Troubleshooting Manual Model 1250AJP 3128411 April 5, 2007 ? INTRODUCTION 3128411 1250AJP A-3 SECTION A. INTRODUCTION A.1 HOW TO USE THIS MANUAL Troubleshooting system problems can be difficult. System wiring and hydraulic diagrams are provided in this book to help isolate problems. Follow the flow chart of Figure A-1. Troubleshooting Flowchart on Pg. 3. Only perform calibrations when indicated in proce- dures or in section 5.1 Calibration Instructions on Pg. 289. Each troubleshooting step setup is specified in the step instructions and applies only to that step. Any special wiring, dis- connected connectors, programming modes, etc. should be removed, re-connected, restored, etc. after completing the step unless directed otherwise. Some procedures call for swapping components, connections, etc. All instructions to repair refer to the machine as assembled before the procedure started. Reinstall to proper locations all swapped compo- nents, connections before repairing machine. When a function will not operate with the same speed or power as a machine in good working condition, refer to the topic which most closely describes the problem. Conclude each session by rerunning the system test, checking for other problems. If this method does not identify the problem, contact the factory for assistance. Figure A-1. Troubleshooting Flowchart Is Distress Lamp Blinking? Plug in Analyzer and read Help Message No Yes Start Troubleshoot by Help Message in Section 1 Problem Solved? No Yes Identify Fault Repair Machine Done Using Analyzer, find logged Help Messages “Ground/ Everything OK” Using Analyzer, Run Platform and Ground System Tests Yes No INTRODUCTION A-4 1250AJP 3128411 A.2 VISUAL INSPECTION Perform a thorough visual and “hands on” inspection before starting any troubleshooting procedure. Also, perform a visual inspection at every connector, sensor, hose, harness, etc. opened or accessed during the procedure. You can quickly find the cause of many problems just by looking. Has the machine been serviced recently? Check that everything has been reconnected properly. Inspect Hoses for: • Correct routing • Pinches and kinks • Splits, cuts, or breaks. Inspect Wiring for: • Contact with sharp edges • Contact with hot surfaces • Pinched, burned or chafed insulation • Proper routing and connections Check Sensors and Actuators for Damage. Check Electrical Connectors for: • Corrosion on pins • Moisture in the housing or on the contacts • Bent or damaged pins • Contacts not properly seated in housing • Bad wire crimps to terminals A.3 READING FAULT CODES Current and logged system fault codes and ADE service flash codes can be read from the analyzer. Refer to 4.2 Using the Analyzer on Pg. 261. Fault logs are separated by POWER CYCLE messages. In Troubleshooting, you may be asked to see all of the currently active faults. This simply means all of the faults since the latest power cycle. Scroll through the chronolog- ical faults on the analyzer, listing all the faults until the first “POWER CYCLE” message. Troubleshoot each of these items separately unless instructed otherwise. ADE service flash codes can also be read from the green LED on the face of the ground module or the system distress lamp in the platform console, see Figure A-2. Ground Module and Platform Fault (System Distress) Lights on Pg. 4. Use the table in A.8 Service Fault Code Cross References on Pg. 9 to find possible faults based on the flashed code. Figure A-2. Ground Module and Platform Fault (System Distress) Lights 1705744 A 1705745 B 1702938 1705170 A 1705171 A J1 J4 J2 J3 FAULT CODE LIGHT INTRODUCTION 3128411 1250AJP A-5 A.4 CONNECTOR REFERENCES Electrical connectors are given a three digit identifier number preceded with “X”. See 2.1 Connector Index on Pg. 209 for a list. For Example: [X006.21] refers to terminal 21 (pin and socket) of connector X006. [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. INTRODUCTION A-6 1250AJP 3128411 A.6 CONTROL MODULE POWER Always make sure that all of the control models are properly powered. See Figure A-3. Basic Electronic Module Connections on Pg. 6 1. For Ground Module operation, Terminals [X001.24], and [X008.2] should have a voltage of Vbatt. Terminal [X008.1] should be grounded. 2. CAN communication wires should have 60Ω resistance between CAN HI and CAN LO whenever both the Platform Module and Chassis Module are connected or 120Ω when one of them are disconnected. Both CAN HI and CAN LO should be isolated (show very high resistance or overload, OL) from the shield and ground. A CAN termination 120Ω resistor is located at both ends of the CAN bus. One is embedded in the platform module. The other terminator is jum- pered in the chassis module. Figure A-3. Basic Electronic Module Connections Chassis Power Relay X266 Platform Module Ground Module CAN Shield CAN HI CAN LO Platform Ground Platform Power Ground from B- Vbatt from Power Down Relay 13 14 3 2 4 1 3 X007 X008 X001 Analyzer Power Analyzer RS232 Receive Analyzer RS232 Transmit Analyzer Ground Analyzer 28 29 30 31 CAN HI CAN LO 31 30 X169 Constant Battery (Vbatt) 24 120Ω X170 2 1 BLAM Module CAN HI CAN LO 6 7 X086 8 CAN Shield X090 Analyzer Power Analyzer RS232 Receive Analyzer RS232 Transmit Analyzer Ground Analyzer 9 10 11 12 X089 1 2 3 4 5 CAN HI CAN LO CAN Shield Load Pin Main Lift PVG Tower Tele PVG Tower Lift PVG ABDE 123412341234 Chassis Module CAN HI CAN LO 6 7 X229 8 CAN Shield X233 Analyzer Power Analyzer RS232 Receive Analyzer RS232 Transmit Analyzer Ground Analyzer 9 10 11 12 120Ω 3 X002 8 11 Tower Tele PVG Power Main Lift PVG Power Tower Lift PVG Power X066 X067 X065 X062 Main Boom Angle #1 1234 X048 5 Main Boom Angle #2 1234 X049 5 32 10 21 Vbatt from Ground Module X008.4 Ground from Ground Module X008.3 5 4 Ignition Power 