JLG 1250AJP Troubleshooting Manual
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JLG 1250AJP Troubleshooting Manual

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Troubleshooting Manual
Model
1250AJP
3128411
April 5, 2007
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Summary of Contents for JLG 1250AJP

  • Page 1 Troubleshooting Manual Model 1250AJP 3128411 April 5, 2007...

  • Page 3: Section A. Introduction

    Is Distress and read Help Ground System Lamp Blinking? Message Tests “Ground/ Everything OK” Troubleshoot by Help Message in Section 1 Using Analyzer, find logged Help Messages Identify Fault Repair Machine Problem Solved? Done Figure A-1. Troubleshooting Flowchart 3128411 1250AJP...

  • Page 4: Visual Inspection

    A.8 Service Fault Code Cross References on Pg. 9 to find possible faults based on the flashed code. FAULT CODE LIGHT 1705744 A 1705745 B 1702938 1705170 A 1705171 A Figure A-2. Ground Module and Platform Fault (System Distress) Lights 1250AJP 3128411...

  • Page 5: Connector References

    [X006.21.soc] refers to the socket side of terminal 21, connector X006. [X006.21.pin] refers to the pin side of terminal 21, connector X006. A.5 GROUND REFERENCE Battery negative [X117] should be used as the ground reference for voltage measurements, unless stated otherwise. 3128411 1250AJP...

  • Page 6: Control Module Power

    Ground Platform Power Battery - CAN HI X233 CAN LO Analyzer Power X235 Analyzer RS232 Receive Analyzer Analyzer RS232 Transmit Note: BLAM and Chassis Module Analyzer connections for download only Analyzer Ground Figure A-3. Basic Electronic Module Connections 1250AJP 3128411...

  • Page 7: Critical Sensors

    In transport position typical values are: MAIN LIFT 1 ANGLE A/D: 2800 - 6000 MAIN LIFT 2 ANGLE A/D: 26000 - 30010 MAIN LIFT 1 RAW ANGLE A/D: 15 - 33 MAIN LIFT 2 RAW ANGLE A/D: 145 - 165 3128411 1250AJP...
  • Page 8 BLAM module. Each sensor should measure 5k Ω resistance between the A and B pins. In transport position typical values are: TOWER LENGTH 1 SENSOR: 305.4" TOWER LENGTH 2 SENSOR: 305.4" TOWER LENGTH 1 A/D: 880 TOWER LENGTH 2 A/D: 1180 1250AJP 3128411...

  • Page 9: Service Fault Code Cross References

    2-5 DRIVE PREVENTED - BOOM SELECTED ......................1-68 2-5 DRIVE PREVENTED - TILTED & ABOVE ELEVATION ..................1-68 2-5 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER ........1-87 2-5 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER ......... 1-87 3128411 1250AJP...
  • Page 10 3-3 LEFT FORWARD DRIVE PUMP SHORT TO BATTERY ..................1-93 3-3 LEFT FORWARD DRIVE PUMP SHORT TO GROUND ..................1-93 3-3 LEFT REVERSE DRIVE PUMP OPEN CIRCUIT ....................1-93 3-3 LEFT REVERSE DRIVE PUMP SHORT TO BATTERY ..................1-93 A-10 1250AJP 3128411...
  • Page 11 3-3 SWING LEFT OPEN CIRCUIT .......................... 1-142 3-3 SWING LEFT SHORT TO BATTERY ......................... 1-142 3-3 SWING RIGHT OPEN CIRCUIT ........................1-142 3-3 SWING RIGHT SHORT TO BATTERY ......................1-143 3-3 THROTTLE ACTUATOR OPEN CIRCUIT ......................1-143 3128411 1250AJP A-11...
  • Page 12 3-4 JIB UP OPEN CIRCUIT ............................. 1-92 3-4 JIB UP SHORT TO BATTERY ........................... 1-92 3-4 JIB UP SHORT TO GROUND ........................... 1-92 3-4 PLATFORM CONTROL VALVE OPEN CIRCUIT ....................1-123 3-4 PLATFORM CONTROL VALVE SHORT TO BATTERY ..................1-123 A-12 1250AJP 3128411...
  • Page 13 4-5 TOWER LIFT PVG VALVE SEND UNRECOGNIZED FAULT ................1-152 4-5 TOWER LIFT PVG VALVE SETUP FAULT ......................1-152 4-5 TOWER LIFT PVG VALVE STUCK EXTENDED ....................1-152 4-5 TOWER LIFT PVG VALVE STUCK NEUTRAL ....................1-152 3128411 1250AJP A-13...
  • Page 14 8-3 BASKET LEVELING SENSOR 1 SHORT TO GROUND OR OPEN CIRCUIT ........... 1-39 8-3 BASKET LEVELING SENSOR 2 SHORT TO BATTERY ................... 1-39 8-3 BASKET LEVELING SENSOR 2 SHORT TO GROUND OR OPEN CIRCUIT ........... 1-39 8-3 BASKET LEVELING SYSTEM TIMEOUT ......................1-39 A-14 1250AJP 3128411...
  • Page 15 8-4 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE LOW ................ 1-170 8-4 TWR TRN SW DISAGREEMENT ........................1-171 8-4 WRONG MAIN LIFT RESPONSE ........................1-173 8-4 WRONG MAIN TELE RESPONSE ........................1-173 8-4 WRONG TWR LIFT RESPONSE ........................1-173 3128411 1250AJP A-15...
  • Page 16 8-6 RT FNT STEER LT STB OR OC ........................1-138 8-6 RT FNT STEER LT STG ............................ 1-138 8-6 RT FNT STEER RT STB OR OC ........................1-138 8-6 RT FNT STEER RT STG ........................... 1-138 8-6 RT REAR STEER LT STB OR OC ........................1-138 A-16 1250AJP 3128411...
  • Page 17 9-9 PLATFORM MODULE FAILURE HWFS CODE 1 ..................... 1-123 9-9 PLATFORM MODULE SOFTWARE UPDATE REQUIRED ................1-123 9-9 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE .................. 1-124 9-9 RUNNING AT CREEP - CREEP SWITCH OPEN ....................1-139 9-9 STEER SENSORS NOT CALIBRATED ......................1-142 3128411 1250AJP A-17...
  • Page 18 INTRODUCTION This Page Left Blank Intentionally A-18 1250AJP 3128411...

  • Page 19: Section B. Troubleshooting Safety Precautions

    Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of • Use only approved, nonflammable cleaning solvents. the system. 3128411 1250AJP B-19...

  • Page 20: Revision Log

    January 16, 2006 - Original issue of fault guide for use with P7.0 Software. August 29, 2006 - Incremental release. Updated and added many procedures. February 12, 2007 - Fault definitions added. April 5, 2007 - Cover icon added. 1250AJP 3128411...

  • Page 21: Table Of Contents

    BASKET LEVELING SYSTEM TIMEOUT ..........1-39 3128411 1250AJP...
  • Page 22 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST ....... . 1-63 1250AJP...
  • Page 23 GLOW PLUG OPEN CIRCUIT ........... . 1-88 3128411 1250AJP...
  • Page 24 LEFT REVERSE DRIVE PUMP SHORT TO BATTERY ........1-93 1250AJP...
  • Page 25 MAIN LIFT ENABLE OPEN CIRCUIT ..........1-110 3128411 1250AJP...
  • Page 26 PLATFORM MODULE FAILURE: HWFS CODE 1 ........1-123 1250AJP...
  • Page 27 START SOLENOID SHORT TO GROUND ......... . . 1-142 1.291 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH ......1-142 3128411 1250AJP...
  • Page 28 TOWER TELESCOPE APU OPEN CIRCUIT ......... 1-154 1250AJP...
  • Page 29 COMMON STG PROCEDURE ........... . 1-175 3128411 1250AJP...
  • Page 30 To Connect the JLG Control System Analyzer ........
  • Page 31 Hydraulic Schematic - Traction Control - Sheet 1 of 2 ....... . . 3-256 3128411 1250AJP...
  • Page 32 X233 (J5) Chassis Module Pinout ..........2-218 1250AJP...
  • Page 33 Calibrations Listed by Service Action ..........5-289 3128411 1250AJP...
  • Page 34 TABLE OF CONTENTS (Continued) This Page Left Blank Intentionally 1250AJP 3128411...

  • Page 35: Section 1. Fault Dictionary And Selected Troubleshooting

    Axle retract short to battery or open circuit. The control system detected a short to battery or open circuit on the axle retract valves output [X230.12] controlling the front axles retract solenoid [X209] and the rear axles retract solenoid [X221]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-35...

  • Page 36: Axle Ret Stg

    1.17 BASKET LEFT SHORT TO BATTERY Flash Code: 3-4 Basket left short to battery. The platform module J7 platform rotate left output [X169.5] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1-36 1250AJP 3128411...

  • Page 37: Basket Left Short To Ground

    [X136] and level down installed common to level up solenoid [X136] and solenoid [X135] with the cartridge common to level down solenoid [X135] rotate right [X138] and rotate left [X139]. Does Go to step 1.19.11 the crackpoint calibrate? 3128411 1250AJP 1-37...

  • Page 38: Basket Leveling Crackpoint Up Not Calibrated

    Go to step 1.20.10 Go to step 1.20.9 1.20.9 Turn off machine. Discon- Does the platform dump solenoid [X135] Clean/repair/replace platform dump valve [X135] measure about 6.4 Ω? nect platform dump sole- cartridge. noid [X135]. Replace platform dump solenoid [X135] 1-38 1250AJP 3128411...

  • Page 39: Basket Leveling Override Off

    Basket leveling system timeout. The control system detected the platform tilt angle was not within 5.0° of the setpoint for at least 2 seconds while out of transport or for at least 15 seconds while in the transport position. These values are program- 3128411 1250AJP 1-39...
  • Page 40 2000 cylinder assembly platform valve. Start engine. psi? Also, activate level up to end of stroke. Repair/replace relief valve that does not produce Does pressure measure or adjust to about proper pressure. 2500 psi? 1-40 1250AJP 3128411...

  • Page 41: Basket Leveling Tilt Reference 1 Out Of Range

    Is there continuity between platform level sen- Replace platform level sensor 1 [X150] sensor 1 [X150] and plat- sor 1 pin 2 [X150.2.pin] and platform module Go to step 1.30.6 form module J1 J1 socket 25 [X165.25.soc]? 3128411 1250AJP 1-41...
  • Page 42 1 [X150] and plat- sor 1 pin 3 [X150.3.pin] and ground. Also, is Repair/replace harness(es) that did not have con- form level sensor 2 [X148]. there continuity between platform level sensor tinuity. Ground meter. 2 pin 3 [X148.3.pin] and ground. 1-42 1250AJP 3128411...

  • Page 43: Basket Leveling Tilt Sensor 2 Communications Lost

    Go to step 1.31.12 sor 1 pin 1 [X150.1.pin] and pin 3 Go to step 1.31.11 [X150.3.pin]. -AND- measure voltage between platform level sensor 2 pin 1 [X148.1.pin] and pin 3 [X148.3.pin]. Do they measure about 12 VDC? 3128411 1250AJP 1-43...

  • Page 44: Basket Leveling Tilt Sensor Difference Too Great

    1.34 BASKET RIGHT SHORT TO BATTERY Flash Code: 3-4 Basket right short to battery. The platform module J7 platform rotate right output [X169.6] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1-44 1250AJP 3128411...

  • Page 45: Basket Right Short To Ground

    Battery too low - system shut down. A warning that the voltage at ground module J8 [X008.2] is below 9 volts. The system will shut down after about 5 seconds. Remove any corrosion on battery terminals and battery cable terminals. Recharge or replace battery. 3128411 1250AJP 1-45...

  • Page 46: Blam Backup Communications Link Faulty

    1.44.11 Disconnect RS-232 Is there continuity between RS-232 passthru Replace ground module passthru [X015] and ground socket 8[X015.8.soc] and ground module J1 Repair/replace harness between RS-232 module J1 socket 9 [X002.9.soc]? passthru [X015] and ground module J1 1-46 1250AJP 3128411...

