JLG T 350, T 500J boom lift Troubleshooting Manual
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Quảng cáo
Troubleshooting Manual
Models
T350
T500J
3121203
September 7, 2005
REVISION LOG
September 7, 2005 - Original Issue Of Manual
3
REVISION LOG
4
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.
Each troubleshooting step setup is specified in the step instructions and applies only to that step. Any special wiring
should be removed after completing the step.
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
Is Distress
Lamp Blinking?
No
No
Yes
Troubleshoot by function in Section
1
Possible Causes
Component
Checks
Yes
Identify Fault
Repair Machine
Problem
Solved?
Yes
Done
Figure A-1. Troubleshooting Flow Chart
Plug in Analyzer and read Help
Message
Troubleshoot by
Help Message in
Section 2
A-5
INTRODUCTION
A.2 VISUAL INSPECTION
Perform a thorough visual and “hands on” inspection before starting any troubleshooting procedure. You can quickly find the cause of many problems just by looking.
Has the vehicle 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
• Bent or damaged pins
• Contacts not properly seated in housing
• Bad wire crimps to terminals
A.3 CONNECTOR REFERENCES
X404.21 refers to terminal 21 (pin and socket) of connector X404.
X404.21.soc refers to the socket side of terminal 21, connector 404.
X404.21.pin refers to the pin side of terminal 21, connector 404.
A.4 READING FAULT CODES
Current and logged system fault codes can be read from the analyzer. Refer to 9.3 Using the Analyzer
A-6
Figure A-2. Ground Module Fault LED
INTRODUCTION
On electric powered machines, power module flash codes can be read from the flashing of the green LED located on the
power module as seen in Figure A-3.. Refer to A.8 Power Module Flash Codes for fault descriptions.
Figure A-3. Power Module Fault LED
A.5 USER FAULT CODES
7
8
5
6
9
3
4
1
2
Flash
Code
Description of Difficulty
Procedure
Vehicle Setup
Battery / Charge System
Excessive Duty Cycle
Start Engine / Turn-Off System
Unused
Unused
Unused
Vehicle Requires Service
A-7
INTRODUCTION
A.6 USER FAULT CODE CROSS REFERENCES
CODE - MESSAGE PAGE NO.
0
Chassis Tilt Sensor Out Of Range
Running At Creep - Material Hook Mode
1
Function Locked Out - Joystick Not Centered At Startup
Function Locked Out - Trigger Permanently Closed
Function Problem - Engine Choke Permanently Selected
Function Problem - Engine Start Permanently Selected
Function Problem - Jib Down Permanently Selected
Function Problem - Jib Up Permanently Selected
Function Problem - Level Down Permanently Selected
Function Problem - Level Up Permanently Selected
Function Problem - Lift Down Permanently Selected
Function Problem - Lift Up Permanently Selected
Function Problem - Outrigger Set Permanently Selected
Function Problem - Outrigger Stow Permanently Selected
Function Problem - Swing Left Permanently Selected
Function Problem - Swing Right Permanently Selected
Function Problem - Telescope In Permanently Selected
Function Problem - Telescope Out Permanently Selected
Joystick Moved But Trigger Switch Open
Trigger Closed Too Long While In Neutral
2
Drive & O/R Prevented - Operate From Platform
Drive & O/R Prevented - Place Boom On Rest
Drive & O/R Prevented - Set Hand Brake
Drive Prevented - Lift Down
Drive Prevented - Stow Outriggers
Drive Prevented - Telescope In
Lift Down Prevented - Tele In First
Lift Up & Tele Out Prevented - Tilted & Above Elevation
Lift Up & Tele Out Prevented - Tilted,Unset,& Above Elevation
............................................................................................... 2-92
Lift Up & Tele Out Prevented - Unset & Above Elevation
Lift Up Prevented - Check Outriggers
Lift Up Prevented - Lift Down Then Set Outriggers
Lift Up Prevented - Tilted
Model Changed - Hydraulics Suspended - Cycle EMS
Outrigger Stow Prevented - Tele In First
Outriggers Prevented - Elevated
Running At Creep - Tilted & Above Elevation
Running At Creep - Unset & Above Elevation
Tele Out Prevented - Set Outriggers
Tele Out Prevented - Tilted
3
Battery Voltage Too High - System Shutdown
Battery Voltage Too Low - System Shutdown
No Charge System Output
4
Functions At Cutback - Power Module Current Limit
Power Module Too Hot - Please Wait
5
Battery Voltage Too High - System Shutdown
Battery Voltage Too Low - System Shutdown
Engine Not Running
A-8
INTRODUCTION
9
Accessory Fault
CANBUS Failure - Accessory Module Communications Lost
CANBUS Failure - Drive Module
CANBUS Failure - Platform Module
CANBUS Failure - Power Module
Chassis Tilt Sensor Gain Not Calibrated
Chassis Tilt Sensor Gain Out Of Range
Chassis Tilt Sensor Not Calibrated
Choke Hold Solenoid Open Circuit
Choke Hold Solenoid Short To Battery
Choke Hold Solenoid Short To Ground
Choke Pull Relay Open Circuit
Choke Pull Relay Short To Battery
Choke Pull Relay Short To Ground
Drive Enable Solenoid Short To Battery
Drive Enable Solenoid Short To Ground Or Open Circuit
Drive Left Forward Solenoid Open Circuit
Drive Left Forward Solenoid Short To Battery
Drive Left Forward Solenoid Short To Ground
Drive Left Reverse Solenoid Open Circuit
Drive Left Reverse Solenoid Short To Battery
Drive Left Reverse Solenoid Short To Ground
Drive Right Forward Solenoid Open Circuit
Drive Right Forward Solenoid Short To Battery
Drive Right Forward Solenoid Short To Ground
Drive Right Reverse Solenoid Open Circuit
Drive Right Reverse Solenoid Short To Battery
Drive Right Reverse Solenoid Short To Ground
Dump Solenoid Open Circuit
Dump Solenoid Short To Battery
Dump Solenoid Short To Ground
EEPROM Failure - Check All Settings
Extend O/R Solenoid Open Circuit
Extend O/R Solenoid Short To Battery
Extend O/R Solenoid Short To Ground
Front-Left O/R Solenoid Open Circuit
Front-Left O/R Solenoid Short To Battery
Front-Left O/R Solenoid Short To Ground
Front-Right O/R Solenoid Open Circuit
Front-Right O/R Solenoid Short To Battery
Front-Right O/R Solenoid Short To Ground
Function Problem - Jib Up And Down Both Selected
Function Problem - Level Up And Down Both Selected
Function Problem - Lift Up And Down Both Selected
Function Problem - Outrigger Set And Stow Both Selected
Function Problem - Rotary Selector Switch
Function Problem - Swing Left And Right Both Selected
Function Problem - Telescope In And Out Both Selected
Functions Locked Out - Constant Data Version Improper
Functions Locked Out - Platform Module Software Version Improper
........................................................................................2-78
Functions Locked Out - Power Module Software Version Improper
...........................................................................................2-79
Ground Alarm Short To Battery
Ground Alarm Short To Ground
Ground Module Failure Ref Voltage Out Of Range
Ground Module Failure Vlow Fet Failure
Hourmeter Short To Battery
Jib Down Solenoid Open Circuit
A-9
INTRODUCTION
Jib Down Solenoid Short To Battery
Jib Down Solenoid Short To Ground
Jib Up Solenoid Open Circuit
Jib Up Solenoid Short To Battery
Jib Up Solenoid Short To Ground
Joystick Faulty - X axis Wiper Out Of Range
Joystick Faulty - Y axis Wiper Out Of Range
Keyswitch Faulty
Level Down Solenoid Open Circuit
Level Down Solenoid Short To Battery
Level Down Solenoid Short To Ground
Level Up Solenoid Open Circuit
Level Up Solenoid Short To Battery
Level Up Solenoid Short To Ground
Lift Down Solenoid Open Circuit
Lift Down Solenoid Short To Battery
Lift Down Solenoid Short To Ground
Lift Up Solenoid Open Circuit
Lift Up Solenoid Short To Battery
Lift Up Solenoid Short To Ground
Open-Circuit Pump Motor Wiring
Optional Ground Alarm Short To Battery
Optional Ground Alarm Short To Ground
Platform Position Detection Faulty
Power Module Failure Check Power Circuits Or Mosfet Short Circuit
....................................................................................... 2-98
Power Module Failure Internal Error
Power Module Failure Personality Range Error
Rear-Left O/R Solenoid Open Circuit
Rear-Left O/R Solenoid Short To Battery
Rear-Left O/R Solenoid Short To Ground
Rear-Right O/R Solenoid Open Circuit
Rear-Right O/R Solenoid Short To Battery
Rear-Right O/R Solenoid Short To Ground
Retract O/R Solenoid Open Circuit
Retract O/R Solenoid Short To Battery
Retract O/R Solenoid Short To Ground
Start Solenoid Open Circuit
Start Solenoid Short To Battery
Start Solenoid Short To Ground
Swing Left Solenoid Open Circuit
Swing Left Solenoid Short To Battery
Swing Left Solenoid Short To Ground
Swing Right Solenoid Open Circuit
Swing Right Solenoid Short To Battery
Swing Right Solenoid Short To Ground
Telescope In Solenoid Open Circuit
Telescope In Solenoid Short To Battery
Telescope In Solenoid Short To Ground
Telescope Out Solenoid Open Circuit
Telescope Out Solenoid Short To Battery
Telescope Out Solenoid Short To Ground
Throttle Hold Solenoid Open Circuit
Throttle Hold Solenoid Short To Battery
Throttle Hold Solenoid Short To Ground
Throttle Pull Relay Open Circuit
Throttle Pull Relay Short To Battery
Throttle Pull Relay Short To Ground
A-10
INTRODUCTION
A.7 SERVICE FAULT CODE CROSS REFERENCES
CODE - MESSAGE PAGE NO.
0
0 Chassis Tilt Sensor Out Of Range
0 Engine Not Running
0 Joystick Moved But Trigger Switch Open
0 Running At Creep - Material Hook Mode
0 Running At Creep - Tilted & Above Elevation
0 Running At Creep - Unset & Above Elevation
2-?
2-1 Keyswitch Faulty
2-1 Platform Position Detection Faulty
2-2 Function Locked Out - Joystick Not Centered At Startup
2-2 Function Locked Out - Trigger Permanently Closed
2-2 Function Problem - Engine Choke Permanently Selected
2-2 Function Problem - Engine Start Permanently Selected
2-2 Function Problem - Rotary Selector Switch
2-2 Joystick Faulty - X axis Wiper Out Of Range
2-2 Joystick Faulty - Y axis Wiper Out Of Range
2-2 Trigger Closed Too Long While In Neutral
2-3 Function Problem - Engine Choke Permanently Selected
2-3 Function Problem - Engine Start Permanently Selected
2-3 Function Problem - Jib Down Permanently Selected
2-3 Function Problem - Jib Up And Down Both Selected
2-3 Function Problem - Jib Up Permanently Selected
2-3 Function Problem - Level Down Permanently Selected
2-3 Function Problem - Level Up And Down Both Selected
2-3 Function Problem - Level Up Permanently Selected
2-3 Function Problem - Lift Down Permanently Selected
2-3 Function Problem - Lift Up And Down Both Selected
2-3 Function Problem - Lift Up Permanently Selected
2-3 Function Problem - Outrigger Set And Stow Both Selected
2-3 Function Problem - Outrigger Set Permanently Selected
2-3 Function Problem - Outrigger Stow Permanently Selected
2-3 Function Problem - Swing Left And Right Both Selected
2-3 Function Problem - Swing Left Permanently Selected
2-3 Function Problem - Swing Right Permanently Selected
2-3 Function Problem - Telescope In And Out Both Selected
2-3 Function Problem - Telescope In Permanently Selected
2-3 Function Problem - Telescope Out Permanently Selected
2-5 Drive & O/R Prevented - Operate From Platform
2-5 Drive & O/R Prevented - Place Boom On Rest
2-5 Drive & O/R Prevented - Set Hand Brake
2-5 Drive Prevented - Lift Down
2-5 Drive Prevented - Stow Outriggers
2-5 Drive Prevented - Telescope In
2-5 Lift Down Prevented - Tele In First
2-5 Lift Up & Tele Out Prevented - Tilted & Above Elevation
2-5 Lift Up & Tele Out Prevented - Tilted,Unset,& Above Elevation
.........................................................................................2-92
2-5 Lift Up & Tele Out Prevented - Unset & Above Elevation
2-5 Lift Up Prevented - Check Outriggers
2-5 Lift Up Prevented - Lift Down Then Set Outriggers
2-5 Lift Up Prevented - Tilted
2-5 Model Changed - Hydraulics Suspended - Cycle EMS
2-5 Outrigger Stow Prevented - Tele In First
2-5 Outriggers Prevented - Elevated
A-11
INTRODUCTION
2-5 Tele Out Prevented - Set Outriggers
2-5 Tele Out Prevented - Tilted
3-?
3-3 Choke Hold Solenoid Open Circuit
3-3 Choke Hold Solenoid Short To Battery
3-3 Choke Hold Solenoid Short To Ground
3-3 Choke Pull Relay Open Circuit
3-3 Choke Pull Relay Short To Battery
3-3 Choke Pull Relay Short To Ground
3-3 Drive Enable Solenoid Short To Battery
3-3 Drive Enable Solenoid Short To Ground Or Open Circuit
3-3 Drive Left Forward Solenoid Open Circuit
3-3 Drive Left Forward Solenoid Short To Battery
3-3 Drive Left Forward Solenoid Short To Ground
3-3 Drive Left Reverse Solenoid Open Circuit
3-3 Drive Left Reverse Solenoid Short To Battery
3-3 Drive Left Reverse Solenoid Short To Ground
3-3 Drive Right Forward Solenoid Open Circuit
3-3 Drive Right Forward Solenoid Short To Battery
3-3 Drive Right Forward Solenoid Short To Ground
3-3 Drive Right Reverse Solenoid Open Circuit
3-3 Drive Right Reverse Solenoid Short To Battery
3-3 Drive Right Reverse Solenoid Short To Ground
3-3 Dump Solenoid Open Circuit
3-3 Dump Solenoid Short To Battery
3-3 Dump Solenoid Short To Ground
3-3 Extend O/R Solenoid Open Circuit
3-3 Extend O/R Solenoid Short To Battery
3-3 Extend O/R Solenoid Short To Ground
3-3 Front-Left O/R Solenoid Open Circuit
3-3 Front-Left O/R Solenoid Short To Battery
3-3 Front-Left O/R Solenoid Short To Ground
3-3 Front-Right O/R Solenoid Open Circuit
3-3 Front-Right O/R Solenoid Short To Battery
3-3 Front-Right O/R Solenoid Short To Ground
3-3 Ground Alarm Short To Battery
3-3 Ground Alarm Short To Ground
3-3 Hourmeter Short To Battery
3-3 Jib Down Solenoid Open Circuit
3-3 Jib Down Solenoid Short To Battery
3-3 Jib Down Solenoid Short To Ground
3-3 Jib Up Solenoid Open Circuit
3-3 Jib Up Solenoid Short To Battery
3-3 Jib Up Solenoid Short To Ground
3-3 Level Down Solenoid Open Circuit
3-3 Level Down Solenoid Short To Battery
3-3 Level Down Solenoid Short To Ground
3-3 Level Up Solenoid Open Circuit
3-3 Level Up Solenoid Short To Battery
3-3 Level Up Solenoid Short To Ground
3-3 Lift Down Solenoid Open Circuit
3-3 Lift Down Solenoid Short To Battery
3-3 Lift Down Solenoid Short To Ground
3-3 Lift Up Solenoid Open Circuit
3-3 Lift Up Solenoid Short To Battery
3-3 Lift Up Solenoid Short To Ground
3-3 Optional Ground Alarm Short To Battery
3-3 Optional Ground Alarm Short To Ground
3-3 Rear-Left O/R Solenoid Open Circuit
A-12
INTRODUCTION
3-3 Rear-Left O/R Solenoid Short To Battery
3-3 Rear-Left O/R Solenoid Short To Ground
3-3 Rear-Right O/R Solenoid Open Circuit
3-3 Rear-Right O/R Solenoid Short To Battery
3-3 Rear-Right O/R Solenoid Short To Ground
3-3 Retract O/R Solenoid Open Circuit
3-3 Retract O/R Solenoid Short To Battery
3-3 Retract O/R Solenoid Short To Ground
3-3 Start Solenoid Open Circuit
3-3 Start Solenoid Short To Battery
3-3 Start Solenoid Short To Ground
3-3 Swing Left Solenoid Open Circuit
3-3 Swing Left Solenoid Short To Battery
3-3 Swing Left Solenoid Short To Ground
3-3 Swing Right Solenoid Open Circuit
3-3 Swing Right Solenoid Short To Battery
3-3 Swing Right Solenoid Short To Ground
3-3 Telescope In Solenoid Open Circuit
3-3 Telescope In Solenoid Short To Battery
3-3 Telescope In Solenoid Short To Ground
3-3 Telescope Out Solenoid Open Circuit
3-3 Telescope Out Solenoid Short To Battery
3-3 Telescope Out Solenoid Short To Ground
3-3 Throttle Hold Solenoid Open Circuit
3-3 Throttle Hold Solenoid Short To Battery
3-3 Throttle Hold Solenoid Short To Ground
3-3 Throttle Pull Relay Open Circuit
3-3 Throttle Pull Relay Short To Battery
3-3 Throttle Pull Relay Short To Ground
4-?
4-2 Functions At Cutback - Power Module Current Limit
4-2 Power Module Too Hot - Please Wait
4-3 No Charge System Output
4-4 Battery Voltage Too High - System Shutdown
4-4 Battery Voltage Too Low - System Shutdown
6-?
6-6 CANBUS Failure - Accessory Module Communications Lost
..............................................................................................2-42
6-6 CANBUS Failure - Drive Module
6-6 CANBUS Failure - Platform Module
6-6 CANBUS Failure - Power Module
6-7 Accessory Fault
7-?
7-7 Open-Circuit Pump Motor Wiring
8-?
8-1 Chassis Tilt Sensor Not Calibrated
9-?
9-9 Chassis Tilt Sensor Gain Not Calibrated
9-9 Chassis Tilt Sensor Gain Out Of Range
9-9 EEPROM Failure - Check All Settings
9-9 Functions Locked Out - Constant Data Version Improper
9-9 Functions Locked Out - Platform Module Software Version Improper
.................................................................................2-78
9-9 Functions Locked Out - Power Module Software Version Improper
.....................................................................................2-79
9-9 Ground Module Failure Ref Voltage Out Of Range
9-9 Ground Module Failure Vlow Fet Failure
9-9 Power Module Failure Check Power Circuits Or Mosfet Short Circuit
.................................................................................2-98
9-9 Power Module Failure Internal Error
A-13
INTRODUCTION
9-9 Power Module Failure Personality Range Error
A.8 POWER MODULE FLASH CODES
FLASH
CODE
FAULT DESCRIPTION TROUBLESHOOTING REFERENCE
Steady - No Fault
Off -
1 -
2 -
3 -
4 -
Internal Failure, Controller Damaged
Personality Out Of Range Or CRC Fault
Input Active On Power Up Or Undefined Input
2.126 Power Module Failure: Internal Error
Short Circuit Detected In Power Block
2.125 Power Module Failure: Check Power Circuits Or Mosfet Short Circuit
Line Contactor Not Responding To Command
2.125 Power Module Failure: Check Power Circuits Or Mosfet Short Circuit
2.127 Power Module Failure: Personality Range Error
5 - Field Loss Detected
6 - Reserved
7 - Battery Voltage High or Low
2.3 Battery Voltage Too High - System Shutdown, 2.4 Battery Voltage Too Low -
2.79 Functions At Cutback - Power Module Current Limit, 2.128 Power Module
9 - Reserved
11 - System Condition Out Of Range
2.9 CANBUS Failure - Power Module
2.126 Power Module Failure: Internal Error
A.9 GROUND REFERENCE
A-14
INTRODUCTION
A.10 CONTROL MODULE POWER
Always make sure that the ground control module is properly powered.
1.
2.
and X060.2 should be grounded.
X007.17 enables the ground module termination resistor.
Ignition Power for Pow er M odule (Vbatt) Electric Only
To Keysw itch Ground Position (Vbatt)
(Electric Powered M achines Only)
Platform
M odule
Ignition Pow er from Ignition R elay 87 (Vbatt)
Ignition Power for Platform M odule (Vbatt)
(M achines with Drive Option O nly)
Ignition Power from Ignition Relay 87 (Vbatt)
Ground from Ignition R elay 85
Figure A-4. Basic Electronic Module Connections
A-15
INTRODUCTION
A.11 TILT
X and Y axis tilt are combined through a calculation to form the tilt value used by the control system. The machine is considered “Tilted” whenever this calculated tilt value is above 2 degrees from calibrated level, zero tilt.
An outrigger is considered set when the pivot pin slides up and closes the outrigger limit switch.
The ground control panel outrigger LEDs blink whenever they are set, but the machine is tilted. Once the outriggers are set and the machine is not tilted, the outrigger LEDs remain on, steady.
The platform outrigger LED blinks till all four outriggers are set, then lights steady. The platform tilt LED lights whenever the machine is tilted.
Orientation
The Ground Module shall be mounted such that the Tilt Sensor's X-Axis responds to Side-to-Side tilt of the vehicle, while the
Y-Axis responds to Front-to-Back tilt of the vehicle. The following table is offered to clarify orientation.
Orientation
Raise Tongue of Vehicle
Lower Tongue of Vehicle
Raise Left Side of Vehicle
Raise Right Side of Vehicle
Tilt Sensor
Response
Y-Axis -
Y-Axis +
X-Axis -
X-Axis +
A.12 CRITICAL VEHICLE INTERLOCK SCENARIOS
The following scenarios have been identified that require unique vehicle interlocks. For readability, the circumstances involved with entering and leaving these situations have been isolated here.
RETRIEVAL-A
Retrieval-A forces the user to stow the boom if the Tilt Warning is ignored and critical stability situations are reached. This scenario is INACTIVE at Power-up.
It becomes ACTIVE when the machine is ELEVATED (transport switch OPEN) AND CRITICALLY TILTED 4.5 degrees or more.
It is INACTIVE otherwise.
RETRIEVAL-B
Retrieval-B forces the user to stow the boom if the Outrigger Unset Warning is ignored and critical stability situations are reached. This scenario is INACTIVE at Power-up.
It becomes ACTIVE under the following circumstances. It is INACTIVE otherwise.
·The vehicle is Elevated AND One Outrigger is Unset AND the vehicle is TILTED
·The vehicle is Elevated AND Two Outriggers are UNSET.
A.13 OUTRIGGERS
Some machine software may refer to the Outriggers (O/R) as Lifting Jacks (L/J).
A-16
SAFETY
SECTION B.
TROUBLESHOOTING SAFETY PRECAUTIONS
B.1 GENERAL
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 VIOLA-
TION.
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 CON-
TROL 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.
B.3 TROUBLESHOOTING SAFETY
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 DUR-
ING 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 CAU-
TIONS ON MACHINE AND IN SERVICE AND OPERA-
TORS MANUALS.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSUR-
IZED 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 DISCONNECTEDDUR-
ING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
MENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
B-17
SAFETY
B-18
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION
SECTION B - TROUBLESHOOTING SAFETY PRECAUTIONS
SECTION 1 - TROUBLESHOOTING BY FUNCTION
All Functions Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
19
TABLE OF CONTENTS
(Continued)
20
TABLE OF CONTENTS
21
TABLE OF CONTENTS
(Continued)
SECTION 3 - COMPONENT CHECKS
22
TABLE OF CONTENTS
SECTION 4 - POSSIBLE CAUSES
SECTION 5 - SYSTEM TEST MESSAGES
23
TABLE OF CONTENTS
(Continued)
24
TABLE OF CONTENTS
25
TABLE OF CONTENTS
(Continued)
SECTION 6 - CALIBRATION MESSAGES
SECTION 7 - ELECTRICAL REFERENCE
SECTION 7 - ELECTRICAL REFERENCE
SECTION 7 - ELECTRICAL REFERENCE
SECTION 8 - HYDRAULIC REFERENCES
26
TABLE OF CONTENTS
SECTION 9 - JLG ANALYZER
SECTION 10 - MULTIMETER BASICS
SECTION 11 - SPECIFICATIONS
LIST OF FIGURES
FIGURE NO.
TITLE PAGE NO.
27
TABLE OF CONTENTS
(Continued)
LIST OF TABLES
TABLE NO.
TITLE PAGE NO.
28
SECTION 1 - TROUBLESHOOTING BY FUNCTION
SECTION 1. TROUBLESHOOTING BY FUNCTION
1.1 ALL FUNCTIONS INOPERATIVE
Step Pretest Instructions Test Result Corrective Action
1.1.1
1.1.2
1.1.3
1.1.4
Basic check of likely causes
Do panel indicator lights blink at power-on?
Try both ground and platform controls
Is the hydraulic pump motor running while activating a function?
Yes
No
Possible Causes: 4.1.66, 4.1.67, 4.1.68
Yes
No
Ground controller not powered. Perform
component check: 3.2 DC Powered
Machine - Power or 3.7 Engine Powered
One set of controls functions
See 1.10 Ground Controls Inoperative or
1.11 Platform Controls Inoperative
Both sets of control inoperable
Perform component check: 3.1 DC
Powered Machine - Hydraulic Pump or
3.6 Engine Powered Machine - Hydraulic Pump
Possible Causes: 4.1.37, 4.1.47
1.1.5 Connect a 0-5000 PSI pressure gauge at the manifold “G” port
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Yes
No
1.1.6 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Yes
No
Possible Causes: 4.1.40, 4.1.10, 4.1.47
Possible Causes: 4.1.37, 4.1.45, 4.1.74,
1.2 PUMP MOTOR WILL NOT OPERATE - DC POWERED MODELS
Step Pretest Instructions
1.2.1
Test
1.2.2 Engage enable and lift up switch
1.2.3 Engage enable and lift up switch
1.2.4 Engage enable and lift up switch
1.2.5 Engage enable and lift up switch
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
See 3.2 DC Powered Machine - Power
Possible Causes: 4.1.70, 4.1.72, 4.1.12
Possible Causes: 4.1.71, 4.1.72, 4.1.12
1-29
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.3 ALL FUNCTIONS INOPERATIVE, ENGINE STARTS AND RUNS - ENGINE MODELS
Step Pretest Instructions Test Result Corrective Action
1.3.1
1.3.2
1.3.3
1.3.4
Connect a 0-5000 PSI pressure gauge at the manifold “G” port
1.3.5
Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
Basic check of likely causes
Try both ground and platform controls
Is the hydraulic pump turning with the engine?
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Yes
No
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Yes
No
One set of controls functions
See 1.10 Ground Controls Inoperative or
1.11 Platform Controls Inoperative
Both sets of control inoperable
Yes
No
Perform component check: 3.6 Engine
Powered Machine - Hydraulic Pump
Possible Causes: 4.1.37, 4.1.47
Possible Causes: 4.1.40, 4.1.10, 4.1.47
Possible Causes: 4.1.37, 4.1.45, 4.1.74,
1.4 ALL FUNCTIONS INOPERATIVE, PUMP MOTOR RUNS - DC POWERED MODELS
Step Pretest Instructions Test Result Corrective Action
1.4.1
1.4.2
Basic check of likely causes
Try both ground and platform controls
One set of controls functions
See 1.10 Ground Controls Inoperative or
1.11 Platform Controls Inoperative
1.4.3
Connect a 0-5000 PSI pressure gauge at the manifold “G” port
1.4.4
Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Both sets of control inoperable
Yes
No
Possible Causes: 4.1.37, 4.1.47
Possible Causes: 4.1.40, 4.1.10, 4.1.47
While holding enable and lift up switch, does pressure rise above 100PSI (minimum function pressure)?
Yes
No
Possible Causes: 4.1.37, 4.1.45, 4.1.39
1-30
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.5 BATTERY CHARGER NOT FUNCTIONING PROPERLY
Delta-Q Charger Normal Operation Description
Stage Description
Startup The charger will automatically turn on and go through a short self-test with the LED indicator alternating red-green for two seconds. If the charger is connected to a battery pack, a trickle current will be applied until a minimum voltage is reached. If the charger is used in an off-board application and the charger is waiting to be plugged into a battery pack, the charging algorithm number will be displayed for 11 seconds before ultimately displaying an under-voltage fault (fault disappears when plugged into battery pack). Typically lasts from 5 seconds to 2 ½ minutes.
Bulk Typically, 80% of the total recharge is restored during the bulk phase where a constant 25 Amp output is being delivered. This time varies depending upon the depth of discharge.
Absorption Output reduced to prevent sulfation build up. Time depends upon the initial level of battery charge and varies from 1hour minimum to 5 ½ hours. At completion of this phase, 90% charge has been obtained.
Finish Delivers 6A for at least 1 hour to finish charge.
There will be a cut back in output any time the charger is below 108 VAC. ANY interruption where there is power loss causes the charger to reset. If left plugged in, the charger will restart in 30 days or when the Voltage drops
Battery Charge Level and Normal Charging Time
Number of
Cycles
15
30
50
66
Battery Charge Level
75% (24.8V)
50% (24.2V)
20% (23.4V)
0% (less than 23.2V)
Recharge time (hours)
12
13.1
14.7
15
Step Pretest Instructions
1.5.1
1.5.2
Test
Does charger go through proper LED sequencing upon start up?
Is the red LED on?
Yes
No
Yes
No
Result
1.5.3
Check the voltage on each battery. 25% - 6.12 V, 100% =
6.32 V
Do all batteries have at least
6.12V?
1.5.4
Using a hydrometer - Check the specific gravity in each battery cell. 25% charged is
1.155, 100% = 1.265
Is the specific gravity of all battery cells between 1.155 and
1.265?
Yes
No
Yes
No
Corrective Action
Check AC power supply.
Possible Causes: 4.1.1, 4.1.3, 4.1.4
Do some function to cause draw on the battery, then start again. Otherwise, go to
1-31
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.6 ENGINE WILL NOT CRANK - ENGINE MODELS
Engine starting is only allowed for engine powered machines when the engine speed feedback is zero.
Result Step Pretest Instructions
1.6.1
Test
Do panel indicator lights blink at power-on?
Yes
No
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
1.6.7
1.6.8
Is Analyzer DIAGNOSTICS ->
SYSTEM -> BATTERY at least
9 Volts?
Yes
No
Does engine turn with manual recoil?
Analyzer DIAGNOSTICS ->
ENGINE -> SPEED = 0 RPM?
Yes
No
Yes
No
Yes
No
While pressing the start button,
Voltage on X089 starter solenoid = Vbatt?
Yes
No
While pressing the start button,
Yes
While pressing the start button,
No
Yes
No
Corrective Action
Ground controller not powered. Perform
component check: 3.7 Engine Powered
Replace engine solenoid fuse at X088
X001.16 to verify, 4.1.21, 4.1.30, 4.1.10
Possible Cause: Broken Wht/Yel 48-6 wire between X022.6 and solenoid
Possible Cause: Broken Wht/Yel 48-6 wire between X002.23 and X022.6
Possible Causes: 4.1.2, 4.1.10
1-32
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.7 ENGINE CRANKS BUT WILL NOT START - ENGINE MODELS
Step Pretest Instructions
1.7.1
Test
Basic check of likely causes
Result
1.7.2
1.7.3 Turn key switch to ground position and pull the emergency stop
1.7.4 Turn key switch to ground position and pull the emergency stop
1.7.5 Turn key switch to ground position and pull the emergency stop
Does engine start with manual recoil?
Yes
Is X090.87a black wire, shorted to ground?
No
Yes
No
Yes
No
Yes
No
Corrective Action
Possible Causes: 4.1.83, 4.1.84,
4.1.85, 4.1.86, 4.1.87, 4.1.88, 4.1.91
Possible Causes: Check start motor
Possible Causes: 4.1.92, 4.1.93
Possible Causes: Broken Yel/Red 2-3 between X022.2 and X090.86, Broken
Possible Causes: Broken Yel/Red 2-3 wire between X022.2 and X009.87, See
1.8 ENGINE HIGH IDLE INOPERATIVE - ENGINE MODELS
The throttle solenoid engages the engine throttle to high speed. To actuate the throttle solenoid, the Ground Module Engine
Throttle Hold output is turned on continuously while the Ground Module Engine Throttle Pull output is momentarily turned on, energizing the Engine Throttle Pull Relay to provide higher current to the throttle solenoid while pulling. The Engine
Throttle Hold output remains on during a function and an additional 1 second afterwards, as well as 5 seconds after engine startup.
Result Step Pretest Instructions
1.8.1 Turn key switch to ground position and pull the emergency stop. Engine Running
1.8.2 Turn key switch to ground position and pull the emergency stop
Test
Yel 48-2-1) = Vbatt momentarily when operating Lift Up?
Yel 48-2) = Vbatt momentarily when operating Lift Up?
Yes
No
Yes
No
1.8.3 Turn key switch to ground position and pull the emergency stop
Yel 48-3) = Vbatt when operating Lift Up?