5 4 Chassis Power J1 J5 J8 J2 J7 J1 J1 J5 J4 J7 J8 Note: BLAM and Chassis Module Analyzer connections for download only 9 10 CAN Jumper Vbatt from EMS Platform Mode Select 2 1 Vbatt from EMS Mode Select from Ground Module X007.14 24 18 Main Angle #1 Power Main Angle #2 Power Engine Module X240 12 13 X060 1234 5 X014 X043 X045 X044 X042 X050 X160 X262 X083 123 1 23 JK J K 1 2 3 1 2 3 1 2 3 A B C X058 10 11 12 X091 X013 X235 Analyzer X171 X166 J2 26 28 29 27 X216 123 CBA CBA A B C X269 X270 45 Ground 45 12 16 16 12 16 12 16 12 87 30 Constant Battery (Vbatt) 86 Ignition Power 85 Battery + Battery - CAN HI CAN LO X268 A B C X084 ABC X263 21 X267 X058 3 2 X097 E E Ignition Power 14 1 Ground from Ground Module X001.8 8 Ground to Engine Module X240.1 INTRODUCTION 3128411 1250AJP A-7 A.7 CRITICAL SENSORS Tower Angle Sensors Tower Boom Angle Sensor #1 (Right) [X099] Tower Boom Angle Sensor #2 (Left) [X100] ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER ANGLE 1 A/D: XXXXX ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER ANGLE 2 A/D: XXXXX Digital Inclinometers measure the angle of the tower boom with respect to gravity. The sensors are mounted such that they generate opposite signals with respect to boom movement. Clockwise rotation of the sensor (looking at the cover) will pro- duce a signal of increased angle. The tower angle sensors communicate with the BLAM module using serial communica- tions. There should be 12 volts between X099.1 and X099.3 on the right sensor and 12 volts between X100.1 and X100.3 on the left sensor. In transport position TOWER ANGLE 1 A/D and TOWER ANGLE 2 A/D are typically between -26 and -35. Tower Cylinder Angle Sensor Tower Lift Cylinder Pivot Pin Angle Sensor [X092] 5V between [X092.A] and [X092.C] ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER CYLINDER ANGLE: XX.X In transport position, the sensor value should be at 5.9 degrees or less ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER CYLINDER ANGLE A/D: XXXXX In transport position, the A/D value should be 4721 - 11385 Fully lifted, the A/D value should be 22871 - 29535 A hall effect analog potentiometer that measures the angle of the tower boom cylinder with respect to the turntable. The sen- sor’s analog output is read by the BLAM module. The sensor is powered by a 5 volt reference and ground from the BLAM module. Main Angle Sensors Main Boom Rotary Angle Sensor #1 (Right) [X048] Main Boom Rotary Angle Sensor #2 (Left) [X049] Measure the angle of the main boom with respect to the tower boom. Power is supplied by the Ground Module so the sen- sors can be turned on separately at startup for identification and diagnostic purposes. Once initialized, a constant 12 volts should be supplied by the Ground Module. Main Angle Sensor #1, [X048.2] is powered by [X002.10]. Main Angle Sensor #2, [X049.2] is powered by [X002.21]. These sensors communicate with the system on the CAN bus. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 1 ANGLE A/D: XXXXX ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 2 ANGLE A/D: XXXXX ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 1 RAW ANGLE A/D: XXXXX ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 2 RAW ANGLE A/D: XXXXX 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 INTRODUCTION A-8 1250AJP 3128411 Tower Length Sensors Tower Boom Length Sensor #1 (Top Right) [X093] Tower Boom Length Sensor #2 (Bottom Left) [X094] ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 1 SENSOR: X.X" ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 2 SENSOR: X.X" ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 1 A/D: XXXXX ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 2 A/D: XXXXX Cable potentiometers that measure the total stroke of the tower boom. The sensors’ analog outputs are read by the BLAM module. Both increase as the boom length increases. Each sensor is powered by a 5 volt reference and ground from the 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 INTRODUCTION 3128411 1250AJP A-9 A.8 SERVICE FAULT CODE CROSS REFERENCES CODE - MESSAGE PAGE NO. 0 0-0 CHASSIS TILT SENSOR OUT OF RANGE ....................................................................................................... 1-62 0-0 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED ............................................................................ 1-73 0-0 EVERYTHING OK ............................................................................................................................................. 1-73 0-0 FSW OPEN ....................................................................................................................................................... 1-86 0-0 LOAD SENSOR READING UNDER WEIGHT ................................................................................................... 1-96 0-0 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED .................................................................. 1-109 0-0 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION ..............................................................................1-140 0-0 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION ......................................................................... 1-141 0-0 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED .............................................................. 1-144 2-? 2-1 FSW FAULTY .................................................................................................................................................... 1-85 2-1 KEYSWITCH FAULTY ....................................................................................................................................... 