  • Page 47: Blam Backup Communications Lost - Hydraulics Suspended

    Note Pretest Instructions Test Result Corrective Action 1.45.1 Have all personnel been removed from basket See 1.44 BLAM BACKUP COMMUNICATIONS and has it been lowered to transport position? LINK FAULTY on Pg. 46 Call JLG for help. 3128411 1250AJP 1-47...

  • Page 48: Blam Can Communications Lost

    Are the BLAM and ground modules BOTH run- Replace the BLAM module. NOSTICS ⇒ VERSIONS ⇒ ning the current software version? Update all the software to the same version (latest GROUND MODULE SOFT- available) WARE: Px.x and B.L.A. MODULE SOFTWARE: Px.x 1-48 1250AJP 3128411...
  • Page 49 J7 connector pin 30 of the platform module J7 connector connector [X169] [X007] [X169.31.pin X169.30.pin] measure 120Ω Replace the platform module and open circuit between pin 31and shield [X169.32.pin] and open circuit between pin 30 and shield [X169.32.pin]? 3128411 1250AJP 1-49...
  • Page 50 19 position tower boom passthru con- measure 120Ω and open circuit between nector [X045] socket 2 and socket 1 [X050.2.soc Go to step 1.46.25 X050.1.soc] and open circuit between socket 3 and socket 1 [X050.3.soc X050.1.soc]? 1-50 1250AJP 3128411...
  • Page 51 Deutz EMR2 Chassis CAN connector [X084] measure 120Ω and open circuit between pin A and the top swivel connector [X083] and pin C [X084.A.pin X084.C.pin] and open circuit between pin B and pin C [X084.B.pin X084.C.pin]? 3128411 1250AJP 1-51...
  • Page 52 2 of the bottom swivel connector Repair/replace the slip ring connections in the [X216.1.soc X216.2.soc] measure 120Ω and swivel open circuit between socket 1 and shield [X216.1.soc X216.3.soc] and open circuit between socket 2 and shield [X216.2.soc X216.3.soc]? 1-52 1250AJP 3128411...

  • Page 53: Blam High Res A/D Failure

    Troubleshoot BLAM J3 [X088] harness wire with [X088]. Disconnect battery nal [X116] and any of the following: BLAM J3, short (+) terminal [X116] socket 1 [X088.1.soc], socket 4 Reprogram/replace BLAM [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]? 3128411 1250AJP 1-53...

  • Page 54: Blam Sensor Supply Out Of Range Low

    Turn on machine. Discon- Is there 12VDC between 12-pin Deutsch Go to step 1.50.11 nect 12-pin Deutsch con- socket 2 [X058.2soc] and socket 5 Leave 12-pin Deutsch connector [X058] dicon- nector [X058]. [X058.5.soc]? nected. Go to step 1.50.6. 1-54 1250AJP 3128411...
  • Page 55 1 [X099.1.soc] Repair/replace the harness and or connectors machine. and socket 3 [X099.3.soc]? between the #1 right side tower boom angle sen- sor [X099] and #1 right side tower boom angle sensor passthru [X095] 3128411 1250AJP 1-55...

  • Page 56: Boom Angle Sensor #2 Communications Fault

    J3 control module J3 socket 3 [X008.3.soc]? the connector bodies and that there is continuity [X008] between all pins. Repair/replace harness and or connectors between 12-pin Deutsch connector [X058] and ground control module J3 socket 3 [X008.3] 1-56 1250AJP 3128411...

  • Page 57: Boom Length Sensor #1 Out Of Range High

    Tower boom length sensor #1 out of range high. The BLAM module J3 input [X088.8] for tower boom length sensor #1 (Top) is reading over 4.95 volts. See 1.366 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE HIGH on Pg. 167. 3128411 1250AJP 1-57...

  • Page 58: Boom Length Sensor #1 Out Of Range Low

    Note Pretest Instructions Test Result Corrective Action 1.59.1 Check fault log for other Have most modules lost communications? See 1.93 EXCESSIVE CAN BUS COMMUNICA- modules having lost com- TION ERRORS on Pg. 73 munication Go to step 1.59.2 1-58 1250AJP 3128411...
  • Page 59 1.59.14 Disconnect the 12 position Is there about 12 VDC at pin 3 of the 12 posi- Go to step 1.59.15 BLAM passthru connector tion BLAM passthru connector [X058.3.pin]? Go to step 1.59.16 [X058]. Turn on machine 3128411 1250AJP 1-59...

  • Page 60: Chassis Sensor Supply Out Of Range High

    Chassis sensor supply out of range high. The supply voltage for steer angle sensors is above the expected range. A power cycle is required. Note Pretest Instructions Test Result Corrective Action 1.60.1 Cycle power Does fault clear? Troubleshooting complete Go to step 1.60.2 1-60 1250AJP 3128411...

  • Page 61: Chassis Sensor Supply Out Of Range Low

    Chassis tilt sensor gain out of range. Chassis tilt sensor calibration information has been corrupted. This calibration data is programmed into the ground module during its manufacture, not in the field. Note Pretest Instructions Test Result Corrective Action 1.62.1 Cycle power Does fault clear? Troubleshooting complete Replace ground module 3128411 1250AJP 1-61...

  • Page 62: Chassis Tilt Sensor Not Calibrated

    Tower cylinder angle sensor/switch disagreement. The BLAM module reads the tower lift cylinder angle from the tower lift cylinder angle sensor [X092]. The BLAM module transmits this angle over the CAN bus to the ground module. As a commu- 1-62 1250AJP 3128411...

  • Page 63: Cylinder Load Pin Can Communications Lost

    1 and terminal 2 of the BLAM module J4 ule J4 connector [X089.1 [X089.1 X089.2] measure 12VDC? connector [X089.1 X089.2] and terminals A and X089.2] B of the load pin connector [X062.A X062.B] Replace the BLAM module 3128411 1250AJP 1-63...

  • Page 64: D/S Joy. Center Tap Bad

    1.75.3 Access the dual capacity Are both switches off cam? Check for mechanical failure of the boom tele- switches #1 [X052] and #2 scope cylinder mechanism. [X053]. Keep access to switches. Keep machine on. Go to step 1.75.4 1-64 1250AJP 3128411...
  • Page 65 Keep machine in same condition. Go to step [X052] and #2 [X053]. Dis- between switch #1 terminals 21 and 22? 1.75.9 . connect dual capacity switch passthru - 3 position [X046]. Turn on machine and switch to 500 lb. mode. 3128411 1250AJP 1-65...
  • Page 66 - 3 position switch passthru - 3 position [X046] probing and grounding contact B [X046.B]? Repair/replace harness between and dual capac- meter near connector. ity switch #1 and dual capacity switch passthru - 3 position [X046] 1-66 1250AJP 3128411...

  • Page 67: Disconnect Analyzer And Cycle Ems To Perform Boom Retrieval

    (ports 3, 4, 5, and about 500psi? Shut down, and reassemble, but keep gauge 6). Tee in a gauge with the installed. hoses at the charge (pres- Go to step 1.78.7. sure) filter (on engine side). Plug open lines. 3128411 1250AJP 1-67...

  • Page 68: Drive Locked - Joystick Moved Before Footswitch

    & boom operation. 1.82 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Flash Code: 2-5 Drive prevented - tilted & above elevation. Notification that drive was selected while tilted and above elevation and tilt is con- figured to cutout drive. 1-68 1250AJP 3128411...

  • Page 69: Eeprom Failure - Check All Settings

    EMR2 ECU equipment connector [X240] and ter- minal 8 of the ground module J1 connector [X001.8] Check the connections, make sure the machine is turned on, and return to step 1.87.3. If the prob- lem persists, replace the ground module 3128411 1250AJP 1-69...

  • Page 70: Engine Shutdown - Axle Lockout Valve Fault

    Pg. 70 or consult the engine control module manual to interpret the engine specific fault code. Table 1-1. Common Deutz Engine Fault Codes Fault Code using Fault Code using Troubleshooting Troubleshooting Fault Description Cause Results JLG Analyzer Deutz SERDIA Engine Machine 190:8 Speed sensor Engine speed sen- Loss of engine Check distance...
  • Page 71 Engine may level. Check oil Machine Program- acceptable value. also shutdown pressure sensor ming the engine will depending on JLG and wiring. Check either Shutdown OR Machine program- engine for other only give a warning ming possible mechani- cal causes.

  • Page 72: Common Deutz Engine Fault Codes Table

    Emer- Warning info gency stop of the engine. But EMR is not programmed to directly shutdown the engine in JLG machines. Only if the JLG machine is programmed to shutdown will this occur 110:0 Coolant tempera-...

  • Page 73: Envelope Control Disabled

    1.91 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED Flash Code: 0-0 Envelope encroached - hydraulics suspended. The system detected a violation of the safe operating area envelope. If plat- form is stuck in the air call JLG for help. Note Pretest Instructions Test...
  • Page 74 J7 connector [X007.13] and CAN LO conti- position connector [X045] nuity between terminal 2 of the MTB pass thru Go to step 1.93.10 - 19 position connector [X043.2] and terminal 24 of the ground module J7 connector [X007.24]? 1-74 1250AJP 3128411...
  • Page 75 #2 connector [X049.5] and terminal 24 of the ground module J7 connector [X007.24]? 1.93.17 Does the BLAM software version show "??" in Go to step 1.93.18 ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS Go to step 1.93.19 ⇒ B.L.A. MODULE SOFTWARE:?? 3128411 1250AJP 1-75...
  • Page 76 [X240.13] and terminal 24 of the ground module J7 connector [X007.24]? 1.93.27 Does the Chassis software version show "??" Go to step 1.93.28 in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS Go to step 1.93.29 ⇒ CHASSIS MODULE SOFTWARE:?? 1-76 1250AJP 3128411...

  • Page 77: Footswitch Selected Before Start

    This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor. Note Pretest Instructions Test Result Corrective Action 1.95.1 Is the front left wheel kept from moving? Free the wheel from any obstructions Go to step 1.95.2 3128411 1250AJP 1-77...

  • Page 78: Front Left Wheel Sensor Fault - Check Mounting

    When fully retracted, the steering will be mechanically limited to about 25°. As the axle is extended, the mechanical limit will increase to about 45°, however the control system will maintain a 25° limit until the 1-78 1250AJP 3128411...
  • Page 79 1.96.11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between front left steer J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-79...

  • Page 80: Front Left Wheel Sensor Out Of Range High

    1.97.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between front left steer J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231] Replace chassis module 1-80 1250AJP 3128411...

  • Page 81: Front Left Wheel Sensor Out Of Range Low

    1.98.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between front left steer J3. Turn on machine. 4 [X231.4.pin] and pin 6 [X231.6.pin]? passthru [X202] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-81...

  • Page 82: Front Right Wheel Blocked

    10% on load sense 1.99.9 Swap valve section with the Does condition follow valve section to other Repair/replace valve section one on the other side of side of machine? Repair/replace front left steer cylinder and/or machine. hoses. 1-82 1250AJP 3128411...

  • Page 83: Front Right Wheel Sensor Fault - Check Mounting

    1.100.11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between front right steer J3. Turn on machine. 1 [X231.1.pin] and pin 3 [X231.3.pin]? passthru [X201] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-83...

  • Page 84: Front Right Wheel Sensor Out Of Range High

    1.101.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between front right steer J3. Turn on machine. 1 [X231.1.pin] and pin 3 [X231.3.pin]? passthru [X201] and chassis module J3 [X231] Replace chassis module 1-84 1250AJP 3128411...

  • Page 85: Front Right Wheel Sensor Out Of Range Low

    Flash Code: 2-1 Footswitch faulty. The two footswitch inputs [X169.8 X007.15] have read the same state for more than one second. These signals should always be opposite. Check the footswitch and wiring for shorts or open circuits. 3128411 1250AJP 1-85...