Yes
No
Corrective Action
Possible Causes: Fusible link from B+ to X091.30 broken, Throttle Pull Diode at
Possible Causes: Wht/Yel 48-2 wire from X003.9 to X022.3 or X022.3 to
Possible Causes: Throttle cable froze or
binding, Engine throttle stuck, 4.1.78
Possible Causes: Wht/Yel 48-3 wire from X003.11 to X022.4 or X022.4 to
1.9 ENGINE LOW IDLE INOPERATIVE - ENGINE MODELS
Possible Causes: 4.1.83, 4.1.84, 4.1.85, 4.1.86, 4.1.90, 4.1.89, 4.1.93
1-33
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.10 GROUND CONTROLS INOPERATIVE
Step Pretest Instructions
1.10.1
Test
Do panel indicator lights blink at power-on? (Normal 3 second wakeup alarm should also sound)
Yes
No
Result Corrective Action
Possible Causes: Check the Analyzer connection and look for faults again,
Ground controller not powered. Perform
component check: 3.2 DC Powered
Machine - Power or 3.7 Engine Powered Machine - Power
1.11 PLATFORM CONTROLS INOPERATIVE
Step Pretest Instructions
1.11.1
Test
Do panel indicator lights blink at power-on? (Normal 3 second wakeup alarm should also sound)
Yes
No
1.11.2 Place key switch in platform position and pull the emergency stop switches. Engage and hold the trigger.
Yes
No
Result Corrective Action
Platform controller not powered. Per-
form component check: 3.13 Platform
Possible Causes: 4.1.38, Rotary Select
switch may be defective, See 2.96 Joystick Moved But Trigger Switch Open
Joystick trigger switch may be defective,
See 2.96 Joystick Moved But Trigger
1.12 GROUND LEVELING NOT FUNCTIONING PROPERLY
The ground module uses its embedded tilt sensor and feedback from the outrigger switches to automatically level the machine when the outrigger extend switch is held. It will first try extending the appropriate outriggers to achieve level. If the switch is still held and level is not yet achieved, it will try retracting the appropriate outriggers to achieve level. If the ground is too uneven or the slope is too great, the outriggers will not be able to level the machine.
Step Pretest Instructions
1.12.1
Test
Basic check of likely causes
Result
1.12.2
1.12.3
ANALYZER -> DIAGNOSTICS -
> GROUND -> Outrigger switch indicators agree with O/
R positions?
Are some outriggers operating properly?
Yes
No
Yes
No
Corrective Action
Possible Causes:4.1.37, 4.1.34, 4.1.36,
Possible Causes:4.1.20, 4.1.19, 4.1.18,
Possible Causes:4.1.62, 4.1.10
Possible Causes:4.1.63, 4.1.62, 4.1.10
1-34
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.13 LIFT DOWN FUNCTION INOPERATIVE
Step Pretest Instructions
1.13.1
1.13.2
Test
Basic check of likely causes
Does Manual Descent lower the boom?
Yes
No
Result Corrective Action
Possible Causes: 4.1.33, 4.1.37, 4.1.49
Possible Causes: 4.1.38, 4.1.59, 4.1.48,
Possible Causes: 4.1.41, 4.1.47, 4.1.10
1.14 LIFT UP FUNCTION INOPERATIVE
Step Pretest Instructions
1.14.1
1.14.2 Engage enable and lift up switch
Test
Basic check of likely causes
DC - Is pump motor running?
Yes
No
Gas - Is engine running at high idle
Yes
No
Result
1.14.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.14.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.14.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the lift up cylinder cap end.
Engage the enable and Lift up switch. Check the pressure.
Engage the enable and Lift up switch. Check pressure at manifold P port
Check pressure at lift cylinder while activating lift up at ground controls
Above Min. Lift Up Pressure psi
Below Min. Lift Up Pressure psi
Above Min. Lift Up Pressure psi
Below Min. Lift Up Pressure psi
Above Min. Lift Up Pressure psi
Below Min. Lift Up Pressure psi
Corrective Action
Possible Causes: 4.1.32, 4.1.33, 4.1.37
See 1.2 Pump Motor Will Not Operate -
See 1.8 Engine High Idle Inoperative -
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Possible Causes: 4.1.10, 4.1.46,
4.1.47, 4.1.74, 4.1.45, 4.1.39
Possible Causes: 4.1.49, 4.1.48, 4.1.41
Possible Causes: 4.1.42, 4.1.58
1-35
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.15 TELESCOPE OUT FUNCTION INOPERATIVE
Step Pretest Instructions Test Result Corrective Action
1.15.1
1.15.2 Engage enable and telescope out switch
Basic check of likely causes
DC - Is pump motor running?
Gas - Is engine running at high idle
Yes
No
Yes
No
Possible Causes: 4.1.32, 4.1.33, 4.1.37
See 1.2 Pump Motor Will Not Operate -
See 1.8 Engine High Idle Inoperative -
1.15.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold
G port
1.15.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.15.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the lift up cylinder cap end.
Engage the enable and Telescope Out switch. Check the pressure.
Engage the enable and Telescope Out switch. Check pressure at manifold P port
Above Min. Tele Out Pressure psi
Below Min. Tele Out Pressure psi
Above Min. Tele Out Pressure psi
Below Min. Tele Out Pressure psi
Check pressure at the telescope cylinder while activating telescope out at ground controls
Above Min. Tele Out Pressure psi
Below Min. Tele Out Pressure psi
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Possible Causes: 4.1.10, 4.1.46,
4.1.47, 4.1.74, 4.1.45, 4.1.39
Possible Causes: 4.1.49, 4.1.48, 4.1.41
Possible Causes: 4.1.42, 4.1.50
1.16 TELESCOPE IN FUNCTION INOPERATIVE
Step Pretest Instructions
1.16.1
Test
Basic check of likely causes
1.16.2 Engage enable and telescope in switch
DC - Is pump motor running?
Yes
No
Gas - Is engine running at high idle
Yes
No
Result Corrective Action
Possible Causes: 4.1.32, 4.1.33,
See 1.2 Pump Motor Will Not Operate -
See 1.8 Engine High Idle Inoperative -
1.16.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.16.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.16.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the lift up cylinder cap end.
Engage the enable and Telescope in switch. Check the pressure.
Engage the enable and Telescope in switch. Check pressure at manifold P port
Above Min. Tele In Pressure psi
Below Min. Tele In Pressure psi
Above Min. Tele In Pressure psi
Below Min. Tele In Pressure psi
Check pressure at the telescope cylinder while activating telescope in at ground controls
Above Min. Tele In Pressure psi
Below Min. Tele In Pressure psi
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Possible Causes: 4.1.10, 4.1.46,
4.1.47, 4.1.74, 4.1.45, 4.1.39
Possible Causes: 4.1.49, 4.1.48,
Possible Causes: 4.1.42, 4.1.51
1-36
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.17 SWING LEFT FUNCTION INOPERATIVE
Step Pretest Instructions
1.17.1
1.17.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.17.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.17.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the swing motor.
Test
Basic check of likely causes
1.17.2 Engage enable and swing left switch
DC - Is pump motor running?
Yes
No
Gas - Is engine running at high idle
Yes
No
Engage the enable and swing left switch. Check the pressure.
Engage the enable and swing left switch. Check pressure at manifold P port
Check pressure at the swing motor while activating swing left at ground controls
Result Corrective Action
Possible Causes: 4.1.32, 4.1.33,
See 1.2 Pump Motor Will Not Operate -
See 1.8 Engine High Idle Inoperative -
Above Min. Swing Left Pressure psi (bar)
Below Min. Swing Left Pressure psi (bar)
Above Min. Swing Left Pressure psi (bar)
Below Min. Swing Left Pressure psi (bar)
Above Min. Swing Left Pressure psi (bar)
Below Min. Swing Left Pressure psi (bar)
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Possible Causes: 4.1.10, 4.1.46,
4.1.47, 4.1.74, 4.1.45, 4.1.39
Possible Causes: 4.1.49, 4.1.48,
Possible Causes: 4.1.42, 4.1.53
1.18 SWING RIGHT FUNCTION INOPERATIVE
Step Pretest Instructions Test Result Corrective Action
1.18.1
1.18.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.18.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the swing motor cylinder
Basic check of likely causes
1.18.2 Engage enable and swing right switch
1.18.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
DC - Is pump motor running?
Gas - Is engine running at high idle
Engage the enable and swing right switch. Check the pressure.
Yes
No
See 1.2 Pump Motor Will Not Operate -
Yes
No
See 1.8 Engine High Idle Inoperative -
Above Min. Swing Right Pressure psi (bar)
Below Min. Swing Right Pressure psi (bar)
Engage the enable and swing right switch. Check pressure at manifold P port
Check pressure at the swing motor while activating swing right at ground controls
Above Min. Swing Right Pressure psi (bar)
Possible Causes: 4.1.32, 4.1.33,
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Below Min. Swing Right Pressure psi (bar)
Possible Causes: 4.1.10, 4.1.46,
4.1.47, 4.1.74, 4.1.45, 4.1.39
Above Min. Swing Right Pressure psi (bar)
Possible Causes: 4.1.49, 4.1.48,
Below Min. Swing Right Pressure psi (bar)
Possible Causes: 4.1.42, 4.1.52
1-37
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.19 PLATFORM LEVELING UP FUNCTION INOPERATIVE
Step Pretest Instructions Test Result Corrective Action
1.19.1
1.19.2 Engage enable and Level Up switch
1.19.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.19.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.19.5 Put boom in transport and activate Platform Level Down to relieve pressure. Some working pressure will still be in the line. Install a 0 to 5000 PSI
(345 bar) pressure gauge at the manifold GA port
Basic check of likely causes
Possible Causes: 4.1.32, 4.1.33,
DC - Is pump motor running?
Yes
No
See 1.2 Pump Motor Will Not Operate -
Gas - Is engine running at high idle
Yes
No
See 1.8 Engine High Idle Inoperative -
Engage the enable and Level
Up switch. Check the pressure.
Above Min. Level Up Pressure psi
Engage the enable and Level
Up switch. Check pressure at manifold P port
Engage the enable and Level
Up switch. Check pressure at manifold GA port. Relieve the pressure before removing the gauge.
Below Min. Level Up Pressure psi
Above Min. Level Up Pressure psi
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Below Min. Level Up Pressure psi
Possible Causes: 4.1.46, 4.1.47,
4.1.74, 4.1.45, 4.1.39, 4.1.10
Above Min. Level Up Pressure psi
Possible Causes: 4.1.49, 4.1.48,
Below Min. Level Up Pressure psi
Possible Causes: 4.1.42, 4.1.55,
1-38
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.20 PLATFORM LEVELING DOWN FUNCTION INOPERATIVE
Step Pretest Instructions
1.20.1
1.20.2 Engage enable and Level Up switch
1.20.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.20.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
1.20.5 Put boom in transport and activate Platform Level Up to relieve pressure. Some working pressure will still be in the line. Install a 0 to 5000 PSI
(345 bar) pressure gauge at the manifold GB port
Test Result Corrective Action
Basic check of likely causes
Possible Causes: 4.1.32, 4.1.33,
DC - Is pump motor running?
Gas - Is engine running at high idle
Engage the enable and Level
Down switch. Check the pressure.
Yes
No
See 1.2 Pump Motor Will Not Operate -
Yes
No
See 1.8 Engine High Idle Inoperative -
Above Min. Level Down Pressure psi (bar)
Below Min. Level Down Pressure psi (bar)
Engage the enable and Level
Down switch. Check pressure at manifold P port
Above Min. Level Down Pressure psi (bar)
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Below Min. Level Down Pressure psi (bar)
Possible Causes: 4.1.46, 4.1.47,
4.1.74, 4.1.45, 4.1.39, 4.1.10
Engage the enable and Level
Down switch. Check pressure at manifold GB port. Relieve the pressure before removing the gauge.
Above Min. Level Down Pressure psi (bar)
Below Min. Level Down Pressure psi (bar)
Possible Causes: 4.1.49, 4.1.48,
Possible Causes: 4.1.42, 4.1.57,
1-39
SECTION 1 - TROUBLESHOOTING BY FUNCTION
1.21 JIB UP FUNCTION INOPERATIVE
Step Pretest Instructions
1.21.1
Test
Basic check of likely causes
1.21.2 Engage enable and jib up switch
DC - Is pump motor running?
Yes
No
Gas - Is engine running at high idle
Yes
No
Result Corrective Action
Possible Causes: 4.1.32, 4.1.33,
See 1.2 Pump Motor Will Not Operate -
See 1.8 Engine High Idle Inoperative -
1.21.3 Install a 0 to 5000 PSI (345 bar) pressure gauge at the manifold G port
1.21.4 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the manifold P port
Engage the enable and jib up switch. Check the pressure.
Engage the enable and jib up switch. Check pressure at manifold P port
1.21.5 Plumb a 0 to 5000 PSI (345 bar) pressure gauge into the hose from the jib cylinder cap end.
Check pressure at the jib cylinder while activating jib up at ground controls
Above Min. Jib Up Pressure psi
Below Min. Jib Up Pressure psi
Above Min. Jib Up Pressure psi
Below Min. Jib Up Pressure psi
Above Min. Jib Up Pressure psi
Below Min. Jib Up Pressure psi
Possible Causes: 4.1.38, 4.1.45,
4.1.74, 4.1.40, 4.1.10, 4.1.43
Possible Causes: 4.1.46, 4.1.47,
4.1.74, 4.1.45, 4.1.39, 4.1.10
Possible Causes: 4.1.49, 4.1.48,
Possible Causes: 4.1.42, 4.1.60
1.22 JIB DOWN FUNCTION INOPERATIVE
Step Pretest Instructions
1.22.1
Test
Basic check of likely causes
1.22.2
Does Manual Descent lower the jib?
Yes
No
Result Corrective Action
Possible Causes: 4.1.33, 4.1.37,
Possible Causes: 4.1.38, 4.1.61,
Possible Causes: 4.1.41, 4.1.47,
1.23 OUTRIGGER SET FUNCTION INOPERATIVE
See 1.12 Ground Leveling Not Functioning Properly
1.24 OUTRIGGER STOW FUNCTION INOPERATIVE
See 1.12 Ground Leveling Not Functioning Properly
1-40
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
SECTION 2.
TROUBLESHOOTING BY FAULT MESSAGES
2.1 ACCESSORY FAULT
Distress Lamp: 9 ADE Code: 6-7
An attached accessory is communicating a fault to the ground control.
Step Pretest Instructions
2.1.1
Test
Is an accessory installed?
Yes
Result
No
Corrective Action
Refer to Information Supplied with
Accessory
2.2 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
Distress Lamp: 3 ADE Code: 4-4
The system detected a battery voltage above 36 Volts for an electric powered machine.
ELECTRIC POWERED MACHINES ONLY
Functions Disabled (Electric Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R), Drive
Possible Causes: 4.1.2, 4.1.3, 4.1.4
2.3 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN
Distress Lamp: 5 ADE Code: 4-4
The system detected a battery voltage above 18 Volts for an engine powered machine.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R), Engine Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold,
Drive
Possible Causes: 4.1.2, 4.1.3, 4.1.4
2.4 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
Distress Lamp: 3 ADE Code: 4-4
The system detected a battery voltage below 16 Volts for an electric powered machine.
ELECTRIC POWERED MACHINES ONLY
Functions Disabled (Electric Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R), Drive
Possible Causes: 4.1.2, 4.1.3, 4.1.4
2-41
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.5 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN
Distress Lamp: 5 ADE Code: 4-4
The system detected a battery voltage below 9 Volts for an engine powered machine.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R), Engine Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold,
Drive
Possible Causes: 4.1.2, 4.1.3, 4.1.4
2.6 CANBUS FAILURE - ACCESSORY MODULE COMMUNICATIONS LOST
Distress Lamp: 9 ADE Code: 6-6
System cannot communicate with an installed accessory
Step Pretest Instructions
2.6.1
Test
Is an accessory installed?
Yes
No
Result Corrective Action
Refer to Information Supplied with
Accessory
2-42
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.7 CANBUS FAILURE - DRIVE MODULE
Distress Lamp: 9 ADE Code: 6-6
System cannot communicate with the drive module.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Machines With Drive Option Only): Drive
Step Pretest Instructions
2.7.1
Test
Basic check of likely causes
2.7.2
Pull the ground emergency stop switch and place key switch in ground position
2.7.3
Make sure that machine is powered off and drive module is properly connected
2.7.4
Disconnect drive module at
X075
2.7.5
2.7.6
Voltage between X074.1 and
X074.2 = Vbatt?
Yes
No
Measured RESISTANCE between X012.3 Red wire and
Yes
No
Measured RESISTANCE between X075.9.soc and
X075.10.soc = 60
Ω?
Measured RESISTANCE between X057.A.pin and
Yes
No
Yes
Measured RESISTANCE between X054.1.soc and
No
Yes
No
2.7.7
Make sure that machine is powered off and drive module is properly connected
Test for continuity between
2.7.8
Make sure that machine is powered off and drive module is properly connected
Test for continuity between
Yes
No
Yes
No
2.7.9
2.7.10 Disconnect Ground Module at
Ω?
Ω?
2.7.11 Disconnect X007 Test harness for continuity between X007.6.soc and
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: 4.1.9, 4.1.10,
Electric Machine - Go to Step 2.7.9
Engine Machine - Go to Step 2.7.10
Repair platform CAN termination resistor at X057
Repair red wire between X075.9 and
Possible Causes: 4.1.9, 4.1.10,
Repair black wire between X075.10
Repair or replace black jumper wire between X007.6.soc and
2-43
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.8 CANBUS FAILURE - PLATFORM MODULE
Distress Lamp: 9 ADE Code: 6-6
System cannot communicate with the platform module.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R), Engine Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
Step Pretest Instructions Test
2.8.1
Pull the ground emergency stop switch and place key switch in the platform position
Do the platform lights blink when the platform emergency stop switch is pulled?
2.8.2
Make sure that machine is powered off and platform module is properly connected
2.8.3
Measured RESISTANCE between X060.3 Red wire and
Yes
No
Yes
No
Measured RESISTANCE between X054.1.soc and
Yes
No
2.8.4
Disconnect X054 and X057 Measured RESISTANCE between X057.A.pin and
Ω?
Yes
No
2.8.5
2.8.6
2.8.7
2.8.8
Ω?
2.8.9
Ω?
2.8.10 Disconnect X007 Test harness for continuity between X007.6.soc and
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
See 3.13 Platform Module - Power
Electric Machine - Go to Step 2.8.7
Engine Machine - Go to Step 2.8.9
Repair platform CAN termination resistor at X057
Repair red wire between X060.3and
Possible Causes: 4.1.11, 4.1.10,
Repair black wire between X060.4 and
Repair CAN wiring between X010 and
Possible Causes: 4.1.14, 4.1.11
Repair or replace black jumper wire between X007.6.soc and
2-44
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.9 CANBUS FAILURE - POWER MODULE
Distress Lamp: 9 ADE Code: 6-6
System cannot communicate with the electric power control module.
ELECTRIC POWERED MACHINES ONLY
Functions Disabled: Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up, Level Down, Front Left
O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Step Pretest Instructions
2.9.1
Pull the ground emergency stop switch and place key switch in the ground position
2.9.2
Make sure that machine is powered off and power module is properly connected
2.9.3
2.9.4
Test
Does the power module LED light solidly when the ground emergency stop switch is pulled?
Measured RESISTANCE between X010.10 Red wire and X010.11 Black = 60
Measured RESISTANCE between X010.10.pin and
Ω?
Measured RESISTANCE between X054.1.soc and
Yes
No
Yes
No
Yes
No
Yes
No
2.9.5
Yes
No
2.9.6
2.9.7
Yes
No
Yes
No
Result Corrective Action
Repair platform CAN termination resistor at X057
Repair red wire between X010.10 and
Possible Causes: 4.1.12, 4.1.10,
Repair black wire between X010.11 and X007.24
Possible Causes: 4.1.12, 4.1.10,
Repair CAN wiring between X010 and
2.10 CHASSIS TILT SENSOR GAIN NOT CALIBRATED
Distress Lamp: 9 ADE Code: 9-9
Indicates that the chassis tilt sensor calibration information has become corrupted. Vehicle will indicate that it is tilted at all times. This calibration data is programmed at the factory.
Functions Disabled: Same as Tilted
2.11 CHASSIS TILT SENSOR GAIN OUT OF RANGE
Distress Lamp: 9 ADE Code: 9-9
Indicates that the chassis tilt sensor calibration information has become corrupted. Vehicle will indicate that it is tilted at all times. This calibration data is programmed at the factory.
Functions Disabled: Same as Tilted
2-45
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.12 CHASSIS TILT SENSOR NOT CALIBRATED
Distress Lamp: 9 ADE Code: 8-1
The tilt sensor calibration has not been performed for the chassis tilt sensor. Tilt reading displayed as 90° and vehicle assumed to be tilted.
Functions Disabled: Same as Tilted
Step Pretest Instructions
2.12.1
Test
Has the tilt sensor calibration been run?
Yes
No
Result Corrective Action
Run the tilt sensor calibration
2.13 CHASSIS TILT SENSOR OUT OF RANGE
Distress Lamp: None ADE Code: None
Tilt Sensor read angle greater than 19° for more than 4 seconds after 2 second power-up delay. Tilt reading displayed as
90° and vehicle assumed to be tilted.
Functions Disabled: Same as Tilted
Step Pretest Instructions
2.13.1
Test
Is the machine tilted 19° or more?
2.13.2
2.13.3
Is the ground module properly oriented and mounted?
Has a tilt sensor calibration been run recently?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Level machine before operating
Properly secure the ground module with the machine resting on a level surface. Run the tilt sensor calibra-
tion
Properly secure the ground module with the machine resting on a level surface. Run the tilt sensor calibra-
tion
2-46
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.14 CHOKE HOLD SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Hold digital output may be disconnected from solenoid or the solenoid may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Hold
Step Pretest Instructions
2.14.1
Run system test
Test
Do other functions fail system test?
Yes
Result
2.14.2
Rerun System Test
2.14.3
Replace X003.7 with a jumper to X003.3
Rerun System Test
No
Corrective Action
Check: 4.1.15, 4.1.1, otherwise go to
Replace solenoid and/or connector
Wire WHT/YEL 48-5 broken. Repair or replace
2.15 CHOKE HOLD SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Hold digital output may be shorted to battery or other function.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Hold
Step Pretest Instructions
2.15.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.15.2 Disconnect solenoid at X098 and isolate wires
Rerun System Test
2.15.3 Remove wire WHT/YEL 48-5 from X003.7
Rerun System Test
No
Corrective Action
Possible Cause: 4.1.15, 4.1.1, other-
Replace solenoid
Wire WHT/YEL 48-5 shorted to battery. Repair or replace
2-47
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.16 CHOKE HOLD SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Hold digital output may be shorted to ground or solenoid may be defective
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Hold
Step Pretest Instructions
2.16.1 Disconnect solenoid at X098 and isolate wires
Test
Rerun System Test
2.16.2 Remove wire WHT/YEL 48-5 from X003.7
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire WHT/YEL 48-5 shorted to ground. Repair or replace
2.17 CHOKE PULL RELAY OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Pull digital output may be disconnected from the relay or the relay may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Pull
Step Pretest Instructions
2.17.1
Run system test
2.17.2
Disconnect relay at X093. At harness end, short X093.86
Test
Do other functions fail system test?
Rerun System Test
2.17.3
Replace X003.4 with a jumper to X003.3
Rerun System Test
Result Corrective Action
Yes
Check: 4.1.15, 4.1.1, otherwise go to
No
Replace solenoid and/or connector
Wire WHT/YEL 48-4 broken. Repair or replace
2-48
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.18 CHOKE PULL RELAY SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Pull digital output may be shorted to battery or other function.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Pull
Step Pretest Instructions
2.18.1 Run system test
2.18.2 Disconnect relay at X093 and isolate wires
Rerun System Test
2.18.3 Remove wire WHT/YEL 48-4 from X003.4
Test
Do other functions fail system test?
Rerun System Test
Result Corrective Action
Yes
Possible Cause: 4.1.15, 4.1.1, other-
No
Replace solenoid
Wire WHT/YEL 48-4 shorted to battery. Repair or replace
2.19 CHOKE PULL RELAY SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Choke Pull digital output may be shorted to ground or the relay may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Choke Pull
Step Pretest Instructions
2.19.1 Disconnect solenoid at X093 and isolate wires
Test
Rerun System Test
2.19.2 Remove wire WHT/YEL 48-4 from X003.4
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire WHT/YEL 48-4 shorted to ground. Repair or replace
2-49
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.20 DRIVE & O/R PREVENTED - OPERATE FROM PLATFORM
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive or Outriggers, but X007.7 is not at Battery Voltage, as it should be when the platform console is plugged into the platform position.
Using the JLG Analyzer, view the Platform Position status under DIAGNOSTICS -> SYSTEM. The vehicle must be in “AWP
MODE” (not “HOOK MODE”) with PLTPOS1 +B and PLTPOS2 GND.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
Step Pretest Instructions
2.20.1
Test
Is the platform console plugged into the platform?
Yes
No
Result Corrective Action
Connect the platform console at the platform position and try again
2.20.2 Using the JLG Analyzer, view the Platform Position status under DIAGNOSTICS -> SYS-
TEM. The vehicle must be in
“AWP MODE” (not “HOOK
MODE”) with PLTPOS1 +B and PLTPOS2 GND.
Is PLTPOS1 +B?
2.20.3 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
2.20.4 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
Is the voltage on X059.D.pin
= VBatt?
Yes
No
Yes
No
Yes
No
Is the voltage on
X054.10.soc = VBatt?
Yes
No
Yes
No
Is the voltage on X019.10.pin
= VBatt?
Yes
No
Possible Cause:
See 2.124 Platform Position Detection Faulty
See 2.124 Platform Position Detection Faulty
See 2.124 Platform Position Detection Faulty
Possible Cause: Orn/Red 49-10 wire open or swapped with Orn/Red 49-9 wire.
See 2.124 Platform Position Detection Faulty
Possible Cause: Orn/Blk boom wire open or swapped with Blu/Blk wire.
See 2.124 Platform Position Detection Faulty
2-50
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.21 DRIVE & O/R PREVENTED - PLACE BOOM ON REST
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive or Outriggers but the Boom was not detected by the Turntable position sensor at X073, or an error was detected with the sensor. When the boom is against the rest, TURNTABLE1 input,
X074.3 = +B and TURNTABLE2 input, X074.4 = 0V. This could be caused by the boom not being properly stowed on the rest, an obstruction over the switch, the switch adjusted too far from the boom (should be within 0.188" of the boom), or a faulty transport limit switch or turntable position switch. If an error has been detected, the switch must be reset before drive will function.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
2.22 DRIVE & O/R PREVENTED - SET HAND BRAKE
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive or Outriggers but the Hand Brake was not detected by the hand brake position sensor at X072 as set (applied) or an error was detected with the sensor. If the hand brake appears to be in the proper position, examine the Hand Brake Sensor wiring and adjustment. When the hand brake is applied, BRAKE1 input,
X074.5 = +B and BRAKE2 input, X074.6 = 0V.This could be caused by the brake linkage or cable not being properly adjusted, an obstruction over the switch, the switch adjusted too far from the cylinder (should be within 0.188" of the extended cylinder), or a faulty switch. If an error has been detected, the switch must be reset before drive will function.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
2.23 DRIVE ENABLE SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Enable Valve PWM output may be shorted to battery or the solenoid may be defective
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
Step Pretest Instructions
2.23.1 Run system test
Test
Do other functions fail system test?
2.23.2 Disconnect solenoid at
X071and isolate wires
2.23.3 Remove wire Orn 55-1 from
X074.11
Rerun System Test
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid
Wire Orn 55-1 shorted to battery.
Repair or replace
2-51
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.24 DRIVE ENABLE SOLENOID SHORT TO GROUND OR OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Enable Valve PWM output may be disconnected, shorted to ground, or the solenoid may be defective.
DRIVE OPTION MACHINES ONLY
Step Pretest Instructions
2.24.1 Disconnect solenoid at X071 and measure resistance
Test
Is the solenoid resistance
2.24.2 Remove wire Orn 55-1 from
X074.11
Is X074.11.soc shorted or open to X074.2.soc?
Yes
No
Yes - Open
No
Result
Yes-Short to Ground
Corrective Action
Repair/Replace solenoid
Possible Causes: Open in Orn 55-1 or
Black or Red/Blk boom wire. Repair or replace
Possible Causes: Wire Orn 55-1 shorted to ground. Repair or replace
2.25 DRIVE LEFT FORWARD SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Left Forward Valve PWM output may be disconnected or the solenoid may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Forward
Step Pretest Instructions
2.25.1
Run system test
Test
Do other functions fail system test?
Yes
Result
2.25.2
Short X067.1.soc to
X067.2.soc
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
Replace solenoid and/or connector
2.25.3
Replace X074.7 with a jumper to X074.2
Rerun System Test
No
Wire Orn 7-4 broken. Repair or replace
2-52
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.26 DRIVE LEFT FORWARD SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Left Forward Valve PWM output may be shorted to battery or the solenoid may be defective
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Forward
Step Pretest Instructions
2.26.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.26.2 Disconnect solenoid at X074 and isolate wires
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
2.26.3 Remove wire Orn 7-4 from
X074.7
Rerun System Test
No
Wire Orn 7-4 shorted to battery. Repair or replace
2.27 DRIVE LEFT FORWARD SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the drive left forward digital output may be shorted to ground or the relay may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Forward
Step Pretest Instructions
2.27.1 Disconnect solenoid at X074 and isolate wires
Test
Rerun System Test
2.27.2 Remove wire Orn 7-4 from
X074.7
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Orn 7-4 shorted to ground. Repair or replace
2-53
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.28 DRIVE LEFT REVERSE SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Left Reverse Valve PWM output may be disconnected or the solenoid may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Reverse
Step Pretest Instructions
2.28.1
Run system test
2.28.2
Short X069.1.soc to
X069.2.soc
Test
Do other functions fail system test?
Rerun System Test
2.28.3
Replace X074.8 with a jumper to X074.2
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
No
Replace solenoid and/or connector
Orn 8-4 wire broken. Repair or replace
2.29 DRIVE LEFT REVERSE SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Left Reverse Valve PWM output may be shorted to battery or the solenoid may be defective
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Reverse
Step Pretest Instructions
2.29.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.29.2 Disconnect solenoid at X069 and isolate wires
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
2.29.3 Remove wire Orn 8-4 from
X074.8
Rerun System Test
No
Wire Orn 8-4 shorted to battery. Repair or replace
2-54
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.30 DRIVE LEFT REVERSE SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the drive left reverse digital output may be shorted to ground or the relay may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Left Reverse
Step Pretest Instructions
2.30.1 Disconnect solenoid at X069 and isolate wires
2.30.2 Remove wire Orn 8-4 from
X074.8
Test
Rerun System Test
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Orn 8-4 shorted to ground. Repair or replace
2.31 DRIVE PREVENTED - LIFT DOWN
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive or Outriggers but the Boom was not detected to be stowed by the
Transport limit switch at X040. When the boom is stowed in transport position, TRANS LMT SW input, X004.11 = +B.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
See 3.17 Transport Limit Switch
2.32 DRIVE PREVENTED - STOW OUTRIGGERS
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive but at least one outrigger was detected to be set. All outriggers must be unset before drive will function. Outrigger status can be viewed on the ground control panel LEDs or with the Analyzer in Diagnostics -> Ground
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
Stow all outriggers. If message is still present, See 3.12 Outrigger Switches - All Stowed
2.33 DRIVE PREVENTED - TELESCOPE IN
Distress Lamp: 2 ADE Code: 2-5
In Platform Mode, an attempt was made to operate Drive but the boom was not detected to be telescoped in by the Telescope limit switch at X041. When the boom is stowed in transport position, TELE LMT SW input, X004.21 = +B.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive
See 3.15 Telescope Limit Switch
2-55
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.34 DRIVE RIGHT FORWARD SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Right Forward Valve PWM output may be disconnected or the solenoid may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Forward
Step Pretest Instructions
2.34.1
Run system test
Test
Do other functions fail system test?
Yes
Result
2.34.2
Short X068.1.soc to
X068.2.soc
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
Replace solenoid and/or connector
2.34.3
Replace X074.9 with a jumper to X074.2
Rerun System Test
No
Wire Orn 7-2 broken. Repair or replace
2.35 DRIVE RIGHT FORWARD SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Right Forward Valve PWM output may be shorted to battery or the solenoid may be defective
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Forward
Step Pretest Instructions
2.35.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.35.2 Disconnect solenoid at X068 and isolate wires
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
2.35.3 Remove wire Orn 7-2 from
X002.9
Rerun System Test
No
Wire Orn 7-2 shorted to battery. Repair or replace
2-56
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.36 DRIVE RIGHT FORWARD SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the drive right forward digital output may be shorted to ground or the relay may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Forward
Step Pretest Instructions
2.36.1 Disconnect solenoid at X068 and isolate wires
Test
Rerun System Test
2.36.2 Remove wire WHT/YEL 48-4 from X074.9
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire WHT/YEL 48-4 shorted to ground. Repair or replace
2.37 DRIVE RIGHT REVERSE SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Right Reverse Valve PWM output may be disconnected or the solenoid may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Reverse
Step Pretest Instructions
2.37.1
Run system test
2.37.2
Short X070.1.soc to
X070.2.soc
2.37.3
Replace X074.10 with a jumper to X074.2
Test
Do other functions fail system test?
