIFT DN XXX%
Displays/adjusts fixed tower lift down 0 to 100%
speed
Not displayed if TOWER LIFT=NO
100
100
JIB (U/D) XXX%
Displays/adjusts jib lift speed
Not 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
ENGINE XXXX RPM
Control generator/welder RPM. Not
displayed if GEN SET/WELDER = 0
1200-2800
1800
1800
GEN SET/WELDER:
NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine performance.
Stop watch should start when the function is activated. Not with the controller or switch.
Unless noted, function speeds should be measured from platform.
Platform speed knob must be at full speed (fully clockwise).
All test should be done with the oil temp above 100° F (38° C).
4150453-D
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SECTION 4 - JLG ANALYZER
Test Notes
4.6 MACHINE ORIENTATION WHEN SETTING
SPEEDS
1. Personality settings can be adjusted anywhere
within the adjustment range in order to achieve optimum machine performance
Lift Up: From platform control, lowest elevation up to maximum elevation, boom retracted.
2. Stop watch should start when the function is activated.Not with the controller or switch.
Lift Down: From platform control, maximum elevation
down to minimum elevation, boom retracted.
3. Unless noted, function speeds should be measured
from platform.
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 smooth
level surface. High Speed - Low Torque setting, drive 200
ft. (61 m) front wheels to front wheels. Timed after
machine has obtained maximum speed.
4. Platform speed knob must be at full speed (fully
clockwise).
5. All test should be done with the oil temp above 100°
F (38° C).
4.7 SYSTEM TEST
The Control System Incorporates a built-in system test to
check the system components and functions. To use this
function, use the following procedures.
Test from the Platform
1. Position the Platform/Ground select switch to the
Platform position.
Drive Reverse (Max): Test should be done on a smooth
level surface. High Speed - Low Torque setting, drive 200
ft. (61 m) front wheels to front wheels. Timed after
machine has obtained maximum speed.
Drive Forward (Creep Max): Test should be done on a
smooth level surface. High Torque - Low Speed setting,
platform speed knob at full creep.
Drive Reverse (Creep Max): Test should be done on a
smooth level surface. High Torque - Low Speed setting,
platform speed knob at full creep.
Drive Forward (Elevated Max - Boom Beyond Transport): Test should be done on a smooth level surface.
High speed - Low Torque setting, platform speed knob out
of creep, Lift boom above transport, drive forward 50 ft.
(15.2 m).
Drive Reverse (Elevated Max - Boom Beyond Transport): Test should be done on a smooth level surface.
High speed - Low Torque setting, platform speed knob out
of creep, Lift boom above transport, drive forward 50 ft.
(15.2 m).
Platform Rotate: Platform level and completely rotated
one direction. Rotate the opposite direction, Record Time.
Rotate the other direction, Record Time.
Articulating Jib: Platform level and centered with the
boom. Start with the Jib down. Jib Up, Record Time. Jib
Down, Record Time.
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SECTION 4 - JLG ANALYZER
2. Plug the analyzer into the connector at the base of
the platform control box.
4. The analyzer screen should read:
3. Pull out the Emergency Stop switch and Start the
engine.
5. Use the arrow button to reach SYSTEM TEST. Hit
Enter. The analyzer will prompt you asking if you
want to activate the system test; hit Enter again to
activate.
6. Follow the flow path in Figure 4-10. System Test
Flow Chart - Platform Tests on Pg. 209 and go
through the component tests. Hit the ESC key during any part of the test to return to the main menu
without completing all tests or wait until all tests are
complete. During the TEST ALL INPUTS sequence,
the analyzer allows control switches to be operated
and shows if they are closed (CL) or open (OP).
4-200
1200SJP 1350SJP
3128463
SECTION 4 - JLG ANALYZER
Figure 4-10. System Test Flow Chart - Platform Tests
3128463
1200SJP 1350SJP
4-201
SECTION 4 - JLG ANALYZER
Test from the Ground Station
4. The analyzer screen should read:
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the
Ground control box.
5. Use the arrow button to reach SYSTEM TEST. Hit
Enter. The analyzer will prompt you asking if you
want to activate the system test; hit Enter again to
activate.
6. Follow the flow path in Figure 4-11. System Test
Flow Chart - Ground Station Tests on Pg. 211 and
go through the component tests. Hit the ESC key
during any part of the test to return to the main menu
without completing all tests or wait until all tests are
complete. During the TEST ALL INPUTS sequence,
the analyzer allows control switches to be operated
and shows if they are closed (CL) or open (OP).
3. Pull out the Emergency Stop switch. and Start the
engine.
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3128463
SECTION 4 - JLG ANALYZER
Figure 4-11. System Test Flow Chart - Ground Station Tests
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1200SJP 1350SJP
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Table 4-3. System Test Messages
Message Displayed on
Analyzer
Message Displayed on
Analyzer
RUNNING
Initial display when system test is run; certain “critical” checks are made. Problems that can be reported include below messages.
ONLY 1 ANALYZER!