  • Page 86: Fsw Interlock Tripped

    J7 [X007]. With a helper or ground module J7 terminal 15 [X007.15]? ground module an object, hold the foot- Go to step 1.105.9 switch down. Ground the meter near the main terminal box. Take the following mea- surement by backprobing. 1-86 1250AJP 3128411...

  • Page 87: Fuel Sensor Short To Battery

    Load the same version of software in the platform and ground modules. 1.111 GEN SET/WELDER OPEN CIRCUIT Flash Code: 3-3 Generator set/welder open circuit. The output for the generator [X001.22] is open. See 1.377 COMMON STB OR OC PRO- CEDURE on Pg. 174. 3128411 1250AJP 1-87...

  • Page 88: Gen Set/Welder Short To Battery

    Ground alarm short to battery. The ground alarm output [X002.27] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.120 GROUND ALARM SHORT TO GROUND Flash Code: 3-3 Ground alarm short to ground. The ground alarm output [X002.27] is shorted to ground. See 1.378 COMMON STG PROCE- DURE on Pg. 175. 1-88 1250AJP 3128411...

  • Page 89: Head Tail Light Open Circuit

    1.126 HEAD TAIL LIGHT SHORT TO BATTERY Flash Code: 3-3 Head tail light short to battery. The head and tail light output [X002.26] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-89...

  • Page 90: Head Tail Light Short To Ground

    Hour meter short to battery. The hourmeter output [X004.12] is shorted to battery. See 1.377 COMMON STB OR OC PRO- CEDURE on Pg. 174. 1.135 HOUR METER SHORT TO GROUND Flash Code: 3-3 Hour meter short to ground. The hourmeter output [X004.12] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1-90 1250AJP 3128411...

  • Page 91: Jib Down Open Circuit

    Jib down short to ground. The jib down output [X169.26] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.141 JIB LEFT OPEN CIRCUIT Flash Code: 3-4 Jib left open circuit. The jib swing left output [X169.28] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-91...

  • Page 92: Keyswitch Faulty

    1.151 KEYSWITCH FAULTY Flash Code: 2-1 Keyswitch faulty. Both platform [X007.2] and ground [X007.3] modes are selected simultaneously. This could be due to a bad keyswitch [X030], wiring, or bad diodes at the power down relay [X011]. 1-92 1250AJP 3128411...

  • Page 93: L/S Joy. Center Tap Bad

    1.160 LEFT REVERSE DRIVE PUMP SHORT TO GROUND Flash Code: 3-3 Left reverse drive pump short to ground. The left reverse drive pump output [X090.2] is shorted to ground. See 1.378 COM- MON STG PROCEDURE on Pg. 175. 3128411 1250AJP 1-93...

  • Page 94: Length Sensor Ref Voltage High

    Lift up & telescope out prevented - platform overloaded. Notification that the machine is configured with load system cut- outs, the platform is overloaded, and lift up or tele out is selected. Lift up and telescope out are prevented while the platform is overloaded. 1-94 1250AJP 3128411...

  • Page 95: Lift/Swing Locked - Joystick Moved Before Footswitch

    TIONS LOST or LOAD PIN/TOWER LIFT CYL- Go to step 1.170.2 INDER ANGLE DISAGREEMENT fault present? 1.170.2 Is the load pin mounting hardware in good Go to step 1.170.3 condition and secure, including the keeper pin Repair as needed and keeper pin bolt? 3128411 1250AJP 1-95...

  • Page 96: Load Pin Sensor Fault

    Low oil pressure. This fault should only occur on machines configured with non-ECM engines. Notification that the oil pres- sure input [X001.15] is below 8 PSI and the engine has been running for at least 10 seconds. 1-96 1250AJP 3128411...

  • Page 97: Lt Fnt Steer Lt Stb Or Oc

    Repair/replace harness between Auxiliary Power terminal [X117] Pump negative terminal and the negative bat- Pump negative terminal and negative battery ter- tery terminal [X117]. minal. Repair/replace harness between Upper Swivel connector and Auxiliary Power Pump negative connector. 3128411 1250AJP 1-97...

  • Page 98: Lt Fnt Steer Lt Stg

    Are there loose, bent, broken or corroded Repair/Replace harness between terminal 5 of the wires or contacts or moisture in the connec- Repair/Replace connector as needed. bottom swivel connector tors? [X216.5.soc] and the left front steer right solenoid connector [X207] 1-98 1250AJP 3128411...

  • Page 99: Lt Fnt Steer Rt Stg

    Left rear steer right short to battery or open circuit. the control system detected a short to battery or open circuit on the chas- sis module left rear steer right valve output [X233.7]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-99...

  • Page 100: Lt Rear Steer Rt Stg

    Is there 60 Ω between main boom angle sen- 1.185.8 Disconnect the main boom Go to step 1.185.9 angle sensor 1 (right) con- sor 1 socket 4 and socket 5 [X048.4.soc See 1.46 BLAM CAN COMMUNICATIONS LOST nector [X048] X048.5.soc]? on Pg. 48 1-100 1250AJP 3128411...

  • Page 101: Main Angl1 Invalid Angle

    Manually adjust angle sensor that failed cali- Troubleshooting complete bration previous in step. Perform boom cali- Repeat this step. If a sensor cannot be adjusted or bration. Does it pass? continually falls outside of calibration replace the sensor. 3128411 1250AJP 1-101...

  • Page 102: Main Angl2 Can Communications Lost

    Is there 60 Ω between main boom angle sen- 1.187.8 Disconnect the main boom Go to step 1.187.9 angle sensor 2 (left) con- sor 2 socket 4 and socket 5 [X049.4.soc See 1.46 BLAM CAN COMMUNICATIONS LOST nector [X049] X049.5.soc]? on Pg. 48 1-102 1250AJP 3128411...

  • Page 103: Main Angl2 Invalid Angle

    Manually adjust angle sensor that failed cali- Troubleshooting complete bration previous in step. Perform boom cali- Repeat this step. If a sensor cannot be adjusted or bration. Does it pass? continually falls outside of calibration replace sensor. 3128411 1250AJP 1-103...

  • Page 104: Main Angle Movement Without Cmd

    Check the fault log for primary faults, MAIN Troubleshoot the primary fault before continuing ANGL1 CAN COMMUNICATIONS LOST, MAIN Go to step 1.190.2 ANGL1 INVALID ANGLE, MAIN ANGL2 CAN COMMUNICATIONS LOST, or MAIN ANGL2 INVALID ANGLE. Are any primary faults present? 1-104 1250AJP 3128411...

  • Page 105: Main Angle Sensor Not Detecting Angle Change

    1.191.3 View fault log Are any engine faults indicated? Troubleshoot them first Go to step 1.191.4 1.191.4 Are there any leaks between function pump, Repair/replace as needed PVG main lift valve, and main lift cylinder? Go to step 1.191.5 3128411 1250AJP 1-105...
  • Page 106 "MP1" port on the using the adjustment screw under the low Repair/replace function pump/low pressure relief main valve block. pressure relief adjustment cover nut on the function pump. Does the gauge read 450 psi or adjust to it? 1-106 1250AJP 3128411...
  • Page 107 Go to step 1.191.22 nect PVG enable [X068]. the connector of the PVG enable solenoid Repair/replace harness to ground including MTB Ground meter. (See Section [X068] and ground? ground bus connector [X009] 6. Multimeter Basics on Pg. 319 for details.) 3128411 1250AJP 1-107...

  • Page 108: Main Boom Trn Angle Sw/Sensor Disagreement

    Remove main transport angle switch [X051] Do not re-install sensor mount. Go to step completely mount. is the sensor flush +/- 0.015 inches 1.192.7. with bottom of counterbore in sensor mount? Adjust sensor to achieve proper distance. 1-108 1250AJP 3128411...

  • Page 109: Main Dump Open Circuit

    1.200 MAIN LIFT APU OPEN CIRCUIT Flash Code: 3-3 Main lift auxiliary power unit pilot valve open circuit. The main lift pilot valve output [X002.1] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-109...

  • Page 110: Main Lift Apu Short To Battery

    CAN bus problem or a ground module problem. Note Pretest Instructions Test Result Corrective Action 1.208.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION Troubleshoot that fault first ERRORS present? Go to step 1.208.2 1.208.2 Cycle power. Does problem clear? Troubleshooting complete Reprogram/replace ground module 1-110 1250AJP 3128411...

  • Page 111: Main Lift Pvg Valve Communications

    See Min/Max on Pg. 319 for details. Is it per- 2 [X259.2] and 3 [X259.3], forming properly? or use insulated alligator clips to those terminals. 3128411 1250AJP 1-111...

  • Page 112: Main Lift Pvg Valve Internal Fault

    Is there about 12 VDC between main lift PVG Transient caused condition. If it occurs again valve connector [X065]. valve socket 2 [X065.2.soc] and socket 3 troubleshoot charging and 12 VDC electrical Turn on machine. [X065.3.soc]? power generation system. Go to step 1.213.5 1-112 1250AJP 3128411...

  • Page 113: Main Lift Pvg Valve Obstructed

    (for drive pump). Take note of filters/housings that have contamination. 1.214.7 Do machine hydraulics function properly? Troubleshooting complete Replace hydraulic components that are not func- tioning properly. Focus first on components upstream of any filters/housings with contamina- tion. Calibrate if necessary. 3128411 1250AJP 1-113...

  • Page 114: Main Lift Pvg Valve Parameters Incorrect

    1.220 MAIN LIFT PVG VALVE STUCK RETRACTED Flash Code: 4-5 Main lift PVG valve stuck retracted. Main lift PVG valve spool did not move in the required time. Follow same procedure as 1.214 MAIN LIFT PVG VALVE OBSTRUCTED on Pg. 113. 1-114 1250AJP 3128411...

  • Page 115: Main Lift Pvg Valve Timeout

    STG PROCEDURE on Pg. 175. 1.226 MAIN TELE FLOW CONTROL OPEN CIRCUIT Flash Code: 3-3 Main telescope flow control valve open circuit. The main telescope proportional valve output [X002.9] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-115...

  • Page 116: Main Tele Flow Control Short To Battery

    Ground. Is it about 12 VDC? and turntable pass thru - 21 position pin E Ground multimeter. [X044.E.soc] Repair/replace harness between main boom transport angle switch socket 1 [X051.1.soc] and turntable pass thru - 21 position pin B [X044.B.soc] 1-116 1250AJP 3128411...
  • Page 117 N [X044.N.soc] and MTB sor to a part of the boom. Does it measure passthru - 21 position pin N [X042.N.pin] about 12VDC? Repair/replace harness between turntable passthru pin N [X044.N.pin] and boom transport angle switch socket 4 [X051.4.soc] 3128411 1250AJP 1-117...

  • Page 118: Main Trn Len Sw Disagreement

    21 position socket B [X042.B.soc] and tower passthru - 21 position [X042.B.soc]? boom passthru socket B [X044.B.soc] [X042]. Take the following Repair/replace harness between MTB passthru - measurement by backprob- 21 position socket B [X042.B.soc] and Power ing. Down Relay [X011] 1-118 1250AJP 3128411...
  • Page 119 J7 socket 12 [X007.12.soc]? replace ground module. passthru - 21 position Repair/replace harness between MTB passthru - [X042]. Take the following 21 position pin S [X042.S.pin] and ground mod- measurement by backprob- ule J7 socket 12 [X007.12.soc] ing. 3128411 1250AJP 1-119...

  • Page 120: Model Changed - Hydraulics Suspended - Cycle Ems

    Note Pretest Instructions Test Result Corrective Action 1.232.1 Cycle power Does fault still occur? Go to step 1.232.2 Troubleshooting complete 1.232.2 Perform 5.8 Boom Sensor Does fault still occur? Replace ground module Calibration on Pg. 309 Troubleshooting complete 1-120 1250AJP 3128411...

  • Page 121: New Load Pin Detected Fault

    Flash Code: 4-3 Oil pressure short to battery. This fault should only occur on machines configured with non-ECM engines. The engine oil pressure input [X001.15] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-121...