Rerun System Test
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
No
Replace solenoid and/or connector
Wire Orn 8-2 broken. Repair or replace
2-57
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.38 DRIVE RIGHT REVERSE SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the Drive Right Reverse Valve PWM output may be shorted to battery or the solenoid may be defective
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Reverse
Step Pretest Instructions
2.38.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.38.2 Disconnect solenoid at X070 and isolate wires
Rerun System Test
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
2.38.3 Remove wire Orn 8-2 from
X074.10
Rerun System Test
No
Wire Orn 8-2 shorted to battery. Repair or replace
2.39 DRIVE RIGHT REVERSE SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Drive module feedback shows that the drive right reverse digital output may be shorted to ground or the relay may be defective.
DRIVE OPTION MACHINES ONLY
Functions Disabled (Drive Option Machines Only): Drive Right Reverse
Step Pretest Instructions
2.39.1 Disconnect solenoid at X070 and isolate wires
2.39.2 Remove wire Orn 8-2 from
X074.10
Test
Rerun System Test
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Orn 8-2 shorted to ground. Repair or replace
2-58
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.40 DUMP SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Dump Valve PWM output may be disconnected or the solenoid may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R)
Step Pretest Instructions
2.40.1
Run system test
Test
Do other functions fail system test?
2.40.2
Rerun System Test
2.40.3
Replace X002.9 with a jumper to X002.14
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
No
Replace solenoid and/or connector
Wire Red/Wht 50-1-1 or Red/Wht 50-
1 broken. Repair or replace
2.41 DUMP SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Dump Valve PWM output may be shorted to battery or the solenoid may be defective
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R)
Step Pretest Instructions
2.41.1 Run system test
2.41.2 Disconnect solenoid at X087 and isolate wires
Test
Do other functions fail system test?
Rerun System Test
2.41.3 Remove wire Red/Wht 50-1-1 from X002.9
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid
Wire Red/Wht 50-1-1 or Red/Wht 50-1 shorted to battery. Repair or replace
2-59
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.42 DUMP SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Dump Valve PWM output may be shorted to ground or the solenoid may be defective
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R)
Step Pretest Instructions
2.42.1 Disconnect solenoid at X087 and isolate wires
Test
Rerun System Test
2.42.2 Remove wire Red/Wht 50-1-1 from X002.9
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Red/Wht 50-1-1 or Red/Wht 50-1 shorted to ground. Repair or replace
2.43 EEPROM FAILURE - CHECK ALL SETTINGS
Distress Lamp: 9 ADE Code: 9-9
The control system detected an internal memory failure. Personalities and Machine Setup settings may be reset to default values.
Functions Disabled: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib Down, Level Up,
Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R), Engine
Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
Possible Causes: 4.1.16, 4.1.10
2.44 ENGINE NOT RUNNING
Distress Lamp: 5 ADE Code: None
The control system does not detect that the engine is running (Engine RPM is Zero AND Machine Setup's POWER is set to
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up,
Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Step Pretest Instructions
2.44.1 Start Engine
2.44.2
Test
ANALYZER -> DIAGNOS-
TICS -> ENGINE SPEED >
0RPM?
Check for continuity between X001.16.soc and
Yes
No
Yes
No
Result Corrective Action
Possible Cause:4.1.21, 4.1.21, 4.1.2,
Repair WHT/YEL 48-7 or WHT/YEL 48-
2-60
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.45 EXTEND O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Extend Outrigger digital output may be disconnected from the relay or the relay may be defective.
Functions Disabled: Set (Extend O/R)
Step Pretest Instructions
2.45.1
Run system test
Test
Do other functions fail system test?
Yes
Result Corrective Action
Possible Cause: Black ground wire
Replace solenoid and/or connector 2.45.2
Rerun System Test
2.45.3
Replace X003.13 with a jumper to X003.3
Rerun System Test
No
Wire Orn/Wht 55-3-1 or Orn/Wht 55-3 broken. Repair or replace
2.46 EXTEND O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Extend Outrigger Valve digital output may be shorted to battery or the solenoid may be defective.
Functions Disabled: Set (Extend O/R)
Step Pretest Instructions
2.46.1 Run system test
Test
Do other functions fail system test?
2.46.2 Disconnect solenoid at X086 and isolate wires
Rerun System Test
2.46.3 Remove wire Orn/Wht 55-3-1 from X003.13
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Orn/Wht 55-3-1 or Orn/Wht 55-3 shorted to battery. Repair or replace
2-61
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.47 EXTEND O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Extend Outrigger Valve digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Set (Extend O/R)
Step Pretest Instructions
2.47.1 Disconnect solenoid at X086 and isolate wires
Test
Rerun System Test
2.47.2 Remove wire Orn/Wht 55-3-1 from X003.13
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Orn/Wht 55-3-1 or Orn/Wht 55-3 shorted to ground. Repair or replace
2.48 FRONT-LEFT O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Left Outrigger digital output may be disconnected from the relay or the relay may be defective.
Functions Disabled: Front Left O/R
Step Pretest Instructions
2.48.1
Run system test
Test
Do other functions fail system test?
2.48.2
Rerun System Test
2.48.3
Replace X003.2 with a jumper to X003.3
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
No
Replace solenoid and/or connector
Wire Orn/Red 49-5 or White wire to
X046 broken. Repair or replace
2-62
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.49 FRONT-LEFT O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Left Outrigger Valve digital output may be shorted to battery or the solenoid may be defective.
Functions Disabled: Front Left O/R
Step Pretest Instructions
2.49.1 Run system test
Test
Do other functions fail system test?
2.49.2 Disconnect solenoid at X046 and isolate wires
Rerun System Test
2.49.3 Remove wire Orn/Red 49-5 from X003.2
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Orn/Red 49-5 or White wire to
X046 shorted to battery. Repair or replace
2.50 FRONT-LEFT O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Left Outrigger Valve digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Front Left O/R
Step Pretest Instructions
2.50.1 Disconnect solenoid at X046 and isolate wires
Test
Rerun System Test
2.50.2 Remove wire Orn/Red 49-5 from X003.2
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Orn/Red 49-5 or White wire to
X046 shorted to ground. Repair or replace
2-63
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.51 FRONT-RIGHT O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Right Outrigger digital output may be disconnected from the relay or the relay may be defective.
Functions Disabled: Front Right O/R
Step Pretest Instructions
2.51.1
Run system test
Test
Do other functions fail system test?
2.51.2
Rerun System Test
2.51.3
Replace X003.6 with a jumper to X003.3
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
No
Replace solenoid and/or connector
Wire Orn/Red 49-6 or White wire to
X047 broken. Repair or replace
2.52 FRONT-RIGHT O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Right Outrigger Valve digital output may be shorted to battery or the solenoid may be defective.
Functions Disabled: Front Right O/R
Step Pretest Instructions
2.52.1 Run system test
Test
Do other functions fail system test?
2.52.2 Disconnect solenoid at X047 and isolate wires
Rerun System Test
2.52.3 Remove wire Orn/Red 49-6 from X003.6
Rerun System Test
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
No
Wire Orn/Red 49-6 or White wire to
X047 shorted to battery. Repair or replace
2-64
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.53 FRONT-RIGHT O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Front-Right Outrigger Valve digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Front Right O/R
Step Pretest Instructions
2.53.1 Disconnect solenoid at X047 and isolate wires
Test
Rerun System Test
2.53.2 Remove wire Orn/Red 49-6 from X003.6
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Orn/Red 49-6 or White wire to
X047 shorted to ground. Repair or replace
2.54 FUNCTION LOCKED OUT - JOYSTICK NOT CENTERED AT STARTUP
Distress Lamp: 1 ADE Code: 2-2
The joystick signal was not at the proper voltage level for neutral (determined from personalities) when the platform was powered.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R)
Step Pretest Instructions Test Result
2.54.1
2.54.2
Does the joystick return to the centered position when moved?
Perform a check of the Joy-
Yes
No
Fault still present after power cycle
2.54.3 Perform the voltmeter joystick
test of 3.10 Joystick Diagnostics while powering the
machine
Using a multimeter, is the voltage between X061.4 and
Yes
No
2.54.4 Perform the voltmeter joystick
test of 3.10 Joystick Diagnostics while powering the
machine
Using a multimeter, is the voltage between X061.3 and
Yes
No
Corrective Action
Possible Causes: 4.1.22, 4.1.11
Possible Causes: 4.1.22, 4.1.11
2-65
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.55 FUNCTION LOCKED OUT - TRIGGER PERMANENTLY CLOSED
Distress Lamp: 1 ADE Code: 2-2
The platform trigger was closed when the platform was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R)
Step
2.55.1
Pretest Instructions
2.55.2 Disconnect X061. Make sure trigger is not engaged.
Test
Is the trigger mechanically stuck?
Pull the ground emergency stop switch and place key switch in platform position
Result
Yes
No
Yes
No
Yes 2.55.4 Place key switch in the platform position and pull the emergency stop switches.
Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM
Does the displayed function selected change as you change the rotatory select switch?
2.55.5 Place key switch in the platform position and pull the emergency stop switches.
Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM
With the rotary selector switch in the platform leveling position which function does the analyzer show is selected?
No
Diagnostic Message “LEVEL
SELECT”
Diagnostic Message “LIFT/
SWING SEL”
Diagnostic Message “JIB/TELE
SELECT”
Corrective Action
Repair or replace the joystick trigger
Repair the Yel/Red 2-17 wire between
X060.6 and X063 or the rotary select switch
Possible Causes: Short in wire Orn/
Possible Causes: Short in wire Orn/
Repair short in wire Orn/Red 49-31
2.56 FUNCTION PROBLEM - ENGINE CHOKE PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-2
The platform engine choke switch was closed when the platform was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
ENGINE POWERED MACHINES ONLY
Functions Disabled at Platform Only: Engine Choke Pull, Engine Choke Hold
Step
2.56.1
Pretest Instructions Test
Is the switch mechanically stuck?
2.56.3 Place key switch in the platform position and pull the emergency stop switches.
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Orn/Red 49-
2-66
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.57 FUNCTION PROBLEM - ENGINE CHOKE PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground engine choke switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
ENGINE POWERED MACHINES ONLY
Functions Disabled: Engine Choke Pull, Engine Choke Hold
Step Pretest Instructions
2.57.1
Test
Is the switch mechanically stuck?
Yes
No
Yes
No
2.57.2 Disconnect X035. Place key switch in ground position and pull the emergency stop switch.
2.57.3 Remove X014.13.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.57.4 Pull the emergency stop switches and place key switch in the ground position
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Wht/Yel 48-
9 wire
Possible Causes: Short in Wht/Yel 48-
2.58 FUNCTION PROBLEM - ENGINE START PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-2
The platform engine start switch was closed when the platform was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
ENGINE POWERED MACHINES ONLY
Functions Disabled at Platform Only: Engine Start, Engine Throttle Pull, Engine Throttle Hold
Step
2.58.1
Pretest Instructions Test
Is the switch mechanically stuck?
Yes
No
Yes
No
Result
2.58.3 Place key switch in the platform position and pull the emergency stop switches.
Yes
No
Corrective Action
Repair or replace the switch
Possible Causes: Short in Wht/Yel 48-
2-67
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.59 FUNCTION PROBLEM - ENGINE START PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground engine start switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
ENGINE POWERED MACHINES ONLY
Functions Disabled: Engine Start, Engine Throttle Pull, Engine Throttle Hold
Step
2.59.1
Pretest Instructions Test
Is the switch mechanically stuck?
2.59.2 Disconnect X036. Place key switch in ground position and pull the emergency stop switch.
2.59.3 Remove X014.14.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.59.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Wht/Yel 48-
1 wire
Possible Causes: Short in Wht/Yel 48-
2.60 FUNCTION PROBLEM - JIB DOWN PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground jib down switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
T500J MODELS ONLY
Functions Disabled at Ground Only: Jib Down
Step Pretest Instructions
2.60.1
Test
Is the switch mechanically stuck?
2.60.2 Disconnect X032. Place key switch in ground position and pull the emergency stop switch.
2.60.3 Remove X014.24.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.60.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Blue 28-2 wire
Possible Causes: Short in Blue 28-2-1
2-68
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.61 FUNCTION PROBLEM - JIB UP AND DOWN BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both jib up and jib down ground panel switches are active.
T500J MODELS ONLY
Functions Disabled at Ground Only: Jib Up, Jib Down
Step Pretest Instructions Test
2.61.2 Disconnect X014. Hold the enable switch.
Yes
No
Yes
2.61.3 Disconnect X014. Hold the enable switch.
2.61.4 Remove X004.19.soc from
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: Short in Blue 27-2 wire.
Possible Causes: Short in Blue 28-2 wire.
Possible Causes: Short in Blue 27-2-1 wire or Blue 28-2-1 wire
2.62 FUNCTION PROBLEM - JIB UP PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground jib up switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
T500J MODELS ONLY
Functions Disabled at Ground Only: Jib Up
Step Pretest Instructions
2.62.1
Test
Is the switch mechanically stuck?
2.62.2 Disconnect X032. Place key switch in ground position and pull the emergency stop switch.
2.62.3 Remove X014.25.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.62.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Blue 27-2 wire
Possible Causes: Short in Blue 27-2-1
2-69
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.63 FUNCTION PROBLEM - LEVEL DOWN PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground level down switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Level Down
Step Pretest Instructions
2.63.1
Test
Is the switch mechanically stuck?
2.63.2 Disconnect X034. Place key switch in ground position and pull the emergency stop switch.
2.63.3 Remove X014.26.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.63.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Pink 26-2 wire
Possible Causes: Short in Pink 26-2-1
2.64 FUNCTION PROBLEM - LEVEL UP AND DOWN BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both level up and level down ground panel switches are active.
Functions Disabled at Ground Only: Level Up, Level Down
Step Pretest Instructions Test
2.64.2 Disconnect X014. Hold the enable switch.
Yes
No
Yes
No
2.64.3 Disconnect X014. Hold the enable switch.
Yes
2.64.4 Remove X004.17.soc from
No
Yes
No
Result Corrective Action
Possible Causes: Short in Pink 25-2 wire.
Possible Causes: Short in Pink 26-2 wire.
Possible Causes: Short in Pink 25-2-1 wire or Pink 26-2-1 wire
2-70
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.65 FUNCTION PROBLEM - LEVEL UP PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground level up switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Level Up
Step Pretest Instructions
2.65.1
Test
Is the switch mechanically stuck?
2.65.2 Disconnect X034. Place key switch in ground position and pull the emergency stop switch.
2.65.3 Remove X014.27.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.65.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Pink 25-2 wire
Possible Causes: Short in Pink 25-2-1
2.66 FUNCTION PROBLEM - LIFT DOWN PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground lift down switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Lift Down
Step Pretest Instructions
2.66.1
Test
Is the switch mechanically stuck?
2.66.2 Disconnect X031. Place key switch in ground position and pull the emergency stop switch.
2.66.3 Remove X014.22.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.66.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Tan 4-2 wire
Possible Causes: Short in Tan 4-2-1
2-71
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.67 FUNCTION PROBLEM - LIFT UP AND DOWN BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both lift up and lift down ground panel switches are active.
Functions Disabled at Ground Only: Lift Up, Lift Down
Step Pretest Instructions Test
2.67.2 Disconnect X014. Hold the enable switch.
2.67.3 Disconnect X014. Hold the enable switch.
2.67.4 Remove X004.23.soc from
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: Short in Tan 3-2 wire.
Possible Causes: Short in Tan 4-2 wire.
Possible Causes: Short in Tan 3-2-1 wire or Tan 4-2-1 wire
2.68 FUNCTION PROBLEM - LIFT UP PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground lift up switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Lift Up
Step Pretest Instructions
2.68.1
Test
Is the switch mechanically stuck?
2.68.2 Disconnect X031. Place key switch in ground position and pull the emergency stop switch.
2.68.3 Remove X014.23.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.68.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Tan 3-2 wire
Possible Causes: Short in Tan 3-2-1
2-72
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.69 FUNCTION PROBLEM - OUTRIGGER SET AND STOW BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both O/R stow and O/R set ground panel switches are active.
Functions Disabled: Set (Extend O/R), Stow (Retract O/R)
Step Pretest Instructions Test
Yes
No
2.69.2 Disconnect X014. Hold the enable switch.
Yes
2.69.3 Disconnect X014. Hold the enable switch.
2.69.4 Remove X004.20.soc from
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: Short in Orn/Wht 55-
2 wire.
Possible Causes: Short in Orn/Wht 55-
1 wire.
Possible Causes: Short in Orn/Wht 55-
2-1 wire or Orn/Wht 55-1-1 wire
2.70 FUNCTION PROBLEM - OUTRIGGER SET PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground O/R Set switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Set (Extend O/R)
Step Pretest Instructions
2.70.1
Test
Is the switch mechanically stuck?
2.70.2 Disconnect X023. Place key switch in ground position and pull the emergency stop switch.
X014. Place key switch in ground position and pull the emergency stop switch.
2.70.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Orn/Wht 55-
2 wire
Possible Causes: Short in Orn/Wht 55-
2-73
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.71 FUNCTION PROBLEM - OUTRIGGER STOW PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground Outrigger Stow switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Stow (Retract O/R)
Step
2.71.1
Pretest Instructions
2.71.2 Disconnect X023. Place key switch in ground position and pull the emergency stop switch.
X014. Place key switch in ground position and pull the emergency stop switch.
2.71.4 Place key switch in ground position and pull the emergency stop switch.
Test
Is the switch mechanically stuck?
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Orn/Wht 55-
1 wire
Possible Causes: Short in Orn/Wht 55-
2.72 FUNCTION PROBLEM - ROTARY SELECTOR SWITCH
Distress Lamp: 9 ADE Code: 2-2
More than one of the three digital inputs from the platform rotary selector switch are active. Only one of the inputs should be active at one time to indicate the selected mode.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R)
Step Pretest Instructions Test Result
present?
2.72.2 Place key switch in the platform position and pull the emergency stop switches.
Turn the selector switch to the center position, Lift/Swing.
While holding the enable switch, check Level, Lift/SW, and JIB/Tele switches for
“Closed” status in ANA-
LYZER -> DIAGNOSTICS ->
PLATFORM
Yes
No
LIFT/SW CLOSED and LEVEL
CLOSED
LIFT/SW CLOSED and JIB/TELE
CLOSED
Any other combination
2.72.3 Place key switch in the platform position and pull the emergency stop switches.
Turn the selector switch to the right position, JIB/Tele
While holding the enable switch, check Level, Lift/SW, and JIB/Tele switches for
“Closed” status in ANA-
LYZER -> DIAGNOSTICS ->
PLATFORM
JIB/TELE CLOSED and LEVEL
CLOSED
JIB/TELE CLOSED and LIFT/SW
CLOSED
Any other combination
Corrective Action
Possible Causes: Short in Orn/Red 49-
Possible Causes: Short in Orn/Red 49-
Possible Causes: Short in Orn/Red 49-
Possible Causes: Short in Orn/Red 49-
2-74
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
When Rotary Select Switch is turned to the “LEVEL” position, the circuit is completed to
X060.9
When Rotary Select Switch is centered in the “LIFT/SWING” position the circuit is completed to X060.10
When Rotary Select Switch is turned to the “TELE/JIB” position, the circuit is completed to X060.15
Level Tele/Jib
X063
1 2 3 4 5 6
Level
X060.9 Orn/
Red 49-27
Input from
Trigger Switch
X061.6 Yel/
Red 2-17
Lift/Swing
X060.10 Orn/
Red 49-28
Figure 2-1. Platform Rotary Select Switch
Tele/Jib
X060.15 Orn/
Red 49-29
2.73 FUNCTION PROBLEM - SWING LEFT AND RIGHT BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both swing left and swing right ground panel switches are active.
Functions Disabled at Ground Only: Swing Left, Swing Right
Step Pretest Instructions Test
2.73.2 Disconnect X014. Hold the enable switch.
2.73.3 Disconnect X014. Hold the enable switch.
Yes
No
Yes
No
Yes
2.73.4 Remove X004.35.soc from
No
Yes
No
Result Corrective Action
Possible Causes: Short in White 22-2 wire.
Possible Causes: Short in White 21-2 wire.
Possible Causes: Short in White 22-2-
1 wire or White 21-2-1 wire
2-75
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.74 FUNCTION PROBLEM - SWING LEFT PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground swing left switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Swing Left
Step Pretest Instructions
2.74.1
Test
Is the switch mechanically stuck?
2.74.2 Disconnect X024. Place key switch in ground position and pull the emergency stop switch.
2.74.3 Remove X014.19.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.74.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in White 21-2 wire
Possible Causes: Short in White 21-2-
2.75 FUNCTION PROBLEM - SWING RIGHT PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground swing right switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Swing Right
Step Pretest Instructions
2.75.1
Test
Is the switch mechanically stuck?
2.75.2 Disconnect X024. Place key switch in ground position and pull the emergency stop switch.
2.75.3 Remove X014.18.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.75.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in White 22-2 wire
Possible Causes: Short in White 22-2-
2-76
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.76 FUNCTION PROBLEM - TELESCOPE IN AND OUT BOTH SELECTED
Distress Lamp: 9 ADE Code: 2-3
The digital inputs from both telescope in and telescope out ground panel switches are active.
Functions Disabled at Ground Only: Telescope In, Telescope Out
Step Pretest Instructions Test
2.76.2 Disconnect X014. Hold the enable switch.
2.76.3 Disconnect X014. Hold the enable switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: Short in Brown 13-2 wire.
Possible Causes: Short in Brown 14-2 wire.
Possible Causes: Short in Brown 13-
2-1 wire or Brown 14-2-1 wire
2.77 FUNCTION PROBLEM - TELESCOPE IN PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground telescope in switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Telescope In
Step Pretest Instructions
2.77.1
Test
Is the switch mechanically stuck?
2.77.2 Disconnect X033. Place key switch in ground position and pull the emergency stop switch.
2.77.3 Remove X014.20.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.77.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Brown 13-2 wire
Possible Causes: Short in Brown 13-
2-77
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.78 FUNCTION PROBLEM - TELESCOPE OUT PERMANENTLY SELECTED
Distress Lamp: 1 ADE Code: 2-3
The ground telescope out switch was closed when the machine was powered. The switch could be accidentally held, mechanically stuck, or electrically shorted.
Functions Disabled at Ground Only: Telescope Out
Step Pretest Instructions
2.78.1
Test
Is the switch mechanically stuck?
2.78.2 Disconnect X033. Place key switch in ground position and pull the emergency stop switch.
2.78.3 Remove X014.21.pin from
X014. Place key switch in ground position and pull the emergency stop switch.
2.78.4 Place key switch in ground position and pull the emergency stop switch.
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace the switch
Possible Causes: Short in Brown 14-2 wire
Possible Causes: Short in Brown 14-
2.79 FUNCTIONS AT CUTBACK - POWER MODULE CURRENT LIMIT
Distress Lamp: 4 ADE Code: 4-2
The Power Module is approaching its thermal limit and must reduce output to continue operation. The Power Module LED is
ELECTRIC POWERED MACHINES ONLY
All Functions Operable, but output from power module is at reduced power
Possible Causes: 4.1.1, 4.1.39, 4.1.12
2.80 FUNCTIONS LOCKED OUT - CONSTANT DATA VERSION IMPROPER
Distress Lamp: 9 ADE Code: 9-9
Ground Module detected that the Application's Constant Data Version did not match the version embedded in Constant
Data's Flash Structure. The control system may resume operation once the difficulty has been corrected
Functions Disabled: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib Down, Level Up,
Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R), Engine
Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
2.81 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER
Distress Lamp: 9 ADE Code: 9-9
The Platform Module reported a Software Major Version that was not compatible with the rest of the system. The control system may resume operation once the difficulty has been corrected.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R), Engine Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
Possible Causes: 4.1.13, 4.1.11
2-78
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.82 FUNCTIONS LOCKED OUT - POWER MODULE SOFTWARE VERSION IMPROPER
Distress Lamp: 9 ADE Code: 9-9
The Power Module reported a Software Major Version that was not compatible with the rest of the system. The control system may resume operation once the difficulty has been corrected.
ELECTRIC POWERED MACHINES ONLY
Functions Disabled: Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up, Level Down, Front Left
O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Possible Causes: 4.1.13, 4.1.12
2.83 GROUND ALARM SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the ground alarm PWM output may be shorted to battery or another function
All Functions Operable
Step Pretest Instructions Test
2.83.1 Disconnect alarm at X028 and isolate wires
Is the fault removed?
2.83.2 Remove X014.17 from X014
Is the fault removed?
2.83.3 Remove X002.19 from X002
Is the fault removed?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Wire Orn/Red 49-11 or black ground wire shorted to battery. Repair or replace
Wire Orn/Red 49-11-1 shorted to battery. Repair or replace
2.84 GROUND ALARM SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that ground alarm PWM output may be shorted to ground or the solenoid may be defective
All Functions Operable
Step Pretest Instructions Test
2.84.1 Disconnect alarm at X028 and isolate wires
Is the fault removed?
2.84.2 Remove X014.17 from X014
Is the fault removed?
2.84.3 Remove X002.19 from X002
Is the fault removed?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Wire Orn/Red 49-11 or black ground wire shorted to ground. Repair or replace
Wire Orn/Red 49-11-1 shorted to ground. Repair or replace
2-79
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.85 GROUND MODULE FAILURE: REF VOLTAGE OUT OF RANGE
Distress Lamp: 9 ADE Code: 9-9
The Ground Module has detected that the +7V reference voltage source is out of range. This may be caused by a wiring short to one of the reference voltage pins on the Ground Module, or by a faulty Ground Module
All Functions Operable
2.86 GROUND MODULE FAILURE: VLOW FET FAILURE
Distress Lamp: 9 ADE Code: 9-9
The control system will not function because the Ground Module has experienced a hardware failure that prevents it from reading High-Sensing Digital Inputs.
Functions Disabled: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib Down, Level Up,
Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R), Engine
Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
2.87 HOURMETER SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the hourmeter output may be shorted to battery or another function
(Open Circuit and Short to Ground detection are disabled since they cannot be detected reliably with this style load)
All Functions Operable
Possible Causes: Short in Brn/Wht 47-7-1, Short in Brn/Wht 47-7, 4.1.24, 4.1.10
2.88 JIB DOWN SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Jib Down PWM output may be disconnected or the solenoid may be defective.
T500J MODELS ONLY
Functions Disabled: Jib Down
Step Pretest Instructions
Test
Is the fault removed?
Is the fault removed?
2.88.4 Short X002.20.pin to B-
Is the fault removed?
Is the fault removed?
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair/Replace solenoid
Yel/Blk or Brn/Blk boom wire broken between X055 and X056. Repair or replace
Yel/Blk or Brn/Blk boom wire broken
between X019 and X055. Repair or replace
Blue 28-3-1 or black wire broken between X002 and X019. Repair or replace
2-80
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.89 JIB DOWN SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Lift Down PWM output may be shorted to battery or other function
T500J MODELS ONLY
Functions Disabled: Jib Down
Step Pretest Instructions
2.89.1 Disconnect solenoid at X056 and isolate wires
Test
Rerun System Test
2.89.2 Remove wire Blue 28-3-1 from X002.20
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Blue 28-3-1 or Yel/Blk boom wire shorted to battery. Repair or replace
2.90 JIB DOWN SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Jib Down PWM output may be shorted to ground or the solenoid may be defective
T500J MODELS ONLY
Functions Disabled: Jib Up
Step Pretest Instructions
2.90.1 Disconnect solenoid at X056 and isolate wires
Test
Rerun System Test
2.90.2 Remove wire Blue 28-3-1 from X002.20
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Blue 28-3-1 or Blue 28-3 shorted to ground. Repair or replace
2-81
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.91 JIB UP SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Jib Up digital output may be disconnected or the solenoid may be defective.
T500J MODELS ONLY
Functions Disabled: Jib Up
Step Pretest Instructions
2.91.1
Run system test
Test
Do other functions fail system test?
2.91.2
2.91.3
Replace X002.12 with a jumper to X002.14
Rerun System Test
Rerun System Test
Result Corrective Action
Yes
Possible Causes: Black ground wire from X002.14 broken, 4.1.1 otherwise
No
Analyzer Message “JIB UP VALVE
Replace solenoid and/or connector
Analyzer Message “JIB UP VALVE
Analyzer Message “JIB UP VALVE
Analyzer Message “JIB UP VALVE
Wire Blue 27-3-1 or Blue 27-3 broken.
Repair or replace
2.92 JIB UP SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Jib Up digital output may be shorted to battery or other function
T500J MODELS ONLY
Functions Disabled: Jib Up
Step Pretest Instructions
2.92.1 Run system test
Test
Do other functions fail system test?
2.92.2 Disconnect solenoid at X079 and isolate wires
Rerun System Test
2.92.3 Remove wire Blue 27-3-1 from X002.12
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Analyzer Message “JIB UP VALVE
Replace solenoid
Analyzer Message “JIB UP VALVE
Analyzer Message “JIB UP VALVE
Wire Blue 27-3-1 or Blue 27-3 shorted to battery. Repair or replace
Analyzer Message “JIB UP VALVE
2-82
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.93 JIB UP SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Jib Up digital output may be shorted to ground or the solenoid may be defective
T500J MODELS ONLY
Functions Disabled: Jib Up
Step Pretest Instructions
2.93.1 Disconnect solenoid at X079 and isolate wires
Test
Rerun System Test
2.93.2 Remove wire Blue 27-3-1 from X002.12
Rerun System Test
Result Corrective Action
Analyzer Message “JIB UP VALVE
Repair/Replace solenoid
Analyzer Message “JIB UP VALVE
Analyzer Message “JIB UP VALVE
Wire Blue 27-3-1 or Blue 27-3 shorted to ground. Repair or replace
Analyzer Message “JIB UP VALVE
2.94 JOYSTICK FAULTY - X AXIS WIPER OUT OF RANGE
Distress Lamp: 9 ADE Code: 2-2
The joystick X-axis (side to side when facing the console) wiper signal input is outside the acceptable voltage range. The wiper wire being off, the wiper wire shorted to B+, or the wiper wire shorted to B- (ground) could cause this difficulty
Functions Disabled at Platform Only: Swing Left, Swing Right, Telescope In, Telescope Out, Front Left O/R, Front Right O/R,
Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Step Pretest Instructions Test
2.94.1
2.94.2 Hold the joystick at the left extent. Using the analyzer, navigate to DIAGNOSTICS ->
PLATFORM -> X-JOYSTK
Does the joystick return to the centered position when moved?
Is the X-Joystk Voltage between 0.75 and 2.25
Volts?
2.94.3 Hold the joystick at the right extent. Using the analyzer, navigate to DIAGNOSTICS ->
PLATFORM -> X-JOYSTK
Is the X-Joystk Voltage between 2.75 and 4.25
Volts?
2.94.4 Place key switch in platform position and pull the emergency stop switches.
2.94.5 Disconnect X061. Place key switch in platform position and pull the emergency stop switches.
2.94.6 Place key switch in platform position and pull the emergency stop switches.
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Cause: 4.1.26, 4.1.23
Possible Cause: Short or Open in Yel/
Red 2-18 or Black joystick ground,
Possible Cause: Short or Open in Orn/
Red 49-22
2-83
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.95 JOYSTICK FAULTY - Y AXIS WIPER OUT OF RANGE
Distress Lamp: 9 ADE Code: 2-2
The joystick Y-axis (fore and aft when facing the console) wiper signal input is outside the acceptable voltage range. The wiper wire being off, the wiper wire shorted to B+, or the wiper wire shorted to B- (ground) could cause this difficulty
Functions Disabled at Platform Only: Lift Up, Lift Down, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right
O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Step Pretest Instructions Test
2.95.1
2.95.5 Disconnect X061. Place key switch in platform position and pull the emergency stop switches.
Does the joystick return to the centered position when moved?
2.95.2 Hold the joystick at the forward extent. Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM -> Y-JOYSTK
2.95.3 Hold the joystick at the rear extent. Using the analyzer, navigate to DIAGNOSTICS ->
PLATFORM -> Y-JOYSTK
2.95.4 Place key switch in platform position and pull the emergency stop switches.
Is the Y-Joystk Voltage between 0.75 and 2.25
Volts?
Is the Y-Joystk Voltage between 2.75 and 4.25
Volts?
2.95.6 Place key switch in platform position and pull the emergency stop switches.
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Cause: 4.1.26, 4.1.23
Possible Cause: Short or Open in Yel/
Red 2-18 or Black joystick ground,
Possible Cause: Short or Open in Orn/
Red 49-21
2-84
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.96 JOYSTICK MOVED BUT TRIGGER SWITCH OPEN
Distress Lamp: 1 ADE Code: None
The platform module senses the joystick is out of center, but did not first sense the trigger switch. This could be due to improper operation or a problem with the trigger switch, joystick, or rotary function select switch.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R)
Step Pretest Instructions Test
2.96.1
Was the trigger closed before moving the joystick?