1-92 2-2 D/S JOY. CENTER TAP BAD ............................................................................................................................ 1-64 2-2 D/S JOY. OUT OF RANGE HIGH ..................................................................................................................... 1-64 2-2 D/S JOY. OUT OF RANGE LOW ...................................................................................................................... 1-64 2-2 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH ..................................................................... 1-68 2-2 FSW INTERLOCK TRIPPED ............................................................................................................................. 1-86 2-2 STEER LOCKED - SELECTED BEFORE FOOTSWITCH ................................................................................. 1-142 2-2 STEER SWITCHES FAULTY ............................................................................................................................. 1-142 2-2 WAITING FOR FSW TO BE OPEN ................................................................................................................... 1-172 2-3 FOOTSWITCH SELECTED BEFORE START ................................................................................................... 1-77 2-3 L/S JOY. CENTER TAP BAD ............................................................................................................................ 1-93 2-3 L/S JOY. OUT OF RANGE HIGH ...................................................................................................................... 1-93 2-3 L/S JOY. OUT OF RANGE LOW ....................................................................................................................... 1-93 2-3 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH ............................................................ 1-95 2-3 PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM ......................................................................... 1-125 2-3 PUMP SWITCHES LOCKED - SELECTED BEFORE AUX POWER ................................................................. 1-125 2-3 PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH ............................................................... 1-125 2-3 PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH ............................................................ 1-125 2-3 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH ..................................................................... 1-142 2-5 BACKUP BLAM COMMUNICATIONS ACTIVE ................................................................................................. 1-36 2-5 BOOM PREVENTED - DRIVE SELECTED ........................................................................................................ 1-58 2-5 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED ..................................................................... 1-58 2-5 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL ......................................... 1-67 2-5 DRIVE PREVENTED - ABOVE ELEVATION ..................................................................................................... 1-68 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 INTRODUCTION A-10 1250AJP 3128411 2-5 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER .............................. 1-87 2-5 GENERATOR MOTION CUTOUT ACTIVE ....................................................................................................... 1-88 2-5 JIB SWING PREVENTED - IN 1000# MODE ................................................................................................... 1-92 2-5 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS .................................................................. 1-120 3-? 3-3 ALTERNATOR POWER SHORT TO GROUND ................................................................................................ 1-35 3-3 AUX POWER OPEN CIRCUIT .......................................................................................................................... 1-35 3-3 AUX POWER SHORT TO BATTERY ................................................................................................................. 1-35 3-3 AUX POWER SHORT TO GROUND ................................................................................................................. 1-35 3-3 BASKET DOWN OVERRIDE OPEN CIRCUIT ................................................................................................... 1-36 3-3 BASKET DOWN OVERRIDE SHORT TO BATTERY ......................................................................................... 1-36 3-3 BASKET DOWN OVERRIDE SHORT TO GROUND ......................................................................................... 1-36 3-3 BASKET UP OVERRIDE OPEN CIRCUIT ......................................................................................................... 1-45 3-3 BASKET UP OVERRIDE SHORT TO BATTERY ............................................................................................... 1-45 3-3 BASKET UP OVERRIDE SHORT TO GROUND ............................................................................................... 1-45 3-3 COLD START ADVANCE SOLENOID OPEN CIRCUIT .................................................................................... 1-62 3-3 COLD START ADVANCE SOLENOID SHORT TO BATTERY .......................................................................... 1-62 3-3 COLD START ADVANCE SOLENOID SHORT TO GROUND .......................................................................... 1-62 3-3 COMMON STB OR OC PROCEDURE ............................................................................................................. 