  • Page 122: Oil Pressure Short To Ground

    11VDC or more between socket 12 and socket sor passthru - 19 position connector [X050] and nector [X050] 16 of the boom sensor passthru - 19 position the 19 position platform control box passthru connector [X050.12.soc X050.16.soc]? connector [X160] Go to step 1.243.7 1-122 1250AJP 3128411...

  • Page 123: Platform Control Valve Open Circuit

    Troubleshooting complete Replace platform module 1.248 PLATFORM MODULE SOFTWARE UPDATE REQUIRED Flash Code: 9-9 Platform module software update required. The platform module software is a different major version than the ground mod- ule. Load new platform module software. 3128411 1250AJP 1-123...

  • Page 124: Platform Sensor Ref Voltage Out Of Range

    [X199] pin 4 [X199.4.pin] and pin 6 form module J1 [X165]. [X165.34.soc]. Is there a short? [X199.6.pin] and platform module J1 [X 165] socket 13 [X165.13.soc] and socket 34 [X165.34.soc] Short inside module. Replace platform module 1-124 1250AJP 3128411...

  • Page 125: Pump Switches Faulty - Check Diagnostics/Boom

    Run ANALYZER ⇒ SYSTEM TEST from the ground controls and platform controls to find the specific switch. 1.254 PVG VALVE ENABLE OPEN CIRCUIT Flash Code: 3-3 PVG valve enable open circuit. The PVG valve enable output [X002.31] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 3128411 1250AJP 1-125...

  • Page 126: Pvg Valve Enable Short To Battery

    STEER VALUE = XX. gauge on port MS1. Adjust relief next to port to 2000 psi ± 10% on port MS2. ESC out of cali- brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear? 1-126 1250AJP 3128411...

  • Page 127: Rear Left Wheel Sensor Fault - Check Mounting

    2 [X238.2.soc] and chassis module J3 steer passthru - 4 pos. passthru pin 2 [X237.2.pin]? socket 11 [X231.11.soc] [X237] Repair/replace harness between rear left wheel sensor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin] 3128411 1250AJP 1-127...

  • Page 128: Rear Left Wheel Sensor Out Of Range High

    Is there 5VDC between rear left steer passthru Repair/replace harness between rear left steer passthru - 4 pos. [X237]. socket 1 [X237.1.soc] and socket 3 passthru [X237] and rear left wheel sensor Turn on machine. [X237.3.soc]? [X238] Go to step 1.259.9 1-128 1250AJP 3128411...

  • Page 129: Rear Left Wheel Sensor Out Of Range Low

    1.260.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between rear left steer J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X237] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-129...

  • Page 130: Rear Right Wheel Blocked

    10% on load sense 1.261.9 Swap valve section with the Does condition follow valve section to other Repair/replace valve section one on the other side of side of machine? Repair/replace front left steer cylinder and/or machine. hoses. 1-130 1250AJP 3128411...

  • Page 131: Rear Right Wheel Sensor Fault - Check Mounting

    1.262.11 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between rear right steer J3. Turn on machine. 10 [X231.10.pin] and pin 12 [X231.12.pin]? passthru [X236] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-131...

  • Page 132: Rear Right Wheel Sensor Out Of Range High

    1.263.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between rear right steer J3. Turn on machine. 7 [X231.7.pin] and pin 9 [X231.9.pin]? passthru [X236] and chassis module J3 [X231] Replace chassis module 1-132 1250AJP 3128411...

  • Page 133: Rear Right Wheel Sensor Out Of Range Low

    1.264.9 Disconnect chassis module Is there 5VDC between chassis module J3 pin Repair/Replace harness between rear right steer J3. Turn on machine. 7 [X231.10.pin] and pin 9 [X231.9.pin]? passthru [X236] and chassis module J3 [X231] Replace chassis module 3128411 1250AJP 1-133...

  • Page 134: Restricted To Transport - Axle Lockout Valve Stb Or Oc

    (bottom) swivel out valve solenoid DIN connector terminal 1 of the axle lockout valve solenoid con- connector [X216.8] [X212.1.soc] measure 12VDC? nector [212.1] and terminal 8 of the chassis (bot- tom) swivel connector [X216.8] Go to step 1.265.12 1-134 1250AJP 3128411...

  • Page 135: Restricted To Transport - Osc Axle Press Sw Disagreement

    When out of transport position, drive/steer, tower lift up, main lift up, and main telescope out are prevented. This fault will be 3128411 1250AJP 1-135...
  • Page 136 A3, a4, A5, has been warmed up. Does the gauge read Repair/replace traction valve. A6, B3, B4, B5, and B6. about 500psi? Plug/cap open lines and ports. Tee a gauge in with the hoses at the charge filter. 1-136 1250AJP 3128411...

  • Page 137: Restricted To Transport - Parking Brake Stb

    1.269 RIGHT FORWARD DRIVE PUMP SHORT TO BATTERY Flash Code: 3-3 Right forward drive pump short to battery. The right forward drive pump output [X087.1] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-137...

  • Page 138: Right Forward Drive Pump Short To Ground

    Flash Code: 8-6 Right rear steer left short to ground. The control system detected a short to ground on the chassis module right rear steer left valve output [233.6]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1-138 1250AJP 3128411...

  • Page 139: Rt Rear Steer Rt Stb Or Oc

    CW 1/4 turn to 9 o’clock Go to step 1.282.9 position. 1.282.8 Turn on machine. Rotate Does fault message clear? Normal operation. Troubleshooting complete. function speed control knob Reprogram/replace ground module CW 1/4 turn to 9 o’clock position. 3128411 1250AJP 1-139...

  • Page 140: Running At Creep - Platform Overloaded

    STOWED? Perform 5.8 Boom Sensor Calibration on Pg. ground. ANALYZER ⇒ DIAGNOSTICS ⇒ TRANS- PORT DATA 1.284.4 Is the Tilt indicator on? Perform 5.7 Calibrating Tilt Sensor on Pg. 307 Repair/reprogram ground module 1-140 1250AJP 3128411...

  • Page 141: Running At Cutback - Out Of Transport Position

    [X001.16] is indicating a speed that greater than 4000 RPM or approxi- mately 8875 Hz. 1.288 START SOLENOID OPEN CIRCUIT Flash Code: 3-3 Start solenoid open circuit. The engine start solenoid output [X001.11] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 3128411 1250AJP 1-141...

  • Page 142: Start Solenoid Short To Battery

    Swing left short to battery. The swing left valve output [X002.34] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.297 SWING RIGHT OPEN CIRCUIT Flash Code: 3-3 Swing right open circuit. The swing right valve output [X002.35] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1-142 1250AJP 3128411...

  • Page 143: Swing Right Short To Battery

    Go to step 1.303.4 boom. ANALYZER ⇒ DIAG- 1.5°? Replace sensor out of specified range NOSTICS ⇒ BOOM SEN- SORS ⇒ TOWER ANGLE # SENSOR 1.303.4 Calibrate boom Did boom calibrate successfully? Troubleshooting complete Troubleshoot according to calibration fault 3128411 1250AJP 1-143...

  • Page 144: Tower Envelope Encroached - Hydraulics Suspended

    400 inches (33’ 4"). (Do not allow A [X093.A.pin] to pin C cable to retract in an uncontrolled or rapid [X093.C.pin]. manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? 1-144 1250AJP 3128411...

  • Page 145: Tower Length Switch/Sensor Disagreement

    90 degrees from the switch body 1.306.3 Is there any loose hardware on the length sen- Tighten any loose hardware sors [X093 X094], length switch [X056], Go to step 1.306.4 mounting points, or cable mounts 3128411 1250AJP 1-145...
  • Page 146 Go to step 1.306.15 position Mate-N-Lok connector in the main Repair/Replace the black wire between the terminal box [X017.2] should measure 12VDC switch and terminal 2 of the 6 position Mate-N- Lok connector in the main terminal box [X017.2] 1-146 1250AJP 3128411...

  • Page 147: Tower Lift Apu Valve Open Circuit

    1.308 TOWER LIFT APU VALVE SHORT TO BATTERY Flash Code: 3-3 Tower lift auxiliary power unit pilot valve short to battery. The tower lift pilot valve output [X002.12] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 3128411 1250AJP 1-147...

  • Page 148: Tower Lift Apu Valve Short To Ground

    CAN bus problem or a ground module problem. Note Pretest Instructions Test Result Corrective Action 1.315.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION Troubleshoot that fault first ERRORS present? Go to step 1.315.2 1.315.2 Cycle power. Does problem clear? Troubleshooting complete Reprogram/replace ground module 1-148 1250AJP 3128411...

  • Page 149: Tower Lift Pvg Valve Communications

    2 See Min/Max on Pg. 319 for details. Is it per- [X260.2] and 3 [X260.3], or forming properly? use insulated alligator clips to those terminals. 3128411 1250AJP 1-149...

  • Page 150: Tower Lift Pvg Valve Internal Fault

    Is there about 12 VDC between tower lift PVG Transient caused condition. If it occurs again valve connector [X066]. valve socket 2 [X066.2.soc] and socket 3 troubleshoot charging and 12 VDC electrical Turn on machine. [X066.3.soc]? power generation system. Go to step 1.320.5 1-150 1250AJP 3128411...

  • Page 151: Tower Lift Pvg Valve Obstructed

    (for drive pump). Take note of filters/housings that have contamination. 1.321.7 Do machine hydraulics function properly? Troubleshooting complete Replace hydraulic components that are not func- tioning properly. Focus first on components upstream of any filters/housings with contamina- tion. Calibrate if necessary. 3128411 1250AJP 1-151...

  • Page 152: Tower Lift Pvg Valve Parameters Incorrect

    1.327 TOWER LIFT PVG VALVE STUCK RETRACTED Flash Code: 4-5 Tower lift PVG valve stuck retracted. Tower lift PVG valve spool did not move in the required time. Follow same procedure as 1.321 TOWER LIFT PVG VALVE OBSTRUCTED on Pg. 151. 1-152 1250AJP 3128411...

  • Page 153: Tower Lift Pvg Valve Timeout

    COMMON STB OR OC PROCEDURE on Pg. 174. 1.333 TOWER TELE ENABLE SHORT TO GROUND Flash Code: 3-3 Tower telescope enable short to ground. The tower telescope enable valve output [X001.6] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 3128411 1250AJP 1-153...

  • Page 154: Tower Tele Enable Stuck Open

    4 pos. [X067] and ground pos. socket 2 [X067.2.soc] and ground mod- [X067] and battery ground module J2 [X002] ule J1 socket? [X001.?.soc]? Repair harness between tower tele PVG - 4 pos. [X067] and ground module J1 1-154 1250AJP 3128411...

  • Page 155: Tower Telescope Pvg Valve High Voltage

    Are there any 6-6 communication faults? Troubleshoot those first Go to step 1.341.2 1.341.2 Cycle machine power. Keep power off at least Replace tower tele PVG valve actuator [X067] 20 seconds. Does fault still occur? Troubleshooting complete 3128411 1250AJP 1-155...

  • Page 156: Tower Telescope Pvg Valve Location Improper

    Repair harness between ground module J1 ment by backprobing. Turn J1 terminal 3 [X001.3] and ground module J8 [X001] and MTB ground bus -12 pos. [X009] on machine after setting up terminal 1? Reprogram/replace ground module measurement. 1-156 1250AJP 3128411...

  • Page 157: Tower Telescope Pvg Valve Obstructed

    1.345.1 Calibrate boom valves. See Did it pass calibration? Troubleshooting complete. If fault is recurring 5.4 Calibrating Boom replace tower tele PVG valve [X067] actuator. Valves on Pg. 296 for Replace tower tele PVG valve [X067] actuator details. 3128411 1250AJP 1-157...

  • Page 158: Tower Telescope Pvg Valve Sent Unrecognized Fault

    Tower telescope PVG valve timeout. Position instructions were not received by the tower telescope PVG valve within the allowed amount of time. Note Pretest Instructions Test Result Corrective Action 1.351.1 Is EXCESSIVE CAN BUS COMMUNICATION Troubleshoot those faults first ERRORS or other CAN bus communication Go to step 1.351.2 error faults present? 1-158 1250AJP 3128411...