Yes
No
2.96.2
Was the joystick moved out of the center position?
2.96.3 Place key switch in platform position and pull the emergency stop switches. Engage and hold the trigger.
2.96.4 Place key switch in the platform position and pull the emergency stop switches.
Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM
With the rotary select switch in the LIFT/SW position and trigger engaged, does the
Diagnostic Message read
“LIFT/SWING SEL”?
Yes
No
Yes
No
Yes
No
2.96.5 Place key switch in the platform position and pull the emergency stop switches.
Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM
With the rotary select switch in the JIB/TELE position and trigger engaged, does the
Diagnostic Message read
“JIB/TELE SELECT”?
Yes
No
2.96.6 Place key switch in the platform position and pull the emergency stop switches.
Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM
With the rotary select switch in the LEVEL position and trigger engaged, does the
Diagnostic Message read
“LEVEL SELECT”?
2.96.7 Place key switch in platform position and pull the emergency stop switches.
Yes
No
Yes
No
2.96.8 Disconnect X061. Engage and hold the trigger.
Yes
No
Result Corrective Action
Cycle power and try again
Possible Cause: 4.1.18, broken wire
Orn/Red 49-28
Possible Cause: 4.1.18, broken wire
Orn/Red 49-29
Possible Cause: 4.1.18, broken wire
Orn/Red 49-27
Possible Cause: Open in wire Yel/Red
2-19
Possible Cause: Open in wire Yel/Red
2-17
2-85
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.97 KEYSWITCH FAULTY
Distress Lamp: 9 ADE Code: 2-1
The control system will default to Ground Mode.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R), Engine Start, Engine Throttle Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold
Step Pretest Instructions Test
2.97.1 Extract X014.15. Switch Key to Ground Mode and pull the ground emergency stop switch
2.97.2 Extract X014.15. Switch Key to Ground Mode and pull the ground emergency stop switch
Is the fault removed?
Ground Mode and pull the ground emergency stop switch
Is the fault removed?
2.97.4 Extract X019.6. Switch Key to
Ground Mode and pull the ground emergency stop switch
Is the fault removed?
2.97.5 Extract X007.1. Switch Key to
Ground Mode and pull the ground emergency stop switch
Is the fault removed?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Replace or repair select switch in ground panel
Replace or repair Yel/Red 2-4 wire
Possible Causes: Short in Yel/Red 2-4 or Orange or Yellow Boom wires
Possible Causes: Short in Yel/Red 2-
Possible Causes: Short in Yel/Red 2-
2-86
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.98 LEVEL DOWN SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Platform Level Down digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Level Down
Step Pretest Instructions
2.98.1
Run system test
Test
Do other functions fail system test?
2.98.2
Rerun System Test
Yes
Result Corrective Action
Possible Causes: Black ground wire
Replace solenoid and/or connector
2.98.3
Replace X002.7 with a jumper to X002.14
Rerun System Test
No
Wire Pink 26-3-1 or Pink 26-3 broken.
Repair or replace
2.99 LEVEL DOWN SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Platform Level Down digital output may be shorted to battery or other function
Functions Disabled: Level Down
Step Pretest Instructions
2.99.1 Run system test
Test
Do other functions fail system test?
2.99.2 Disconnect solenoid at X081 and isolate wires
Rerun System Test
2.99.3 Remove wire Pink 26-3-1 from X002.7
Rerun System Test
Yes
Result
No
Corrective Action
Possible Causes: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Pink 26-3-1 or Pink 26-3 shorted to battery. Repair or replace
2-87
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.100 LEVEL DOWN SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Platform Level Down digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Level Down
Step Pretest Instructions
2.100.1 Disconnect solenoid at X081 and isolate wires
Test
Rerun System Test
2.100.2 Remove wire Pink 26-3-1 from X002.7
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Pink 26-3-1 or Pink 26-3 shorted to ground. Repair or replace
2.101 LEVEL UP SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Platform Level Up digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Level Up
Step Pretest Instructions
2.101.1 Run system test
Test
Do other functions fail system test?
Rerun System Test
2.101.3 Replace X002.5 with a jumper to X002.14
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
Wire Pink 25-3-1 or Pink 25-3 broken.
Repair or replace
2-88
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.102 LEVEL UP SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Platform Level Up digital output may be shorted to battery or other function
Functions Disabled: Level Up
Step Pretest Instructions
2.102.1 Run system test
Test
Do other functions fail system test?
2.102.2 Disconnect solenoid at X080 and isolate wires
Rerun System Test
2.102.3 Remove wire Pink 25-3-1 from X002.5
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Pink 25-3-1 or Pink 25-3 shorted to battery. Repair or replace
Repair/Replace wire Pink 25-3-1
2.103 LEVEL UP SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Platform Level Up digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Level Up
Step Pretest Instructions
2.103.1 Disconnect solenoid at X080 and isolate wires
Test
Rerun System Test
2.103.2 Remove wire Pink 25-3-1 from X002.5
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Pink 25-3-1 or Pink 25-3 shorted to ground. Repair or replace
2-89
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.104 LIFT DOWN PREVENTED - TELE IN FIRST
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the controls in the lift down position, but the boom telescope limit switch is open and
telescoped in, closing the telescope limit switch, before the boom can be lowered.
Functions Disabled: Lift Down
Step Pretest Instructions
2.104.1
2.104.2
2.104.3
2.104.4
Test
Is the boom fully retracted?
Yes
Is the machine tilted more than 4.5 degrees?
No
Yes
Have any outriggers come unset?
No
Yes
No
Yes ANALYZER ->DIAGNOS-
TICS -> SYSTEM -> TILT
>= 4.5 DEG (platform tilt
LED illuminated)
No
Result Corrective Action
See 3.15 Telescope Limit Switch
Retract the boom before lowering
Retract the boom before lowering
See 3.11 Outrigger Switches - All Set
2.105 LIFT DOWN SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Lift Down PWM output may be disconnected or the solenoid may be defective.
Functions Disabled: Lift Down
Step Pretest Instructions
Test
Is the fault removed?
Is the fault removed?
2.105.3 Short X002.22.pin to B-
Is the fault removed?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair/Replace solenoid
Tan 4-3 or black wire broken between
X016 and X039. Repair or replace
Tan 4-3-1 or black wire broken between X002 and X016. Repair or replace
2-90
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.106 LIFT DOWN SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Lift Down PWM output may be shorted to battery or other function
Functions Disabled: Lift Down
Step Pretest Instructions
2.106.1 Disconnect solenoid at X039 and isolate wires
Test
Rerun System Test
2.106.2 Remove wire Tan 4-3-1 from
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Tan 4-3-1 or Tan 4-3 shorted to battery. Repair or replace
2.107 LIFT DOWN SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Lift Down PWM output may be shorted to ground or the solenoid may be defective
Functions Disabled: Lift Down
Step Pretest Instructions
2.107.1 Disconnect solenoid at X039 and isolate wires
Test
Rerun System Test
2.107.2 Remove wire Tan 4-3-1 from
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Tan 4-3-1 or Tan 4-3 shorted to ground. Repair or replace
2.108 LIFT UP & TELE OUT PREVENTED - TILTED & ABOVE ELEVATION
Distress Lamp: 2 ADE Code: 2-5
active, the boom cannot be lifted up or telescoped out any further to prevent further destabilization.
Functions Disabled: Lift Up, Telescope Out
Step Pretest Instructions
2.108.1
2.108.2
Test
Is the machine tilted more than 4.5 degrees?
ANALYZER -> DIAGNOS-
TICS -> SYSTEM -> TILT
>= 4.5 DEG (platform tilt
LED illuminated)
Yes
No
Yes
No
Result Corrective Action
Retract, lower the boom and level the machine before lifting or telescoping out.
2-91
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.109 LIFT UP & TELE OUT PREVENTED - TILTED,UNSET,& ABOVE ELEVATION
Distress Lamp: 2 ADE Code: 2-5
further to prevent further destabilization.
Functions Disabled: Lift Up, Telescope Out
Step Pretest Instructions
2.109.1
2.109.2
2.109.3
Test
Is the machine tilted more than 2 degrees?
Yes
ANALYZER -> DIAGNOS-
TICS -> SYSTEM -> TILT
>= 2 DEG (platform tilt LED illuminated)
Have any outriggers come unset?
No
Yes
No
Yes
No
Result Corrective Action
Retract, lower the boom and level the machine before lifting or telescoping out.
See 3.11 Outrigger Switches - All Set
2.110 LIFT UP & TELE OUT PREVENTED - UNSET & ABOVE ELEVATION
Distress Lamp: 2 ADE Code: 2-5
any further to prevent further destabilization.
Functions Disabled: Lift Up, Telescope Out
Step Pretest Instructions
2.110.1
2.110.2
Test
Is the boom elevated?
Yes
No
Are any outriggers unset?
Yes
No
Result Corrective Action
Retract, lower the boom and level the machine before trying again
See 3.11 Outrigger Switches - All Set
2.111 LIFT UP PREVENTED - CHECK OUTRIGGERS
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the control in the lift up position, but the machine is elevated and all four outriggers are unset. If all four outriggers are unset, the control system allows lift up to function up to the elevation switch point for moving the platform to a safe position for boarding. Once the boom lifts beyond the transport switch position, opening the transport switch, lift up is prevented. Lift down will operate at creep speed till back in transport position. Lift down, set the outriggers, and level the machine before attempting to lift beyond the transport switch position.
Functions Disabled: Lift Up
Step Pretest Instructions
2.111.1
Test
Is the boom elevated?
Yes
No
Result Corrective Action
See 2.110 Lift Up & Tele Out Prevented
2-92
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.112 LIFT UP PREVENTED - LIFT DOWN THEN SET OUTRIGGERS
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the controls in the lift up position, but the platform is stowed and the outriggers are not completely set or stowed. Lift up is prevented until all outriggers are either set or stowed. While outriggers are stowed, functions should only be used for aligning the boom for transport.
Functions Disabled: Lift Up
Step Pretest Instructions
2.112.1
2.112.2
Test
Are all outriggers set?
Yes
No
Are all outriggers stowed?
Yes
2.112.3
Are you attempting to align the boom for transport?
No
Yes
No
Result Corrective Action
See 3.11 Outrigger Switches - All Set
See 3.12 Outrigger Switches - All
Stow all outriggers and try again
Set all outriggers and try again
2.113 LIFT UP PREVENTED - TILTED
Distress Lamp: 2 ADE Code: 2-5
Lift Up is being attempted while the Platform is Stowed, all four Outriggers are Set, but the vehicle is Tilted.
The ground module senses the controls in the lift up position, the platform is stowed and the outriggers are all set, but the vehicle is tilted. Lift up is prevented until all outriggers are either set or stowed. While outriggers are stowed, functions should only be used for aligning the boom for transport.
Functions Disabled: Lift Up
Step Pretest Instructions
2.113.1
2.113.2
Test
Is the machine tilted more than 2 degrees?
Yes
Analyzer DIAGNOSTICS ->
SYSTEM -> TILT >= 2 DEG
(platform tilt LED illuminated)
No
Yes
No
Result Corrective Action
Level the machine and try again
2-93
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.114 LIFT UP SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Lift Up digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Lift Up
Step Pretest Instructions
2.114.1 Run system test
Test
Do other functions fail system test?
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
2.114.2 Disconnect solenoid at X084.
Rerun System Test
2.114.3 Replace X002.11 with a jumper to X002.14
Rerun System Test
No
Wire Tan 3-3-1 or Tan 3-3 broken.
Repair or replace
2.115 LIFT UP SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Lift Up digital output may be shorted to battery or other function
Functions Disabled: Lift Up
Step Pretest Instructions
2.115.1 Run system test
Test
Do other functions fail system test?
2.115.2 Disconnect solenoid at X084 and isolate wires
Rerun System Test
2.115.3 Remove wire Tan 3-3-1 from
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Tan 3-3-1 or Tan 3-3 shorted to battery. Repair or replace
Repair/Replace wire Tan 3-3-1
2-94
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.116 LIFT UP SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that Lift Up digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Lift Up
.
Step Pretest Instructions
2.116.1 Disconnect solenoid at X084 and isolate wires
Test
Rerun System Test
2.116.2 Remove wire Tan 3-3-1 from
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Tan 3-3-1 or Tan 3-3 shorted to ground. Repair or replace
2.117 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS
Distress Lamp: 2 ADE Code: 2-5
The user changed the Model Selection using the JLG Analyzer. All functions are being prevented until the EMS is cycled.
Functions Disabled: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib Down, Level Up,
Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
2.118 NO CHARGE SYSTEM OUTPUT
Distress Lamp: 3 ADE Code: 4-3
The engine has been running for at least 15 seconds and the battery voltage is still below 11.5V (except when operating Outriggers).
ENGINE POWERED MACHINES ONLY
Functions Disabled (Electric Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope
Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/
R), Stow (Retract O/R)
Step Pretest Instructions
2.118.1
Test
Does the electric start work? Yes
No
Result Corrective Action
Possible Cause: 4.1.4, 4.1.3, 4.1.29,
2-95
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.119 OPEN-CIRCUIT PUMP MOTOR WIRING
Distress Lamp: 9 ADE Code: 7-7
The Power Module detected an error in the Pump Motor Wiring. Check power wiring and re-cycle power to clear difficulty.
Alternately, there may be an issue (open field, armature, or brush) with the Motor.
Functions Disabled: Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Level Up, Level Down, Front Left
O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R), Engine Start, Engine Throttle
Pull, Engine Throttle Hold, Engine Choke Pull, Engine Choke Hold, Drive
Step Pretest Instructions
2.119.1
Test
While operating Lift Up, is the
Yes
No
Result Corrective Action
See Open-Circuit Pump Motor in 3.3
DC Powered Machine - Power Module
See 3.3 DC Powered Machine - Power
2.120 OPTIONAL GROUND ALARM SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the optional ground alarm PWM output may be shorted to battery or another function
All Functions Operable
Step Pretest Instructions Test
2.120.1 Disconnect alarm at X050 and isolate wires
Is the fault removed?
2.120.2 Remove X017.4 from X017
Is the fault removed?
2.120.3 Remove X002.8 from X002
Is the fault removed?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Wire Yel/Red 2-13 or black ground wire
between X017 and X050 shorted to battery. Repair or replace
Wire Yel/Red 2-13 between X017 and
X002 shorted to battery. Repair or replace
2.121 OPTIONAL GROUND ALARM SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that optional ground alarm PWM output may be shorted to ground or the solenoid may be defective
All Functions Operable
Step Pretest Instructions Test
2.121.1 Disconnect alarm at X050 and isolate wires
Is the fault removed?
2.121.2 Remove X017.4 from X017
Is the fault removed?
2.121.3 Remove X002.8 from X002
Is the fault removed?
Yes
No
Yes
No
Yes
No
Result Corrective Action
Wire Yel/Red 2-13 or black ground wire shorted to ground. Repair or replace
Wire Yel/Red 2-13 shorted to ground.
Repair or replace
2-96
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.122 OUTRIGGER STOW PREVENTED - TELE IN FIRST
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the ground panel outrigger switch is in the stow position, but the boom telescope limit switch is open. The boom must be completely telescoped in, closing the telescope limit switch, before the outriggers can be stowed.
Functions Disabled: Stow (Retract O/R)
Step Pretest Instructions
2.122.1
Test
Is the boom fully retracted?
Yes
No
Result Corrective Action
See 3.15 Telescope Limit Switch
Retract the boom
2.123 OUTRIGGERS PREVENTED - ELEVATED
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the ground panel outrigger switch is in the set or stow position, but the boom transport limit switch is open. The boom must be completely lowered into transport position, closing the transport limit switch, before the outriggers can be moved.
Functions Disabled: Set (Extend O/R)
Step Pretest Instructions
2.123.1
Test
Is the boom fully lowered?
Yes
No
Result Corrective Action
See 3.17 Transport Limit Switch
Lower the boom
2.124 PLATFORM POSITION DETECTION FAULTY
Distress Lamp: 9 ADE Code: 2-1
Ground Module and wiring within the Platform Console.
Functions in Creep Mode: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out
Step Pretest Instructions Test
2.124.1 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Cause: Orn/Red 49-9
Possible Cause: Shorted Blu/Blk
2-97
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
Step Pretest Instructions Test
2.124.6 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
2.124.7 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
2.124.8 With t he console in the platform position, pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Cause: Shorted Blu/Blk between X058 and X054
Possible Cause: Shorted Blu/Blk between X059.J and X059.H
Possible Cause: Shorted Blu/Blk between X059 and X058
Possible Cause: Broken Orn/Blk wire
Possible Cause: Broken Orn/Blk wire between X058 and X054
Possible Cause: Broken Orn/Blk wire between X059 and X058
Possible Cause: Broken Orn/Blk wire between X059.K and X059.D, or see
2.125 POWER MODULE FAILURE: CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT
Distress Lamp: 9 ADE Code: 9-9
The Power Module detected an error in the Power Wiring for the Pump. Alternately, the Power Module has failed a self-test.
Check wiring and motor or replace the Power Module. Re-cycle power to clear difficulty.
3 Flashes on Power Module may indicate a Short-Circuit in the Armature Wiring or a faulty Power Module
No Flashes on Power Module may indicate a faulty Power Module
Functions Disabled (Electric Powered Machines Only): Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up,
Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Possible Cause: Pump Wiring Shorted, 4.1.39, 4.1.12
2.126 POWER MODULE FAILURE: INTERNAL ERROR
Distress Lamp: 9 ADE Code: 9-9
The Power Module detected an internal error. Alternately, the Power Module has failed a self-test. Check all power wiring, see
cycle power to clear difficulty.
Functions Disabled (Electric Powered Machines Only): Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up,
Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
2-98
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.127 POWER MODULE FAILURE: PERSONALITY RANGE ERROR
Distress Lamp: 9 ADE Code: 9-9
The Power Module detected an out-of-range or corrupt personality setting. Reset control system Personalities to default settings to clear difficulty. Enter Access Level 1 on the JLG Analyzer, re-select Model, and cycle EMS after 5 seconds. May indi-
cate a Power Module issue if it cannot be reset. Reference 3.3 DC Powered Machine - Power Module.
Functions Disabled (Electric Powered Machines Only): Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up,
Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Possible Causes: Personality setting out of range, 4.1.12
2.128 POWER MODULE TOO HOT - PLEASE WAIT
Distress Lamp: 4 ADE Code: 4-2
The Power Module has reached thermal cutout. Allow to cool by powering down. May indicate that the vehicle is operating in
Functions Disabled (Electric Powered Machines Only): Lift Up, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up,
Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract O/R)
Possible Causes: High operating temperature, 4.1.12
2.129 REAR-LEFT O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Left Outrigger digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Rear Left O/R
Step Pretest Instructions
2.129.1 Run system test
Test
Do other functions fail system test?
2.129.2 Disconnect solenoid at X048.
Rerun System Test
2.129.3 Replace X003.8 with a jumper to X003.3
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid and/or connector
Wire Orn/Red 49-7 or White wire between X020 and X048 broken.
2-99
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.130 REAR-LEFT O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Left Outrigger digital output may be shorted to battery or other function
Functions Disabled: Rear Left O/R
Step Pretest Instructions
2.130.1 Run system test
Test
Do other functions fail system test?
2.130.2 Disconnect solenoid at X048 and isolate wires
Rerun System Test
2.130.3 Remove wire Orn/Red 49-7 from X003.8
Rerun System Test
Result Corrective Action
Yes
No
Possible Cause: Black Ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Orn/Red 49-7 or White wire
between X020 and X048 shorted to battery. Repair or replace
Repair/Replace wire Orn/Red 49-7
2.131 REAR-LEFT O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Left Outrigger digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Rear Left O/R
Step Pretest Instructions
2.131.1 Disconnect solenoid at X048 and isolate wires
Test
Rerun System Test
2.131.2 Remove wire Orn/Red 49-7 from X003.8
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Orn/Red 49-7 or White wire
between X020 and X048 shorted to ground. Repair or replace
2-100
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.132 REAR-RIGHT O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Right Outrigger digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Rear Right O/R
Step Pretest Instructions
2.132.1 Run system test
Test
Do other functions fail system test?
2.132.2 Disconnect solenoid at X049.
Rerun System Test
2.132.3 Replace X003.10 with a jumper to X003.3
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid and/or connector
Wire Orn/Red 49-8 or White wire between X020 and X049 broken.
2.133 REAR-RIGHT O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Right Outrigger digital output may be shorted to battery or other function
Functions Disabled: Rear Right O/R
Step Pretest Instructions
2.133.1 Run system test
Test
Do other functions fail system test?
2.133.2 Disconnect solenoid at X049 and isolate wires
Rerun System Test
2.133.3 Remove wire Orn/Red 49-8 from X003.10
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid
Wire Orn/Red 49-8 or White wire
between X020 and X049 shorted to battery. Repair or replace
Repair/Replace wire Orn/Red 49-8
2-101
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.134 REAR-RIGHT O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Rear Right Outrigger digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Rear Right O/R
Step Pretest Instructions
2.134.1 Disconnect solenoid at X049 and isolate wires
Test
Rerun System Test
2.134.2 Remove wire Orn/Red 49-8 from X003.10
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Orn/Red 49-8 or White wire
between X020 and X049 shorted to ground. Repair or replace
2.135 RETRACT O/R SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Retract (Stow) Outriggers digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Stow (Retract O/R)
Step Pretest Instructions
2.135.1 Run system test
Test
Do other functions fail system test?
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
2.135.2 Disconnect solenoid at X085.
Rerun System Test
2.135.3 Replace X003.14 with a jumper to X003.3
Rerun System Test
No
Wire Orn/Wht 55-4-1 or Orn/Wht 55-4 broken. Repair or replace
2-102
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.136 RETRACT O/R SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Retract (Stow) Outriggers digital output may be shorted to battery or other function
Functions Disabled: Stow (Retract O/R)
Step Pretest Instructions
2.136.1 Run system test
Test
Do other functions fail system test?
2.136.2 Disconnect solenoid at X085 and isolate wires
Rerun System Test
2.136.3 Remove wire Orn/Wht 55-4-1 from X003.14
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Orn/Wht 55-4-1 or Orn/Wht 55-4 shorted to battery. Repair or replace
Repair/Replace wire Orn/Wht 55-4-1
2.137 RETRACT O/R SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Retract (Stow) Outriggers digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Stow (Retract O/R)
Step Pretest Instructions
2.137.1 Disconnect solenoid at X085 and isolate wires
Test
Rerun System Test
2.137.2 Remove wire Orn/Wht 55-4-1 from X003.14
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Orn/Wht 55-4-1 or Orn/Wht 55-4 shorted to ground. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.138 RUNNING AT CREEP - MATERIAL HOOK MODE
Distress Lamp: None ADE Code: None
All function speeds are limited to creep because at the vehicle is being operated in Ground Mode while the Material Hook is in use.
Functions in Creep Mode: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out
Step
2.138.1
2.138.2
Pretest Instructions Test
Is the platform console plugged into the optional material hook harness?
Is the key switch turned to the platform position?
Yes
No
Yes
No
Result Corrective Action
See 2.124 Platform Position Detection
Turn the key to platform position for material hook operation with the platform console
Possible Causes: Faulty keyswitch wir-
ing, See 2.97 Keyswitch Faulty, 4.1.10
2.139 RUNNING AT CREEP - TILTED & ABOVE ELEVATION
Distress Lamp: 2 ADE Code: None
All function speeds are limited to creep because the vehicle is tilted and the platform is elevated.
Functions in Creep Mode: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out
Step
2.139.1
2.139.2
2.139.3
Pretest Instructions Test
Is the platform elevated?
Yes
No
Yes Is the machine tilted more than 2 degrees?
ANALYZER -> DIAGNOS-
TICS -> SYSTEM -> TILT
>= 2 DEG (platform tilt LED illuminated)
No
Yes
No
Result Corrective Action
See 3.17 Transport Limit Switch
The machine will operate at lower speed while tilted and elevated
2.140 RUNNING AT CREEP - UNSET & ABOVE ELEVATION
Distress Lamp: 2 ADE Code: None
All function speeds are limited to creep because the outriggers are not completely set and the platform is elevated.
Functions in Creep Mode: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out
Step
2.140.1
2.140.2
Pretest Instructions Test
Is the platform elevated?
Yes
No
Are any outriggers unset?
Yes
No
Result Corrective Action
See 3.17 Transport Limit Switch
Retract, lower the boom and level the machine before trying again
See 3.11 Outrigger Switches - All Set
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.141 START SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Start digital output may be disconnected or the solenoid may be defective.
The start solenoid fuse should be checked.
ENGINE POWERED MODELS ONLY
Functions Disabled (Engine Powered Machines Only): Engine Start
Step Pretest Instructions
2.141.1
Test
2.141.2 Disconnect solenoid at X089.
Rerun System Test
2.141.3 Replace X002.23 with a jumper to X002.14
Rerun System Test
Result Corrective Action
Yes Replace the fuse
No
Replace solenoid and/or connector
Wire Wht/Yel 48-6 or wire between
X022 and X089 broken. Repair or replace
2.142 START SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Start digital output may be shorted to battery or other function.
Functions Disabled (Engine Powered Machines Only): Engine Start
Step Pretest Instructions
2.142.1 Disconnect solenoid at X089 and isolate wires
Test
Rerun System Test
2.142.2 Remove wire Wht/Yel 48-6 from X002.23
Rerun System Test
Result Corrective Action
Replace solenoid
Wire Wht/Yel 48-6 or wire between
X022 and X089 shorted to battery.
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.143 START SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Start digital output may be shorted to ground or the solenoid may be defective
Functions Disabled (Engine Powered Machines Only): Engine Start
Step Pretest Instructions
2.143.1 Disconnect solenoid at X089 and isolate wires
Test
Rerun System Test
2.143.2 Remove wire Wht/Yel 48-6 from X002.23
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Wht/Yel 48-6 or wire between
X022 and X089 shorted to ground.
2.144 SWING LEFT SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Left digital output may be disconnected or the solenoid may be defective.
The start solenoid fuse should be checked.
Functions Disabled: Swing Left
Step Pretest Instructions
2.144.1 Run system test
Test
Do other functions fail system test?
2.144.2 Disconnect solenoid. Short
2.144.3 Replace X002.34 with a jumper to X002.14
Rerun System Test
Rerun System Test
Result Corrective Action
Yes
No
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
Wire White 21-3-1 or White 21-3 broken. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.145 SWING LEFT SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Left digital output may be shorted to battery or other function.
Functions Disabled: Swing Left
Step Pretest Instructions
2.145.1 Run system test
Test
Do other functions fail system test?
2.145.2 Disconnect solenoid at X077
Rerun System Test
2.145.3 Remove wire White 21-3-1 from X002.34
Rerun System Test
Result Corrective Action
Yes
No
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire White 21-3-1 or White 21-3 shorted to battery. Repair or replace
2.146 SWING LEFT SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Left digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Swing Left
Step Pretest Instructions Test
2.146.1 Disconnect solenoid at X077
Rerun System Test
2.146.2 Remove wire White 21-3-1 from X002.34
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire White 21-3-1 or White 21-3 shorted to ground. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.147 SWING RIGHT SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Right digital output may be disconnected or the solenoid may be defective.
The start solenoid fuse should be checked.
Functions Disabled: Swing Right
Step Pretest Instructions
2.147.1 Run system test
Test
Do other functions fail system test?
2.147.2 Disconnect solenoid. Short
Rerun System Test
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
2.147.3 Replace X002.35 with a jumper to X002.14
Rerun System Test
No
Wire White 22-3-1 or White 22-3 broken. Repair or replace
2.148 SWING RIGHT SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Right digital output may be shorted to battery or other function.
Functions Disabled: Swing Right
Step Pretest Instructions
2.148.1 Run system test
Test
Do other functions fail system test?
2.148.2 Disconnect solenoid at X078
Rerun System Test
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
2.148.3 Remove wire White 22-3-1 from X002.35
Rerun System Test
No
Wire White 22-3-1 or White 22-3 shorted to battery. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.149 SWING RIGHT SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Swing Right digital output may be shorted to ground or the solenoid may be defective
Functions Disabled: Swing Right
Step Pretest Instructions Test
2.149.1 Disconnect solenoid at X078
Rerun System Test
Corrective Action
Repair/Replace solenoid
2.149.2 Remove wire White 22-3-1 from X002.35
Rerun System Test
Result
Wire White 22-3-1 or White 22-3 shorted to ground. Repair or replace
2.150 TELE OUT PREVENTED - SET OUTRIGGERS
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the controls in the telescope out position while the Platform is Stowed, but the vehicle's Outriggers are improperly set. Telescope Out is prevented until all outriggers are set.
Functions Disabled: Telescope Out
Step Pretest Instructions
2.150.1
2.150.2
Test
Is the boom elevated?
Yes
No
Are any outriggers unset?
Yes
No
Result Corrective Action
Level the machine before trying again
See 3.11 Outrigger Switches - All Set
2.151 TELE OUT PREVENTED - TILTED
Distress Lamp: 2 ADE Code: 2-5
The ground module senses the controls in the telescope out position, the platform is stowed, but the vehicle is tilted.
Functions Disabled: Telescope Out
Step Pretest Instructions
2.151.1
2.151.2
Test
Is the machine tilted more than 2 degrees?
Yes
Analyzer DIAGNOSTICS ->
SYSTEM -> TILT >= 2 DEG
(platform tilt LED illuminated)
No
Yes
No
Result Corrective Action
Level the machine and try again
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.152 TELESCOPE IN SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Telescope In digital output may be disconnected or the solenoid may be defective.
The start solenoid fuse should be checked.
Functions Disabled: Telescope In
Step Pretest Instructions
2.152.1 Run system test
Test
Do other functions fail system test?
2.152.2 Disconnect solenoid. Short
Rerun System Test
2.152.3 Replace X002.4 with a jumper to X002.14
Rerun System Test
Yes
Result
No
Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid and/or connector
Wire Brown 13-3-1 or Brown 13-3 broken. Repair or replace
2.153 TELESCOPE IN SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Telescope In digital output may be shorted to battery or other function.
Functions Disabled: Telescope In
Step Pretest Instructions
2.153.1 Run system test
Test
Do other functions fail system test?
2.153.2 Disconnect solenoid at X083
Rerun System Test
2.153.3 Remove wire Brown 13-3-1 from X002.4
Rerun System Test
Result Corrective Action
Yes
No
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
Wire Brown 13-3-1 or Brown 13-3 shorted to battery. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.154 TELESCOPE IN SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Telescope In digital output may be shorted to ground or the solenoid may be defective.
Functions Disabled: Telescope In
Step Pretest Instructions Test
2.154.1 Disconnect solenoid at X083
Rerun System Test
2.154.2 Remove wire Brown 13-3-1 from X002.4
Rerun System Test
Result Corrective Action
Repair/Replace solenoid
Wire Brown 13-3-1 or Brown 13-3 shorted to ground. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.155 TELESCOPE OUT SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Telescope Out digital output may be disconnected or the solenoid may be defective.
Functions Disabled: Telescope Out
Step Pretest Instructions
2.155.1 Run system test
Test
Do other functions fail system test?
2.155.2 Disconnect solenoid. Short
2.155.3 Replace X002.16 with a jumper to X002.14
Rerun System Test
Rerun System Test
Result Corrective Action
Yes Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
No
Replace solenoid and/or connector
Wire Brown 14-3-1 or Brown 14-3 broken. Repair or replace
2.156 TELESCOPE OUT SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Telescope Out digital output may be shorted to battery or other function.
Functions Disabled: Telescope Out
Step Pretest Instructions
2.156.1 Run system test
Test
Do other functions fail system test?
2.156.2 Disconnect solenoid at X082
Rerun System Test
2.156.3 Remove wire Brown 14-3-1 from X002.16
Rerun System Test
Yes
Result Corrective Action
Possible Cause: Black ground wire
broken, 4.1.1, otherwise go to step
Replace solenoid
No
Wire Brown 14-3-1 or Brown 14-3 shorted to battery. Repair or replace
2-112
SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.157 TELESCOPE OUT SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Telescope Out digital output may be shorted to ground or solenoid may be defective.
Functions Disabled: Telescope Out
.
Step Pretest Instructions Test
2.157.1 Disconnect solenoid at X082
Rerun System Test
2.157.2 Remove wire Brown 14-3-1 from X002.16
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire Brown 14-3-1 or Brown 14-3 shorted to ground. Repair or replace
2.158 THROTTLE HOLD SOLENOID OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Hold digital output may be disconnected from solenoid or the solenoid may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Hold
Step Pretest Instructions
2.158.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.158.2 Disconnect solenoid at X097.