1-174 3-3 COMMON STG PROCEDURE ......................................................................................................................... 1-175 3-3 ELECTRIC PUMP OPEN CIRCUIT ................................................................................................................... 1-69 3-3 ELECTRIC PUMP SHORT TO BATTERY ......................................................................................................... 1-69 3-3 ELECTRIC PUMP SHORT TO GROUND ......................................................................................................... 1-69 3-3 GEN SET/WELDER OPEN CIRCUIT ................................................................................................................ 1-87 3-3 GEN SET/WELDER SHORT TO BATTERY ...................................................................................................... 1-88 3-3 GEN SET/WELDER SHORT TO GROUND ...................................................................................................... 1-88 3-3 GLOW PLUG OPEN CIRCUIT .......................................................................................................................... 1-88 3-3 GLOW PLUG SHORT TO BATTERY ................................................................................................................ 1-88 3-3 GLOW PLUG SHORT TO GROUND ................................................................................................................ 1-88 3-3 GROUND ALARM OPEN CIRCUIT ................................................................................................................... 1-88 3-3 GROUND ALARM SHORT TO BATTERY ......................................................................................................... 1-88 3-3 GROUND ALARM SHORT TO GROUND ......................................................................................................... 1-88 3-3 HEAD TAIL LIGHT OPEN CIRCUIT .................................................................................................................. 1-89 3-3 HEAD TAIL LIGHT SHORT TO BATTERY ........................................................................................................ 1-89 3-3 HEAD TAIL LIGHT SHORT TO GROUND ........................................................................................................ 1-90 3-3 HORN OPEN CIRCUIT ..................................................................................................................................... 1-90 3-3 HORN SHORT TO BATTERY ........................................................................................................................... 1-90 3-3 HORN SHORT TO GROUND ........................................................................................................................... 1-90 3-3 HOUR METER SHORT TO BATTERY .............................................................................................................. 1-90 3-3 HOUR METER SHORT TO GROUND .............................................................................................................. 1-90 3-3 LEFT FORWARD DRIVE PUMP OPEN CIRCUIT .............................................................................................. 1-93 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 CODE - MESSAGE PAGE NO. INTRODUCTION 3128411 1250AJP A-11 3-3 LEFT REVERSE DRIVE PUMP SHORT TO GROUND ..................................................................................... 1-93 3-3 MAIN DUMP OPEN CIRCUIT ........................................................................................................................... 1-109 3-3 MAIN DUMP SHORT TO BATTERY .................................................................................................................. 1-109 3-3 MAIN DUMP SHORT TO GROUND .................................................................................................................. 1-109 3-3 MAIN IN OPEN CIRCUIT .................................................................................................................................. 1-109 3-3 MAIN IN SHORT TO BATTERY ......................................................................................................................... 1-109 3-3 MAIN IN SHORT TO GROUND ......................................................................................................................... 1-109 3-3 MAIN LIFT APU OPEN CIRCUIT ....................................................................................................................... 1-109 3-3 MAIN LIFT APU SHORT TO BATTERY ............................................................................................................. 1-110 3-3 MAIN LIFT APU SHORT TO GROUND ............................................................................................................. 1-110 3-3 MAIN LIFT ENABLE OPEN CIRCUIT ................................................................................................................ 1-110 3-3 MAIN LIFT ENABLE SHORT TO BATTERY ...................................................................................................... 1-110 3-3 MAIN LIFT ENABLE SHORT TO GROUND ...................................................................................................... 1-110 3-3 MAIN LIFT PILOT PRESSURE FAILURE .......................................................................................................... 1-110 3-3 MAIN LIFT PILOT PRESSURE SWITCH FAILURE ........................................................................................... 1-110 3-3 MAIN OUT OPEN CIRCUIT .............................................................................................................................. 