Do not connect two Analyzers while running the system test.
BATTERY TOO LOW
The system test cannot run with battery voltage below minimum (9 V).
BATTERY TOO HIGH
The system test cannot run with battery voltage above maximum. (16 V).
CHECK CAN WIRING
The system test cannot run in platform mode unless data is being received from
the platform and ground modules. The system test cannot run in ground mode
unless data is being received from the platform module.
CHECK SPEED
There is an open- or short- circuit in the speed encoder wiring. Check speed
encoder.
BAD GROUND MODULE
An internal problem was detected in the ground module.
HIGH TILT ANGLE
The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt
sensor.
HOT ENGINE
The engine temperature exceeds 100C. This is only a warning.
BAD I/O PORTS
The controller detected a problem with its internal circuits at switch on. If other
problems are also detected, the controller may need replacing.
SUSPECT EEPROM
The controller detected a problem with its EEPROM stored personality settings
at switch on. Check and, if necessary correct, all personality settings.
OPEN FSW
In platform mode, the footswitch must be open at the start of the test.
CLOSE FSW
In platform mode, the footswitch must be closed when this message is displayed; 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 wiring.
TESTING VALVES
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Description
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 correctly. 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-circuited. Check valve wiring.
XXXXXXX O/C
The named valve is drawing too little current so is presumed to be open-circuit.
Check valve wiring.
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Table 4-3. System Test Messages
Message Displayed on
Analyzer
Message Displayed on
Analyzer
CHECKING INPUTS
Description
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 cutouts 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.
TESTS COMPLETE
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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.
Indicates that the system test is complete. Any problems reported should have
been noted and should now be rectified. Press ESC/CANCEL to return to the
RUN SYSTEM TEST Analyzer menu.
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SECTION 5 - CALIBRATIONS
SECTION 5. CALIBRATIONS
5.1 CALIBRATION INSTRUCTIONS
Table 5-2. Calibrations Listed by Service Action
This machine incorporates a variety of sensors and a high
degree of function interaction. For safety and proper
machine functionality, the calibration procedures must be
repeated for any control module replacement, system calibration related fault, or removal or replacement of any
sensors, valves, coils, motors, or pumps. The chart below
lists the calibrations required and potential reasons for recalibration.
All calibration procedures are menu driven through the
use of the standard JLG analyzer. With the exception of
steering calibration, no external tools are required to complete the calibration procedures. The user is prompted to
exercise the machine in a specific order to use the
machines physical properties to consistently establish
sensor response and the interaction of valves, pumps,
and motors. Steering calibration also uses the analyzer
and is performed on one side of the machine at a time
requiring the use of a string or other means to determine
when the tires are in line with each other. With the exception of the load control calibration, all calibrations are
accessed by connecting the analyzer into the control system inside the main terminal box or on the bottom of the
platform control box. Calibration of the platform load sensing system is accessed by connecting the analyzer
directly into the LSS module.
Table 5-1. Calibrations Listed by Symptom
Symptom
Calibration
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
Drive
Tilt indication inaccuracy
Chassis Tilt
Wheel misaligned persistently
Steering
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Calibration
BLAM removal
Boom Sensors
BLAM replacement
Boom Sensors
Drive
Boom angle sensor removal or replacement
Boom Sensors
Boom length sensor removal or replacement
Boom Sensors
Boom lift flow control valve/coil replacement
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 Sensors
Chassis Tilt
Ground Module replacement
Boom Sensors
Chassis Tilt
Drive
Lift Crack Point
Tele Crack Point
Platform Level Crack Point
Steering
Load cell removal or replacement
Platform Load Sensing
LSS module replacement
Platform Load Sensing
Main terminal box removal or replacement Chassis Tilt
Boom control system inaccuracy
Speed control for slow speed is poor
Service Action
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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1. Position the Platform/Ground select switch to the
Platform position.
5.2 CALIBRATING STEER
When calibrating steering, each individual wheel must be
calibrated in order to make the tire and wheel parallel with
the frame. Two methods to help ensure proper calibration
are the use of a carpenter’s square to square the spindle
to the axle or aligning the two wheels on one side using a
stretched string.
2. Plug the analyzer into the connector at the base of
the platform control box.
3. Pull out the Emergency Stop switch and Start the
engine.
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4. The analyzer screen should read:
8. Use the arrow keys to reach Steer. The screen will
read:
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
9. Hit Enter. The screen will read:
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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10. Hit Enter. The screen will read:
13. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read:
14. Repeat steps 10 thru 12 for left rear steer.
15. Left Rear Steer Calibration will be followed by Right
Forward Steer Calibration which will be followed by
Right Rear Steer Calibration.
16. After completing all the Steer Calibrations, hit ESC
twice to go back to CALIBRATIONS.
5.3 CALIBRATING DRIVE
1. Position the Platform/Ground select switch to the
Platform position.
12. Activate the steer control until the tire and wheel are
straight in relationship with the chassis, then leave
off the control. The display will read FRT LEFT =
and show the numeric calibration value for that
wheel.