Rerun System Test
2.158.3 Replace X003.11 with a jumper to X003.3
Rerun System Test
No
Corrective Action
Check: 4.1.15, 4.1.1, otherwise go to
Replace solenoid and/or connector
Wire WHT/YEL 48-3 broken. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.159 THROTTLE HOLD SOLENOID SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Hold digital output may be shorted to battery or other function.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Hold
Step Pretest Instructions
2.159.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.159.2 Disconnect solenoid at X097 and isolate wires
2.159.3 Remove wire WHT/YEL 48-3 from X003.11
Rerun System Test
Rerun System Test
No
Corrective Action
Possible Cause: 4.1.15, 4.1.1, other-
Replace solenoid
Wire WHT/YEL 48-3 shorted to battery. Repair or replace
2.160 THROTTLE HOLD SOLENOID SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Hold digital output may be shorted to ground or solenoid may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Hold
Step Pretest Instructions
2.160.1 Disconnect solenoid at X097 and isolate wires
Test
Rerun System Test
2.160.2 Remove wire WHT/YEL 48-3 from X003.11
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire WHT/YEL 48-3 shorted to ground. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.161 THROTTLE PULL RELAY OPEN CIRCUIT
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Pull digital output may be disconnected from the relay or the relay may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Pull
Step Pretest Instructions
2.161.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.161.2 Disconnect relay at X091. At harness end, short X091.86
Rerun System Test
2.161.3 Replace X003.9 with a jumper to X003.3
Rerun System Test
No
Corrective Action
Check: 4.1.15, 4.1.1, otherwise go to
Replace solenoid and/or connector
Wire WHT/YEL 48-2 broken. Repair or replace
2.162 THROTTLE PULL RELAY SHORT TO BATTERY
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Pull digital output may be shorted to battery or other function.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Pull
Step Pretest Instructions
2.162.1 Run system test
Test
Do other functions fail system test?
Yes
Result
2.162.2 Disconnect relay at X091 and isolate wires
Rerun System Test
2.162.3 Remove wire WHT/YEL 48-2 from X003.9
Rerun System Test
No
Corrective Action
Possible Cause: 4.1.15, 4.1.1, other-
Replace solenoid
Wire WHT/YEL 48-2 shorted to battery. Repair or replace
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SECTION 2 - TROUBLESHOOTING BY FAULT MESSAGES
2.163 THROTTLE PULL RELAY SHORT TO GROUND
Distress Lamp: 9 ADE Code: 3-3
Ground module feedback shows that the Engine Throttle Pull digital output may be shorted to ground or the relay may be defective.
ENGINE POWERED MACHINES ONLY
Functions Disabled (Engine Powered Machines Only): Engine Throttle Pull
Step Pretest Instructions
2.163.1 Disconnect solenoid at X091 and isolate wires
Test
Rerun System Test
2.163.2 Remove wire WHT/YEL 48-2 from X003.9
Rerun System Test
Result
Corrective Action
Repair/Replace solenoid
Wire WHT/YEL 48-2 shorted to ground. Repair or replace
2.164 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
Distress Lamp: 1 ADE Code: 2-2
The Trigger Switch in the Platform Control Box was closed for more than seven seconds while the Joystick was in the neutral position (centered). Release switch or repair the switch / wiring to clear the difficulty.
Functions Disabled at Platform Only: Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib
Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/R), Stow (Retract
O/R)
Step Pretest Instructions Test Result
2.164.1
Was the switch held for more than 7 seconds?
Yes
No
“LIFT/SWING SEL” 2.164.2 Switch Key to Platform Mode and pull the ground and platform emergency stop switches. Turn the select switch to the Lift/Swing Position. Do NOT hold the joystick.
Analyzer DIAGNOSTICS ->
PLATFORM ->
“LEVEL SELECT”
“JIB/TELE SELECT”
“TRIGGER OPEN”
Corrective Action
Release switch and try again
Possible Cause: 4.1.19, 4.1.18,
Shorted Yel/Red2-17, 4.1.22, 4.1.11
See 2.72 Function Problem - Rotary
See 2.72 Function Problem - Rotary
See 2.72 Function Problem - Rotary
2-116
SECTION 3 - COMPONENT CHECKS
SECTION 3.
COMPONENT CHECKS
3.1 DC POWERED MACHINE - HYDRAULIC PUMP
Step Pretest Instructions
3.1.1
Test
Yes
No
3.1.2
Engage enable and lift up switch
3.1.3
Engage enable and lift up switch
3.1.4
Engage enable and lift up switch
3.1.5
Engage enable and lift up switch
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Causes: 4.1.70, 4.1.72,
Possible Causes: 4.1.71, 4.1.72,
3.2 DC POWERED MACHINE - POWER
Step Pretest Instructions
3.2.1
3.2.2
Test
Disconnect batteries and check for 6V across each battery
less than 6V
6V or greater
Result
0V
3.2.3
3.2.4
Pull the ground emergency stop switch and place key switch in ground position
3.2.5
Pull the ground emergency stop switch and place key switch in ground position
24V
0V
24V
0V
Vbatt
0V
Vbatt
Corrective Action
Charge or replace batteries
Repair open in battery cables or terminals
Repair open in battery cables or terminals
Battery Power OK
See 3.9 Ignition Relay - Power
Repair open in YEL/RED 2-8
3.3 DC POWERED MACHINE - POWER MODULE
Theory of Operation
The Power Module is essentially a “low-side” switch for the pump motor. The positive terminal of the pump is tied to Battery
Positive after the Line Contactor. The negative terminal of the pump connects to the P Terminal of the Power Module, which switches current through MOSFET transistors to the Battery Negative.
For variable speed pump operation, the MOSFET transistors switch On and Off at high frequencies (16kHz). The Duty Cycle is varied to control the voltage applied to the pump motor. When the MOSFET’s spend 50% of the period On and 50% Off,
3-117
SECTION 3 - COMPONENT CHECKS
approximately ½ of the available Battery Voltage will be applied to the pump motor. Similarly, the MOSFET are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the pump motor.
Line Contactor
Series DC
Pump Motor
(M 1)
+B
A
(M2)
60
Ω
-B
Power Module
24V
Ignition Power (X002.3)
CAN HI
CAN LO
Figure 3-1. Power Module Circuit
When the Control System is energized, the voltage at the P Terminal will be approximately +24V (referenced to B-) when the pump is static. The A (M2) Terminal will be approximately at +1V (referenced to B-) when the pump is running at full speed.
Common Difficulties
The following difficulties can be examined using the JLG Analyzer, a voltmeter, and simple hand tools. Unless otherwise noted, the Control System shall be energized in Ground Mode during testing. The vehicle should be placed on a firm, level surface for all analysis.
Ground Module Interlocks
There are a variety of interlocks that prevent Lift Up due to system events (Tilted, Tilt Sensor Not Calibrated, etc.). Before investigating Pump System issues, examine the JLG Analyzer's HELP Menu while attempting to Lift Up from Ground Mode.
Refer to Section 2. Troubleshooting by Fault Messages for explanations of the Help Messages.
Power Module Diagnostic Issues
The Power Module executes a self-test during every power-up to ensure proper functionality. If a Diagnostic Issue is detected, the Power Module will not energize the Line Contactor. Instead, it will flash the Green LED.
Open-Circuit between M1 Terminal and Pump Motor Positive Terminal
This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP, the JLG Analyzer will show PUMP
PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.
The voltage measured between the Pump Motor Positive Terminal and Ground Reference should be 24V. If it is not, examine the cable between the terminal and the Power Module compartment. Inspect crimps for corrosion and ensure that bolted connections are tight. Ensure that the cable is not crushed.
Open-Circuit between Pump Motor Negative Terminal and M2 Terminal
This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP, the JLG Analyzer will show PUMP
PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.
After ensuring there is not an Open-Circuit between the M1 Terminal and Pump Motor Positive Terminal, check that the voltage measured between the Pump Motor Negative Terminal and Ground Reference is 24V. If not, examine the issues within
examine the cable between the terminal and the Power Module compartment (M2 Terminal). Inspect crimps for corrosion and ensure that bolted connections are tight. Ensure that the cable is not crushed.
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SECTION 3 - COMPONENT CHECKS
Open-Circuit Pump Motor
This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP, the JLG Analyzer will show PUMP
PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.
Pull the Main Battery Disconnect to completely de-energize the Control System. Next, detach the cable from Pump Motor
Positive Terminal. Using a voltmeter set for resistance measurement (Ohms), ensure that the resistance between the Pump
Motor Positive and Negative Terminals is less than 2 Ohms. If not, examine the pump motor for worn brushes or broken terminals. After examination, re-connect the Pump Motor Positive Terminal and the Main Battery Disconnect.
Short-Circuit between Pump Motor Positive and Negative Terminals
This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP, the JLG Analyzer will show an erratic reading for PUMP PWM% and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode.
Pull the Main Battery Disconnect to completely de-energize the Control System. Next, detach both Pump Motor Terminals and insulate them independently. Re-connect the Main Battery Disconnect and re-try Lift Up. If the same symptoms persist
(erratic PUMP PWM%, PUMP CUR around 150A), examine the cabling between the Pump Motor and Power Module compartment for a short-circuit. If the symptoms change, suspect a short-circuited (or mechanically frozen) pump motor.
A clamp-on ammeter (set for 200A DC) can be placed on either Pump Motor Cable for verification. During Lift Up, the ammeter will read approximately 150A.
Power Module Electrical Evaluation
Several basic electrical tests can be performed on the Power Module. Failure of one of these evaluations is significant and may indicate that the device is physically damaged. If a Power Module is suspected to be faulty, thoroughly examine the rest of the system for possible damage.
Make all measurements with a voltmeter set to resistance scale (Ohms). Disconnect the Main Battery Disconnect and all cables from the Power Module during this analysis. Wait 60 seconds after power is disconnected to allow internal charge to dissipate (risk of hazard, improper readings otherwise).
1.
Resistance >100kOhms all Terminals to Housing. Ensure that there is an open-circuit between all terminals of the
Power Module and the module's aluminum housing. The device is fully potted and all electronics are insulted from the housing. Place the Black meter lead on the housing and use the Red meter lead to probe all terminals.
2.
Resistance < 2 Ohms between B+ and M1. Ensure that there is a short-circuit between the B+ and M1 Terminals.
Internally, there is a low-impedance current measurement shunt for the Armature portion of Traction. Place the Red meter lead on B+, and the Black meter lead on M1.
3.
Resistance >1MegaOhms between F1 and B-; F2 and B-. Ensure that there is an open-circuit between the two Field
Terminals (F1 & F2) and B-. Internally, there are MOSFET transistors between these terminals that should be highimpedance when the module is un-powered. Place the Black meter lead on B- and the Red meter lead on F1 / F1.
4.
Resistance >1MegaOhms between F1 and B+; F2 and B+. Ensure that there is an open-circuit between the two Field
Terminals (F1 & F2) and B+. Internally, there are MOSFET transistors between these terminals that should be highimpedance when the module is un-powered. Place the Black meter lead on B+ and the Red meter lead on F1 / F1.
5.
Resistance >100kOhms between P and B-. Ensure that there is an open-circuit between the P and the B- Terminals.
Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on B-, and the Red meter lead on P. Note that a measurement of increasing resistance (capacitor charge) is normal, but a persistently low impedance is not.
6.
Resistance >1kOhms between M2 and B-. Ensure that there is an open-circuit between the M2 and B- Terminals. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is unpowered. Place the Black meter lead on B-, and the Red meter lead on M2. Note that a measurement of increasing resistance (capacitor charge) is normal, but a persistently low impedance is not.
7.
Resistance 120 Ohms between Pins 10 & 11. Ensure that the resistor that terminates the CAN bus is within tolerance between pins 10 and 11 on the 12 position Mini-Fit Jr. (Connector “B”). Place the Red meter lead on pin 10, and the
Black meter lead on pin 11. The resistance should measure between 110 - 130 Ohms.
3-119
SECTION 3 - COMPONENT CHECKS
Pump Motor Electrical Evaluation
Several basic electrical tests can be performed on the Pump Motor. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.
1.
Make all measurements with a voltmeter set to resistance scale (Ohms). Disconnect the Main Battery Disconnect and all pump motor cables during this analysis.
2.
Resistance < 5 Ohms between Motor Terminals. The internal windings are very low impedance and should appear to be a short-circuit for an ordinary voltmeter (other tests can determine if the windings are truly shorted). High resistance can signal worn brushes, a faulty commutator, or open windings.
3.
Resistance > 1 MegaOhm between Motor Terminals and Motor Housing. The internal windings should be electrically isolated from the motor housing. Low resistance may be an indication of a broken motor terminal, damaged brush, faulty commutator, or burned winding.
3.4 DRIVE MODULE - POWER
Step Pretest Instructions
3.4.1
3.4.2
Pull the ground emergency stop switch and place key switch in ground position
Test
Voltage between X074.2 and
Yes
No
Yes
No
Voltage on X009.87 = Vbatt? Yes
3.4.3
Pull the ground emergency stop switch and place key switch in ground position
3.4.4
3.4.5
3.4.6
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Repair or replace Yel/Red 2-16 wire between X012.1 and X074.1
Repair or replace Yel/Red 2-16 wire between X009.87 and X012.1
See 3.9 Ignition Relay - Power
Repair or replace Black wire between
Repair or replace Black wire between
Repair or replace Black wire between
Consult Factory
3.5 DRIVE SENSOR RESET
If an error is detected with the turntable position sensor or hand brake position sensor, they need to be reset before the control system will accept their values and allow drive and set functions.
Turntable Position Sensor
If an error is detected with the switch or the transport switch does not agree with the turntable position switch, then “TURN-
TBL SW ERR” is displayed in the diagnostics. When the boom is set on the boom rest, the transport switch should already be closed (Transport), Turntable1 should change from Off to On, and Turntable2 should change from On to Off. Turntable1
3-120
SECTION 3 - COMPONENT CHECKS
and Turntable2 should always be in opposite states. To reset the switch, lift boom till transport switch opens, then lower onto rest again.
Result Step Pretest Instructions
3.5.1
Place boom on rest,
Check Analyzer -> Diagnostics -> Drive
3.5.2
Check Analyzer -> Diagnostics -> Drive
Test
“TURNTBL SW ERR” displayed
“TURNTABLE1 ON” displayed
3.5.3
Check Analyzer -> Diagnostics -> Drive
“TURNTABLE2 OFF” displayed
Yes
No
Yes
No
Yes
No
3.5.4
Check Analyzer -> Diagnostics -> System
“TRANS LMT SW CL” displayed
Yes
3.5.5
Is boom on rest?
No
Yes
No
Corrective Action
Switch is already reset
Possible Causes: Orn/Red 59-1 wire
Lift boom till transport switch opens, then lower onto rest again to reset the switch
Possible Causes: Bad transport
switch, see 3.17 Transport Limit
Possible Causes: Switch
obstructed, 4.1.20, Orn/Red 58-1 wire broken, 4.1.18
Place boom on rest and try again
Hand Brake Position Sensor
If an error is detected with the switch, “HAND BRK SW ERR” is displayed in the diagnostics. As the hand brake is applied,
Brake1 should change from Off to On, and Brake2 should change from On to Off. Brake1 and Brake2 should always be in opposite states. To reset the switch, cycle the hand brake.
Step Pretest Instructions Test
3.5.6
Apply hand brake, Check
Analyzer -> Diagnostics -
> Drive
3.5.7
Check Analyzer -> Diagnostics -> Drive
“HAND BRK SW ERR” displayed
“BRAKE1 ON” displayed
Yes
No
Yes
No
3.5.8
Check Analyzer -> Diagnostics -> Drive
“BRAKE2 OFF” displayed Yes
No
3.5.9
Is hand brake applied?
Yes
No
Result Corrective Action
Switch is already reset
Cycle hand brake to reset the switch
Possible Causes: Orn/Red 57-1 wire
Possible Causes: Switch obstructed, Orn/Red 56-1 wire bro-
ken, brake cable broken, 4.1.20,
Place boom on rest and try again
3-121
SECTION 3 - COMPONENT CHECKS
3.6 ENGINE POWERED MACHINE - HYDRAULIC PUMP
Step Pretest Instructions
3.6.1
Test
Does the engine turn the pump?
Yes
Result
No
3.7 ENGINE POWERED MACHINE - POWER
Step Pretest Instructions
3.7.1
3.7.2
3.7.3
Pull the ground emergency stop switch and place key switch in ground position
3.7.4
Pull the ground emergency stop switch and place key switch in ground position
Test
Disconnect battery and check for 12V across terminals
Result
less than 12V
12V or greater
Vbatt
0V
0V
Vbatt
0V
Vbatt
3.8 GROUND MODULE - POWER
Step Pretest Instructions
3.8.1
Pull the ground emergency stop switch and place key switch in ground position
3.8.2
Test
Yes
No
Yes
X008.1 and B- (X101 for electric, X100 for engine)
No
Result
Corrective Action
Possible Causes: 4.1.37, 4.1.43,
Corrective Action
Charge or replace batteries
Battery Power OK
See 3.9 Ignition Relay - Power
Repair open in YEL/RED 2-8
Corrective Action
Ground Module Power OK. Possible
Repair black ground wire between
3-122
3.9 IGNITION RELAY - POWER
Step Pretest Instructions
3.9.1
Pull the ground emergency stop switch and place key switch in the OFF position
3.9.2
Pull the ground emergency stop switch and place key switch in ground position
3.9.3
Pull the ground emergency stop switch and place key switch in ground position
3.9.4
Pull the ground emergency stop switch and place key switch in ground position
3.9.5
Pull the ground emergency stop switch and place key switch in ground position
Test
3.9.6
Pull the ground emergency stop switch and place key switch in ground position
3.9.7
Pull the ground emergency stop switch and place key switch in ground position
3.9.8
Pull the ground emergency stop switch and place key switch in ground position
0V
Vbatt
0V
Vbatt
0V
Vbatt
3.9.9
0V
0V
Vbatt
0V
Vbatt
0V
0V
Vbatt
0V
Vbatt
Vbatt
Result
Vbatt
SECTION 3 - COMPONENT CHECKS
Corrective Action
Repair/Replace Ignition Relay
Repair/Replace diode at X009.86
Repair open in YEL/RED 2-5 or YEL/
RED 2-10
Repair open in YEL/RED 2-5
Repair/Replace key switch
Repair open in YEL/RED 2-1 or YEL/
RED 2-2
Otherwise, repair open between
Repair open in Red 1-1
3-123
SECTION 3 - COMPONENT CHECKS
3.10 JOYSTICK DIAGNOSTICS
Step Pretest Instructions Test
3.10.1 Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM -> X-JOYSTK
Is the X-Joystk Voltage between 2.25 and 2.75?
3.10.2 Using the analyzer, navigate to
DIAGNOSTICS -> PLAT-
FORM -> Y-JOYSTK
Is the Y-Joystk Voltage between 2.25 and 2.75?
3.10.3 Pull the ground emergency stop switch and place key switch in platform position.
Keep the joystick centered
3.10.4 Pull the ground emergency stop switch and place key switch in platform position.
Keep the joystick centered
3.10.5
3.10.6
Using a multimeter, is the voltage between X061.4 and
Using a multimeter, is the voltage between X061.3 and
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
3.11 OUTRIGGER SWITCHES - ALL SET
Step Pretest Instructions
3.11.1
3.11.2
Test
Analyzer DIAGNOSTICS ->
GROUND -> F-L O/R SET
OFF
ON
Yes
No
Result
Result
3.11.3
3.11.4
Analyzer DIAGNOSTICS
GROUND -> F-R O/R SET
OFF
ON
Yes
No
3.11.5
3.11.6
Analyzer DIAGNOSTICS
GROUND -> R-L O/R SET
OFF
ON
Yes
No
3-124
Corrective Action
Possible Causes: 4.1.23, 4.1.22
Possible Causes: Intermittent Voltage
Repair broken wire Yel/Red 2-18 or black between Platform module and joystick
Corrective Action
Possible Causes: Broken Orn/Red 49-
Possible Causes: 4.1.19, 4.1.20,
4.1.18, broken white or black wire between X020 and X042
Possible Causes: Broken Orn/Red 49-
Possible Causes: 4.1.19, 4.1.20,
4.1.18, broken white or black wire between X020 and X043
Possible Causes: Broken Orn/Red 49-
Possible Causes: 4.1.19, 4.1.20,
4.1.18, broken white or black wire between X020 and X044
Step Pretest Instructions
3.11.7
3.11.8
Test
Analyzer DIAGNOSTICS
GROUND -> R-R O/R SET
OFF
ON
Yes
No
Result
SECTION 3 - COMPONENT CHECKS
Corrective Action
Possible Causes: 4.1.23, 4.1.10
Possible Causes: Broken Orn/Red 49-
Possible Causes: 4.1.19, 4.1.20,
4.1.18, broken white or black wire between X020 and X045
3.12 OUTRIGGER SWITCHES - ALL STOWED
Step Pretest Instructions
3.12.1
3.12.2
Test
Analyzer DIAGNOSTICS
GROUND -> F-L O/R SET
OFF
ON
Yes
3.12.3
3.12.4
3.12.5
3.12.6
3.12.7
3.12.8
No
Analyzer DIAGNOSTICS
GROUND -> F-R O/R SET
OFF
ON
Yes
No
Analyzer DIAGNOSTICS
GROUND -> R-L O/R SET
OFF
ON
Yes
No
Analyzer DIAGNOSTICS
GROUND -> R-R O/R SET
OFF
ON
Yes
No
Result Corrective Action
Possible Causes: 4.1.19, 4.1.20,
4.1.18, shorted black wire between
Possible Causes: Orn/Red 49-1
Possible Causes: 4.1.19, 4.1.20,
4.1.18, shorted black wire between
Possible Causes: Orn/Red 49-2
Possible Causes: 4.1.19, 4.1.20,
4.1.18, shorted black wire between
Possible Causes: Orn/Red 49-3
Possible Causes: 4.1.23, 4.1.10
Possible Causes: 4.1.19, 4.1.20,
4.1.18, shorted black wire between
Possible Causes: Orn/Red 49-3
3-125
SECTION 3 - COMPONENT CHECKS
3.13 PLATFORM MODULE - POWER
Step Pretest Instructions Test
3.13.1 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.13.2 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.13.3 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.13.4 Pull the ground and platform emergency stop switches and place key switch in the platform position
Voltage on X008.2 = Vbatt? Yes
No
3.13.5 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.13.6 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.13.7 Pull the ground and platform emergency stop switches and place key switch in the platform position
Yes
No
3.14 POWER MODULE - POWER
Step Pretest Instructions
3.14.1 Pull the ground emergency stop switch and place key switch in ground position
3.14.2 Pull the ground emergency stop switch and place key switch in ground position
3.14.3
Test
Is the power module fault
LED flashing?
Yes
No
Is the power module LED illuminated?
Yes
No
Yes
No
Result
Result
Corrective Action
Repair Platform wiring between X059 and X060
See 3.9 Ignition Relay - Power
Repair power Yel/Red 2-11 or Black wire between X019 and X008
Repair power wires between X055
Repair Blue or Red/Blk power wires between X059 and X057
Repair Blue or Red/Blk power wires between X057 and X055
Corrective Action
See A.8 Power Module Flash Codes
Possible Causes: 4.1.72, 4.1.12
3-126
3.15 TELESCOPE LIMIT SWITCH
Step Pretest Instructions
3.15.1
3.15.2
3.15.3
3.15.4
Test
ANALYZER -> DIAGNOS-
TICS -> SYSTEM -> TELE
LMT SW
Does the Telescope limit switch (X041) spring pull the lever into the slot in the boom?
OP
CL
Yes
No
Yes
No
Yes
3.15.5
3.15.6
3.15.7
3.15.8
No
Yes
No
Yes
No
Yes
No
Yes
No
3.16 TILT SENSOR
Step Pretest Instructions
3.16.1
Test
Is the ground module securely mounted in a level position?
Yes
No
Result
Result
SECTION 3 - COMPONENT CHECKS
Corrective Action
Possible Cause: 4.1.23, 4.1.10
Possible Cause: 4.1.19, 4.1.18
Wire Orn/Red 49-72 broken. Repair or replace
Black wire broken between X018 and
White wire broken between X018 and
Wire Yel/Red 2-26-1 or Yel/Red 2-26 broken. Repair or replace
Corrective Action
Possible Causes: 4.1.17, 4.1.10
Mount ground module securely to frame, level, and in the upright posi-
3-127
SECTION 3 - COMPONENT CHECKS
3.17 TRANSPORT LIMIT SWITCH
Step Pretest Instructions
3.17.1 Stow the boom
3.17.2
3.17.3
3.17.4
Test
ANALYZER -> DIAGNOS-
TICS -> SYSTEM ->
TRANS LMT SW
Does the Transport limit switch (X040) spring pull the lever against the cylinder cam?
OP
CL
Yes
No
Yes
No
Yes
3.17.5
3.17.6
3.17.7
3.17.8
No
Yes
No
Yes
No
Yes
No
Yes
No
Result Corrective Action
Possible Cause: 4.1.23, 4.1.10
Possible Cause: 4.1.19, 4.1.18
Wire Orn/Red 49-53 broken. Repair or replace
Black wire broken between X015 and
White wire broken between X015 and
Wire Yel/Red 2-26-1 or Yel/Red 2-26 broken. Repair or replace
3-128
SECTION 4 - POSSIBLE CAUSES
SECTION 4.
POSSIBLE CAUSES
4.1.8
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.1.14
4.1.22
4.1.23
4.1.24
4.1.25
4.1.26
4.1.27
4.1.28
4.1.29
4.1.15
4.1.16
4.1.17
4.1.18
4.1.19
4.1.20
4.1.21
4.1.30
4.1.31
4.1.32
4.1 POSSIBLE CAUSES
Item
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.33
4.1.34
4.1.35
Possible Cause Possible Solution
Bad contacts at connector
System Setup information may be incorrect
Battery or charger may be installed incorrectly
Improper battery level
Black battery ground wire may be damaged between
X008.1 and B- (engine:X100 or electric:X101)
Repair or replace
Make sure the setup displayed on the analyzer matches the machine
Check battery wiring and polarity
Charge or replace batteries
Repair or replace
Ignition relay at X009 may be defective
X009.86 may be shorted to battery
Repair or replace
Isolate wire shorted to battery and repair. Check Yel/Red 2-5, Yel/Red 2-
10, Yel/Red 2-7, Yel/Red 2-44, Yel/Red 2-9
Contact Factory Battery Charger may be defective
Drive module may be defective
Ground module may be defective
Platform module may be defective
Power module may be defective
Contact Factory
Contact Factory
Contact Factory
Contact Factory
Improper or incompatible software may be installed Check software versions and replace if necessary
CAN wiring between ground and platform may be defective
Black ground wire from battery, X100 may be cut
Check contacts at X007, X019, X010, X055, X051, X052, or repair CAN wiring
Check continuity to X100 and repair wire or connectors
On board system memory may have been corrupted Check / correct all settings and re-cycle power to clear difficulty
Integrated Tilt sensor may be defective Contact Factory
Switch may be defective
Switch may be stuck
Repair or replace
Check for obstructions and switch freedom of motion
Limit Switch may be out of adjustment
Engine speed pickup may be defective
Joystick may be defective
Intermittent voltage fluctuation
Adjust the switch to the specified trip level and retighten
Repair or replace
See 3.10 Joystick Diagnostics or Repair or replace
Check the Help Log for recent recorded problems; Test all conditions
Hourmeter may be defective
Alarm may be defective
Joystick calibration may be corrupt
LED or LED module may be defective
Engine Start / Charge Fuse may be blown
Engine Charge coil may be defective
Engine Voltage Rectifier may be defective
Optional Lift Hook harness may be defective
The boom may be latched to the trailer
Repair or replace
Repair or replace
Calibrate
Repair or replace
See Engine Owner’s Manual for fuse replacement
Repair or replace, See Engine Owner’s Manual for more information
Repair or replace, See Engine Owner’s Manual for more information
Check for shorts, opens, and miswired connectors
Engage lift down, telescope in, and platform leveling until boom is relieved of pressure, unlatch boom and try the function again.
The ground control is being operated without enable Use enable and try again
The ground may be too uneven for proper outrigger deployment and leveling
Find a more even and/or level area
The ground module may not be mounted properly Level and properly mount the ground module
4-129
SECTION 4 - POSSIBLE CAUSES
4.1.62
4.1.63
4.1.64
4.1.65
4.1.66
4.1.67
4.1.54
4.1.55
4.1.56
4.1.57
4.1.58
4.1.59
4.1.60
4.1.61
4.1.46
4.1.47
4.1.48
4.1.49
4.1.50
4.1.51
4.1.52
4.1.53
4.1.39
4.1.40
4.1.41
4.1.42
4.1.43
4.1.44
4.1.45
4.1 POSSIBLE CAUSES
Item
4.1.36
4.1.37
4.1.38
4.1.68
4.1.69
4.1.70
4.1.71
4.1.72
4.1.73
Possible Cause Possible Solution
The outrigger switch or solenoid wires may be swapped
Assure that the outriggers are wired correctly.
Hydraulic fluid level may be low Check for leaks. Fill hydraulic reservoir to recommended level.
Personality may need to be increased to initiate flow Increase the personality using the analyzer as described in the Operators
Manual
Pump may be defective Repair or replace
Oil filter may be restricted
Cylinder may be defective
Hose may be pinched at turntable
Hydraulic Manifold may be defective
Check Valve may be defective
Main Relief Valve may be defective
Incorrect hose routing to tank
Torn hose
Replace oil filter
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair hose routing
Repair or replace
Holding valve may be defective
Motion may be mechanically limited
Telescope Out valve may be defective
Telescope In valve may be defective
Swing Left valve may be defective
Swing Right valve may be defective
Level Up (Extend) valve may be defective
Level Up (Extend) Relief may be set incorrectly
Enable switch is not held
Hydraulic Pump Motor may be defective
Red Pump Motor Positive wire may be cut
Black Pump Motor Negative wire may be cut
Power wire terminals may be corroded or loose
Hydraulic pump engine coupling may be defective
Repair or replace
Remove any obstructions
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Check or Set, See Service Manual
Level Down (Retract) valve may be defective
Level Down (Retract) Relief may be set incorrectly
Lift up valve may be defective
Lift Down valve may be defective
Repair or replace
Check or Set, See Service Manual
Repair or replace
Repair or replace
Jib up valve may be defective
Jib Down valve may be defective
Repair or replace
Repair or replace
Outrigger Enable valve on cylinder may be defective Repair or replace
Outrigger Extend/Retract valve may be defective Repair or replace
X011 is not connected to the battery
30A fuse in ground control box blown
Key switch not on
Emergency stop switch is pushed
Connect X011 red wire to B+, X011 black wire to B-
Replace fuse
Turn to either ground or platform control
Pull ground emergency stop switch for ground operation or both ground and platform emergency stop switches for platform operation
Hold enable switch while operating
Repair or replace
Repair or replace
Repair or replace
Clean terminals and tighten if loose
Repair or replace
4-130
SECTION 4 - POSSIBLE CAUSES
4.1.87
4.1.88
4.1.89
4.1.90
4.1.91
4.1.92
4.1.93
4.1.79
4.1.80
4.1.81
4.1.82
4.1.83
4.1.84
4.1.85
4.1.86
4.1 POSSIBLE CAUSES
Item
4.1.74
4.1.75
4.1.76
4.1.77
4.1.78
Possible Cause Possible Solution
(Gas Only) Dump Valve may be defective
(Gas Only) High Idle Inoperable
(Gas Only) Engine may be mechanically defective
(Gas Only) Engine start solenoid may be defective
Repair or replace
See1.8 Engine High Idle Inoperative - Engine Models
Contact Factory
Repair or replace
(Gas Only) Engine throttle pull solenoid may be defective
Repair or replace
(Gas Only) Engine start motor may be defective
(Gas Only) Engine throttle relay may be defective
(Gas Only) Engine stop relay may be defective
(Gas Only) Engine speed feedback incorrect
(Gas Only) Engine may be out of fuel
(Gas Only) Fuel may be old or bad
(Gas Only) Fuel valve may be turned off
(Gas Only) Engine choke may be open
Repair or replace
Repair or replace
Repair or replace
Repair Wht/Yel 48-7 between X001.16 and X095 or contact factory
Refuel
Drain fuel tank and carburetor. Refuel with fresh gasoline
Move engine fuel lever to ON
Engage the choke, unless engine is warm
(Gas Only) Engine oil level may be low
(Gas Only) Spark plug may be faulty
(Gas Only) Fuel filter may be clogged
(Gas Only) Air filter may be clogged
(Gas Only) Fuel system may be clogged
(Gas Only) Carburetor may be flooded
(Gas Only) Engine idle setting may be too low
Check/Add oil
Gap or replace spark plug
Clean or replace
Clean or replace
Repair or replace
Dry and reinstall spark plug. Start engine with throttle in fast position
Increase idle speed to specified value
4-131
SECTION 4 - POSSIBLE CAUSES
4-132
SECTION 5 - SYSTEM TEST MESSAGES
SECTION 5.
SYSTEM TEST MESSAGES
This section Lists all of the possible message responses from the system test mode.
5.1 BATTERY 1/4 LAMP ON
Platform system test is illuminating the platform battery indicator.
ELECTRIC POWERED MACHINES ONLY.
Step Pretest Instructions
5.1.1
Test
Does battery indicator illuminate properly?