1-115 3-3 MAIN OUT SHORT TO BATTERY ..................................................................................................................... 1-115 3-3 MAIN OUT SHORT TO GROUND ..................................................................................................................... 1-115 3-3 MAIN TELE FLOW CONTROL OPEN CIRCUIT ................................................................................................ 1-115 3-3 MAIN TELE FLOW CONTROL SHORT TO BATTERY ...................................................................................... 1-116 3-3 MAIN TELE FLOW CONTROL SHORT TO GROUND ...................................................................................... 1-116 3-3 NO MAIN LIFT PILOT PRESSURE ................................................................................................................... 1-121 3-3 PARKING BRAKE OPEN CIRCUIT ................................................................................................................... 1-122 3-3 PARKING BRAKE SHORT TO BATTERY ......................................................................................................... 1-122 3-3 PARKING BRAKE SHORT TO GROUND .......................................................................................................... 1-122 3-3 PVG VALVE ENABLE OPEN CIRCUIT .............................................................................................................. 1-125 3-3 PVG VALVE ENABLE SHORT TO BATTERY .................................................................................................... 1-126 3-3 PVG VALVE ENABLE SHORT TO GROUND .................................................................................................... 1-126 3-3 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE STB OR OC ......................................................... 1-134 3-3 RESTRICTED TO TRANSPORT - PARKING BRAKE STB ................................................................................1-137 3-3 RIGHT FORWARD DRIVE PUMP OPEN CIRCUIT ........................................................................................... 1-137 3-3 RIGHT FORWARD DRIVE PUMP SHORT TO BATTERY ................................................................................. 1-137 3-3 RIGHT FORWARD DRIVE PUMP SHORT TO GROUND ................................................................................. 1-138 3-3 RIGHT REVERSE DRIVE PUMP OPEN CIRCUIT ............................................................................................. 1-138 3-3 RIGHT REVERSE DRIVE PUMP SHORT TO BATTERY ................................................................................... 1-138 3-3 RIGHT REVERSE DRIVE PUMP SHORT TO GROUND ...................................................................................1-138 3-3 START SOLENOID OPEN CIRCUIT ................................................................................................................. 1-141 3-3 START SOLENOID SHORT TO BATTERY ....................................................................................................... 1-142 3-3 START SOLENOID SHORT TO GROUND ....................................................................................................... 1-142 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 CODE - MESSAGE PAGE NO. INTRODUCTION A-12 1250AJP 3128411 3-3 THROTTLE ACTUATOR SHORT TO BATTERY ............................................................................................... 1-143 3-3 THROTTLE ACTUATOR SHORT TO GROUND ............................................................................................... 1-143 3-3 TOWER LIFT APU VALVE OPEN CIRCUIT ...................................................................................................... 1-147 3-3 TOWER LIFT APU VALVE SHORT TO BATTERY ............................................................................................. 1-147 3-3 TOWER LIFT APU VALVE SHORT TO GROUND ............................................................................................. 1-148 3-3 TOWER LIFT APU VALVE STUCK OPEN ......................................................................................................... 1-148 3-3 TOWER LIFT ENABLE OPEN CIRCUIT ............................................................................................................ 1-148 3-3 TOWER LIFT ENABLE SHORT TO BATTERY .................................................................................................. 1-148 3-3 TOWER LIFT ENABLE SHORT TO GROUND .................................................................................................. 1-148 3-3 TOWER LIFT ENABLE STUCK OPEN .............................................................................................................. 1-148 3-3 TOWER TELE APU VALVE STUCK OPEN ....................................................................................................... 1-153 3-3 TOWER TELE ENABLE OPEN CIRCUIT .......................................................................................................... 1-153 3-3 TOWER TELE ENABLE SHORT TO BATTERY ................................................................................................ 1-153 3-3 TOWER TELE ENABLE SHORT TO GROUND ................................................................................................ 1-153 3-3 TOWER TELE ENABLE STUCK OPEN ............................................................................................................ 1-154 3-3 TOWER TELESCOPE APU OPEN CIRCUIT .................................................................................................... 1-154 3-3 TOWER TELESCOPE APU SHORT TO BATTERY ........................................................................................... 