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2. Plug the analyzer into the connector at the base of
the platform control box.
4. The analyzer screen should read:
3. Pull out the Emergency Stop switch and Start the
engine.
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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8. Use the arrow keys to reach DRIVE.
10. Hit Enter again. The screen will read:
9. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read:
12. Activate the Drive Joystick forward full stroke until
the machine just begins to move, then leave off the
joystick immediately. The display will read CRK PT =
and show the numeric crack point value.
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13. Hit Enter. The number displayed will be the value
that 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 by
Right Forward Drive Calibration which will be followed by Right Reverse Calibration.
17. After completing all the Drive Calibrations, hit ESC
twice to go back to CALIBRATIONS.
14. Hit Enter. The screen will read:
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b. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has
been lost).
5.4 ELECTRONIC PLATFORM LEVELING
Platform Leveling Fault Warning
c. The platform alarm will sound.
If a fault occurs in the platform leveling system the following will occur:
1. Automatic platform leveling will stop (except when
there is a fault in only one sensor automatic leveling
will remain active as the control system will use the
other sensor to control leveling)
2. The level fault lamp will flash
d. A system fault will be logged.
e. All function speeds (lift, swing, telescope and
drive) will be placed in creep mode (except
when the platform is in the transport position).
2. In the case of a short to battery on one of the platform leveling valves, the valve cannot be turned off
and the following will occur:
3. The audible alarm will sound
a. The platform dump valve will be turned off to
prevent unintended tilting of the platform.
4. All functions will default to creep speed if the platform is out of the transport position.
b. All interactions with platform leveling shall
cease.
To reset the fault the emergency stop switch should be
recycled.
c. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has
been lost).
d. The platform alarm will sound.
IF THE FAULT PERSISTS BRING THE PLATFORM TO THE
GROUND POSITION, SWITCH THE MACHINE OFF AND CONTACT
A QUALIFIED SERVICE REPRESENTATIVE TO INVESTIGATE THE
FAULT.
Fault Response
ERROR RESPONSE
If basket level varies from the current setpoint by ± 5.5° for
more than 1.5 seconds when the platform is not in the
transport position, the following events will occur:
e. A system fault will be logged.
f. All function speeds (lift, swing, telescope and
drive) will be placed in creep mode (except
when the platform is in the transport position)
3. In the case of a short to battery on the platform
dump valve, the valve cannot be turned off. The controllability of the platform leveling function will be
impaired and the following will occur:
a. All interactions with platform leveling shall
cease.
1. The platform dump valve will be disabled (level,
rotate and jib functions disabled).
b. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the leveling function has
been lost).
2. The level system fault lamp will flash (to indicate that
the leveling function has been lost).
c. The platform alarm will sound.
3. The platform alarm will sound.
d. A system fault will be logged.
4. A system fault will be logged.
e. All function speeds (lift, swing, telescope and
drive) will be placed in creep mode (except
when the platform is in the transport position).
5. All function speeds (lift, swing, telescope and drive)
will be placed in creep mode (except when the platform is in the transport position see below).
When the unit is in the transport position and driving and
the current setpoint varies by ± 5.5° for more than 8 seconds the events 1,2,3 & 4 above will occur. (note function
speeds will operate normally). Cycling the EMS will clear
the fault and allow the operator to operate the machine as
a new level setpoint is taken.
VALVE DRIVER ERRORS
There are three possible level valve driver errors, short to
battery, 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 following will occur:
a. All interactions with platform leveling shall cease
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Lift, swing, drive and telescope will continue to operate
In each of the cases above it shall be necessary to recycle the EMS to clear the fault. Operable functions shall
be in the creep mode except while below elevation.
TILT SENSOR ERRORS
If the secondary tilt sensor is faulty, the control system will
continue to utilize information from the primary sensor.
If the primary sensor is faulty, the control system will
switch 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).
2. The platform alarm will sound.
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3. A system fault will be logged.
4. All function speeds (lift, swing, telescope, jib and
drive) will be placed in creep mode (except when
the 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-cycle
the EMS to clear the fault. Operable functions shall be in
the creep mode except while below elevation.
When both sensors appear to be working but have measurements that disagree by ±5.5° The following will occur:
1. All interactions with platform leveling shall cease.
2. The Electronic Leveling System Fault Lamp shall
flash (to indicate that the 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 platform is in the transport position)
cycle will be the same as would otherwise have been
commanded to the flow control valve.
Only one platform or jib function is allowed at one time to
limit the amount of current draw, minimizing the voltage
drop on the supply to the Platform Module.
The function is enabled first shall remain active until it is
released. Any other function commanded while another
function is active is ignored.
Platform Leveling Calibration Procedure
STEP 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 following personalities. Refer to Table 4-2. Machine
Personality Settings and Speeds on page 202 for
proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
At this point, the operator must use the level up and down
toggle switch to manually level during descent. It shall be
necessary to re-cycle the EMS to clear the fault.