Yes
No
Result Corrective Action
Press ENTER on the analyzer to continue the system test
5.2 BATTERY 1/2 LAMP ON
5.3 BATTERY 3/4 LAMP ON
5.4 BATTERY FULL LAMP ON
5.5 BATTERY VOLTAGE TOO HIGH
5.6 BATTERY VOLTAGE TOO LOW
5.7 CHECK CHOKE SWITCH
System test response indicating that the module input from the choke switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
ENGINE POWERED MACHINES ONLY
See 2.56 Function Problem - Engine Choke Permanently Selected
5.8 CHECK GROUND/PLATFORM SELECT
System test response indicating that the ground module inputs for ground mode and platform mode are both or neither true.
A properly wired and functioning machine will show either ground or platform mode true, not both.
5-133
SECTION 5 - SYSTEM TEST MESSAGES
5.9 CHECK JIB DOWN SWITCH
System test response indicating that the ground module input from the ground panel jib down switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
MODEL T500J ONLY
See 2.60 Function Problem - Jib Down Permanently Selected
5.10 CHECK JIB UP SWITCH
System test response indicating that the ground module input from the ground panel jib up switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
MODEL T500J ONLY
See 2.62 Function Problem - Jib Up Permanently Selected
5.11 CHECK LEVEL DOWN SWITCH
System test response indicating that the ground module input from the ground level down switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.63 Function Problem - Level Down Permanently Selected
5.12 CHECK LEVEL UP SWITCH
System test response indicating that the ground module input from the ground level up switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.65 Function Problem - Level Up Permanently Selected
5.13 CHECK LIFT DOWN SWITCH
System test response indicating that the ground module input from the ground lift down switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.66 Function Problem - Lift Down Permanently Selected
5.14 CHECK LIFT UP SWITCH
System test response indicating that the ground module input from the ground lift up switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.68 Function Problem - Lift Up Permanently Selected
5.15 CHECK OUTRIGGER SET SWITCH
System test response indicating that the ground module input from the ground outrigger set switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.70 Function Problem - Outrigger Set Permanently Selected
5.16 CHECK OUTRIGGER STOW SWITCH
System test response indicating that the ground module input from the ground outrigger stow switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.71 Function Problem - Outrigger Stow Permanently Selected
5-134
SECTION 5 - SYSTEM TEST MESSAGES
CHECK POWER & CAN WIRING TO DRIVE MODULE
DRIVE OPTION MACHINES ONLY
System test cannot communicate with the drive module
See 2.7 CANBUS Failure - Drive Module
5.17 CHECK POWER & CAN WIRING TO PLATFORM
System test cannot communicate with the platform module
See 2.8 CANBUS Failure - Platform Module
5.18 CHECK POWER & CAN WIRING TO POWER MODULE
ELECTRIC POWERED MACHINES ONLY
System test cannot communicate with the power module
See 2.8 CANBUS Failure - Platform Module
5.19 CHECK START SWITCH
System test response indicating that the ground module input from the ground start switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
ENGINE POWERED MACHINES ONLY
See 2.58 Function Problem - Engine Start Permanently Selected
5.20 CHECK SWING LEFT SWITCH
System test response indicating that the ground module input from the ground swing left switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.74 Function Problem - Swing Left Permanently Selected
5.21 CHECK SWING RIGHT SWITCH
System test response indicating that the ground module input from the ground swing right switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.75 Function Problem - Swing Right Permanently Selected
5.22 CHECK TELESCOPE IN SWITCH
System test response indicating that the ground module input from the ground telescope in switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.77 Function Problem - Telescope In Permanently Selected
5.23 CHECK TELESCOPE OUT SWITCH
System test response indicating that the ground module input from the ground telescope out switch was closed when the system test began testing switch inputs. This may indicate a permanent switch closure.
See 2.78 Function Problem - Telescope Out Permanently Selected
5-135
SECTION 5 - SYSTEM TEST MESSAGES
5.24 CHECKING INPUTS
System test status message indicating that it has begun testing digital inputs to the module being tested (ground or platform).
5.25 CHOKE CL
ENGINE POWERED MACHINES ONLY
System test response indicating that the ground choke switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.26 CHOKE HOLD
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.27 CHOKE HOLD SOLENOID OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open circuit in the choke hold circuit.
See 2.14 Choke Hold Solenoid Open Circuit
5.28 CHOKE HOLD SOLENOID SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the choke hold circuit.
See 2.15 Choke Hold Solenoid Short To Battery
5.29 CHOKE HOLD SOLENOID SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the choke hold circuit.
See 2.16 Choke Hold Solenoid Short To Ground
5.30 CHOKE PULL
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.31 CHOKE PULL RELAY OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open circuit in the choke pull circuit.
See 2.17 Choke Pull Relay Open Circuit
5-136
SECTION 5 - SYSTEM TEST MESSAGES
5.32 CHOKE PULL RELAY SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the choke pull circuit.
See 2.18 Choke Pull Relay Short To Battery
5.33 CHOKE PULL RELAY SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the choke pull circuit.
See 2.19 Choke Pull Relay Short To Ground
5.34 CHOKE SWITCH CL
ENGINE POWERED MACHINES ONLY
System test response indicating that the platform choke switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.35 CL CHOKE
ENGINE POWERED MACHINES ONLY
System test prompt to close the ground panel choke switch. Push the choke button at the ground panel to test the choke switch input and continue the test
5.36 CL CHOKE SWITCH
ENGINE POWERED MACHINES ONLY
System test prompt to close the platform panel choke switch. Push the choke button at the platform panel to test the choke switch input and continue the test.
5.37 CL DRIVE SWITCH
DRIVE OPTION MACHINES ONLY
System test prompt to close the platform panel drive switch. Push the drive button at the platform panel to test the drive switch input and continue the test.
5.38 CL JIB DOWN
T500J ONLY
System test prompt to close the ground panel Jib down switch. Push the Jib switch at the ground panel to the Down position to test the switch input and continue the test.
5.39 CL JIB UP
T500J ONLY
System test prompt to close the ground panel Jib up switch. Push the Jib switch at the ground panel to the Up position to test the switch input and continue the test.
5.40 CL LEVEL DOWN
System test prompt to close the Platform Levelling Down switch. Push the Platform Levelling switch at the ground panel to the Down position to test the switch input and continue the test.
5-137
SECTION 5 - SYSTEM TEST MESSAGES
5.41 CL LEVEL UP
System test prompt to close the Platform Levelling Up switch. Push the Platform Levelling switch at the ground panel to the
Up position to test the switch input and continue the test.
5.42 CL LIFT DOWN
System test prompt to close the Lift Down switch. Push the Lift switch at the ground panel to the Down position to test the switch input and continue the test.
5.43 CL LIFT UP
System test prompt to close the Lift Up switch. Push the Lift switch at the ground panel to the Up position to test the switch input and continue the test.
5.44 CL O/R SET
System test prompt to close the ground panel Outrigger Set switch. Push the Outrigger switch at the ground panel to the Set position to test the switch input and continue the test.
5.45 CL O/R STOW
System test prompt to close the ground panel Outrigger Stow switch. Push the Outrigger switch at the ground panel to the
Stow position to test the switch input and continue the test.
5.46 CL START
ENGINE POWERED MACHINES ONLY
System test prompt to close the ground Start switch. Push the Start button at the ground panel to test the Start switch input and continue the test.
5.47 CL START SWITCH
ENGINE POWERED MACHINES ONLY
System test prompt to close the platform Start switch. Push the Start button at the platform panel to test the Start switch input and continue the test.
5.48 CL SWING LEFT
System test prompt to close the Swing Left switch. Push the Swing switch at the ground panel to the Left position to test the switch input and continue the test.
5.49 CL SWING RIGHT
System test prompt to close the Swing Right switch. Push the Swing switch at the ground panel to the Right position to test the switch input and continue the test.
5.50 CL TELE IN
System test prompt to close the Telescope In switch. Push the Telescope switch at the ground panel to the In position to test the switch input and continue the test.
5-138
SECTION 5 - SYSTEM TEST MESSAGES
5.51 CL TELE OUT
System test prompt to close the Telescope Out switch. Push the Telescope switch at the ground panel to the Out position to test the switch input and continue the test.
5.52 CLOSE TRIGGER
System test prompt to close the platform joystick Trigger switch. Push the Trigger switch at the platform panel to test the switch input and continue the test.
5.53 DRIVE SWITCH CL
DRIVE OPTION MACHINES ONLY
System test response indicating that the platform drive switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.54 DRV ENABLE
DRIVE OPTION MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.55 DRV ENABLE SHORT TO GROUND OR OPEN CIRCUIT
DRIVE OPTION MACHINES ONLY
The system test detected an open circuit or short to ground in the drive enable valve circuit.
See 2.24 Drive Enable Solenoid Short To Ground Or Open Circuit
5.56 DRV ENABLE VALVE SHORT TO BATTERY
DRIVE OPTION MACHINES ONLY
The system test detected a short to battery in the drive enable valve circuit.
See 2.23 Drive Enable Solenoid Short To Battery
5.57 DRV LEFT FWD
DRIVE OPTION MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.58 DRV LEFT FWD VALVE OPEN CIRCUIT
DRIVE OPTION MACHINES ONLY
The system test detected an open circuit in the drive right reverse valve circuit.
See 2.25 Drive Left Forward Solenoid Open Circuit
5-139
SECTION 5 - SYSTEM TEST MESSAGES
5.59 DRV LEFT FWD VALVE SHORT TO BATTERY
DRIVE OPTION MACHINES ONLY
The system test detected a short to battery in the drive left forward valve circuit.
See 2.26 Drive Left Forward Solenoid Short To Battery
5.60 DRV LEFT FWD VALVE SHORT TO GROUND
DRIVE OPTION MACHINES ONLY
The system test detected a short to ground in the drive left forward valve circuit.
See 2.27 Drive Left Forward Solenoid Short To Ground
5.61 DRV LEFT REV
DRIVE OPTION MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.62 DRV LEFT REV VALVE OPEN CIRCUIT
DRIVE OPTION MACHINES ONLY
The system test detected an open circuit in the drive right reverse valve circuit.
See 2.28 Drive Left Reverse Solenoid Open Circuit
5.63 DRV LEFT REV VALVE SHORT TO BATTERY
DRIVE OPTION MACHINES ONLY
The system test detected a short to battery in the drive left reverse valve circuit.
See 2.29 Drive Left Reverse Solenoid Short To Battery
5.64 DRV LEFT REV VALVE SHORT TO GROUND
DRIVE OPTION MACHINES ONLY
The system test detected a short to ground in the drive left reverse valve circuit.
See 2.30 Drive Left Reverse Solenoid Short To Ground
5.65 DRV RIGHT FWD
DRIVE OPTION MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.66 DRV RIGHT FWD VALVE OPEN CIRCUIT
DRIVE OPTION MACHINES ONLY
The system test detected an open circuit in the drive right forward valve circuit.
See 2.34 Drive Right Forward Solenoid Open Circuit
5-140
SECTION 5 - SYSTEM TEST MESSAGES
5.67 DRV RIGHT FWD VALVE SHORT TO BATTERY
DRIVE OPTION MACHINES ONLY
The system test detected a short to battery in the drive right forward valve circuit.
See 2.35 Drive Right Forward Solenoid Short To Battery
5.68 DRV RIGHT FWD VALVE SHORT TO GROUND
DRIVE OPTION MACHINES ONLY
The system test detected a short to ground in the drive right forward valve circuit.
See 2.36 Drive Right Forward Solenoid Short To Ground
5.69 DRV RIGHT REV
DRIVE OPTION MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.70 DRV RIGHT REV VALVE OPEN CIRCUIT
DRIVE OPTION MACHINES ONLY
The system test detected an open circuit in the drive right reverse valve circuit.
See 2.37 Drive Right Reverse Solenoid Open Circuit
5.71 DRV RIGHT REV VALVE SHORT TO BATTERY
DRIVE OPTION MACHINES ONLY
The system test detected a short to battery in the drive right reverse valve circuit.
See 2.38 Drive Right Reverse Solenoid Short To Battery
5.72 DRV RIGHT REV VALVE SHORT TO GROUND
DRIVE OPTION MACHINES ONLY
The system test detected a short to ground in the drive right reverse valve circuit.
See 2.39 Drive Right Reverse Solenoid Short To Ground
5.73 DUMP VALVE
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.74 DUMP VALVE OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open circuit in the dump valve circuit.
See 2.40 Dump Solenoid Open Circuit
5-141
SECTION 5 - SYSTEM TEST MESSAGES
5.75 DUMP VALVE SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the dump valve circuit.
See 2.41 Dump Solenoid Short To Battery
5.76 DUMP VALVE SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the dump valve circuit.
See 2.42 Dump Solenoid Short To Ground
5.77 ENABLE LAMP ON
System test prompt to check that the platform enable lamp is illuminated. If lamp is illuminating properly, press ENTER on
the analyzer to continue the system test. Otherwise, see possible cause 4.1.11
5.78 EXTEND VALVE
System test prompt indicating that it is currently testing this circuit.
5.79 EXTEND VALVE OPEN CIRCUIT
The system test detected an open in the extend valve circuit.
See 2.45 Extend O/R Solenoid Open Circuit
5.80 EXTEND VALVE SHORT TO BATTERY
The system test detected a short to battery in the extend valve circuit.
See 2.46 Extend O/R Solenoid Short To Battery
5.81 EXTEND VALVE SHORT TO GROUND
The system test detected a short to ground in the extend valve circuit.
See 2.47 Extend O/R Solenoid Short To Ground
5.82 F-L O/R VALVE
System test prompt indicating that it is currently testing this circuit.
5-142
SECTION 5 - SYSTEM TEST MESSAGES
5.83 F-L OUTRIGGER LAMP ON
System test prompt to check that the ground F-L Outrigger lamp is illuminated.
Step
5.83.1
5.83.2
5.83.3
5.83.4
Pretest Instructions Test
Does this indicator illuminate properly?
Yes
No
Do other indicators illuminate instead?
Yes
No
Voltage at X030.2 = 12VDC? Yes
No
Yes
Result
No
5.84 F-L OUTRIGGER VALVE OPEN CIRCUIT
The system test detected an open in the F-L Outrigger valve circuit.
See 2.48 Front-Left O/R Solenoid Open Circuit
5.85 F-L OUTRIGGER VALVE SHORT TO BATTERY
The system test detected a short to battery in the F-L Outrigger valve circuit.
See 2.49 Front-Left O/R Solenoid Short To Battery
5.86 F-L OUTRIGGER VALVE SHORT TO GROUND
The system test detected a short to ground in the F-L Outrigger valve circuit.
See 2.50 Front-Left O/R Solenoid Short To Ground
5.87 F-R O/R VALVE
System test prompt indicating that it is currently testing this circuit.
5.88 F-R OUTRIGGER LAMP ON
System test prompt to check that the ground F-R Outrigger lamp is illuminated.
Step
5.88.1
5.88.2
5.88.3
Pretest Instructions Test
Does this indicator illuminate properly?
Yes
No
Do other indicators illuminate instead?
Yes
No
Voltage at X030.6 = 12VDC? Yes
No
Result
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Check wiring
Possible Causes: Check wires Brn/
Wht 47-25, Brn/Wht 47-25-1, and
Black
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Check wiring
5-143
SECTION 5 - SYSTEM TEST MESSAGES
Step Pretest Instructions
5.88.4
Test
Yes
Result
No
5.89 F-R OUTRIGGER VALVE OPEN CIRCUIT
The system test detected an open in the F-R Outrigger valve circuit.
See 2.51 Front-Right O/R Solenoid Open Circuit
5.90 F-R OUTRIGGER VALVE SHORT TO BATTERY
The system test detected a short to battery in the F-R Outrigger valve circuit.
See 2.52 Front-Right O/R Solenoid Short To Battery
5.91 F-R OUTRIGGER VALVE SHORT TO GROUND
The system test detected a short to ground in the F-R Outrigger valve circuit.
See 2.53 Front-Right O/R Solenoid Short To Ground
5.92 GROUND ALARM ON
Ground system test is sounding the ground alarm.
Step Pretest Instructions
5.92.1
Test
Does ground alarm sound properly?
Yes
No
Result
Corrective Action
Possible Causes: Check wires Brn/
Wht 47-22, Brn/Wht 47-22-1, and
Black
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Broken Orn/Red
49-11 or black wire, Bad ground
5.93 HIGH TILT ANGLE
5.94 JIB DN VALVE
System test prompt indicating that it is currently testing this circuit.
5.95 JIB DOWN CL
System test response indicating that the ground Jib Down switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.96 JIB DOWN VALVE OPEN CIRCUIT
The system test detected an open in the Jib Down valve circuit.
See 2.88 Jib Down Solenoid Open Circuit
5-144
SECTION 5 - SYSTEM TEST MESSAGES
5.97 JIB DOWN VALVE SHORT TO BATTERY
The system test detected a short to battery in the Jib Down valve circuit.
See 2.89 Jib Down Solenoid Short To Battery
5.98 JIB DOWN VALVE SHORT TO GROUND
The system test detected a short to ground in the Jib Down valve circuit.
See 2.90 Jib Down Solenoid Short To Ground
5.99 JIB UP CL
System test response indicating that the ground Jib Up switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.100 JIB UP VALVE
System test prompt indicating that it is currently testing this circuit.
5.101 JIB UP VALVE OPEN CIRCUIT
The system test detected an open in the Jib Up valve circuit.
See 2.91 Jib Up Solenoid Open Circuit
5.102 JIB UP VALVE SHORT TO BATTERY
The system test detected a short to battery in the Jib Up valve circuit.
See 2.92 Jib Up Solenoid Short To Battery
5.103 JIB UP VALVE SHORT TO GROUND
The system test detected a short to ground in the Jib Up valve circuit.
See 2.93 Jib Up Solenoid Short To Ground
5.104 JOYSTICK FORWARD TO MAX
System test prompt to move the platform joystick forward to the extent for the system to check the voltage. Move the joystick
all the way forward to continue the system test. Otherwise, see possible cause 4.1.22
5.105 JOYSTICK LEFT TO MAX
System test prompt to move the platform joystick left to the extent for the system to check the voltage. Move the joystick all
the way left to continue the system test. Otherwise, see possible cause 4.1.22
5.106 JOYSTICK REVERSE TO MAX
System test prompt to move the platform joystick reverse to the extent for the system to check the voltage. Move the joystick
all the way rearward to continue the system test. Otherwise, see possible cause 4.1.22
5-145
SECTION 5 - SYSTEM TEST MESSAGES
5.107 JOYSTICK RIGHT TO MAX
System test prompt to move the platform joystick right to the extent for the system to check the voltage. Move the joystick all
the way right to continue the system test. Otherwise, see possible cause 4.1.22
5.108 LEVEL DN VALVE
System test prompt indicating that it is currently testing this circuit.
5.109 LEVEL DOWN CL
System test response indicating that the ground level down switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.110 LEVEL DOWN VALVE OPEN CIRCUIT
The system test detected an open in the Level Down valve circuit.
See 2.98 Level Down Solenoid Open Circuit
5.111 LEVEL DOWN VALVE SHORT TO BATTERY
The system test detected a short to battery in the Level Down valve circuit.
See 2.99 Level Down Solenoid Short To Battery
5.112 LEVEL DOWN VALVE SHORT TO GROUND
The system test detected a short to ground in the Level Down valve circuit.
See 2.100 Level Down Solenoid Short To Ground
5.113 LEVEL UP CL
System test response indicating that the ground level up switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.114 LEVEL UP VALVE
System test prompt indicating that it is currently testing this circuit.
5.115 LEVEL UP VALVE OPEN CIRCUIT
The system test detected an open in the Level Up valve circuit.
See 2.101 Level Up Solenoid Open Circuit
5.116 LEVEL UP VALVE SHORT TO BATTERY
The system test detected a short to battery in the Level Up valve circuit.
See 2.102 Level Up Solenoid Short To Battery
5-146
SECTION 5 - SYSTEM TEST MESSAGES
5.117 LEVEL UP VALVE SHORT TO GROUND
The system test detected a short to ground in the Level Up valve circuit.
See 2.103 Level Up Solenoid Short To Ground
5.118 LIFT DN VALVE
System test prompt indicating that it is currently testing this circuit.
5.119 LIFT DOWN CL
System test response indicating that the ground lift down switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.120 LIFT DOWN VALVE OPEN CIRCUIT
The system test detected an open in the Lift Down valve circuit.
See 2.105 Lift Down Solenoid Open Circuit
5.121 LIFT DOWN VALVE SHORT TO BATTERY
The system test detected a short to battery in the Lift Down valve circuit.
See 2.106 Lift Down Solenoid Short To Battery
5.122 LIFT DOWN VALVE SHORT TO GROUND
The system test detected a short to ground in the Lift Up valve circuit.
See 2.107 Lift Down Solenoid Short To Ground
5.123 LIFT UP CL
System test response indicating that the ground lift up switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.124 LIFT UP VALVE
System test prompt indicating that it is currently testing this circuit.
5.125 LIFT UP VALVE OPEN CIRCUIT
The system test detected an open in the Lift Up valve circuit.
See 2.114 Lift Up Solenoid Open Circuit
5.126 LIFT UP VALVE SHORT TO BATTERY
The system test detected a short to battery in the Lift Up valve circuit.
See 2.115 Lift Up Solenoid Short To Battery
5-147
SECTION 5 - SYSTEM TEST MESSAGES
5.127 LIFT UP VALVE SHORT TO GROUND
The system test detected a short to ground in the Lift Up valve circuit.
See 2.116 Lift Up Solenoid Short To Ground
5.128 MULTIPLE CLOSURE
System test response indicating that multiple switches have been closed when a single switch was expected. The desired switch may or may not be one of the switches closing. Make sure that no other switches are being activated or check the switch wiring.
5.129 O/R SET CL
System test response indicating that the ground Outrigger Set switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.130 O/R SET LAMP ON
System test prompt to check that the platform outriggers set lamp is illuminated. If lamp is illuminating properly, press
ENTER on the analyzer to continue the system test. Otherwise, see possible cause 4.1.11
5.131 O/R STOW CL
System test response indicating that the ground Outrigger Stow switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.132 OP CHOKE
System test prompt to open the ground panel engine Choke switch. Release the switch at the ground panel to test the switch input and continue the test.
5.133 OP CHOKE SWITCH
System test prompt to open the platform panel engine Choke switch. Release the switch at the platform panel to test the switch input and continue the test.
5.134 OP DRIVE SWITCH
System test prompt to open the platform panel drive switch. Release the switch at the platform panel to test the switch input and continue the test.
5.135 OP JIB DOWN
System test prompt to open the ground panel Jib Down switch. Release the switch at the ground panel to test the switch input and continue the test.
5.136 OP JIB UP
System test prompt to open the ground panel Jib Up switch. Release the switch at the ground panel to test the switch input and continue the test.
5-148
SECTION 5 - SYSTEM TEST MESSAGES
5.137 OP LEVEL DOWN
System test prompt to open the ground panel Level Down switch. Release the switch at the ground panel to test the switch input and continue the test.
5.138 OP LEVEL UP
System test prompt to open the ground panel Level Up switch. Release the switch at the ground panel to test the switch input and continue the test.
5.139 OP LIFT DOWN
System test prompt to open the ground panel Lift Down switch. Release the switch at the ground panel to test the switch input and continue the test.
5.140 OP LIFT UP
System test prompt to open the ground panel Lift Up switch. Release the switch at the ground panel to test the switch input and continue the test.
5.141 OP O/R SET
System test prompt to open the ground panel Outrigger Set switch. Release the switch at the ground panel to test the switch input and continue the test.
5.142 OP O/R STOW
System test prompt to open the ground panel Outrigger Stow switch. Release the switch at the ground panel to test the switch input and continue the test.
5.143 OP START
System test prompt to open the ground panel engine Start switch. Release the switch at the ground panel to test the switch input and continue the test.
5.144 OP START SWITCH
System test prompt to open the platform panel engine Start switch. Release the switch at the platform panel to test the switch input and continue the test.
5.145 OP SWING LEFT
System test prompt to open the ground panel Swing Left switch. Release the switch at the ground panel to test the switch input and continue the test.
5.146 OP SWING RIGHT
System test prompt to open the ground panel Swing Right switch. Release the switch at the ground panel to test the switch input and continue the test.
5-149
SECTION 5 - SYSTEM TEST MESSAGES
5.147 OP TELE IN
System test prompt to open the ground panel Telescope In switch. Release the switch at the ground panel to test the switch input and continue the test.
5.148 OP TELE OUT
System test prompt to open the ground panel Telescope Out switch. Release the switch at the ground panel to test the switch input and continue the test.
5.149 OPEN TRIGGER
System test prompt to open the platform trigger switch. Release the switch at the platform panel to test the switch input and continue the test.
5.150 OPT GROUND ALARM ON
Ground system test is sounding the optional ground (motion) alarm.
Step Pretest Instructions
5.150.1
Test
Does the alarm sound properly?
Yes
Result
No
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Broken Yel/Red 2-
13 or Yel/Red 2-14 or black wire, Bad
5.151 PLATFORM ALARM ON
System test prompt to check that the platform alarm is sounding. If alarm is sounding properly, press ENTER on the analyzer
to continue the system test. Otherwise, see possible cause 4.1.11
5.152 RETRACT VALVE
System test prompt indicating that it is currently testing this circuit.
5.153 RETRACT VALVE OPEN CIRCUIT
The system test detected an open in the Retract Outriggers valve circuit.
See 2.135 Retract O/R Solenoid Open Circuit
5.154 RETRACT VALVE SHORT TO BATTERY
The system test detected a short to battery in the Retract Outriggers valve circuit.
See 2.136 Retract O/R Solenoid Short To Battery
5.155 RETRACT VALVE SHORT TO GROUND
The system test detected a short to ground in the Retract Outriggers valve circuit.
See 2.137 Retract O/R Solenoid Short To Ground
5-150
SECTION 5 - SYSTEM TEST MESSAGES
5.156 R-L O/R VALVE
System test prompt indicating that it is currently testing this circuit.
5.157 R-L OUTRIGGER LAMP ON
System test prompt to check that the ground Rear-Left Outrigger lamp is illuminated.
Step
5.157.1
5.157.2
5.157.3
5.157.4
Pretest Instructions Test
Does this indicator illuminate properly?
Yes
Do other indicators illuminate instead?
No
Yes
No
Voltage at X030.3 = 12VDC? Yes
No
Yes
Result
No
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Check wiring
Possible Causes: Check wires Brn/
Wht 47-24, Brn/Wht 47-24-1, and
Black
5.158 R-L OUTRIGGER VALVE OPEN CIRCUIT
The system test detected an open in the Rear-Left Outriggers valve circuit.
See 2.129 Rear-Left O/R Solenoid Open Circuit
5.159 R-L OUTRIGGER VALVE SHORT TO BATTERY
The system test detected a short to battery in the Rear-Left Outriggers valve circuit.
See 2.130 Rear-Left O/R Solenoid Short To Battery
5.160 R-L OUTRIGGER VALVE SHORT TO GROUND
The system test detected a short to ground in the Rear-Left Outriggers valve circuit.
See 2.131 Rear-Left O/R Solenoid Short To Ground
5.161 ROTARY TO JIB/TELE
Platform system test prompt to turn the rotary select switch to the Jib/Telescope position.
5.162 ROTARY TO LEVEL
Platform system test prompt to turn the rotary select switch to the Platform Leveling position.
5.163 ROTARY TO LIFT/SWING
Platform system test prompt to turn the rotary select switch to the Lift/Swing position.
5-151
SECTION 5 - SYSTEM TEST MESSAGES
5.164 R-R O/R VALVE
System test prompt indicating that it is currently testing this circuit.
5.165 R-R OUTRIGGER LAMP ON
System test prompt to check that the ground Rear-Right Outrigger lamp is illuminated.
Step
5.165.1
5.165.2
5.165.3
5.165.4
Pretest Instructions Test
Does this indicator illuminate properly?
Yes
Do other indicators illuminate instead?
No
Yes
No
Voltage at X030.7 = 12VDC? Yes
No
Yes
Result
No
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Check wiring
Possible Causes: Check wires Brn/
Wht 47-23, Brn/Wht 47-23-1, and
Black
5.166 R-R OUTRIGGER VALVE OPEN CIRCUIT
The system test detected an open in the Rear-Right Outrigger valve circuit.
See 2.132 Rear-Right O/R Solenoid Open Circuit
5.167 R-R OUTRIGGER VALVE SHORT TO BATTERY
The system test detected a short to battery in the Rear-Right Outriggers valve circuit.
See 2.133 Rear-Right O/R Solenoid Short To Battery
5.168 R-R OUTRIGGER VALVE SHORT TO GROUND
The system test detected a short to ground in the Rear-Right Outriggers valve circuit.
See 2.134 Rear-Right O/R Solenoid Short To Ground
5.169 RUNNING
System test prompt indicating that it is currently running tests
5.170 START CL
ENGINE POWERED MACHINES ONLY
System test response indicating that the ground start switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5-152
SECTION 5 - SYSTEM TEST MESSAGES
5.171 START SOLENOID
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.172 START SOLENOID OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open in the Start circuit.
See 2.141 Start Solenoid Open Circuit
5.173 START SOLENOID SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the Engine Start circuit.
See 2.142 Start Solenoid Short To Battery
5.174 START SOLENOID SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the Engine Start circuit.
See 2.143 Start Solenoid Short To Ground
5.175 START SWITCH CL
ENGINE POWERED MACHINES ONLY
System test response indicating that the platform start switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.176 SWING LEFT CL
ENGINE POWERED MACHINES ONLY
System test response indicating that the ground swing left switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.177 SWING LEFT VALVE OPEN CIRCUIT
The system test detected an open in the Swing Left valve circuit.
See 2.144 Swing Left Solenoid Open Circuit
5.178 SWING LEFT VALVE SHORT TO BATTERY
The system test detected a short to battery in the Swing Left valve circuit.
See 2.145 Swing Left Solenoid Short To Battery
5-153
SECTION 5 - SYSTEM TEST MESSAGES
5.179 SWING LEFT VALVE SHORT TO GROUND
The system test detected a short to ground in the Swing Left valve circuit.
See 2.146 Swing Left Solenoid Short To Ground
5.180 SWING LT VALVE
System test prompt indicating that it is currently testing this circuit.
5.181 SWING RIGHT CL
System test response indicating that the ground Swing Right switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.182 SWING RIGHT VALVE OPEN CIRCUIT
The system test detected an open in the Swing Right valve circuit.
See 2.147 Swing Right Solenoid Open Circuit
5.183 SWING RIGHT VALVE SHORT TO BATTERY
The system test detected a short to battery in the Swing Right valve circuit.
See 2.148 Swing Right Solenoid Short To Battery
5.184 SWING RIGHT VALVE SHORT TO GROUND
The system test detected a short to ground in the Swing Right valve circuit.
See 2.149 Swing Right Solenoid Short To Ground
5.185 SWING RT VALVE
System test prompt indicating that it is currently testing this circuit.
5.186 SYSTEM DISTRESS LAMP ON
System test prompt to check that the system distress lamp is illuminated.
Step Pretest Instructions
5.186.1
5.186.2
5.186.3
Test Result
Does this indicator illuminate properly?
Yes
No
Do other indicators illuminate instead?
Yes
No
Which test is running?
Ground System Test
Platform System Test
Corrective Action
Press ENTER on the analyzer to continue the system test
Possible Causes: Check wiring
Possible Causes: Brn/Wht 47-20 wire
5-154
SECTION 5 - SYSTEM TEST MESSAGES
5.187 TELE IN CL
System test response indicating that the ground Telescope In switch has been closed when a different switch was expected.
Make sure the correct switch is being activated or check the switch wiring.
5.188 TELE IN VALVE
System test prompt indicating that it is currently testing this circuit.
5.189 TELE OUT CL
System test response indicating that the ground Telescope Out switch has been closed when a different switch was expected. Make sure the correct switch is being activated or check the switch wiring.
5.190 TELE OUT VALVE
System test prompt indicating that it is currently testing this circuit.
5.191 TELESCOPE IN VALVE OPEN CIRCUIT
The system test detected an open in the Telescope In valve circuit.
See 2.152 Telescope In Solenoid Open Circuit
5.192 TELESCOPE IN VALVE SHORT TO BATTERY
The system test detected a short to battery in the Telescope In valve circuit.
See 2.153 Telescope In Solenoid Short To Battery
5.193 TELESCOPE IN VALVE SHORT TO GROUND
The system test detected a short to ground in the Telescope In valve circuit.
See 2.154 Telescope In Solenoid Short To Ground
5.194 TELESCOPE OUT VALVE OPEN CIRCUIT
The system test detected an open in the Telescope Out valve circuit.
See 2.155 Telescope Out Solenoid Open Circuit
5.195 TELESCOPE OUT VALVE SHORT TO BATTERY
The system test detected a short to battery in the Telescope Out valve circuit.
See 2.156 Telescope Out Solenoid Short To Battery
5.196 TELESCOPE OUT VALVE SHORT TO GROUND
The system test detected a short to ground in the Telescope Out valve circuit.