1-154 3-3 TOWER TELESCOPE APU SHORT TO GROUND ........................................................................................... 1-154 3-3 TWO SPEED OPEN CIRCUIT ........................................................................................................................... 1-160 3-3 TWO SPEED SHORT TO BATTERY ................................................................................................................. 1-160 3-3 TWO SPEED SHORT TO GROUND ................................................................................................................. 1-160 3-4 BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT ........................................................................... 1-36 3-4 BASKET DOWN SHORT TO GROUND ............................................................................................................ 1-36 3-4 BASKET LEFT OPEN CIRCUIT ........................................................................................................................ 1-36 3-4 BASKET LEFT SHORT TO BATTERY ............................................................................................................... 1-36 3-4 BASKET LEFT SHORT TO GROUND ............................................................................................................... 1-37 3-4 BASKET RIGHT OPEN CIRCUIT ...................................................................................................................... 1-44 3-4 BASKET RIGHT SHORT TO BATTERY ............................................................................................................ 1-44 3-4 BASKET RIGHT SHORT TO GROUND ............................................................................................................ 1-45 3-4 BASKET UP SHORT TO BATTERY OR OPEN CIRCUIT .................................................................................. 1-45 3-4 BASKET UP SHORT TO GROUND .................................................................................................................. 1-45 3-4 JIB DOWN OPEN CIRCUIT .............................................................................................................................. 1-91 3-4 JIB DOWN SHORT TO BATTERY .................................................................................................................... 1-91 3-4 JIB DOWN SHORT TO GROUND .................................................................................................................... 1-91 3-4 JIB LEFT OPEN CIRCUIT ................................................................................................................................. 1-91 3-4 JIB LEFT SHORT TO BATTERY ....................................................................................................................... 1-92 3-4 JIB LEFT SHORT TO GROUND ....................................................................................................................... 1-92 3-4 JIB RIGHT OPEN CIRCUIT ............................................................................................................................... 1-92 3-4 JIB RIGHT SHORT TO BATTERY ..................................................................................................................... 1-92 3-4 JIB RIGHT SHORT TO GROUND ..................................................................................................................... 1-92 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 CODE - MESSAGE PAGE NO. INTRODUCTION 3128411 1250AJP A-13 3-4 PLATFORM CONTROL VALVE SHORT TO GROUND .....................................................................................1-123 4-? 4-3 AIR FILTER BYPASSED .................................................................................................................................... 1-35 4-3 COOLANT TEMPERATURE SHORT TO GROUND .......................................................................................... 1-62 4-3 ENGINE TROUBLE CODE ................................................................................................................................ 1-70 4-3 FUEL SENSOR SHORT TO BATTERY ............................................................................................................. 1-87 4-3 FUEL SENSOR SHORT TO GROUND ............................................................................................................. 1-87 4-3 HIGH ENGINE TEMP ........................................................................................................................................ 1-90 4-3 LOW OIL PRESSURE ....................................................................................................................................... 1-96 4-3 NO ALTERNATOR OUTPUT ............................................................................................................................. 1-121 4-3 OIL PRESSURE SHORT TO BATTERY ............................................................................................................ 1-121 4-3 OIL PRESSURE SHORT TO GROUND ............................................................................................................ 1-122 4-3 THROTTLE ACTUATOR FAILURE .................................................................................................................... 1-143 4-3 WRONG ENGINE SELECTED - ECM PRESENT ............................................................................................. 1-172 4-4 BATTERY LOW ................................................................................................................................................. 