CAN Errors
6. Recycle EMS.
The Ground Module has two direct outputs dedicated to
overriding the Platform Module’s control of the leveling
valves. The Ground Module “Platform Level Up/Down”
outputs are used to control the platform level up and
down valves.
STEP 2: CALIBRATING THE PLATFORM LEVEL
SENSORS
1. Put machine into “Ground Mode”.
2. Start machine and plug in Analyzer.
When in ground mode, if the Ground Module reads a platform leveling switch command, the switch command is
communicated over CAN to the Platform Module where it
is handled normally.
3. Manually level the platform with the switch on the
MTB.
If Ground Module determines that CAN communication is
inoperable, it turns on the platform control valve and the
appropriate platform leveling override outputs while the
switch is engaged.
5. Enter “33271” to get into Access Level 1 mode.
If the Platform Module is still running when CAN is down
nothing will operate when in platform mode. When the
operator switches to ground mode, the platform will not
control any of its valve outputs and a CAN error message
is signaled.
8. Hit ENTER. “Calibrate?” prompt should appear.
Additional Platform and Jib Valves
6. Go to the “Calibrations” menu and hit ENTER.
7. Use RIGHT ARROW go to “Plat. Leveling” screen.
9.
Hit ENTER again to calibrate level sensors.
10. When calibration has been successful “Cal. Complete” should appear.
11. Cycle power to the machine.
The high side drivers for the platform left and right and the
jib up and down valves are be located in the Platform
Module and are proportional. Flow through the valves is
individually controllable. The individually controlled duty
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4. Go to the “Access Level 2” screen.
STEP 3: BLEEDING THE PLATFORM VALVES
1. Put machine into “Ground Mode”.
2. Start machine and plug in Analyzer.
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3. Go to the “Access Level 2” screen.
4. Enter “33271” to get into Access Level 1 mode.
STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND
DOWN VALVE CRACKPOINTS
1. Put machine into “Ground Mode”.
5. Go to the “Personalities” menu.
6. Using the left arrow button, go to the “Ground
Mode” menu.
2. Start machine and plug in Analyzer.
3. Go to the “Access Level 2” screen.
7. Hit ENTER.
4. Enter “33271” to get into Access Level 1 mode.
8. Using the UP/DOWN arrows, adjust the following
personalities to 100%.
5. Go to the “Calibrations” menu and hit ENTER.
6. Go to the “Basket U Crkpt” Screen. Hit ENTER.
Basket Rotate
Basket Level
Jib U/D (if configured)
7. “Calibrate?” prompt should appear. Hit ENTER
again.
Start up the machine and exercise each above platform function (from the ground) eight (8) to ten (10)
times for 5 seconds in each direction.
9. Using UP ARROW, increase the value until you see
the basket up movement.
8. You will hear engine go to 1800 rpm.
9. Return the personality settings back to the values as
shown in Table 4-2. Machine Personality Settings
and Speeds on page 202.
10. Recycle EMS.
10. Hit ENTER again. “Cal. Complete” message should
appear
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 ENTER
again.
15. You will hear engine go to 1800 rpm.
Using DOWN ARROW, decrease the value until you see
the basket down movement.
Hit ENTER again. “Cal. Complete” message should
appear
Engine should again return to idle.
Hit ESC to exit.
Cycle power to the machine.
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4. The analyzer screen should read:
5.5 CALIBRATING PLATFORM LEVEL
STEP 1: SETTING THE PLATFORM VALVE
MINIMUMS
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the
Ground control box.
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the arrow button to reach PERSONALITIES
adjust the following personalities. Refer to Table 4-2.
Machine Personality Settings and Speeds on page
202 for proper setting values.
Basket Level Up Min
Basket Level Up Max
Basket Level Down Max
Jib Up Min
Jib Down Min
8. Recycle EMS.
3. Pull out the Emergency Stop switch and start the
engine.
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STEP 2: CALIBRATING THE PLATFORM LEVEL
SENSORS
5. The analyzer screen should read:
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the
Ground control box.
6. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
7. Enter the Access Code, 33271.
8. Use the arrow button to reach CALIBRATIONS menu
and hit ENTER.
9. Use right arrow go to PLAT. LEVELING screen.
10. Hit ENTER. The screen should read:
3. Pull out the Emergency Stop switch and start the
engine.
4. Manually level the platform with the switch on the
Main Terminal Box.
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11.
Hit ENTER again to calibrate level sensors.
4. The analyzer screen should read:
12. When calibration has been successful CAL. COMPLETE should appear.
13. Cycle power to the machine.
STEP 3: BLEEDING THE PLATFORM VALVES
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the
Ground control box.
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Go to the PERSONALITIES menu.
8. Using the left arrow button, go to the GROUND
MODE menu.
9. Hit ENTER.
10. Using the UP/DOWN arrows, adjust the following
personalities to 100%.
Basket Rotate
Basket Level
Jib U/D (if configured)
Start up the machine and exercise each above platform function (from the ground) eight (8) to ten (10)
times for 5 seconds in each direction.