See 2.157 Telescope Out Solenoid Short To Ground
5-155
SECTION 5 - SYSTEM TEST MESSAGES
5.197 TESTS COMPLETE
System test message indicating that the testing is completed.
5.198 THROTTLE HOLD
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.199 THROTTLE HOLD SOLENOID OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open in the Throttle Hold circuit.
See 2.158 Throttle Hold Solenoid Open Circuit
5.200 THROTTLE HOLD SOLENOID SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the Engine Throttle Hold circuit.
See 2.159 Throttle Hold Solenoid Short To Battery
5.201 THROTTLE HOLD SOLENOID SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the Engine Throttle Hold valve circuit.
See 2.160 Throttle Hold Solenoid Short To Ground
5.202 THROTTLE PULL
ENGINE POWERED MACHINES ONLY
System test prompt indicating that it is currently testing this circuit.
5.203 THROTTLE PULL RELAY OPEN CIRCUIT
ENGINE POWERED MACHINES ONLY
The system test detected an open in the Throttle Pull circuit.
See 2.161 Throttle Pull Relay Open Circuit
5.204 THROTTLE PULL RELAY SHORT TO BATTERY
ENGINE POWERED MACHINES ONLY
The system test detected a short to battery in the Engine Throttle Pull circuit.
See 2.162 Throttle Pull Relay Short To Battery
5-156
SECTION 5 - SYSTEM TEST MESSAGES
5.205 THROTTLE PULL RELAY SHORT TO GROUND
ENGINE POWERED MACHINES ONLY
The system test detected a short to ground in the Engine Throttle Pull circuit.
See 2.163 Throttle Pull Relay Short To Ground
5.206 TILT LAMP ON
System test prompt to check that the platform tilt lamp is illuminating properly. If the lamp is illuminating properly, press
ENTER on the analyzer to continue the system test. Otherwise, see possible cause 4.1.11
5-157
SECTION 5 - SYSTEM TEST MESSAGES
5-158
SECTION 6 - CALIBRATION MESSAGES
SECTION 6.
CALIBRATION MESSAGES
This section is reserved for messages related to the calibration process using the analyzer.
6-159
SECTION 6 - CALIBRATION MESSAGES
6-160
SECTION 7 - ELECTRICAL REFERENCE
SECTION 7.
ELECTRICAL REFERENCE
3121203
7-161
SECTION 7. ELECTRICAL REFERENCE
Connector Layout
PLATFORM CONTROL PANEL
BOOM AREA
GROUND CONTROL PANEL
OUTRIGGERS
HYDRAULIC VALVES
ELECTRIC POWER (OPT.)
GAS ENGINE (OPT.)
DRIVE AND SET (OPT.)
Platform Module
3
2
1
X098
Choke Solenoid
X097
Throttle Solenoid
GAS ENGINE
X088
X089
Sol. Fuse
Starter Sol.
X092 Oil Level Switch
X095 Eng. Speed
X096
Rectifier
X090
Eng. Stop Relay
X091
Throttle Relay
X093
Choke Relay
X056
T500J Only
Jib Down Valve
(9.8 )
X041
X057
X058
X040
X039
Lift Down Valve
Valve Connections
SECTION 7 - ELECTRICAL REFERENCE
X009
X010
X011
(Electric Pwr. Only)
B+
X101
X102
X103
X104
Main Harness
X008
X001
X002
X007
X003
X004
3121203
See Rear Left
Outrigger View for Detail
X043
X047
X022
X045
X049
X044
Rear Left Outrigger
Limit Switch
X048
Rear Left
Outrigger
Valve
(7.2 )
X046
Front Left Outrigger Valve
X042
X013
X014
X015
X016
X017
X018
X019
X020
X021
X054
X055
Ground Module
Power Module
Electric Powered Only
Figure 7-1. Frame Connector Layout
X080
LEVEL UP
X081
LEVEL DOWN
X082
TELE. OUT
X083
Ω
TELE. IN
(8.0 )
X078
SWING RT.
(8.0 )
X077
SWING LF.
X079
T500 ONLY
JIB UP
( 8.0
Ω
)
X087
ENGINE MODELS ONLY
DUMP
VALVE
(6.0 )
X084
LIFT UP
X086
L/J SET
(8.0 )
Figure 7-2. Ground Control / Valve Connections
X114
X115
X085
L/J STOW
Ω
7-162
Electrical Schematic
3121203
SECTION 7 - ELECTRICAL REFERENCE
F
E
D
C
B
A
H
G
O/R SET
ENABLE
SYSTEM DISTRESS
BATTERY
TILT
SPARE
PLATFORM
CONTROL
BOARD
X060 (J1)
8 7 6 5 4 3
GROUND CONTROL BOX
2 1
13
14
15
11
12
16
7
8
6
9
4
3
5
10
1
2
BLACK
YEL/RED 2-20
RED
BLACK
YEL/RED 2-18
ORN/RED 49-22
BLACK
ORN/RED 49-21
ORN/RED 49-27
ORN/RED 49-28
YEL/RED 2-33
BLACK
WHT/YEL 48-1
ORN/RED 49-30
ORN/RED 49-29
ORN/RED 49-25
ALARM
CHOKE
ENG. ONLY
DRIVE
MODULE
4
GND 5V
9
8
7
6
10
11
12
4
3
5
2
1
4
3
5
2
1
10
9
8
7
6
11
12
3
2
BLACK
ORN/RED 58-1
ORN/RED 59-1
ORN/RED 56-1
ORN RED 57-1
ORN 7-4
ORN 8-4
ORN 7-2
ORN 8-2
ORN 55-1
1
GND 5V
YEL/RED 2-16-2
TURNTABLE POS.1
TURNTABLE POS.2
HAND BRAKE 1
HAND BRAKE 2
X067
X069
X068
X070
X071
LEFT DRIVE FORWARD
LEFT DRIVE REVERSE
RIGHT DRIVE FORWARD
RIGHT DRIVE REVERSE
DRIVE DUMP
BLACK
X073
X072
YEL/RED 2-4
MTB
SELECT
SWITCH
X026
1
3
YEL/RED 2-5
B
YEL/RED
2-1(12)
16
YEL/RED 2-5
2
X013
MTB
EMS
X037
30A
X013
1
FRONT LEFT O/R
REAR LEFT L/J
FRONT RIGHT O/R
REAR RIGHT O/R
CHOKE
(ENG.ONLY)
TELE
LEVEL
IN
OUT
UP
DOWN
BRN/WHT 47-25
BRN/WHT 47-24
BRN/WHT 47-22
BRN/WHT 47-23
BROWN 13-2
BROWN 14-2
PINK 25-2
PINK 26-2
2
6
26
3
21
7
BLACK
2-41-1
START
(ENGINE ONLY)
YEL/RED
2-40-1
YEL/RED 2-41
WHT/YEL 48-1
WHT/YEL 48-9
ENABLE
2-40
14
GRN. IGN. RELAY
13
1
9
12
11
10
BRN/WHT 47-25-1
BRN/WHT 47-24-1
BRN/WHT 47-22-1
BRN/WHT 47-23-1
YEL/RED 2-40
20
27
WHT/YEL 48-1-1
WHT/YEL 48-9-1
BLACK
BROWN 13-2-1
BROWN 14-2-1
PINK 25-2-1
PINK 26-2-1
5
WHITE
GREEN
ANALYZER POWER
ANALYZER GROUND
ANALYZER TRANSMIT
ANALYZER RECEIVE
X076
4
1
3
2
X012
SHIELD
5
4 3
PLATFORM BOX
CONNECTOR
RED/BLK
BLUE
PLTF
EMS
RED
BLACK
SHIELD
ORANGE
YELLOW
BROWN
BLU/BLK
ORN/BLK
YEL/BLK
BRN/BLK
X059
D
H
F
G
E
B
A
C
P
M
N
J
L
K
NOT AVAILABLE
ON JIB MODEL
REMOTE
CONTROL CABLE
X012
2 1
YEL/RED 2-16
BLACK
X009
12V OR 24V
IGN. RELAY
86
85
87
X004.32
30
87a
JIB UP
DOWN
LIFT
SWING
RIGHT
LEFT
UP
DOWN
OUTRIGGERS
SET
STOW
TRANSPORT
LIMIT SWITCH
TELESCOPE
LIMIT SWITCH
21
21
BLUE 27-2
BLUE 28-2
TAN 3-2
TAN 4-2
WHITE 22-2
WHITE 21-2
ORN/WHT 55-2
ORN/WHT 55-1
22
BLACK
WHITE
22
WHITE
BLACK
X018
1
24
22
18
25
23
BLUE 27-2-1
BLUE 28-2-1
TAN 3-2-1
TAN 4-2-1
WHITE 22-2-1
19
6
5
X015
1
2
ORN/WHT 55-1-1
ORN/RED 49-53
YEL/RED 2-26
YEL/RED 2-26-1
2
ORN/RED 49-72
RED/BLK
BLUE
RED
BLACK
SHIELD
ORANGE
BROWN
BLU/BLK
ORN/BLK
YEL/BLK
BRN/BLK
RED
BLACK
GND FROM BATTERY
MTB EMS input
15
P
M
N
J
L
K
X058
D
H
X057
120
E
B
A
C
F
G
RED/BLK
YELLOW
BLU/BLK
ORN/BLK
YEL/BLK
BRN/BLK
RED
BLACK
SHIELD
ORANGE
BROWN
BOOM
CABLE X056 2
CAN BUS CABLE
1
X054
8
4
X052
12
13
14
10
11
9
7
6
5
2
3
1
P
N M L J
K
CAN HI
CAN LO
CAN SHIELD
G F
HOOK GND.
CONTROL REMOTE
(OPTIONAL)
E
B C A
RED/BLK
BLUE
RED
BLACK
SHIELD
ORANGE
YELLOW
BROWN
BLU/BLK
ORN/BLK
YEL/BLK
BRN/BLK
X051
8
6
7
5
2
3
1
4
10
11
12
9
X055
FRAME
HARNESS
GND TO PLATFORM
MTB EMS TO PLATFORM
RED
BLACK
SHIELD
ORANGE
YELLOW
BROWN
3
5
1
6
7
2
X019
RED
BLACK
SHIELD
YEL/RED 2-4
4
X019
8
YEL/RED 2-7
BROWN (SPARE)
BLK
YEL/RED 2-11
IGN. RELAY 86
IGN. RELAY 86
IGN. RELAY 86
IGN. RELAY 86
BLU/BLK
YEL/BLK
BRN/BLK
10
11
12
9 ORN/RED 49-9
ORN/RED 49-10
BLUE 28-3-1
BLACK
J2-20 (F-2)
D H
TURNTABLE
X053
CAN BUS TO
POWER MODULE
RED
BLACK
SHIELD CAN BUS CABLE
6 7 8 9 10
X061
JIB DOWN (PWM)
BLK VIO
FRONT/LEFT OUTRIGGER SET LIMIT SWITCH
FRONT/RIGHT OUTRIGGER SET LIMIT SWITCH
REAR/LEFT OUTRIGGER SET LIMIT SWITCH
REAR/RIGHT OUTRIGGER SET LIMIT SWITCH
21
21
21
21
22
22
22
22
BLACK
BLACK
BLACK
WHITE
BLACK
1
2
3
4
5
ORN/RED 49-1
ORN/RED 49-2
ORN/RED 49-3
ORN/RED 49-4
YEL/RED 2-6
C/D OUT “X”
HALL EFFECT
SENSOR
A/B OUT “Y”
HALL EFFECT
SENSOR
PLATFORM
JOYSTICK
BLACK
SPARK
PLUG
IGN.
COIL
N.O. OIL
PRESSURE
SWITCH
87a
BLACK
87
87a
THROTTLE PULL
WHT/YEL 48-2-1(12)
X097
THROTTLE SOLENOID
BLACK (12)
THROTTLE HOLD
CHOKE PULL
WHT/YEL 48-4-1(12)
CHOKE HOLD
X098
CHOKE SOLENOID
BLACK (12)
87
87a
87
15
AMP
STARTER
MOTOR
SOL.
OPTIONAL 12V
HONDA ENGINE.
30
30
30
85 86
X090 ENGINE STOP RELAY
85 86
85
86
X091 ENGINE THROTTLE PULL RELAY
X093 ENGINE CHOKE PULL RELAY
STARTER
MOTOR
WHT/YEL 48-10
WHT/YEL 48-11
2
LOADING VIEW
POS.
NEG.
YEL/RED 2-3 IGN. RELAY 87
X096 VOLTAGE REGULATOR
WHT/YEL 48-13
ENGINE SPEED PICK-UP
ENGINE START
USE JUMPER FROM 6 TO 17 ON
ENGINE POWERED MACHINES ONLY.
CHOKE PULL
THROTTLE HOLD
THROTTLE PULL
CHOKE HOLD
8
6
7
4
5
3
WHT/YEL 48-4
WHT/YEL 48-3
WHT/YEL 48-2
WHT/YEL 48-5
WHT/YEL 48-7
WHT/YEL 48-6
J1-16 (D-2)
J2-23 (F-2)
7
9
11
4
12
26
1
14
13
29
30
17
5
7
32
4
16
18
6
24
10
12
19
34
20
9
11
33
35
8
23
25
2
21
+12 VDC OUTPUT WHEN
ON GROUND CONTROLS
THE FOLLOWING J4 POSITIONS ARE NOT USED:
1, 2, 3, 4, 5, 6, 10, 12,
15, 18, 22, 27, 28, 31.
THE FOLLOWING J2 POSITIONS ARE NOT USED:
1, 2, 10, 13, 15, 17, 18,
21, 24, 25, 26, 27, 28.
35
12
29
11
23
32
9
6
20
25
10
27
22
17
28
31
5
34
21
33
30
26
14
4
13
24
18
1
15
2
3
16
19
8
7
4
3
2
1
28
3
31
22
27
FOR ELECTRIC ONLY
FOR ENGINE ONLY
THE FOLLOWING J1 POSITIONS ARE NOT USED:
1, 2, 4, 5, 6, 7, 8, 9, 10, 11
12, 13, 14, 15, 17, 18, 19, 20, 21,
22, 23, 25, 26, 27, 32, 33, 34, 35.
THE FOLLOWING J7 POSITIONS ARE NOT USED:
4, 5, 9, 10, 14, 15, 16, 20, 21, 22,
25, 26, 27, 28, 30, 31, 32, 33, 34.
THE FOLLOWING J3 POSITIONS
ARE NOT USED: 1, 5.
X003 (J3) (BLACK)
GROUND BOLT ON
ENGINE HOUSING
12V ENGINE
BATTERY
TO CHARGE COIL
X095
X014
X021
X016
X030
X022
X020
= M.T.B. 31 POS. CONNECTOR AT FRAME HARNESS.
= 12 POS. VALVE CONNECTOR IN FRAME HARNESS.
= 2 POS. CONNECTOR AT FRAME HARNESS.
= 8 POS. CONNECTOR AT GROUND CONTROL LED BOARD.
= 8 POS. CONNECTOR AT FRONT LEFT OUTRIGGER.
= 12 POS. CONN. OUTRIGGER VALVE/ LIMIT SWITCH
REFERENCE 1870172 C
ALL WIRES ARE 18 GA. UNLESS NOTED OTHERWISE.
NOTE: SEE 1870185 FOR ALL TRAILER WIRING,
BRAKE OPTIONS, COUNTRY SPEC. 1870172 IS
FOR TROUBLE SHOOTING THE MACHINE ONLY.
14
10
3
13
6
8
2
27
19
26
32
30
2
15
10
21
5
7
35
34
11
22
12
16
4
9
3
23
33
20
1
29
31
14
17
24
6
28
25
13
18
8
24
25
26
27
16
17
34
32
19
33
21
35
28
29
30
31
9
12
13
23
6
3
2
20
5
10
11
14
15
8
4
18
7
22
1
BRN/WHT 47-20-1
BRN/WHT 47-21-1
ORN/RED 49-11-1
BRN/WHT 47-7-1
BLACK
PINK 25-3-1
PINK 26-3-1
BLUE 27-3-1
BROWN 13-3-1
BROWN 14-3-1
TAN 3-3-1
TAN 4-3-1
WHITE 22-3-1
WHITE 21-3-1
RED/WHT 50-1-1
BLACK
BLACK
BLUE 28-3-1
YEL/RED 2-15
WHT/YEL 48-6
YEL/RED 2-13
IGN. RELAY 85
IGN. RELAY 87
IGN. RELAY 87
YEL/RED 2-43
WHT/YEL 48-7
3
2
3
2
5
4
8
1
1
1
6
9
12
7
17
8
7
2
4
3
BRN/WHT 47-20
BRN/WHT 47-21
ORN/RED 49-11
BLACK
BRN/WHT 47-7
BLACK
PINK 25-3
PINK 26-3
TAN 4-3
BLUE 27-3
BROWN 13-3
BROWN 14-3
TAN 3-3
1
WHITE 22-3
WHITE 21-3
RED/WHT 50-1
BLACK
BLACK
BLACK
YEL/RED 2-14
IGN. RELAY-87
ENGINE MAG. SPEED PICK-UP
(SEE ENGINE AREA B-4)
X002.3
YEL/RED 2-15
X007.13
X007.24
(CAN HI) RED
(CAN LO) BLACK
4
3
5
2
1
9
8
7
6
10
11
12
X010
5
1
ALARM
X028
HOURMETER
X027
JIB DOWN (PWM)-SEE BOOM CABLE AREA, E-4
POWER MODULE- SEE POWER MODULE AREA D-2
ENGINE START- SEE ENGINE AREA B-4
4
X017
3
2
ALARM
1
(OPTIONAL)
YEL/RED 2-12
X080
X081
UP
LEVEL
X079 UP
JIB
X083 IN
X082
X084 UP
DOWN
LIFT
X078
X077
RIGHT
LEFT
SWING
2 X039
X087 DUMP VALVE (PWM)
(ENGINE ONLY)
BLACK
RED
GREEN
WHITE
BLACK/SHIELD
31
30
29
28
B-
B+
M1
24V SYSTEM
WIRING INFO FOR SEVCON
(#1600371)
M2
RED
GREEN
WHITE
BLACK/SHIELD
ANALYZER POWER
ANALYZER RECEIVE
ANALYZER TRANSMIT
ANALYZER GROUND
BATTERY -
BLACK (12)
BLACK (12)
BATTERY +
RED (12)
RED (12)
PUMP +
PUMP -
FOR CONNECTOR WIRING
SEE C2 LOCATION.
12V SYSTEM
B+
1 GA.
POS.
+
PUMP
-
M
NEG.
1 GA.
4
3
2
1
B-
A
SYSTEM DISTRESS
SPARE
GND ALARM STD
24V SYSTEM
B+
BLACK (12)
B-
RED 1-1(12)
B-
B+
SEVCON MILI-PAK
BATTERY
DISCONNECT
B+
1 GA.
POWER MODULE CONNECTOR
DETAIL AND LOCATION
(ELECTRIC ONLY)
BATTERY
CHARGER
B+
B-
1 GA.
ORN/RED 49-5
ORN/RED 49-7
ORN/RED 49-6
ORN/WHT 55-3-1
ORN/WHT 55-4-1
ORN/RED 49-8
BLACK
J2-14
6
7
11
10
8
9
10
BLACK
WHITE
WHITE
WHITE
ORN/WHT 55-3
ORN/WHT 55-4
WHITE
BLACK
12 BLACK
X046
X048
FRONT/LEFT OUTRIGGER
REAR/LEFT OUTRIGGER
X047
X086
X085
FRONT/RIGHT OUTRIGGER
EXTEND O/R
RETRACT O/R
X049 REAR/RIGHT OUTRIGGER
24V
18V
12V
6V
24V MACHINE
BATTERY
H
G
F
E
D
C
B
A
8 7 6 5 4 3 22 1
Figure 7-3. Electrical Schematic
7-163
Wiring Diagram
3121203
SECTION 7 - ELECTRICAL REFERENCE
X035
X036
X027
X026
X040
X029
X039
GROUND CONTROL BOX
X033
X037
X031
X025
X016
TRANSPORT/ABOVE
LEVEL LIMIT SWITCH
X041
TELESCOPE
LIMIT SWITCH
X042
X044
O/R JACK
LIMIT
SWITCH
O/R JACK
LIMIT
SWITCH
X024
X009
IGNITION
RELAY
X015
X018
X020
O/R
JACK
VALVE
X046
X048
O/R
JACK
VALVE
X032
X034
X051
X053
X059
PLATFORM CONSOLE
X060
X019
AC
OUTLET
BOX
X055
X052
X054
LOCATED ON T/T AT
LIFT HOOK STOW
X061
X030
STROBE
LIGHT
X058
X023
X013
X014
X001
X002
X003
O/R
JACK
VALVE
X047
X049
O/R
JACK
VALVE
X028
X017
J1
J2
J3
X008
J7
J4
X038
J8
O/R JACK
LIMIT
SWITCH
O/R JACK
LIMIT
SWITCH
X050
MOTION
ALARM
X007
X004
X043
X045
DRIVE PROXIMITY
SWITCHES (OPTIONAL)
X012
X073
X021
X072
X114
DRIVE DIRECTIONAL
VALVE (OPTIONAL)
X068
X067
DRIVE ENABLE
VALVE
(OPTIONAL)
X070
X115
X074
J1
X057
X071
X102
X101
X075
X076
J2
DRIVE
MODULE
(OPTIONAL)
X056
JIB
VALVE
(T500J
ONLY)
X069
F1
B–
B+
F2
P
M1
X116
X098
M2
X010
X103
X104
SEVCON MODULE
(ELECTRIC POWERED)
LEFT SIDE
MARKER LIGHT
LOCATED AT
PLATFORM
PIVOT X063
X066
BATTERY
CHARGER
(ELECTRIC
POWERED)
VALVE/MOTOR/TANK
(MOTOR SIDE)
(ELECTRIC POWERED
MACHINE SHOWN)
CHOKE
COIL
X096
RECTIFIER
X097
THROTTLE
COIL
X091
CENTER
BRAKE
LIGHT
AUSTRALIAN
& CE SPECS
X105
X064
WITH
HYDRAULIC
BRAKES
RIGHT SIDE
MARKER
LIGHT
X062
X110 X111
X109 X107
X108
ELECTRIC BRAKES
(WHEN EQUIPPED)
X065
BATTERIES
(ELECTRIC POWERED)
X112
BREAKAWAY SWITCH
BATTERY CHARGER
(ELECTRIC BRAKES)
X113
X106
X095
VALVE/MOTOR/TANK
(TANK SIDE)
MAGNETIC
PICKUP
ENGINE
THROTTLE
RELAY
X092
LEFT SIDE
TAILLIGHT
RIGHT SIDE
TAILLIGHT
X011
X099
X022
X088
X093
ENGINE
CHOKE PULL
RELAY
X090
OIL
LEVEL
SWITCH
LEFT
TAILLIGHT
REAR
FOGLIGHT
PLATE
LIGHT
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
LEFT SIDE
MARKER LIGHT
ANSI &
ANSI EXPORT
SPECS
BREAKAWAY SWITCH
(ELECTRIC BRAKES)
WITH
ELECTRIC
BRAKES
OR
X100
X089
BATTERY
(ENGINE POWERED)
STARTER
(ENGINE POWERED)
ENGINE
STOP
RELAY
CENTER
BRAKE
LIGHT
RIGHT
TAILLIGHT
RIGHT SIDE
MARKER LIGHT
WITH
HYDRAULIC
BRAKES
Ref. 1870172 Rev C
Figure 7-4. Electrical Diagram
7-164
SECTION 7 - ELECTRICAL REFERENCE
Drive and Set
3121203
X070
Right Rev
(9.8
Ω
)
X069
Left Rev
(9.8
Ω
)
X068
Right Fwd
(9.8
Ω
)
X067
Left Fwd
(9.8
Ω
)
X071
Drive Enable
(7.2
Ω)
X074
X075
1
9
X073
3
4
5
10
8
2
8
10
1. Flow Divider
2. Drive Enable Valve
3. Proximity Sensor
4. Propulsion Module
5. Drive Engagement Release Valve
6. Brake Release Cylinder
7. Drive Engage Cylinder
8. Friction Drive Wheel
9. Drive Directional Valve
10. Drive Motor
Figure 7-5. Drive and Set
7
X072
3
6
Ref. 0274754
7-165
FIGURE 7ELECTRICAL REFERENCE
7.1 CONNECTOR INDEX
ID Description
X001 Ground Module, J1
X002 Ground Module, J2
X003 Ground Module, J3
X004 Ground Module, J4
X007 Ground Module, J7
X008 Ground Module, J8
X009 IGN Relay
X010 Power Module (Sevcon), P
X011 Main Harness power
X012 Drive Module
X013 Ground Module Supply
X014 Ground Control Panel
X015 Transport Limit Pass-through
X016 Lift Down Pass-through
X017 Strobe/Alarm Pass-through
X018 Tele Limit Pass-through
X019 Boom Cable
X020 Outrigger Switches Pass-through
X021 Valves Pass-through
X022 Engine Pass-through
X023 Ground Outriggers Sw
X024 Ground Swing Sw
X025 Ground Enable Sw
X026 Ground Key Sw
X027 Ground Hour Meter
X028 Ground Alarm
X029 Ground Analyzer Port
X030 Ground LED Board
X031 Ground Lift Sw
X032 Ground Jib Sw
X033 Ground Tele Sw
X034 Ground Level Sw
X035 Ground Choke Sw
X036 Ground Start Sw
X037 Ground EMG Stop
X038 Strobe Light
X039 Lift Down Valve Solenoid
X040 Transport Limit Sw
X041 Tele Limit Sw
X042 F/L Outrigger Limit Sw
X043 F/R Outrigger Limit Sw
X044 R/L Outrigger Limit Sw
X045 R/R Outrigger Limit Sw
X046 F/L Outrigger Valve Solenoid
SECTION 7 - ELECTRICAL REFERENCE
Table 7-1. Connector Index
End 1 ID End 2 ID
No Drawing
No Drawing
No Drawing
No Drawing
--
--
--
--
--
--
No Drawing
--
No Drawing
--
--
DHTP31P (plug) DHTP31R (receptacle)
--
--
--
--
--
--
--
--
--
--
--
--
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
--
--
--
--
--
--
--
--
--
--
--
Location in Schematic,
Drawings
--
--
7-166
ID Description
X047 F/R Outrigger Valve Solenoid
X048 R/L Outrigger Valve Solenoid
X049 R/R Outrigger Valve Solenoid
X050 Motion Alarm
X051 Lift Hook Harness to X019
X052 Lift Hook Harness to X054
X053 Lift Hook Harness to Console X058
X054 Platform Harness to X019
X055 Platform Boom Connector
X056 Jib Down Valve Solenoid
X057 Platform Harness to console X058
X058 Platform Console Main
X059 Console Pass-through
X060 Platform Module
X061 Joystick
X062 EMG Stop
X063 Rotary Select Sw
X064 Choke Sw
X065 Start Sw
X066 Alarm
X067 Drive Left Forward Solenoid
X068 Drive Right Forward Solenoid
X069 Drive Left Reverse Solenoid
X070 Drive Right Reverse Solenoid
X071 Drive Enable Solenoid
X072 Handbrake Position Switch
X073 Turntable Position Switch
X074 Drive Module, J1
X075 Drive Module, J2
X076 Drive Module Analyzer Port
X077 Swing Left Solenoid
X078 Swing Right Solenoid
X079 Jib Up Solenoid
X080 Level Up Solenoid
X081 Level Down Solenoid
X082 Tele Out Solenoid
X083 Tele In Solenoid
X084 Lift Up Solenoid
X085 O/R Stow Solenoid
X086 O/R Set Solenoid
X087 Dump Valve Solenoid
X088 Starter Sol. Fuse
X089 Starter Sol.
X090 Engine Stop Relay
X091 Throttle Pull Relay
X092 Engine Oil Level Switch
7-167
SECTION 7 - ELECTRICAL REFERENCE
Table 7-1. Connector Index
End 1 ID End 2 ID
No Drawing
No Drawing
No Drawing
No Drawing
--
--
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Location in Schematic,
Figure 7-3
Drawings
--
ID Description
X093 Engine Choke Pull Relay
X095 Engine Mag Pickup
X096 Engine Rectifier
X097 Engine Throttle Solenoid
X098 Engine Choke Solenoid
X099 Engine Powered, Battery Pos.
X100 Engine Powered, Battery Neg.
X101 Power Module (Sevcon), B-
X102 Power Module (Sevcon), B+
X103 Power Module (Sevcon), M1+
X104 Power Module (Sevcon), M2-
X105 Power Module Cable In-line
X106 6V Batt 1, Pos.
X107 6V Batt 1, Neg.
X108 6V Batt 2, Pos.
X109 6V Batt 2, Neg.
X110 6V Batt 3, Pos.
X111 6V Batt 3, Neg.
X112 6V Batt 4, Pos.
X113 6V Batt 4, Neg.
X114 Electric Pump Neg.
X115 Electric Pump Pos.
X116 Battery Charger AC Cord
SECTION 7 - ELECTRICAL REFERENCE
Table 7-1. Connector Index
End 1 ID End 2 ID
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
No Drawing
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
Location in Schematic,
Figure 7-3
Drawings
--
--
--
--
--
--
--
--
--
--
--
--
7-168
SECTION 7 - ELECTRICAL REFERENCE
7.2 GROUND MODULE CONNECTOR PINOUTS
PIN
Table 7-2. X001 (J1) Ground Module Pinout
T-SERIES FUNCTION TYPE I/O
1 Depopulated
2 Depopulated
3 Depopulated
4 GROUND
5 GROUND
6 Depopulated
7 Depopulated
8 GROUND
9 GROUND
10 Depopulated
11 Depopulated
12 Depopulated
13 Depopulated
14 NOT USED
15 NOT USED
16 ENGINE MAGNETO (SPEED PICKUP)
Power
-
-
-
-
Analog
Analog
Digital
-
-
-
Power
Power
-
-
Power
Input
-
-
-
-
Input
Input
Input
-
-
-
Output
Output
-
-
Output
17 GROUND
18 GROUND
19 GROUND
20 Depopulated
21 NOT USED
22 Depopulated
23 Depopulated
24 CONSTANT BATTERY
25 Depopulated
26 Depopulated
27 GROUND
28 ANALYZER POWER
29 RS-232 RECEIVE
30 RS-232 TRANSMIT
31 ANALYZER RETURN
32 Depopulated
33 GROUND
34 NOT USED
35 ELECTRIC POWER MODE (FUTURE)
Power
-
-
Power
Power
Serial
Power
Power
Power
-
Digital
Digital
-
Serial
Power
Power
Power
Digital
Digital
Output
Output
Output
-
Input
Output
-
Input
-
-
Output
Output
Input
Output
Output
Output
Output
Input
Input
RANGE (V)
0VDC
-
-
-
-
-
-
AC Coupled Freq.
0VDC
-
-
-
0VDC
0VDC
-
-
0VDC
0VDC
0VDC
-
-
-
-
12VDC
-
-
0VDC
9.5VDC
Digital
Comm.
Digital
Comm.