1-45 4-4 BATTERY TOO HIGH - SYSTEM SHUT DOWN ............................................................................................... 1-45 4-4 BATTERY TOO LOW - SYSTEM SHUT DOWN ................................................................................................ 1-45 4-5 MAIN LIFT PVG VALVE COMMAND IMPROPER ............................................................................................. 1-110 4-5 MAIN LIFT PVG VALVE COMMUNICATIONS .................................................................................................. 1-111 4-5 MAIN LIFT PVG VALVE HIGH VOLTAGE ......................................................................................................... 1-111 4-5 MAIN LIFT PVG VALVE INTERNAL FAULT ...................................................................................................... 1-112 4-5 MAIN LIFT PVG VALVE LOCATION IMPROPER .............................................................................................. 1-112 4-5 MAIN LIFT PVG VALVE LOW VOLTAGE .......................................................................................................... 1-112 4-5 MAIN LIFT PVG VALVE OBSTRUCTED ........................................................................................................... 1-113 4-5 MAIN LIFT PVG VALVE PARAMETERS INCORRECT ...................................................................................... 1-114 4-5 MAIN LIFT PVG VALVE SENT UNRECOGNIZED FAULT ................................................................................1-114 4-5 MAIN LIFT PVG VALVE SETUP FAULT ............................................................................................................ 1-114 4-5 MAIN LIFT PVG VALVE STUCK EXTENDED .................................................................................................... 1-114 4-5 MAIN LIFT PVG VALVE STUCK NEUTRAL ...................................................................................................... 1-114 4-5 MAIN LIFT PVG VALVE STUCK RETRACTED .................................................................................................. 1-114 4-5 MAIN LIFT PVG VALVE TIMEOUT .................................................................................................................... 1-115 4-5 MAIN LIFT PVG VALVE WIRING INCORRECT ................................................................................................. 1-115 4-5 TOWER LIFT PVG VALVE COMMAND IMPROPER ......................................................................................... 1-148 4-5 TOWER LIFT PVG VALVE COMMUNICATIONS .............................................................................................. 1-149 4-5 TOWER LIFT PVG VALVE HIGH VOLTAGE ..................................................................................................... 1-149 4-5 TOWER LIFT PVG VALVE INTERNAL FAULT .................................................................................................. 1-150 4-5 TOWER LIFT PVG VALVE LOCATION IMPROPER .......................................................................................... 1-150 4-5 TOWER LIFT PVG VALVE LOW VOLTAGE ...................................................................................................... 1-150 4-5 TOWER LIFT PVG VALVE OBSTRUCTED ....................................................................................................... 1-151 4-5 TOWER LIFT PVG VALVE PARAMETERS INCORRECT ..................................................................................1-152 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 CODE - MESSAGE PAGE NO. INTRODUCTION A-14 1250AJP 3128411 4-5 TOWER LIFT PVG VALVE STUCK RETRACTED ............................................................................................. 1-152 4-5 TOWER LIFT PVG VALVE TIMEOUT ................................................................................................................ 1-153 4-5 TOWER LIFT PVG VALVE WIRING INCORRECT ............................................................................................. 1-153 4-5 TOWER TELESCOPE PVG VALVE COMMAND IMPROPER ........................................................................... 1-154 4-5 TOWER TELESCOPE PVG VALVE COMMUNICATIONS ................................................................................ 1-154 4-5 TOWER TELESCOPE PVG VALVE HIGH VOLTAGE ....................................................................................... 1-155 4-5 TOWER TELESCOPE PVG VALVE INTERNAL FAULT .................................................................................... 1-155 4-5 TOWER TELESCOPE PVG VALVE LOCATION IMPROPER ............................................................................ 1-156 4-5 TOWER TELESCOPE PVG VALVE LOW VOLTAGE ........................................................................................ 1-156 4-5 TOWER TELESCOPE PVG VALVE OBSTRUCTED ......................................................................................... 1-157 4-5 TOWER TELESCOPE PVG VALVE PARAMETERS INCORRECT .................................................................... 1-157 4-5 TOWER TELESCOPE PVG VALVE SENT UNRECOGNIZED FAULT .............................................................. 1-158 4-5 TOWER TELESCOPE PVG VALVE SETUP FAULT .......................................................................................... 1-158 4-5 TOWER TELESCOPE PVG VALVE STUCK EXTENDED .................................................................................. 1-158 4-5 TOWER TELESCOPE PVG VALVE STUCK NEUTRAL .................................................................................... 1-158 4-5 TOWER TELESCOPE PVG VALVE STUCK RETRACTED ............................................................................... 