3. Pull out the Emergency Stop switch and start the
engine.
11. Return the personality settings back to the values as
shown in Table 4-2. Machine Personality Settings
and Speeds on page 202.
12. Recycle EMS.
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STEP 4: CALIBRATING THE PLATFORM LEVEL
UP AND DOWN VALVE CRACKPOINTS
4. The analyzer screen should read:
1. Position the Platform/Ground select switch to the
Ground position.
2. Plug the analyzer into the connector inside the
Ground control box.
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Go to the CALIBRATIONS menu and hit ENTER.
8. Go to the BASKET U CRKPT Screen. Hit ENTER.
9. CALIBRATE? prompt should appear. Hit ENTER
again.
10. You will hear engine go to 1800 rpm.
11. Using UP ARROW, increase the value until you see
the basket up movement.
12. Hit ENTER again. CAL. COMPLETE message
should appear
3. Pull out the Emergency Stop switch and start the
engine.
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 ENTER
again.
17. You will hear engine go to 1800 rpm.
Using DOWN ARROW, decrease the value until you see
the basket down movement.
Hit ENTER again. CAL. COMPLETE message should
appear
Engine should again return to idle.
Hit ESC to exit and cycle power to the machine.
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5.6 CALIBRATING TILT SENSOR
3. Plug the analyzer into the connector inside the
Ground control box.
A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE
TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED.
DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL
SURFACE.
1. Use the following procedure to calibrate the tilt sensor.
Before the tilt sensor can be calibrated, the following
conditions must be met:
a. Steering previously calibrated.
b. Axles extended.
c. Wheels straight.
4. Pull out the Emergency Stop switch and start the
engine.
d. Turntable centered.
e. Boom fully retracted.
5. The analyzer screen should read:
f. Boom angle is less than 45°.
g. Machine on firm, level ground.
2. Position the Platform/Ground select switch to the
Ground position.
6. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
7. Enter the Access Code, 33271.
8. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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9. Use the arrow keys to reach the TILT SENSOR. The
screen should read:
5.7 CALIBRATING LIFT CRACK POINT
1. Position the Platform/Ground select switch to the
Platform position.
2. Plug the analyzer into the connector at the base of
the platform control box.
10. Press ENTER.
11. When prompted, swing turntable 180° to opposite
end of chassis.
12. Press ENTER. The screen should read:
13. Upon completing swing calibration, swing turntable
180° back to the stowed position.
14. Hit ESC twice to go back to CALIBRATIONS.
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3. Pull out the Emergency Stop switch and Start the
engine.
8. Use the arrow keys to reach Upper Lift Crack Point
(UPPER LIFT CRKPT). The screen will read:
4. The analyzer screen should read:
9. Hit enter. The screen will read:
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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13. Hit enter. The number displayed will be the value
that the crack point is set to. The screen will show:
10. Hit Enter. The screen will read:
11. Hit Enter again. The screen will read:
14. Hit Enter. The screen will read:
12. Activate the Lift Up function by fully stroking the joystick until the boom starts to move, then leave off
immediately. The display will read CRK PT = and
show the numeric crack point value.
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15. Repeat steps 10 thru 12 for the Lift Down function.
16. After completing all the Tele Calibrations, hit ESC
twice to go back to CALIBRATIONS.
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5.8 CALIBRATING TELESCOPE CRACK POINT
3. Pull out the Emergency Stop switch and Start the
engine.
1. Position the Platform/Ground select switch to the
Platform position.
4. The analyzer screen should read:
2. Plug the analyzer into the connector at the base of
the platform control box.
5. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
6. Enter the Access Code, 33271.
7. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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8. Use the arrow keys to reach Upper Telescope Crack
Point (UPPER TELE CRKPT). The screen will read:
10. Hit Enter. The screen will read:
11. Hit enter again. The screen will read:
9. Hit Enter. The screen will read:
12. Activate the Tele Out function until the boom starts to
move, then leave off immediately. The display will
read CRK PT = and show the numeric crack point
value.
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13. Hit enter. The number displayed will be the value
that the crack point is set to. The screen will show:
15. Hit Enter. The screen will read:
16. Repeat steps 10 thru 12 for the Tele In function.
14. Hit Enter. The screen will read:
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17. After completing all the Tele Calibrations, hit ESC
twice to go back to CALIBRATIONS.
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3. Plug the analyzer into the connector inside the
Ground control box.
5.9 CALIBRATING THE BOOM SENSORS
DURING THE BOOM SENSOR CALIBRATION PROCEDURE, IT IS
NORMAL FOR THE REAR WHEEL TO LIFT FROM THE GROUND
APPROXIMATELY 1 INCH (2.5 CM). IF THE WHEEL RAISES
APPRECIABLY MORE THAN THIS (I.E. 4 INCHES [10 CM] OR
MORE), CHECK THE AXLE OSCILLATION SYSTEM FOR PROPER
OPERATION OR THE NEED FOR BLEEDING, THEN PROCEED
WITH THE BOOM SENSOR CALIBRATION PROCEDURE.