  • Page 159: Tower Telescope Pvg Valve Wiring Incorrect

    258? 1.353.4 Disconnect main tele retract Does the fault MAIN IN OPEN CIRCUIT Repair/replace main tele cylinder holding valve [X073] connector appear? Harnesses for main tele retract [X073] and main tele extend [X071] are swapped. Correct them. 3128411 1250AJP 1-159...

  • Page 160: Trn Dual Cap Switches Bad

    PROCEDURE on Pg. 174. 1.357 TWO SPEED SHORT TO GROUND Flash Code: 3-3 Two speed short to ground. The two speed valve output [X001.20] is shorted to ground. See 1.378 COMMON STG PROCE- DURE on Pg. 175. 1-160 1250AJP 3128411...

  • Page 161: Twr Angl1 Invalid Angle

    [X100]. Does the BOOM ANGLE SENSOR #2 boom angle sensor #1 (Right) [X099] with Red, COMMUNICATIONS FAULT show? Blue, and Black wires; and #2 (Left) [X100] with Orange, Yellow and Black wires. See Figure 2-13. BLAM Electrical Schematic on Pg. 201 for details. 3128411 1250AJP 1-161...

  • Page 162: Twr Cyl Angle Movement Without Cmd

    Tower cylinder angle not detecting angle change. The control system did not detect at least 0.5° of movement within 3 sec- onds while the tower lift function was commanded. This fault is not detected for tower lift up angles greater than 79.9° or 1-162 1250AJP 3128411...
  • Page 163 1.361.9 Swap the tower tele enable Will the tower now lift and tele and is the fault Replace the valve cartridge originally from the valve cartridge with the main cleared? tower tele enable lift enable valve cartridge Go to step 1.361.10 3128411 1250AJP 1-163...

  • Page 164: Twr Cyl Angle Sensor Out Of Range High

    Go to step 1.363.5 angle sensor [X092] and sensor pin B [X092.B.pin] and BLAM J3 pin 5 Repair blue wire (including contacts) or replace BLAM J3 [X088]. [X088.5.pin] harness between tower lift cyl angle sensor [X092] and BLAM J3 [X088] 1-164 1250AJP 3128411...

  • Page 165: Twr Length Movement Without Cmd

    Is there fluid flowing continuously out of the Repair/replace tower tele cylinder holding valve same as in step 1.364.6. hose? Repack tower tele cylinder piston seal Disconnect hose on port 2 from tower tele enable valve [X081]. 3128411 1250AJP 1-165...

  • Page 166: Twr Length Sensor Not Detecting Length Change

    Replace PVG enable valve solenoid [X081] 1.365.9 Swap the PVG enable valve Does fault clear? Replace cartridge originally in PVG enable valve [X068] cartridge with the [X081] main lift enable valve [X082] Go to step 1.365.10 cartridge. 1-166 1250AJP 3128411...

  • Page 167: Twr Length Sensor One Value Out Of Range High

    1.366.4 Turn on machine. Discon- Is there about 5VDC between BLAM J 3 pin 7 Repair/replace harness between BLAM J3 nect BLAM J 3 [X088] [X088.7.pin] and pin 9 [X088.7.pin]? [X088] and tower boom length sensor #1 (top) [X093] Replace BLAM 3128411 1250AJP 1-167...

  • Page 168: Twr Length Sensor One Value Out Of Range Low

    1.367.3 Disconnect tower boom Is there about 5VDC between tower boom Leave machine on. Go to step1.367.5 length sensor #1 (top) length sensor #1 (top) socket A [X093.A.soc] Go to step 1.367.4 [X093]. Turn on machine. and socket B [X093.B.soc]? 1-168 1250AJP 3128411...

  • Page 169: Twr Length Sensor Two Value Out Of Range High

    Is there about 5VDC between BLAM J 3 socket Repair/replace harness between BLAM J3 nect BLAM J 3 [X088] 7 [X088.7.pin] and pin 9 [X088.9.pin]? [X088] and tower boom length sensor #2 (bot- tom) [X094] Replace BLAM 3128411 1250AJP 1-169...

  • Page 170: Twr Length Sensor Two Value Out Of Range Low

    1.369.3 Disconnect tower boom Is there about 5VDC between tower boom Leave machine on. Go to step1.369.5 length sensor #2 (bottom) length sensor #2 (bottom) socket A Go to step 1.369.4 [X094]. Turn on machine. [X094.A.soc] and socket B [X094.B.soc]? 1-170 1250AJP 3128411...

  • Page 171: Twr Trn Sw Disagreement

    Repair/Replace the YEL/RED 2-60 wire between ground module J7 connector [X007.29] the 6 position Mate-N-Lok connector in the main should measure 12VDC. terminal box [X017.1] and terminal 29 of the ground module J7 connector [X007.29] Repair/Replace the ground module 3128411 1250AJP 1-171...

  • Page 172: Waiting For Fsw To Be Open

    1.372 WRONG ENGINE SELECTED - ECM PRESENT Flash Code: 4-3 Wrong engine selected - ECM present. The machine is configured to be a non-ECM engine, but an ECM signal is detected on the CAN bus. Change the machine engine configuration. 1-172 1250AJP 3128411...

  • Page 173: Wrong Main Lift Response

    [X080] and the tower lift cylinder? 1.375.4 Raise tower boom. Discon- Does fluid continue to flow from the hose? Repair/replace tower cylinder holding valve nect the hose on the #2 port Repack main cylinder of the tower lift enable valve [X080]. 3128411 1250AJP 1-173...

  • Page 174: Wrong Twr Tele Response

    Some values are given on the sche- matics. For details on what some switch posi- tions mean see Table 2-1. Limit Switch States on Pg. 177. Also, inspect the connector for pins that are damaged, loose pushed out, etc. 1-174 1250AJP 3128411...

  • Page 175: Common Stg Procedure

    Not all components are ing for power or continuity. Typically, the failure powered by 12VDC. isn’t too close to the battery ground terminal because then so many things wouldn’t work, this fault would not be detected. Repair as needed 3128411 1250AJP 1-175...
  • Page 176 If the component and wiring are in question connection to the nearest major good, reprogram/replace the associated module. component. It should have continuity to the Fail Repair as needed module, swivel, bus or other connector in accordance with the schematic. 1-176 1250AJP 3128411...

  • Page 177: Limit Switch States

    LF Axle Extension Closed = Extended X213 Osc Axle Lockout Pressure Closed = Pressure > 200psi X216 Drive Orientation Open = Normal Orientation X225 LR Axle Extension Closed = Extended X226 RR Axle Extension Closed = Extended 3128411 1250AJP 2-177...

  • Page 178: Main Boom Dual Capacity Zones

    Figure 2-1. Main Boom Angle and Length Zones Table 2-2. Main Boom Dual Capacity Zones Functions Main Lift Up 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,3,4,8 Main Lift Down 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,5,6,7,8 Main Tele Out 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,7,8 1,2,7,8 Main Tele In 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8 1,2,3,6,7,8 2-178 1250AJP 3128411...

  • Page 179: Switch States / Boom Length Regions

    On Cam Disagree Off Cam Off Cam Off Cam Disagree On Cam On Cam Disagree Control System Conclusion of Main Transport Disagree Disagree A/D Disagree Switches Control System Conclusion of Main Boom Switch Fault Switch Length Fault 3128411 1250AJP 2-179...
  • Page 180 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-180 1250AJP 3128411...
  • Page 181 SECTION 2 - ELECTRICAL REFERENCE Color Key PLATFORM CONTROL AREA BOOM AREA ENGINE SIDE AREA MAIN VALVE AREA GROUND CONTROL BOX AREA CHASSIS AREA Figure 2-3. Color Key 3128411 1250AJP 2-181...

  • Page 182: Platform Area Solenoids

    X135 Platform Dump X136 Level Up 10.1 X137 Level Down 10.1 X138 Rotate Right 10.1 X139 Rotate Left 10.1 X140 Jig Swing Right 10.1 X141 Jib Swing Left 10.1 X142 Jib Up 10.1 X143 Jib Down 10.1 2-182 1250AJP 3128411...
  • Page 183 X135 LEVEL UP X155 X136 LEVEL DOWN X137 ROTATE RIGHT X138 JIB SWING RIGHT ROTATE LEFT X140 X139 JIB SWING X152 LEFT X141 JIB UP X142 JIB DOWN X143 PLATFORM CONTROL AREA Figure 2-4. Platform Area Connectors 3128411 1250AJP 2-183...
  • Page 184 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-184 1250AJP 3128411...
  • Page 185 ±0.060 (1.52mm) with main SWITCH ANGLE boom pivot pin as shown SENSOR #1 RIGHT X092 X060 X056 TOWER X099 BOOM LENGTH X062 SENSOR #2 BOOM AREA X094 Figure 2-5. Boom Area Connectors 3128411 1250AJP 2-185...
  • Page 186 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-186 1250AJP 3128411...
  • Page 187 X240 X103 X113 STARTER 7500W GENERATOR X120 RIGHT DRIVE FWD X118 RIGHT DRIVE REV X121 LEFT DRIVE FWD X119 LEFT DRIVE REV THESE VIEWS SHOWN FOR CLARITY X250 X251 ENGINE SIDE AREA Figure 2-6. Engine Area Connectors 3128411 1250AJP 2-187...

  • Page 188: Main Valve Area Solenoids

    Main Tele Extend X072 Main Tele Proportional X073 Main Tele Retract X074 Main Dump X075 Tower Lift Pilot X076 Tower Tele Pilot X077 Main Lift Pilot X080 Tower Lift Enable X081 Tower Tele Enable X082 Main Lift Enable 2-188 1250AJP 3128411...
  • Page 189 CONNECTION X065 X071 DUMP MAIN X072 MAIN TELE X073 LIFT PVG EXTEND MAIN TELE MAIN TELE PROPORTIONAL RETRACT X262 X063 * X268 has cable going into valve harness MAIN VALVE AREA Figure 2-7. Main Valve Area Connectors 3128411 1250AJP 2-189...
  • Page 190 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-190 1250AJP 3128411...
  • Page 191 X003 X012 X011 X024 X023 X025 X021 X022 X029 X020 X026 X028 X019 X030 X014 CAN to Ground Module X018 GROUND CONTROL BOX AREA X270 CAN to Platform X269 CAN to BLAM Figure 2-8. Ground Control Connectors 3128411 1250AJP 2-191...