0VDC
0VDC
-
-
7-169
SECTION 7 - ELECTRICAL REFERENCE
PIN
Table 7-3. X002 (J2) Ground Module Pinout
T-SERIES FUNCTION
1 Depopulated
2 Depopulated
3 NOT USED
4 TELESCOPE IN
5 LEVEL UP
6 GROUND
7 LEVEL DOWN
8 OPTIONAL GROUND ALARM
9 DUMP VALVE
10 ROTATE LEFT (FUTURE)
11 LIFT UP
12 JIB UP
13 Depopulated
14 GROUND
15 NOT USED
16 TELESCOPE OUT
17 GROUND
18 GROUND
19 GROUND ALARM
20 JIB DOWN
21 ROTATE RIGHT (FUTURE)
22 LIFT DOWN
23 ENGINE START
24 ENGINE POWER MODE (FUTURE)
25 NOT USED
26 OVERLOAD INDICATOR
27 SYSTEM DISTRESS INDICATOR
28 GROUND
29 GROUND
30 GROUND
31 Depopulated
32 HOUR METER
33 NOT USED
34 SWING LEFT
35 SWING RIGHT
TYPE I/O
Digital
Analog
Digital
Digital
Power
Power
Power
-
Digital
Power
Power
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
-
Power
Digital
-
-
Digital
Digital
Digital
Power
Digital
Input
Input
Output
Output
Output
Output
Output
-
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
Output
-
Output
Output
-
-
Output
Output
Output
Output
Output
RANGE (V)
-
-
0VDC
0VDC
0VDC
-
12VDC
-
12VDC
12VDC
PWM
-
PWM
12VDC
-
-
-
Vbatt
12VDC
-
0VDC
-
12VDC
0VDC
0VDC
PWM
12VDC
12VDC
0VDC
12VDC
PWM
PWM
-
12VDC
7-170
SECTION 7 - ELECTRICAL REFERENCE
PIN
Table 7-4. X003 (J3) Ground Module Pinout
T-SERIES FUNCTION
1 Depopulated
2 FRONT-LEFT O/R
3 GROUND
4 CHOKE PULL RELAY
5 Depopulated
6 FRONT-RIGHT O/R
7 CHOKE HOLD SOLENOID
8 REAR-LEFT O/R
9 THROTTLE PULL RELAY
10 REAR-RIGHT O/R
11 THROTTLE HOLD SOLENOID
12 GROUND
13 EXTEND O/R
14 RETRACT O/R
TYPE
-
Digital
Power
Digital
-
Digital
Digital
Digital
Digital
Digital
Digital
Power
Digital
Digital
I/O RANGE (V)
-
Output
Output
Output
-
Output
Output
Output
Output
Output
Output
Output
Output
Output
12VDC
12VDC
12VDC
12VDC
0VDC
12VDC
12VDC
-
12VDC
0VDC
12VDC
-
12VDC
12VDC
7-171
SECTION 7 - ELECTRICAL REFERENCE
PIN
Table 7-5. X004 (J4) Ground Module Pinout
T-SERIES FUNCTION
1 Depopulated
2 Depopulated
3 Depopulated
4 ENGINE START
5 LEVEL DOWN
6 NOT USED
7 TELESCOPE IN
8 JIB DOWN
9 O/R STOW
10 NOT USED
11 TRANSPORT LIMIT
12 Depopulated
13 REAR-LEFT O/R INDICATOR
14 REAR-RIGHT O/R INDICATOR
15 Depopulated
16 ENGINE CHOKE / GLOW PLUG
17 LEVEL UP
18 NOT USED
19 JIB UP
20 O/R SET
21 TELESCOPE IN LIMIT SWITCH
22 NOT USED
23 LIFT UP
24 IGNITION
25 IGNITION
26 FRONT-RIGHT O/R INDICATOR
27 Depopulated
28 Depopulated
29 FRONT-LEFT O/R INDICATOR
30 TELESCOPE OUT
31 GROUND
32 GROUND
33 LIFT DOWN
34 SWING LEFT
35 SWING RIGHT
TYPE I/O RANGE (V)
Power
Power
Digital
Digital
Digital
Digital
Digital
Power
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Power
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Digital
Output
Output
Output
Output
Output
Output
Input
Output
Input
Input
Input
Input
Input
Input
Input
Input
Output
Input
Input
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
Input
Input
Input
Input
0VDC
0VDC
Vbatt
-
-
Vbatt
Vbatt
0VDC
Vbatt
Vbatt
-
Vbatt
Vbatt
Vbatt
-
Vbatt
0VDC
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
-
Vbatt
-
Vbatt
Vbatt
-
Vbatt
Vbatt
-
Vbatt
-
-
-
7-172
SECTION 7 - ELECTRICAL REFERENCE
PIN
Table 7-6. X007 (J7) Ground Module Pinout
T-SERIES FUNCTION
1 PLATFORM EMS
2 PLATFORM MODE
3 GROUND MODE
4 NOT USED
5 NOT USED
6 CAN TERMINATION
7 PLATFORM POSITION 1
8 PLATFORM POSITION 2
9 GROUND
10 GROUND
11 FRONT-LEFT O/R SET LIMIT SW
12 REAR-RIGHT O/R SET LIMIT SW
13 CAN-HI
14 NOT USED
15 NOT USED
16 NOT USED
17 CAN TERMINATION
18 CAN SHIELD
19 GROUND
20 NOT USED
21 NOT USED
22 NOT USED
23 FRONT-RIGHT O/R SET LIMIT SW
24 CAN-LO
25 GROUND
26 NOT USED
27 NOT USED
28 GROUND
29 IGNITION
30 NOT USED
31 NOT USED
32 NOT USED
33 NOT USED
34 NOT USED
35 REAR-LEFT O/R SET LIMIT SW
TYPE I/O
Serial
Power
Power
Power
Power
Power
Power
Power
Power
Serial
Power
Power
Analog
Digital
Digital
Digital
Power
Power
Power
Digital
Analog
Power
Power
Digital
Digital
Serial
Power
Digital
Power
Power
Power
Analog
Power
Serial
Analog
I/O
Output
Output
Output
Output
Output
Output
Output
Output
I/O
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Input
Output
Output
Input
Input
I/O
Output
Input
Input
Input
Input
Input
Output
I/O
Input
RANGE (V)
Serial
0VDC
-
-
0VDC
Vbatt
-
-
-
Serial
Serial
0VDC
-
-
-
Vbatt
-
-
-
Vbatt
Vbatt
0VDC
0VDC
Vbatt
Vbatt
Serial
-
-
12VDC
12VDC
12VDC
-
-
Serial
Vbatt
PIN
Table 7-7. X008 (J8) Ground Module Pinout
T-SERIES FUNCTION
1 GROUND FROM B-
2 IGN PWR FROM IGN RELAY 87
3 GROUND FOR PLATFORM MODULE
4 IGN PWR FOR PLATFORM MODULE
TYPE
Power
Power
Power
Power
I/O
Input
Input
Output
Output
RANGE (V)
0VDC
Vbatt
0VDC
Vbatt
7-173
SECTION 7 - ELECTRICAL REFERENCE
7.3 PLATFORM MODULE CONNECTOR PINOUT
PIN
Table 7-8. X060 (J1) Platform Module Pinout
T-SERIES FUNCTION TYPE I/O
1 IGNITION
2 SYSTEM GROUND
3 CANH
4 CANL
5 JOYSTICK SUPPLY
6 JOYSTICK X-AXIS
7 JOYSTICK GROUND
8 JOYSTICK Y-AXIS
9 ROTARY POSITION 1
10 ROTARY POSITION 2
11 SWITCH GROUND
12 PLATFORM ALARM
13 START SWITCH
14 CHOKE / GLOW SWITCH
15 ROTARY POSITION 3
16 DRIVE & SET SWITCH
Digital
Digital
Power
Analog
Digital
Digital
Digital
Digital
Power
Power
Serial
Serial
Power
Analog
Power
Analog
Input
Input
Output
Output
Input
Input
Input
Input
Input
Input
I/O
I/O
Output
Input
Output
Input
RANGE (V)
Vbatt
Vbatt
0VDC
0VDC
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
0VDC
Serial
Serial
5VDC
5VDC
0VDC
5VDC
7-174
SECTION 7 - ELECTRICAL REFERENCE
7.4 DRIVE MODULE CONNECTOR PINOUT
PIN
Table 7-9. X074 (J1) Drive Module Pinout
T-SERIES FUNCTION TYPE I/O
1 IGNITION
2 SYSTEM GROUND
3 TURNTABLE POSITION 1
4 TURNTABLE POSITION 2
5 SPARE INPUT 2
6 SPARE INPUT 3
7 DRIVE LEFT FORWARD
8 DRIVE LEFT REVERSE
9 DRIVE RIGHT FORWARD
10 DRIVE RIGHT REVERSE
11 DRIVE ENABLE
12 SPARE OUTPUT 5
Power
Power
Digital
Analog
Analog
Analog
Analog
Analog
Analog
Analog
Analog
Analog
Input
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
RANGE (V)
Vbatt
0VDC
Vbatt
Vbatt
-
-
PWM
PWM
PWM
PWM
PWM
-
PIN
Table 7-10. X075 (J2) Drive Module Pinout
T-SERIES FUNCTION TYPE I/O
1 +5 ANALOG REFERENCE
2 SPARE ANALOG 0
3 ANALOG GROUND
4 ANALYZER +5 REF
5 SPARE ANALOG 1
6 ANALYZER GROUND
7 SPARE ANALOG 2
8 SPARE ANALOG 3
9 CANBUS CANH
10 CANBUS CANL
11 ANALYZER PIN #3
12 ANALYZER PIN #2
Power
Analog
Analog
Power
Analog
Power
Analog
Analog
Serial
Serial
Serial
Serial
Output
Output
Output
Output
Output
Output
Output
Output
I/O
I/O
I/O
I/O
RANGE (V)
5VDC
-
0VDC
5VDC
-
0VDC
-
-
Serial
Serial
Serial
Serial
7-175
SECTION 7 - ELECTRICAL REFERENCE
7.5 CONNECTOR LOADING DIAGRAMS
ID
AMP04P
Description
Amp 4 position plug
Table 7-11. Connector Loading Diagrams
Diagram
4
3
1
AN350P Anderson Power Connector
AS14P Ampseal 14 position
AS351P
(Black)
AS352P
(Neutral)
AS354P
(Gray)
AS355P
(Blue)
DHD14P
Ampseal 35 position
Deutsch 14 position HD series alum. Plug
1
5
10
AMP
14
Socket Rear Insert
1
12
24
AMP
Socket Rear Insert
35
Rear View
7-176
SECTION 7 - ELECTRICAL REFERENCE
ID
DHD14R
Description
Deutsch 14 position HD series alum. Receptacle
Table 7-11. Connector Loading Diagrams
Diagram
DHTP31R
(receptacle)
DHTP31P
(plug)
Deutsch HDP 31 position
DT02P Deutsch 2 position DT series plug
DT02R Deutsch 2 position DT series receptacle
DT03P Deutsch 3 position DT series plug
Rear View
29
28
31
30
18
19
7
17
6
16
15
27
26
20
8
9
2
3
1
4
5
13
14
24
21
10
11
12
25
22
23
Socket Rear Insert
1
2
2
1
B
A
C
DT04P Deutsch 4 position DT series plug
DT04R Deutsch 4 position DT series receptacle
7-177
SECTION 7 - ELECTRICAL REFERENCE
ID
DT06AP
Description
Deutsch 6 position DT series plug
Table 7-11. Connector Loading Diagrams
Diagram
DT06R Deutsch 6 position DT series receptacle
DT08AP Deutsch 8 position DT series plug
DT08AR Deutsch 8 position DT series receptacle
DT12AP Deutsch 12 position DT series plug
DT12AR Deutsch 12 position DT series receptacle
12
11
10
9
8
7
3
4
5
1
2
6
7
8
9
10
11
12
6
5
4
3
2
1
7-178
SECTION 7 - ELECTRICAL REFERENCE
ID
DTM04P
DTM04R
Description
Deutsch 4 position DTM series mini plug
Table 7-11. Connector Loading Diagrams
Diagram
4
3
1
2
Deutsch 4 position DTM series mini receptacle
1
2
4
3
DTM12AP Deutsch 12 position DT series mini plug with A key
7 8 9 10 11 12
DTM12BP Deutsch 12 position DT series mini plug with B key
6 5 4 3 2 1
7
8 9 10 11 12
6
5 4 3 2 1
DTP02P Deutsch 2 position DTP series plug
1
2
DTP02R Deutsch 2 position DTP series receptacle
E06P Eaton Toggle Switch
7-179
2
1
2
3
1
4
5
6
M04P
ID Description
Molex 4 position
SECTION 7 - ELECTRICAL REFERENCE
Table 7-11. Connector Loading Diagrams
Diagram
4
3
2
1
MMF08P Molex Mini Fit 8 position plug
Rear View
MMF10P Molex Mini Fit 10 position plug
1
6
7
8
9
10
2
3
4
5
MMF12P Molex Mini Fit 12 position plug
7 8 9 10 11 12
1 2 3 4 5 6
MMF16P Molex Mini Fit 16 position plug
1
13
14
2
3
15
16
17
18
19
4
5
6
7
8
20
21
22
23
24
9
10
11
12
7-180
SECTION 7 - ELECTRICAL REFERENCE
Table 7-11. Connector Loading Diagrams
Diagram ID
PWP03P
Description
Packard 3 position receptacle
SUM02N Sumitomo 2 position natural
1 2
SUM06N Sumitomo 6 position natural
5
4
6
1
2
3
7.6 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 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.
Pierce 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.
7-181
SECTION 7 - ELECTRICAL REFERENCE
Assembly
Figure 7-6. Connector Assembly Figure 1
1.
2.
Figure 7-7. AMP Connector
7-182
SECTION 7 - ELECTRICAL REFERENCE
Figure 7-8. Connector Assembly Figure 2
3.
After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the lock-
ing latches by squeezing them inward (See Figure 7-9.).
7-183
Figure 7-9. Connector Assembly Figure 3
SECTION 7 - ELECTRICAL REFERENCE
Figure 7-11. Connector Disassembly
4.
Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-10.).
Figure 7-10. Connector Assembly Figure 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.
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.
7-184
SECTION 7 - ELECTRICAL REFERENCE
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.
7-185
Figure 7-12. Connector Installation
SECTION 7 - ELECTRICAL REFERENCE
7.7 WORKING WITH DEUTSCH CONNECTORS
DT/DTP Series Assembly
Figure 7-13. 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 7-14. 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 7-15. HD/HDP Contact Installation
1.
Grasp contact about 25mm behind the contact crimp barrel.
2.
Hold connector with rear grommet facing you.
7-186
SECTION 7 - ELECTRICAL REFERENCE
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 7-16. HD/HDP Locking Contacts Into Position
NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing
HD30/HDP20 Series Disassembly
Figure 7-17. 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 7-18. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
7-187
7.8 TRAILER WIRING
SECTION 7 - ELECTRICAL REFERENCE
Figure 7-19. Electrical Schematic (Trailer)
7-188
SECTION 7 - ELECTRICAL REFERENCE
7-189
SECTION 8 - HYDRAULIC REFERENCES
SECTION 8.
HYDRAULIC REFERENCES
8-190
SECTION 8 - HYDRAULIC REFERENCES
8.1 SOLENOIDS
X046
X047
X048
X049
X067
X068
X069
X070
X071
Connector
X083
X084
X039
X085
X086
X087
X077
X078
X079
X056
X080
X081
X082
Function
Swing Left
Swing Right
Jib Up (T500J)
Jib Down (T500J)
Level Up
Level Down
Telescope Out
Telescope In
Lift Up
Lift Down
Outrigger Stow
Outrigger Set
Dump Valve (Engine Powered)
Front Left Outrigger
Front Right Outrigger
Rear Left Outrigger
Rear Right Outrigger
Drive Left Forward Solenoid
Drive Right Forward Solenoid
Drive Left Reverse Solenoid
Drive Right Reverse Solenoid
Drive Enable Solenoid
Nominal Resistance (Ohms)
8.0
8.0
9.8
8.0
8.0
6.0
8.0
8.0
8.0
9.8
8.0
8.0
8.0
7.2
7.2
7.2
7.2
9.8
9.8
9.8
9.8
7.2
8.2 MINIMUM OPERATING PRESSURE
Function
Swing Left
Swing Right
Jib Up (T500J)
Jib Down (T500J)
Level Up
Level Down
Telescope Out
Telescope In
Lift Up
Lift Down
Outrigger Stow
Outrigger Set
T350 Minimum Pressure For Operation T500J Minimum Pressure For Operation
Min. Swing Left Pressure psi (bar)
Min. Swing Right Pressure psi (bar)
Min. Jib Up Pressure psi (bar)
Min. Jib Down Pressure psi (bar)
Min. Level Up Pressure psi (bar)
Min. Level Down Pressure psi (bar)
Min. Tele Out Pressure psi (bar)
Min. Tele In Pressure psi (bar)
Min. Lift Up Pressure psi (bar)
Min. Lift Down Pressure psi (bar)
Min. O/R Stow Pressure psi (bar)
Min. O/R Set Pressure psi (bar)
Min. Swing Left Pressure psi (bar)
Min. Swing Right Pressure psi (bar)
Min. Jib Up Pressure psi (bar)
Min. Jib Down Pressure psi (bar)
Min. Level Up Pressure psi (bar)
Min. Level Down Pressure psi (bar)
Min. Tele Out Pressure psi (bar)
Min. Tele In Pressure psi (bar)
Min. Lift Up Pressure psi (bar)
Min. Lift Down Pressure psi (bar)
Min. O/R Stow Pressure psi (bar)
Min. O/R Set Pressure psi (bar)
*These values not available at time of printing
8-191
SECTION 8 - HYDRAULIC REFERENCES
Hydraulic Test Ports
T2
MAIN VALVE BLOCK
P
T
LB
GB JA
JB
PA
TA
SA
SB
TB
PB
G
LA
PP
GA
DRIVE DIRECTIONAL VALVE
EA RA
DRIVE ENABLE
VALVE
Figure 8-1. Hydraulic Test Ports
8-192
SECTION 8 - HYDRAULIC REFERENCES
Hydraulic Schematic - Electric Powered Machines
8-193
Figure 8-2. Hydraulic Schematic - Electric Powered Machines (Sheet 1 of 2)
SECTION 8 - HYDRAULIC REFERENCES
Figure 8-3. Hydraulic Schematic - Electric Powered Machines (Sheet 2 of 2)
2792642 F
8-194
SECTION 8 - HYDRAULIC REFERENCES
Hydraulic Schematic - Engine Powered Machines
8-195
Figure 8-4. Hydraulic Schematic - Engine Powered Machines (Sheet 1 of 2)
SECTION 8 - HYDRAULIC REFERENCES
Figure 8-5. Hydraulic Schematic - Engine Powered Machines (Sheet 2 of 2)
2792642 F
8-196
SECTION 8 - HYDRAULIC REFERENCES
Hydraulic Schematic - Engine Powered Drive Option
8-197
Figure 8-6. Hydraulic Schematic - Engine Powered Drive Option (Sheet 1 of 2)
SECTION 8 - HYDRAULIC REFERENCES
Figure 8-7. Hydraulic Schematic - Engine Powered Drive Option (Sheet 2 of 2)
2792642 F
8-198
SECTION 8 - HYDRAULIC REFERENCES
Hydraulic Schematic - Electric Powered Drive Option
8-199
Figure 8-8. Hydraulic Schematic - Electric Powered Drive Option (Sheet 1 of 2)
SECTION 8 - HYDRAULIC REFERENCES
Figure 8-9. Hydraulic Schematic - Electric Powered Drive Option (Sheet 2 of 2)
2792642 F
8-200
SECTION 8 - HYDRAULIC REFERENCES
8-201
SECTION 9 - JLG ANALYZER
SECTION 9. JLG ANALYZER
9.1 INTRODUCTION
The JLG Control System controller has a built in LED to indicate any faults. The system stores recent faults which may be accessed for troubleshooting.
The Control System may be accessed utilizing a custom designed, hand held analyzer (Analyzer Kit, JLG part no.
2901443) which will display two lines of information at a time, by scrolling through the program.
Analyzer Display
Escape Key
To return home or access previous
Up & Down Arrow Keys
Value Selector
Enter Key
Stores and selects Top Level,
Sub Level, and item menus
Left & Right Arrow Keys
Used to move between Top
Level, Sub Level, and item
Figure 9-1. Hand Held Analyzer
9-202
SECTION 9 - JLG ANALYZER
9.2 TO CONNECT THE JLG CONTROL SYSTEM
ANALYZER
1.
Connect the cable supplied with the analyzer, to the controller module in the ground control box and connect the remaining end of the cable to the analyzer.
9.3 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 ground position and pulling the emergency stop button on.
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER. To cancel a selected menu item, press ESC.; then you will be able to scroll using the right and left arrow keys to select a different menu item.
The top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATIONS (view only)
If you press ENTER, at the HELP: PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen. If there was no fault detected, the display will read: HELP: EVERYTHING OK. If powered up at the ground station, the display will read: GROUND OK.
9-203
SECTION 9 - JLG ANALYZER
If ENTER is pressed again, the display moves to the following display:
9.4 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:
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:
PLATFORM
GROUND
PUMP
ENGINE
SYSTEM
VALVES
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.
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.
9-204
SECTION 9 - JLG ANALYZER
Once the correct password is displayed, press ENTER.
The access level should display the following, if the password was entered correctly:
9.5 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:
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings.
PERSONALITIES:
LIFT 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.
9-205
9.6 MACHINE SETUP
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
SECTION 9 - JLG ANALYZER
GROUND ALARM:
2 = MOTION
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: Password 33271 will give you access to level 1, which will permit you to change all machine personality settings.
9-206
SECTION 9 - JLG ANALYZER
9-207
SECTION 9 - JLG ANALYZER
9-208
SECTION 9 - JLG ANALYZER
9-209
9.7 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.
Platform Test
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.
SECTION 9 - JLG ANALYZER
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 9-5., System Test Flow
Chart - Platform Tests and go through the compo-
nent 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).
9-210
SECTION 9 - JLG ANALYZER
9-211
SECTION 9 - JLG ANALYZER
Ground Test
1.
Position the Platform/Ground select switch to the
Ground position.
2.
Plug the analyzer into the connector inside the
Ground control box.
3.
Pull out the Emergency Stop switch. and Start the engine.
4.
The analyzer screen should read:
6.
Follow the flow path in Figure 9-6., System Test Flow
Chart - Ground Station Tests 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).
9.8 USER FAULT CODES
A single digit fault code blinks on the Platform and the
Ground control panel to signal the operator of a procedure fault. These Codes are as follows:
1 --> Procedure (i.e., Did Not Close Trigger, Joystick Not
Centered, etc.)
2 --> Vehicle Setup (i.e., Outriggers Not Set, Machine Not
Level)
3 --> Battery Charger Engaged
4 --> Excessive Duty Cycle/Power Module Thermal Cutout
5 --> Batteries Discharged/Start Engine/Turn Off System
6 --> Not Used
7 --> Not Used
8 --> Not Used
9 --> Vehicle Requires Service
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.
9-212
SECTION 9 - JLG ANALYZER
9-213
SECTION 10 - MULTIMETER BASICS
SECTION 10.
MULTIMETER BASICS
10.1 INTRODUCTION
A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. 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.
• If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual)
• Use firm contact with meter leads
Figure 10-1. Voltage Measurement (DC)
10-214
SECTION 10 - MULTIMETER BASICS
• First test meter and leads by touching leads together. Resistance should read a short circuit (very low resistance)
• 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
10-215
Figure 10-2. Resistance Measurement
• Some meters require a separate button press to enable audible continuity testing
• Circuit power must be turned OFF before testing continuity
• Disconnect component from circuit before testing
• Use firm contact with meter leads
• First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity
Figure 10-3. Continuity Measurement
SECTION 10 - MULTIMETER BASICS
• Set 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
• If meter is not auto ranging, set it to the correct range (See multi meter’s operation manual)
• Use firm contact with meter leads
Figure 10-4. Current Measurement (DC)
10-216
SECTION 10 - MULTIMETER BASICS
10-217
SECTION 11 - SPECIFICATIONS
SECTION 11.
SPECIFICATIONS
11.1 INTRODUCTION
This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
Other Publications Available:
T350 & T500J Operation and Safety Manual .............. 3121197
T350 Service and Maintenance Manual ...................... 3121198
T500J Service and Maintenance Manual .................... 3121200
T350 & T500J Illustrated Parts Manual........................ 3121199
11.2 OPERATING SPECIFICATIONS
MODEL T350
Tongue Weight (ANSI):
Maximum Allowable Tow Speed: (Do NOT exceed legal speed limit)
Maximum Work Load (Capacity) w/Rotator
Maximum Work Load (Capacity) w/o Rotator
Maximum Work Load (Capacity) w/Rotator & Panel Tray
Maximum Work Load (Capacity) w/o Rotator & w/Panel Tray
Material Hook Capacity (Optional)
Accessory Tray Capacity
Panel Tray Capacity (w/Rotator)
Panel Tray Capacity (w/o Rotator)
Swing
Max.Vertical Platform Height (Unrestricted)
Vertical Reach (unrestricted)
Horizontal Reach
(from centerline of machine)
(from outrigger pad edge)
Up and Over Clearance
Maximum Outrigger Load
Maximum Ground Bearing Pressure
Maximum Travel Gradeability
Maximum Sideslope
Max. Hydraulic System Pressure
Maximum Operating Wind Speed
Maximum Horizontal Manual Force
Electrical System Voltage - Electric Machine
Electrical System Voltage - Gas Machine
Gross Machine Weight
(Platform Empty)
252 lbs. (114 kg)
65 mph (105 kph)
440 lbs. (200 kg)
500 lbs. (230 kg)
320 lbs. (145 kg)
350 lbs. (158 kg)
500 lbs. (230 kg)
250 lbs.
*
(114 kg)
70 lbs. (32 kg)
100 lbs. (45 kg)
410° non-continuous
35 ft. (10.6 m)
35 ft. (10.4 m)
20 ft. (6.1 m)
14 ft. (4.27 m)
15 ft. (4.57 m)
1950 lbs. (884.5 kg)
22.5 psi (1.58 kg/cm
2
)
20%
11°
2700 psi (186 Bar)
28 mph (12.5 m/s)
90 lb. force (400 N)
24 volts
12 volts
3330 lbs. (1510 kg)
*
DO NOT exceed axle rating or GVW rating.
T500J
350 lbs. (154 kg)
65 mph (105 kph)
440 lbs. (200 kg)
500 lbs. (230 kg)
320 lbs. (145 kg)
350 lbs. (158 kg)
500 lbs. (230 kg)
250 lbs.
*
(114 kg)
70 lbs. (32 kg)
100 lbs. (45 kg)
410° non-continuous
50 ft. (15.2 m)
50 ft. (15.2 m)
31 ft. (9.45 m)
25 ft. (7.62 m)
18 ft. (5.49 m)
2660 (1206.5 kg)
30.7 psi (2.15 kg/cm
2
)
20%
11°
2950 psi (203 Bar)
28 mph (12.5 m/s)
90 lb. force (400 N)
24 Volts
12 Volts
4750 lbs. (2155 kg)
11-218
SECTION 11 - SPECIFICATIONS
Dimensional Data
Table 11-1. Dimensional Data
T350 T500J
Overall Length
Surge Brake, 2" ball
Surge Brake, 2" ball w/rotator
Electric brake,2" ball
Electric brake,2" ball w/ rotator
Surge Brake Combination, 2"ball
Overall Height (ANSI/CSA)
Overall Height (CE)
Overall Width (outriggers up)
Overall Width (outriggers down -
ANSI)
Overall Width (outriggers down -
CE)
20 ft 5 in (6.2 m)
20 ft 11 in (6.4 m)
20 ft 3 in (6.2 m)
20 ft 9 in (6.3 m)
20 ft 11 in (6.4m)
26 ft 9.75 in (8.2 m)
26 ft 8 in (8.1 m)
6 ft 6.25 in (2 m)
- -
26 ft 10.25 in (8.2 m)
6 ft 7.25 in (2 m)
7 ft 0.5 in (2.1 m)
4 ft 11.25 in (1.5 m) 5ft 10.25 in (1.8 m)
10 ft 5.5 in (3.2 m) 12 ft 7.75 in (3.9 m)
11 ft 3 in (3.4 m) 13 ft 5.25 in (4.1 m)
Fluid Capacities
Fuel Tank
Hydraulic Tank
Filling Volume
Usable Volume
Engine Crankcase
Table 11-2.
1.6 Gal. (6.0 L)
4.4 Gallon (16.65 Liters)
4.0 Gallon (15.1 Liters)
1.16 qt. (1.0 Liter)
Electric Power Unit
Motor
Pump
Table 11-3. Electric Power Unit Specifications
@ 740PSI
(51 Bar)
@1500PSI
(103 Bar)
@ 3000PSI
(207 Bar)
Power
Voltage
Amperage 90 140 230
Speed 4000 rpm 3600 rpm 2900 rpm
Flow Rate
Displacement
3.0 kW
24 VDC
3.0 gpm
(11.3
lpm)
3.0 kW
24 VDC
2.7 gpm
(10.2
lpm)
3.0 kW
24 VDC
2.2 gpm
(8.3 lpm)
0.192 cu.in.
(3.15 cc)
11-219
SECTION 11 - SPECIFICATIONS
Taillight and Marker Light Bulb Information
Table 11-4. Light Bulb Information
Bulb
Stop/Turn/Taillight
Side Marker
Boom Taillight
Side Marker Light
JLG Part #
7026341
7026342
7016626
7027717
Tires
Size
Load Rating
Speed
Category
Inflation
Pressure
Wheel Nut
Torque
Table 11-5. Tire Specifications
T350
(ANSI)
205-R14
1760 lbs. @
50 psi
(798 kg @
345 kPa)
6/C
(CE)
185-R14C
1984 lbs. @
65 psi
(900 kg
@450 kPa)
8/D
T500J
(ANSI) (CE)
225-75-R15 225/75-R16
2540 lbs. @
60 psi
(1152 kg @
414 kPa)
6/D
3190 lbs. @
83 psi
(1450 kg @
575 kPa)
10/E Ply Rating/
Load
Range
Weight 36 lbs. (16 kg)
- -
50 psi (345 kPa)
90-120 ft. lbs. (122-
164 Nm)
36 lbs. (16 kg)
S
66 ft. lbs.
(90 Nm)
46 lbs. (21 kg)
- -
65 psi
(448 kPa)
90-120 ft. lbs. (122-
164 Nm)
52 lbs. (24 kg)
R
60 psi
(414 kPa)
221 ft. lbs.
(300 Nm)
11-220
SECTION 11 - SPECIFICATIONS
Engine
Type
Displacement
Bore x Stroke
Max. Output
Max. Torque
Fuel Consumption
Fuel Type
Spark Plug
Spark Plug Gap
Table 11-6. Engine Specifications
4-stroke, overhead valve, single cylinder
16.5 cu.in. (270 cm
3
)
3.0 x 2.3 in. (77 x 58 mm)
9 bhp (6.6 kW) at 3,600 rpm
14.1 ft.lbs. (19.1 Nm) at 2,500 rpm
0.51 lb/hph (313 g/kWh, 230 g/PSh)
Unleaded gasoline with a pump octane rating of 86 or higher
NGK: BPR6ES
DENSO: W20EPR-U
0.028 - 0.031 in. (0.70 - 0.80 mm)
Table 11-7. Engine Battery Specifications
BCI Group Size 51R
Cranking Performance
Reserve Capacity
550 amps @ 32°F (0°C)
450 amps @ 0°F (-18°C)
80 minutes @ 32°F (0°C)
Batteries (Electric Machines)
Voltage
Amp Hour Rating
Table 11-8. Battery Specifications
6-Volt
@ 20 hour rate - 220
Reserve Capacity @ 75 Amps
AT -40° F (-40° C) Open Circuit Voltage
110 Minutes
Greater or Equal to 6 Volts
Life Cycle Rating
Internal Resistance
600 Cycles
No more than 2.5 mOhms @ 70° F
(21° C) / 4.0 m Ohms @ 0° F (-18°C)
Battery Weight (minimum allowable) 61 lbs. (27.7 kg)
11-221
SECTION 11 - SPECIFICATIONS
Component Weights
Table 11-9. Component Weights - T350
Component
Frame (bare)
Turntable (bare)
Booms & Cylinders Assy.
Main Boom
Engine Assy. (Incl. Tray)
Engine (bare)
Master Cylinder
Axle
Platform w/Rotator
Platform w/o Rotator
Pounds (Kg)
116
57
18
140
592
127
1130
626
143
73
Kilograms
53
26
8
64
269
58
513
284
65
33
Table 11-10. Component Weights - T500J
Component
Frame (bare)
Frame - CE, Aus (bare)
597
892
Turntable (bare) 262
Booms & Cylinders Assy.
1891
Main Boom 957
Engine Assy. (Incl. Tray) 116
57 Engine (bare)
Axle
ANSI
CE
221
271
Platform w/Rotator
Platform w/o Rotator
143
73
Pounds
271
382
119
859
435
53
26
100
123
65
33
Kilograms
Lubrication
HYDRAULIC OIL
Table 11-11. Hydraulic Oil
Hydraulic System
Operating
Temperature Range
+0° to + 180° F
(-18° to +83° C)
+0° to + 210° F
(-18° to +99° C)
+50° to + 210° F
(+10° to +99° C
S.A.E. Viscosity
Grade
10W
10W-20, 10W30
20W-20
NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152.
11-222
SECTION 11 - SPECIFICATIONS
NOTE: When temperatures remain consistently below 20 degrees F. (-7 degrees C.), JLG Industries recommends the use of
Mobil DTE13.
Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact
JLG Industries for proper recommendations.
Table 11-12. Mobilfluid 424 Specs
SAE Grade
Gravity, API
Density, Lb/Gal. 60°F
Pour Point, Max
Flash Point, Min.
Brookfield, cP at -18°C at 40° C at 100° C
Viscosity Index
10W30
29.0
7.35
-46°F (-43°C)
442°F (228°C)
Viscosity
2700
55 cSt
9.3 cSt
152
11-223
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: (61) 2 65 811111
Fax: (61) 2 65 810122
JLG Latino Americana
Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial
Estate
Bredbury
Stockport
SK6 2sP
England
Brazil
Phone: (55) 19 3295 0407
Fax: (55) 19 3295 1025
JLG Europe B.V.
Jupiterstraat 234
JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: (44) 1 698 811005
Fax: (44) 1 698 811055
JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/ lhlpohl
Bei Bremen
2132 HJ Foofddorp
The Netherlands
Phone: (31) 23 565 5665
Fax: (31) 23 557 2493
Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
Germany
Phone: (49) 421 693 500
Fax: (49) 421 693 5035
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese
JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: (47) 6682 2000
Fax: (47) 6682 2001
08755Castellbisbal
Spain
Phone: (34) 93 77 24700
Fax: (34) 93 77 11762
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
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