Use the following step-by-step procedure to calibrate the
boom sensors.
1. Before the boom sensors can be calibrated, the following conditions must be met:
a. Steering, telescope crack points, and tilt previously calibrated
b. Axles Extended
c. Wheels Straight
4. Pull out the Emergency Stop switch and start the
engine.
d. Platform Unloaded
5. The analyzer screen should read:
e. Jib Horizontal
f. Jib Swing Centered
g. Platform Level
h. Platform Centered
i. Turntable Centered
j. Boom Fully Retracted
k. Level Ground (within 1.5°)
Figure 5-1. Boom Sensor Calibration Position 1
2. Position the Platform/Ground select switch to the
Ground position.
6. Use the arrow button to reach ACCESS LEVEL 2. Hit
Enter.
7. Enter the Access Code, 33271.
8. Use the right Arrow key to reach CALIBRATIONS. Hit
Enter.
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9. Use the arrow keys to reach BOOM SENSORS. The
screen should read:
10. Hit Enter. The screen will read:
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11. After verifying all the conditions listed in step 1 are
met, hit Enter. The screen will read:
12. After verifying all load (personnel or material) is
removed from the platform, hit Enter. The screen will
read:
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13. After visually verifying that the jib is horizontal, hit
Enter. The screen will read:
15. After visually verifying the platform is centered, hit
Enter. The screen will read:
14. After visually verifying the platform is level, hit Enter.
The screen will read:
16. After operating telescope in to verify the boom is
fully retracted, hit Enter. The screen will read:
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17. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
The screen will read:
19. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
The screen will read:
18. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
The screen will read:
20. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
The screen will read:
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21. Use the up/down arrows to select YES if the accessory is installed, NO if it is not installed and hit enter.
The screen will read:
22. Use the up/down arrows to select yes if the accessory is installed, no if it is not installed and hit Enter.
The screen will read:
23. After making sure the machine is in Calibration Position 1, hit Enter. The screen will read:
24. Lift up to stop (full stroke of cylinder) for Calibration
Position 2. When the machine is in that position, hit
Enter.
Figure 5-2. Boom Sensor Calibration Position 2
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The screen will read:
When the machine is in the proper position, hit Enter. The
screen will read:
Swing 180 degrees (centered over opposite end of chassis) for Calibration Position 3.
When Position 3 calibrating is complete the screen will
read:
Figure 5-3. Boom Sensor Calibration Position 3
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25. Press Enter. The screen will read:
When the machine is in the proper position, hit Enter. The
screen will read:
26. Swing the machine back 180 degrees (centered
over original end of chassis) for Calibration Position
4.
When Position 4 calibrating is complete, the screen will
read:
Figure 5-4. Boom Sensor Calibration Position 4
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27.
Press Enter. The screen will read:
When the machine is in the proper position, hit Enter. The
screen will read:
Telescope out to stop (boom must be fully extended) for
Calibration Position 5.
28. Retract to stop (boom must be fully retracted) for
Calibration Position 6.
Figure 5-6. Boom Sensor Calibration Position 6
Figure 5-5. Boom Sensor Calibration Position 5
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When the machine is in the proper position, hit
Enter. The screen will read:
When the machine is in the proper position, hit Enter. The
screen will read as follows:
29. Lift down to stop (boom must be on boom rest) for
Calibration Position 7.
When Position 7 Calibrating is complete, the screen will
read:
Figure 5-7. Boom Sensor Calibration Position 7
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Press Enter. The screen read:
When the machine is in the proper position, hit Enter. The
screen will read:
30. Lift until the function stops (controller will stop at 5
degrees above horizontal) for Calibration Position 8.
Press Enter. The screen will read:
Figure 5-8. Boom Sensor Calibration Position 8
31. Telescope to the yellow witness mark (controller will
be close - operator must position the pointer to cen-
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ter line on decal within 0.25" [6 mm]) for Calibration
Position 9.
When Position 9 calibrating is complete, the screen will
read:
Figure 5-9. Boom Sensor Calibration Position 9
When the boom is in the proper position, hit Enter. The
screen will read:
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Press Enter. The screen will read:
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32. Telescope in to green witness mark (controller will
find the position - operator must visually verify the
position).
Press Enter. The screen will read:
Figure 5-10. Boom Sensor Calibration Position 10
When the boom is in the proper position, the screen will
read:
33. After completing all the Boom Sensors Calibrations,
hit ESC twice to go back to Calibrations.
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5.10 WIRE ROPE TENSIONING PROCEDURE
1. Remove the lock plates and nylon collar locknuts
from the wire rope fittings.
With the boom assembly in the fully retracted position and
before making any adjustments to the wire ropes of the
boom assembly, remove any covers necessary to visually
inspect the threaded fittings, taking note of the amount of
adjustment that is left for both the extend and retract wire
ropes for the fly and outer mid booms. Also, take note of
the position of each boom section while the assembly is in
the fully retracted position. Take preliminary measurements and compare them to Figure 5-11., Wire Rope Tensioning Figure A.