  • Page 192: Chassis Area Solenoids

    Axle Lockout Solenoid X214 2 Speed Solenoid X215 Brake Release Solenoid X219 Rear Right Steer Left X220 Rear Left Steer left X221 Rear Axles Retract X222 Rear Right Steer Right X223 Rear Left Steer Right X224 Rear Axles Extend 2-192 1250AJP 3128411...
  • Page 193 REAR RIGHT STEER LEFT RELEASE X219 REAR RIGHT STEER LEFT X222 FRONT RIGHT STEER RIGHT FRONT RIGHT X208 STEER RIGHT X211 STEER LEFT TRACTION CONTROL VALVE VALVES TURNED FOR CLARITY CHASSIS AREA Figure 2-9. Chassis Area Connectors 3128411 1250AJP 2-193...
  • Page 194 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-194 1250AJP 3128411...
  • Page 195 DRIVE ORIENTATION OVERIDE YEL/RED 2-16 YEL/RED 2-16-1 X189 JIB STOW V BAT. WHITE 59-60 YEL/RED 2-16-2 YEL/RED 2-16-3 SOFT TOUCH LIMIT SWITCHS BLACK WHITE ORN/RED 49-67 BLACK WHITE PLATFORM SCH. Ref. 1870197C Figure 2-10. Platform Electrical Schematic 3128411 1250AJP 2-195...
  • Page 196 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-196 1250AJP 3128411...
  • Page 197 DEUTSCH 21 POS. TWIST LOCK IN MTB. TO CHASSIS TO BLAM THRU ENGINE HARNESS TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) Ref. 1870197C TOWER & MAIN BOOM SCH. Figure 2-11. Tower and Main Boom Electrical Schematic 3128411 1250AJP 2-197...
  • Page 198 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-198 1250AJP 3128411...
  • Page 199 DEUTSCH 21 POS. TWIST LOCK IN MTB. X058 TO CHASSIS X083 TO BLAM THRU ENGINE HARNESS X106 X058 TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) GROUND CONTROL SCH. Ref. 1870197C Figure 2-12. Ground Control Electrical Schematic 3128411 1250AJP 2-199...
  • Page 200 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-200 1250AJP 3128411...
  • Page 201 DEUTSCH 19 POS. TWIST LOCK IN MTB. X043 X042 DEUTSCH 21 POS. TWIST LOCK IN MTB. TO CHASSIS X083 X106 TO BLAM THRU ENGINE HARNESS X058 TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) BLAM SCH. Ref. 1870197C Figure 2-13. BLAM Electrical Schematic 3128411 1250AJP 2-201...
  • Page 202 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-202 1250AJP 3128411...
  • Page 203 YELLOW 11-1 LEFT REAR STEER LEFT X220 WHITE BLUE STEER SENSOR BLACK BLACK BLACK BRN/BLK BRN/BLK BLACK GROUND X237 WHITE BLACK J1 GRAY X229 X235 Chassis Analyzer Connection CHASSIS SCH. Ref. 1870197C Figure 2-14. Chassis Electrical Schematic 3128411 1250AJP 2-203...
  • Page 204 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-204 1250AJP 3128411...
  • Page 205 X104 RELAY RELAY X028 HORN X109 FUEL X112 X112 X242 X105 LEVEL TAILLIGHTS SENSOR X022 X019 X017 X029 X020 X016 X111 X111 X002 X011 X015 X030 X018 X012 X004 Figure 2-15. Electrical Wiring (Sheet 1 of 2) 3128411 1250AJP 2-205...
  • Page 206 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-206 1250AJP 3128411...
  • Page 207 LIMIT X267 SWITCH CHASSIS BATTERY CABLE CONNECTIONS POWER RELAY X117 AUX PUMP X108 X203 X116 X238 STARTER STEER STEER X113 START RELAY ANGLE ANGLE POWER SENSOR SENSOR RELAY X112 Figure 2-16. Electrical Wiring (Sheet 2 of 2) 3128411 1250AJP 2-207...
  • Page 208 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-208 1250AJP 3128411...

  • Page 209: Connector Index

    X044 Tower Boom passthru - 21 Position DHD21R DHD21P 2-11. (3E) 2-5. X045 Tower Boom passthru - 19 Position DHD19R DHD21P 2-11. (3G) 2-5. X046 Dual Capacity Switch Passthru - 3 Position DT03P DT03RD 2-11. (4D) 2-5. 3128411 1250AJP 2-209...
  • Page 210 X091 BLAM Analyzer - 4 Position AMP04R 2-13. (3G) 2-7. X092 Tower Lift Cyl Angle Sensor - 3 Position DT03P DT03R 2-13. (7G) 2-5. X093 Tower Boom Length Sensor 1(Top) - 3 Position DT03P DT03R 2-13. (7F) 2-5. 2-210 1250AJP 3128411...
  • Page 211 2-4. X137 Platform Level Down Solenoid DIN43650P 2-10. (4F) 2-4. X138 Platform Rotate Right Solenoid DIN43650P 2-10. (4F) 2-4. X139 Platform Rotate Left Solenoid DIN43650P 2-10. (4F) 2-4. X140 Platform Jib Swing Right DIN43650P 2-10. (4F) 2-4. 3128411 1250AJP 2-211...
  • Page 212 X184 Platform Soft Touch Override Switch 2-10. (7E) 2-4. X185 Platform Jib Swing Switch - 6 Position E06P 2-10. (7B) 2-4. X186 Platform Tower Boom Lift Switch - 6 Position E06P 2-10. (7F) 2-4. X187 Platform Soft Touch Indicator 2-10. (7D) 2-4. 2-212 1250AJP 3128411...
  • Page 213 X231 Chassis Module J3 Connector, Green - 12 Position DT12CP 2-14. (4D) 2-9. X232 Chassis Module J4 Connector, Gray - 8 Position DT08AP 2-14. (1G) 2-9. X233 Chassis Module J5 Connector, Brown - 12 Position DT12DP 2-14. (8C) 2-9. X234 Not Used 3128411 1250AJP 2-213...

  • Page 214: Connector Index

    X268 CAN pass thru for EMR2 - 3 position DT03P DT03R 2-13. (1D) 2-7. X269 CAN 3way - to BLAM, Blue DT03P032BP (Blue) 2-12. (7B) 2-8. X270 CAN 3way - to Platform, Blue DT03P032BP (Blue) 2-12. (7B) 2-8. 2-214 1250AJP 3128411...

  • Page 215: X086 (J1) Blam Module Pinout

    Analog Input 5VDC Ground Ground 0VDC Reference Voltage Other Voltage 5VDC Tower Boom Length Sensor 1 Analog Input 5VDC Ground Ground 0VDC Reference Voltage Other Voltage 5VDC Tower Boom Length Sensor 2 Analog Input 5VDC Ground Ground 0VDC 3128411 1250AJP 2-215...

  • Page 216: X089 (J4) Blam Module Pinout

    Output Oscillating Axles Output Tower Boom Transport Angle Output Spare Output Output Spare Output Output Spare Output Output Spare Output Output Analyzer Power Other Voltage Vbatt RS232 Receive Input/Output Comm RS232 Transmit Input/Output Comm Ground Ground 0VDC 2-216 1250AJP 3128411...

  • Page 217: X229 (J1) Chassis Module Pinout

    0VDC Reference Voltage Other Voltage 5VDC Rear Right Steer Angle Sensor Analog Input 0 - 5VDC Ground Ground 0VDC Reference Voltage Other Voltage 5VDC Rear Left Steer Angle Sensor Analog Input 0 - 5VDC Ground Ground 0VDC 3128411 1250AJP 2-217...

  • Page 218: X232 (J4) Chassis Module Pinout

    Right Rear Steer Left Solenoid Output Vbatt Left Rear Steer Right Solenoid Output Vbatt Left Rear Steer Left Solenoid Output Vbatt Analyzer Power Vbatt Vbatt Analyzer RS-232 Receive Input Comm Analyzer RS-232 Transmit Output Comm Analyzer Ground Ground 0VDC 2-218 1250AJP 3128411...

  • Page 219: Ground Module Connector Pinouts

    Main Lift Pilot Output Vbatt Horn Output Vbatt Platform Control Valve Output Vbatt Main Telescope In Output Vbatt Basket Level Up Override Output Vbatt Ground Ground 0VDC Basket Level Down Override Output Vbatt Tower Telescope Power Output 3128411 1250AJP 2-219...
  • Page 220 Vbatt Tower Up Input Vbatt Main Boom Transport Angle Open Input Vbatt Hour Meter Output Vbatt BCS Calibrated Lamp Output Vbatt Overload Lamp Output Vbatt Spare Output Vbatt Auxiliary Power Input Vbatt Basket Level Up Input Vbatt 2-220 1250AJP 3128411...
  • Page 221 Ground Spare Analog Input 1 Input Main Boom Transport Length #2 Open Input Vbatt Tower Boom Transport Angle Input Vbatt Ground Control Enable Input Vbatt CAN Lo Input/Output Comm Ground Ground 0VDC Reference Voltage Other Voltage 7VDC 3128411 1250AJP 2-221...
  • Page 222 Tower Boom Transport Length Open Input Vbatt Table 2-22. X008 (J8) Ground Module Pinout Function Type Range (V) Ground from Battery Ground 0VDC Ground EMS Output Vbatt Ground to Platform Ground 0VDC Ground EMS Out to Platform Output Vbatt 2-222 1250AJP 3128411...

  • Page 223: Platform Module Connector Pinouts

    Jib Right Input Vbatt Jib Left Input Vbatt Switch Input Battery Vbatt Vbatt Drive Orientation Override Switch Input Vbatt Basket Stow Switch Input Vbatt Tilt Lamp Output Vbatt Enable Lamp Output Vbatt System Distress/Fault Lamp Output Vbatt 3128411 1250AJP 2-223...
  • Page 224 Swing & Lift Joystick Supply Vref 7VDC Lift Center Tap Input 0 - 7VDC Lift Signal Input 0 - 7VDC Swing Signal Input 0 - 7VDC Swing Center Tap Input 0 - 7VDC Not Used Ground Ground 0VDC Not Used 2-224 1250AJP 3128411...
  • Page 225 Output Jib Down Output Jib Right Output Jib Left Output Digital Output Return Ground 0VDC CAN LO Input/Output Comm CAN HI Input/Output Comm CAN Shield Ground 0VDC Secondary Tilt Sensor Ground Ground 0VDC Not Used Not Used 3128411 1250AJP 2-225...
  • Page 226 SECTION 2 - ELECTRICAL REFERENCE Table 2-28. X170 (J8) Platform Module Pinout Function Type Range (V) Ground from Ground Module Ground 0VDC Ground EMS Ground 0VDC 2-226 1250AJP 3128411...

  • Page 227: Connector Loading Diagrams

    Amp 2 position plug AMP02R Amp 2 position recepta- AMPJT82600 Amp 2 position plug AMP04P Amp 4 position plug AMP04R Amp 4 position recepta- AMP06P Amp 6 position plug 3 2 1 6 5 4 AMP06R Amp 6 position recepta- 3128411 1250AJP 2-227...
  • Page 228 AMP15R Amp 15 position recep- tacle AMP25LP Amp Rectangular 25 position plug with key for left AMP25RP Amp Rectangular 25 position plug with key for right AMPPVG4P Amp PVG Valve 4 posi- (Black) tion plug AMPPVG4GP (Gray) 2-228 1250AJP 3128411...
  • Page 229 AMP14P Ampseal 14 position Socket Rear Insert AMP351P Ampseal 35 position (Black) AMP352P (Neutral) AMP354P (Gray) AMP355P (Blue) Socket Rear Insert AN350P Anderson Power Con- nector ANL06P Amphenol 6 Position Sealed Plug BOSCH05P Bosch Relay Sealed Plug 3128411 1250AJP 2-229...
  • Page 230 Deutz Supplied 12 posi- tion receptacle 10 11 DEUTZ12P Deutz Supplied 12 posi- tion plug DEUTZ12R Deutz Supplied 12 posi- tion receptacle 10 11 DEUTZ16P Deutz Supplied 16 posi- tion plug 14 15 DEUTZ16R Deutz Supplied 16 posi- tion receptacle 2-230 1250AJP 3128411...
  • Page 231 DEUTZG Deutz Supplied 2 posi- tion air filter pressure switch Receptacle DIN43650P Din 43650 4 position plug DHD14P Deutsch 14 position HD series alum. Plug Rear View DHD14R Deutsch 14 position HD series alum. Receptacle Rear View 3128411 1250AJP 2-231...
  • Page 232 Deutsch 19 position HD series alum. Plug DHD19R Deutsch 19 position HD series alum. Receptacle DHD1821P Deutsch 21 position HD series alum. Plug DHD1821R Deutsch 21 position HD series alum. Receptacle DHD21P Deutsch 21 position HD series alum. Plug 2-232 1250AJP 3128411...
  • Page 233 DT02R Deutsch 2 position DT series receptacle DT03P Deutsch 3 position DT series plug DT03R Deutsch 3 position DT series receptacle DT03P032GP Deutsch 3 position DT (Green) series plug with over- mold adaptor DT03P032BP (Blue) 3128411 1250AJP 2-233...
  • Page 234 Deutsch 6 position DT series plug DT06EP032R Deutsch 6 position bus receptacle DT06R Deutsch 6 position DT series receptacle DT08AP Deutsch 8 position DT series plug with A keys DT08AR Deutsch 8 position DT series receptacle with A keys 2-234 1250AJP 3128411...
  • Page 235 Deutsch 12 position DT series plug with B keys DT12BR Deutsch 12 position DT series receptacle with B keys DT12CP Deutsch 12 position DT series plug with C keys DT12DP Deutsch 12 position DT series plug with D keys 3128411 1250AJP 2-235...
  • Page 236 Deutsch 4 position DTM series mini receptacle DTM12AP Deutsch 12 position DT 10 11 12 series mini plug with A DTM12BP Deutsch 12 position DT 10 11 12 series mini plug with B DTP02P Deutsch 2 position DTP series plug 2-236 1250AJP 3128411...
  • Page 237 Diagram DTP02R Deutsch 2 position DTP series receptacle E06P Eaton Toggle Switch ITTC12P ITT Cannon 12 position plug MMF02P Molex 2 position plug MMF04P Molex 4 position plug MMF08P Molex Mini Fit 8 position plug Rear View 3128411 1250AJP 2-237...
  • Page 238 Molex Mini Fit 10 posi- tion plug MMF12P Molex Mini Fit 12 posi- tion plug MMF24P Molex Mini Fit 24 posi- tion plug PHEONIX5P Pheonix 5 position M-12 Plug PACKARD2LR Packard Light Recepta- PACKARD2P Packard 2 position plug 2-238 1250AJP 3128411...

  • Page 239: Working With Amp Connectors

    3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it. Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 2-17. Connector Assembly Figure 1). Proceed as follows: 3128411 1250AJP 2-239...
  • Page 240 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Fig- ure 2-19. Connector Assembly Figure 2). Figure 2-18. AMP Connector 2-240 1250AJP 3128411...
  • Page 241 (See Figure 2-20. Connector Assembly Figure 3). Figure 2-20. Connector Assembly Figure 3 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 2-21. Connector Assembly Figure 4). 3128411 1250AJP 2-241...
  • Page 242 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. 2-242 1250AJP 3128411...
  • Page 243 AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the connector seals and could result in system failure. Figure 2-23. Connector Installation 3128411 1250AJP 2-243...

  • Page 244: Working With Deutsch Connectors

    3. Hold the rear seal in place, as removing the contact may displace the seal. HD30/HDP20 Series Assembly Figure 2-26. HD/HDP Contact Installation 1. Grasp contact about 25mm behind the contact crimp barrel. 2. Hold connector with rear grommet facing you. 2-244 1250AJP 3128411...
  • Page 245 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 2-29. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. 3128411 1250AJP 2-245...
  • Page 246 SECTION 2 - ELECTRICAL REFERENCE This Page Left Blank Intentionally 2-246 1250AJP 3128411...
  • Page 247 MAIN TELE SHOCK VALVE RETRACT SHOCK VALVE LS PORT MAIN VALVE MAIN LIFT EXTEND SHOCK VALVE ADJUSTMENT SCREW MAIN LIFT RETRACT SHOCK VALVE TOWER LIFT EXTEND SHOCK VALVE MAIN TELE EXTEND SHOCK VALVE Figure 3-1. Main Valve Layout 3128411 1250AJP 3-247...
  • Page 248 SECTION 3 - HYDRAULIC REFERENCE PUMPS VIEW ROTATED RIGHT SIDE DRIVE PUMP LEFT SIDE DRIVE PUMP FUNCTION PUMP LOW PRESS RELIEF ADJ. HIGH PRESS RELIEF ADJ. Figure 3-2. Pumps Layout 3-248 1250AJP 3128411...
  • Page 249 VALVE PLATFORM LEVEL DOWN RELIEF ADJUST 0.2 GPM PLATFORM LEVEL DOWN RELIEF ADJUST 0.3 GPM JIB UP/DOWN 2.0 GPM JIB UP/DOWN RELIEF ADJUST JIB UP/DOWN SHUTTLE 10 MICRON VALVE FILTER BASKET SUPPORT Figure 3-3. Platform Valve Layout 3128411 1250AJP 3-249...
  • Page 250 B2 - #4 A2 - #3 #3 - A2 A1 - #6 #6 - A1 1200SJP , 1350SJP , 1250AJP CD - #7 #7 - CD SHT. #2 Figure 3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2...
  • Page 251 3400 5000 PSI 1.7in 3 .37in 3 2.74in 3 5000 PSI 550 PSI SWIVEL PORT SWIVEL PORT SWIVEL PORT RESERVOIR BOOM CTL “T3” 2792527 G Figure 3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 3128411 1250AJP 3-251...
  • Page 252 Platform Control Schematic LEVEL CYLINDER 1200SJP-1350SJP Annulus: 16.49 sq. in. Cyl. Area Ratio: 1.19:1 PLATFORM ROTATOR Displacement: 14 c.i.r. .047 LEVEL CYLINDER 1250AJP Annulus: 14.73 sq. in. Cyl. Area Ratio: 1.33:1 2000 PSI (1250AJP) 1500 PSI (1200SJP-1350SJP) 3000 PSI (1250AJP)
  • Page 253 Displacement: 54.7 cu. in. for 180 degrees Annulus: 5.3 sq. in. Cyl. Area Ratio: 1.33:1 .047 2750 PSI 2.0 GPM 0.3 GPM 1200SJP ,1350SJP ,1250AJP 2792527 G Figure 3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2 3128411 1250AJP 3-253...
  • Page 254 SECTION 3 - HYDRAULIC REFERENCE Axle Steer Control Schematic SWIVEL PORT 2000 PSI 2600 PSI 2000 PSI 1200SJP,1350SJP, 1250AJP 2600 PSI 2500 PSI 2500 PSI AXLE EXTENSION CYLINDERS STEERING CYLINDERS ANNULUS: 10.16 SQ. IN. ANNULUS: 6.48 SQ. IN. CYL. AREA RATIO: 1.23:1 CYL.
  • Page 255 SECTION 3 - HYDRAULIC REFERENCE 2500 PSI SWIVEL PORT 2500 PSI 2600 PSI 2000 PSI 2600 PSI 2000 PSI 2792527 G Figure 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 3128411 1250AJP 3-255...
  • Page 256 MLOP 2.74 CU. IN. MAX PRESSURE 1.0 CU. IN. MIN SWITCH 200 PSI FIXED SET POINT SWIVEL PORT SWIVEL PORT SWIVEL PORT 1200SJP ,1350SJP ,1250AJP Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2 3-256 1250AJP 3128411...
  • Page 257 CYL AREA RATIO: 6.25:1 PROVISION FOR ORIFICE 2.74 CU. IN. MAX 1.0 CU. IN. MIN OSC. AXLE L.O. CYL. SWIVEL PORT SWIVEL PORT SWIVEL PORT 2792527 G Figure 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2 3128411 1250AJP 3-257...
  • Page 258 SECTION 3 - HYDRAULIC REFERENCE Boom Control Schematic SWING SWING 3800 ENABLE Main Lift Tower Lift Tower Tele 1250AJP Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 3-258 1250AJP 3128411...
  • Page 259 MAIN TELE AUX. PUMP MAIN TELE PROP . 10 MICRON ABS B10 >= 200 MAIN PLATFORM CTL DUMP “P” 43 PSI BYPASS SWIVEL 2792527 G Figure 3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2 3128411 1250AJP 3-259...
  • Page 260 SECTION 3 - HYDRAULIC REFERENCE This Page Left Blank Intentionally 3-260 1250AJP 3128411...

  • Page 261: Ground Analyzer Connection Point

    SECTION 4 - JLG ANALYZER SECTION 4. JLG ANALYZER 4.1 TO CONNECT THE JLG CONTROL SYSTEM 4.2 USING THE ANALYZER ANALYZER With the machine power on and the analyzer connected properly, the analyzer will display the following: 1. Connect the cable supplied with the analyzer, to the...
  • Page 262 SECTION 4 - JLG ANALYZER If ENTER is pressed again, the display moves to the fol- lowing display: LOGGED HELP 1: POWER CYCLE (0/0) At this point, the analyzer will display the last fault the sys- tem has seen, if any are present. You may scroll through the fault logs to view what the last 25 faults were.

  • Page 263: Analyzer Flow Chart

    SECTION 4 - JLG ANALYZER Figure 4-3. Analyzer Flow Chart NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration. 3128411 1250AJP 4-263...

  • Page 264: Analyzer Flow Chart - Personalities (Software Version 6.X To Present)

    SECTION 4 - JLG ANALYZER Figure 4-4. Analyzer Flow Chart - Personalities (Software Version 6.X to Present) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.

  • Page 265: Analyzer Flow Chart - Machine Setup (Software Version 6.X To Present)

    SECTION 4 - JLG ANALYZER Figure 4-5. Analyzer Flow Chart - Machine Setup (Software Version 6.X to Present) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.

  • Page 266: Analyzer Flow Chart - Calibrations (Software Version 6.X To Present)

    SECTION 4 - JLG ANALYZER Figure 4-6. Analyzer Flow Chart - Calibrations (Software Version 6.X to Present) NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.
  • Page 267 SECTION 4 - JLG ANALYZER Figure 4-7. Analyzer Flow Chart - Diagnostics (Software Version 6.X to Present) - Sheet 1 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.
  • Page 268 SECTION 4 - JLG ANALYZER Figure 4-8. Analyzer Flow Chart - Diagnostics (Software Version 6.X to Present) - Sheet 2 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.
  • Page 269 SECTION 4 - JLG ANALYZER Figure 4-9. Analyzer Flow Chart - Diagnostics(Software Version 6.X to Present) - Sheet 3 of 3 NOTE: The layout shown includes all possible analyzer screens. Please note that some screens may not be available depend- ing upon machine configuration.
  • Page 270 SECTION 4 - JLG ANALYZER 4.3 CHANGING THE ACCESS LEVEL OF THE Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: When the analyzer is first connected, you will be in access...

  • Page 271: Machine Setup

    NOTE: Password 33271 will give you access to level 1, which will permit you to change all machine person- ality settings. There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- FORMANCE OF YOUR MACHINE.
  • Page 272 SECTION 4 - JLG ANALYZER Table 4-1. Machine Configuration Programming Information Default Configuration Digit Number Description Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause...
  • Page 273 SECTION 4 - JLG ANALYZER Table 4-1. Machine Configuration Programming Information Default Configuration Digit Number Description Number GLOW PLUG: NO GLOW PLUGS: No glow plugs installed. AIR INTAKE: Glow plugs installed in the air intake on the manifold. IN-CYLINDER: Glow plugs installed in each cylinder.
  • Page 274 SECTION 4 - JLG ANALYZER Table 4-1. Machine Configuration Programming Information Default Configuration Digit Number Description Number GEN SET/WELDER: NO: No generator installed. BELT DRIVE: Belt driven setup. HYDRAULIC DRIVE: Hydraulic driven setup. GEN SET CUTOUT: MOTION ENABLED: Motion enabled when generator is ON.
  • Page 275 SECTION 4 - JLG ANALYZER Table 4-1. Machine Configuration Programming Information Default Configuration Digit Number Description Number FUNCTION CUTOUT: NO: No drive cutout. BOOM CUTOUT: Boom function cutout while driving above elevation. DRIVE CUTOUT: Drive cutout above elevation. DRIVE CUT E&T: Drive cutout above elevation and tilted.
  • Page 276 SECTION 4 - JLG ANALYZER NOTE: Bold Italic Numbers indicate the default setting. Plain text indicates another available selection. Bold, Italic underlined numbers indicate the default when the option is factory installed. 1250AJP ANSI USA ANSI EXPORT AUSTRALIA JAPAN 1250AJP...
  • Page 277 SECTION 4 - JLG ANALYZER Table 4-2. Machine Personality Settings and Speeds TIME RANGE Submenu (SEC) (SEE 4.6 Parameter (Displayed on DEFAULT Machine (Displayed on Analyzer 2nd Description Range Analyzer 1st VALUES Orientation Line) Line) When Setting Speeds DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec...
  • Page 278 SECTION 4 - JLG ANALYZER Table 4-2. Machine Personality Settings and Speeds TIME RANGE Submenu (SEC) (SEE 4.6 Parameter (Displayed on DEFAULT Machine (Displayed on Analyzer 2nd Description Range Analyzer 1st VALUES Orientation Line) Line) When Setting Speeds SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec...
  • Page 279 SECTION 4 - JLG ANALYZER Table 4-2. Machine Personality Settings and Speeds TIME RANGE Submenu (SEC) (SEE 4.6 Parameter (Displayed on DEFAULT Machine (Displayed on Analyzer 2nd Description Range Analyzer 1st VALUES Orientation Line) Line) When Setting Speeds TOWER TELESCOPE: ACCEL X.Xs...
  • Page 280 SECTION 4 - JLG ANALYZER Table 4-2. Machine Personality Settings and Speeds TIME RANGE Submenu (SEC) (SEE 4.6 Parameter (Displayed on DEFAULT Machine (Displayed on Analyzer 2nd Description Range Analyzer 1st VALUES Orientation Line) Line) When Setting Speeds ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec...
  • Page 281 SECTION 4 - JLG ANALYZER Table 4-2. Machine Personality Settings and Speeds TIME RANGE Submenu (SEC) (SEE 4.6 Parameter (Displayed on DEFAULT Machine (Displayed on Analyzer 2nd Description Range Analyzer 1st VALUES Orientation Line) Line) When Setting Speeds NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine per- formance.