2. Extend the boom 5 to 6 feet (1.5 to 1.8 m) from fully
retracted position while maintaining a horizontal (+/5°) position of boom.
3. Using tool P/N 4120043, torque outer mid retract
adjuster nuts to 80 ft.lb. (112 Nm), alternating
between the two ropes until both maintain the
required torque.
NOTE: The inner mid section is positioned by the hydraulic
cylinder. No adjustments will be made to this section.
The wire ropes within the assembly control the
movement of the outer mid and fly boom sections.
If it is necessary to reposition the outer mid and fly boom
sections to achieve the measurements in Figure 5-11.,
Wire Rope Tensioning Figure A, sound technician judgment should be used to compare the thread adjustment
(that is left on the wire rope fittings) to the position of the
boom sections. The sections can be repositioned slightly
to achieve a more even adjustment at the wire rope fittings
when comparing the extend and retract systems.
8.0 ± 0.5”
203 ± 13 mm
9.5 ± 0.5”
241 ± 13 mm
3.5 ± 0.5”
90.5 ± 13 mm
OUTER MID BOOM
BASE BOOM
FLY BOOM
INNER MID BOOM
NOTE: Boom shown in fully retracted position.
Figure 5-11. Wire Rope Tensioning Figure A
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4. Using tool P/N 4120043, torque fly retract adjuster
nuts to 80 ft.lb. (112 Nm), alternating between the
two ropes until both maintain the required torque.
NOTE: Ensure the boom is not fully retracted for following
steps.
6. Using tool P/N 4120043, torque outer mid extend
adjuster nuts to 80 ft.lb. (112 Nm), alternating
between the two ropes until both maintain the
required torque.
5. Retract boom 2 to 3 feet (0.6 to 0.9 m) from extension point reached in Step #2.
7. Using tool P/N 4120040, torque fly extend adjuster
nuts to 10 ft.lb. (14 Nm), alternating between the four
ropes until all maintain the required torque.
8. Fully retract the boom assembly and verify the
exposed boom section dimensions meet the dimension tolerances shown in Figure 5-11., Wire Rope
Tensioning Figure A.
9. Reinstall nylon collar locknuts to fly extend wire rope
fittings. Torque locknuts to 10 ft.lb. (14 Nm).
10. Reinstall lock plates to remaining adjuster nuts.
11. Install all covers and check for proper function of
boom assembly.
DO NOT REPEAT STEPS #2 THROUGH #7 MULTIPLE TIMES TO
VERIFY ROPE TENSION. VERIFICATION OF THE ROPE TENSION
SHOULD BE DETERMINED BY PROPER FUNCTION OF THE BOOM
ASSEMBLY.
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BOOM SECTION REPOSITIONING EXAMPLE:
If the outer mid boom section is still extended outside of
the tolerance as shown in Figure 5-11., Wire Rope Tensioning Figure A while the boom assembly is fully
retracted, it will be necessary to loosen the outer mid
extend wire rope fittings. After loosening the outer mid
extend wire rope fittings, extend the boom assembly 5 to 6
feet (1.5 to 1.8 m) from the fully retracted position and
repeat the tensioning steps for the outer mid retract ropes.
Steps #5 & #6 should then be repeated. Once those
steps are complete, fully retract the boom assembly and
verify that the exposed boom section dimensions meet
the dimension tolerances of Figure 5-11., Wire Rope Tensioning Figure A.
This same method can be applied to repositioning the fly
boom section by substituting the correct steps for the fly
boom wire ropes. This is also applicable if either of the
sections is positioned too far in, in the retracted position.
The technician should begin the repositioning procedure
with the boom partially extended, slightly loosen the
retract wire ropes, and partially retract the boom.
NOTE: Ensure that the boom is not fully retracted.
At this point, the correct steps should be followed to tension the extend wire ropes for that section. Once those
steps are complete, the steps required to tension the
retract wire ropes should then be performed.
NOTE: Any repositioning of the outer mid boom section will
also effect the position of the fly boom section, as the
outer mid is used to control the movement of the fly.
The best practice is to correctly position the outer
mid boom before repositioning the fly boom.
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1.
2.
3.
2" Socket
3/4” Socket
Retaining Bolt
Figure 5-12. Wire Rope Adjustment Tools
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SECTION 6 - GENERAL ELECTRICAL INFORMATION
SECTION 6. GENERAL ELECTRICAL INFORMATION
6.1 GENERAL
This section contains schematics to be used for locating and correcting most of the operating problems which may develop.
If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
6.2 MULTIMETER BASICS
A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter
with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary.
Please consult the meter operator’s manual for more information.
Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch
it to a good ground. A good ground will be a short circuit to the battery negative terminal or known good ground such as the
platform grounding bolt. Check this with a multimeter on continuity measurement or resistance. If the meter lead won’t reach
a good ground "walk" the meter back to one, finding shorts along the way.
Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically
designed for this technique. Whenever possible insert probes into the side of the connector such that the test also checks
both terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sides
of a connector terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still
attached to the contact and contacts are seated in the connector.
Min/Max
Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while
alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the
solenoid and meter, is held down.
Polarity
Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other
port goes to the positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
Example: 1.2 k = 1200 
Example: 50 mA = 0.05 A
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Voltage Measurement
Resistance Measurement
Figure 6-1. Voltage Measurement (DC)
Figure 6-2. Resistance Measurement
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance)
• Use firm contact with meter leads
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
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Continuity Measurement
Current Measurement
Figure 6-3. Continuity Measurement
Figure 6-4. Current Measurement (DC)
• Some meters require a separate button press to
enable audible continuity testing
• Circuit power must be turned OFF before testing continuity
• Set up the meter for the expected current range
• Be sure to connect the meter leads to the correct
jacks for the current range you have selected
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multi meter’s operation manual)
• Use firm contact with meter leads
• Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
6.3 CONTINUITY MEASUREMENT OVER LONG DISTANCES
When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.
Requirements:
• Harness with at least three separate wires including the wire under test.
• These wires must be able to be isolated from other wires, etc.
• Jumper or method to connect contacts on one side of harness.
• Meter that can measure resistance or continuity.
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Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate measurement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach
of the jumper.
1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
3. On one side, jumper from contact of wire #1 and wire #2.
4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this
test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no continuity, repair wires or consult schematic for other wires to use for test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.
6.4 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. De-energize the circuit.
2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an
open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will
be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two
terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.
Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually operated switches except that the moving object operates the switch. These switches can be tested the same way as a standard switch by manually operating the sensing arm.
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Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive
proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do
not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform
position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find
the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch
as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the
switch and object sensed.
Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.
1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.
2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do
this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for example. The state indicated in the control system should change.
Switch Wiring - Low Side, High Side
When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can measure the voltage at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load.
6.5 WORKING WITH AMP CONNECTORS
Applying Silicone Dielectric Compound To Amp Connectors
Silicone Dielectric Compound must be used on the AMP connections for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and
female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by
using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside
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the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus
preventing the housing latch from engaging.
2. Open one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
Figure 6-5. AMP Connector
Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 6-6. Connector Assembly (1 of 4)). Proceed as follows:
Figure 6-6. Connector Assembly (1 of 4)
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1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 6-7. Connector
Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 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 locking latches by squeezing them inward (See Figure 6-8. Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 6-9. Connector Assembly (4 of 4)).
Figure 6-7. Connector Assembly (2 of 4)
Figure 6-8. Connector Assembly (3 of 4)
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Figure 6-9. Connector Assembly (4 of 4)
Disassembly
1. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
2. Pry open the wedge lock to the open position.
3. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
Figure 6-10. Connector Disassembly
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
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Service - Voltage Reading
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The
resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies
the effectiveness of the connector seals and could result in system failure.
Figure 6-11. Connector Installation
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6.6 WORKING WITH DEUTSCH CONNECTORS
DT/DTP Series Assembly
Figure 6-12. DT/DTP Contact Installation
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in
place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
DT/DTP Series Disassembly
Figure 6-13. DT/DTP Contact Removal
1. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
2. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it
away from the contact with a screwdriver.
3. Hold the rear seal in place, as removing the contact may displace the seal.
HD30/HDP20 Series Assembly
Figure 6-14. HD/HDP Contact Installation
1. Grasp contact about 25mm behind the contact crimp barrel.
2. Hold connector with rear grommet facing you.
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SECTION 6 - GENERAL ELECTRICAL INFORMATION
3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly
locked in place.
Figure 6-15. HD/HDP Locking Contacts Into Position
NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing
HD30/HDP20 Series Disassembly
Figure 6-16. HD/HDP Contact Removal
1. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
2. Slide tool along into the insert cavity until it engages contact and resistance is felt.
3. Pull contact-wire assembly out of connector.
Figure 6-17. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
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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 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
+61 2 65 811111
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
+55 19 3295 1025
+61 2 65 810122
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0) 421 69 350 20
+49 (0) 421 69 350 45
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
+48 (0) 914 320 245
+48 (0) 914 358 200
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0) 161 654 1000
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
+33 (0) 5 53 88 31 70
+33 (0) 5 53 88 31 79
+44 (0) 161 654 1001
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
(852) 2639 5783
(852) 2639 5797
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
+39 029 359 5210
+39 029 359 5845
JLG Industries (Scotland)
Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland
+44 (0) 141 781 6700
+44 (0) 141 773 1907
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762
www.jlg.com
Oshkosh-JLG Singapore
Technology Equipment Pte Ltd.
29 Tuas Ave 4
Jurong Industrial Estate
639379 - Singapore
+65-6591-9030
+65-6591-9031
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0) 850 659 500
+46 (0) 850 659 534
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