  • Page 282: System Test

    SECTION 4 - JLG ANALYZER Test Notes 1. Personality settings can be adjusted anywhere 4.6 MACHINE ORIENTATION WHEN SETTING within the adjustment range in order to achieve opti- SPEEDS mum machine performance 2. Stop watch should start when the function is acti- MAIN BOOM LIFT UP: From platform control, lowest ele- vated.Not with the controller or switch.
  • Page 283 SECTION 4 - JLG ANALYZER 2. Plug the analyzer into the connector at the base of 4. The analyzer screen should read: the platform control box. 3. Pull out the Emergency Stop switch and Start the engine. 5. Use the arrow button to reach SYSTEM TEST. Hit Enter.

  • Page 284: System Test Flow Chart - Platform Tests

    SECTION 4 - JLG ANALYZER Figure 4-10. System Test Flow Chart - Platform Tests 4-284 1250AJP 3128411...
  • Page 285 SECTION 4 - JLG ANALYZER Test from the Ground Station 3. Pull out the Emergency Stop switch. and Start the engine. 1. Position the Platform/Ground select switch to the Ground position. 4. The analyzer screen should read: 2. Plug the analyzer into the connector inside the Ground control box.

  • Page 286: System Test Flow Chart - Ground Station Tests

    SECTION 4 - JLG ANALYZER Figure 4-11. System Test Flow Chart - Ground Station Tests 4-286 1250AJP 3128411...
  • Page 287 SECTION 4 - JLG ANALYZER Table 4-3. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer RUNNING Initial display when system test is run; certain “critical” checks are made. Prob- lems that can be reported include below messages.
  • Page 288 SECTION 4 - JLG ANALYZER Table 4-3. System Test Messages Message Displayed on Message Displayed on Description Analyzer Analyzer CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral.
  • Page 289 All calibration procedures are menu driven through the Main boom angle sensor removal or Boom Sensors use of the standard JLG analyzer. With the exception of replacement steering calibration, no external tools are required to com- Main lift valve/control module replacement Boom Valve plete the calibration procedures.

  • Page 290: Calibrating Steer

    2. Plug the analyzer into the connector at the base of the platform control box. 3. Pull out the Emergency Stop switch and Start the engine. 5-290 1250AJP 3128411...
  • Page 291 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 9. Hit Enter. The screen will read: 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 3128411 1250AJP 5-291...

  • Page 292: Calibrating Drive

    12. Activate the steer control until the tire and wheel are straight in relationship with the chassis, then leave off the control. The display will read FRT LEFT = and show the numeric calibration value for that wheel. 5-292 1250AJP 3128411...
  • Page 293 3. Pull out the Emergency Stop switch and Start the engine. 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 3128411 1250AJP 5-293...
  • Page 294 11. Hit Enter again. The screen will read: 12. Activate the Drive Joystick forward full stroke until the machine just begins to move, then leave off the joystick immediately. The display will read CRK PT = and show the numeric crack point value. 5-294 1250AJP 3128411...
  • Page 295 14. Hit Enter. The screen will read: 15. Repeat steps 10 thru 12 for left reverse drive. 16. Left Reverse Drive Calibration will be followed by Right Forward Drive Calibration which will be fol- lowed by Right Reverse Calibration. 3128411 1250AJP 5-295...

  • Page 296: Calibrating Boom Valves

    Enter. 6. Enter the Access Code, 33271. 7. Use the arrow keys to reach CALIBRATIONS. Hit Enter. 8. Use the arrow keys to reach Boom Valves. The screen will read: 3. Pull out the Emergency Stop switch. 5-296 1250AJP 3128411...
  • Page 297 12. If the tower lift wiring and hosing is properly installed and not damaged, hit enter. The screen will read: 13. If the tower telescope wiring and hosing is properly installed and not damaged, hit enter. The screen will 3128411 1250AJP 5-297...
  • Page 298 LIFT, and TWR TELE valves. This can be confirmed by watching the LED’s on the respective valves as they are being calibrated. When the valves are cali- brated, the screen will read: NOTE: It may take several minutes per valve section for the calibration procedure. 5-298 1250AJP 3128411...

  • Page 299: Electronic Platform Leveling

    TILT SENSOR ERRORS There are three possible level valve driver errors, short to If the secondary tilt sensor is faulty, the control system will battery, short to ground, and open circuit. continue to utilize information from the primary sensor. 3128411 1250AJP 5-299...
  • Page 300 5. Go to the “Personalities” menu and adjust the fol- lost). lowing personalities. Refer to the Personality 3. The platform alarm will sound. Ranges/Defaults table in Section 6 - JLG Control System for proper setting values. 4. A system fault will be logged. Basket Level Up Min 5.
  • Page 301 5 seconds in each direction. 9. Return the personality settings back to the values as shown in the Personality Ranges/Defaults table in Section 6 - JLG Control System. 10. Recycle EMS. STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 1.

  • Page 302: Calibrating Platform Level

    Ranges/Defaults table for proper setting val- ues. Basket Level Up Min Basket Level Up Max Basket Level Down Max Jib Up Min Jib Down Min 8. Recycle EMS. 3. Pull out the Emergency Stop switch and start the engine. 5-302 1250AJP 3128411...
  • Page 303 8. Use the arrow button to reach CALIBRATIONS menu and hit ENTER. 9. Use right arrow go to PLAT. LEVELING screen. 3. Pull out the Emergency Stop switch and start the engine. 4. Manually level the platform with the switch on the Main Terminal Box. 3128411 1250AJP 5-303...
  • Page 304 6. Enter the Access Code, 33271. 7. Go to the PERSONALITIES menu. 8. Using the left arrow button, go to the GROUND MODE menu. 9. Hit ENTER. 10. Using the UP/DOWN arrows, adjust the following personalities to 100%. 5-304 1250AJP 3128411...
  • Page 305 5 seconds in each direction. 11. Return the personality settings back to the values as shown in the Personality Ranges/Defaults table in Section 6 - JLG Control System. 12. Recycle EMS. STEP 4: CALIBRATING THE PLATFORM LEVEL UP AND DOWN VALVE CRACKPOINTS 1.
  • Page 306 SECTION 5 - CALIBRATIONS Hit ENTER again. CAL. COMPLETE message should appear Engine should again return to idle. Hit ESC to exit. Cycle power to the machine. 5-306 1250AJP 3128411...

  • Page 307: Calibrating Tilt Sensor

    2. Position the Platform/Ground select switch to the Ground position. 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 3128411 1250AJP 5-307...
  • Page 308 11. When prompted, swing turntable 180° to opposite end of chassis. 12. Press ENTER. The screen should read: 13. Upon completing swing calibration, swing turntable 180° back to the stowed position. 14. Hit ESC twice to go back to CALIBRATIONS. 5-308 1250AJP 3128411...

  • Page 309: Boom Sensor Calibration

    Potential System Check Failure Messages as displayed on the JLG Analyzer: • BLAM CAN LOST - communications to BLAM module lost • CAN BUS FAULTY - the system is reporting CAN bus issues.
  • Page 310 Visible through DIAGNOSTICS ? LOAD ? JIB IN-LINE SWITCH: XX (CLOSED or OPEN) • LEVEL MACHINE - chassis tilt reading must be less than 1.5°. Visible through DIAGNOSTICS ? SYSTEM ? CHASSIS TILT: XX.X DEGREES. 5-310 1250AJP 3128411...
  • Page 311 #1(right) must be between -46.7° and -26.7°. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER ANGLE 1 A/D: XX.X. • TWR ANGL2 FAILED - the raw tower boom angle #2 (left) must be between -46.7° and -26.7°. Visible through 3128411 1250AJP 5-311...
  • Page 312 Potential Calibration Failure Messages: • CYLINDER ANGL FAULT - raw tower lift cylinder angle sensor A/D counts not between 22871 and 29535. Visi- ble through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER CYLINDER ANGLE A/D: XXXXX. 5-312 1250AJP 3128411...
  • Page 313 ? TOWER LENGTH 2 A/D: XXXXX. • TWR L SW FAULT - control system did not detect change in state of tower transport length switch within tower length readings of 303.9" and 308.9" (771.9 and 784.6 cm) 3128411 1250AJP 5-313...
  • Page 314 12.8° and 18.8°. Visible through DIAGNOSTICS ? BOOM SEN- SORS ? MAIN ANGLE 1 TO TWR XX.X. Potential Calibration Failure Messages: 5-314 1250AJP 3128411...
  • Page 315 Control system will allow additional attempts to correct tower angle. • LOAD PIN FAULT - load pin corrected angle not between -10.0° and 10.0°. Visible through DIAGNOS- TICS ? LOAD PIN ? LOAD PIN ANGLE VALUE: XXX.X. 3128411 1250AJP 5-315...
  • Page 316 • LOAD PIN FAULT - load pin resultant force (V-FORCE. on analyzer) not within 18,140 and 44,140 or load pin cal moment not between 445,000 and 1,577,000. Visible through DIAGNOSTICS ? LOAD PIN ? LOAD PIN MOMENT VALUE: XXXX. 5-316 1250AJP 3128411...
  • Page 317 12.0° and 18.0° when ENTER is pressed. Control system will allow additional attempts to correct main boom angle. • MAIN DWN TO STOP - main boom angle sensor not reading between 12.0° and 18.0° when ENTER is 3128411 1250AJP 5-317...
  • Page 318 SECTION 5 - CALIBRATIONS This Page Left Blank Intentionally 5-318 1250AJP 3128411...
  • Page 319 M = Mega = 1,000,000 * (Displayed Number) k = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 µ = micro = (Displayed Number) / 1,000,000 Example: 1.2 kΩ = 1200 Ω Example: 50 mA = 0.05 A 3128411 1250AJP 6-319...

  • Page 320: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resis- tance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads 6-320 1250AJP 3128411...

  • Page 321: Current Measurement (Dc)

    • Meter that can measure resistance or continuity. Procedure Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate mea- surement. In the example below, the meter tested at 1.4Ω. 3128411 1250AJP 6-321...

  • Page 322: Example Circuit Schematic

    One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through . If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. Figure 6-5. Example Circuit Schematic 6-322 1250AJP 3128411...

  • Page 323: Example Continuity Test Setup

    SECTION 6 - MULTIMETER BASICS Figure 6-6. Example Continuity Test Setup 3128411 1250AJP 6-323...
  • Page 324 SECTION 6 - MULTIMETER BASICS This Page Left Blank Intentionally 6-324 1250AJP 3128411...
  • Page 326 1 JLG Drive McConnellsburg PA. 17233-9533 Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) JLG Deutschland GmbH P.O. Box 5119 Rua Eng. Carlos Stevenson, Unit 12, Southside Max Planck Strasse 21...

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