1-158 4-5 TOWER TELESCOPE PVG VALVE TIMEOUT .................................................................................................. 1-158 4-5 TOWER TELESCOPE PVG VALVE WIRING INCORRECT ............................................................................... 1-159 5-? 5-5 SPEED INPUT LOST ........................................................................................................................................ 1-141 5-5 SPEED SENSOR READING INVALID SPEED .................................................................................................. 1-141 6-? 6-6 BLAM CAN COMMUNICATIONS LOST ........................................................................................................... 1-48 6-6 CHASSIS CAN COMMUNICATIONS LOST ..................................................................................................... 1-58 6-6 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST ..................................................................................1-63 6-6 ENGINE CONTROLLER CAN COMMUNICATIONS LOST .............................................................................. 1-69 6-6 EXCESSIVE CAN BUS COMMUNICATION ERRORS ...................................................................................... 1-73 6-6 MAIN ANGL1 CAN COMMUNICATIONS LOST ............................................................................................... 1-100 6-6 MAIN ANGL2 CAN COMMUNICATIONS LOST ............................................................................................... 1-102 6-6 PLATFORM CAN COMMUNICATIONS LOST .................................................................................................. 1-122 8-? 8-1 CHASSIS TILT SENSOR NOT CALIBRATED ................................................................................................... 1-62 8-2 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED .......................................................................... 1-67 8-2 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED .................................................................. 1-94 8-2 LOAD SENSOR NOT CALIBRATED ................................................................................................................. 1-96 8-2 RUNNING AT CREEP - PLATFORM OVERLOADED ....................................................................................... 1-140 8-3 BASKET LEVELING CRACKPOINT DOWN NOT CALIBRATED ...................................................................... 1-37 8-3 BASKET LEVELING CRACKPOINT UP NOT CALIBRATED ............................................................................. 1-38 8-3 BASKET LEVELING OVERRIDE OFF ............................................................................................................... 1-39 8-3 BASKET LEVELING OVERRIDE ON ................................................................................................................ 1-39 8-3 BASKET LEVELING SENSOR 1 SHORT TO BATTERY ................................................................................... 1-39 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 CODE - MESSAGE PAGE NO. INTRODUCTION 3128411 1250AJP A-15 8-3 BASKET LEVELING TILT REFERENCE 1 OUT OF RANGE ............................................................................. 1-41 8-3 BASKET LEVELING TILT REFERENCE 2 OUT OF RANGE ............................................................................. 1-41 8-3 BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST ................................................................... 1-41 8-3 BASKET LEVELING TILT SENSOR 2 COMMUNICATIONS LOST ................................................................... 1-43 8-3 BASKET LEVELING TILT SENSOR DIFFERENCE TOO GREAT ..................................................................... 1-44 8-4 BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT .............................................................................. 1-54 8-4 BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT .............................................................................. 1-56 8-4 BOOM LENGTH SENSOR #1 OUT OF RANGE HIGH ....................................................................................1-57 8-4 BOOM LENGTH SENSOR #1 OUT OF RANGE LOW .....................................................................................1-58 8-4 BOOM LENGTH SENSOR #2 OUT OF RANGE HIGH ....................................................................................1-58 8-4 BOOM LENGTH SENSOR #2 OUT OF RANGE LOW .....................................................................................1-58 8-4 CYL ANGLE SENSOR/SW DISAGREEMENT ................................................................................................... 1-62 8-4 DCAP LEN SW DISAGREEMENT ..................................................................................................................... 1-64 8-4 INVALID ANGLE SENSOR #1 MODEL ............................................................................................................ 1-91 8-4 INVALID ANGLE SENSOR #2 MODEL ............................................................................................................ 1-91 8-4 MAIN ANGL1 INVALID ANGLE ......................................................................................................................... 1-101 8-4 MAIN ANGL2 INVALID ANGLE ......................................................................................................................... 1-103 8-4 MAIN ANGLE MOVEMENT WITHOUT CMD .................................................................................................... 1-104 8-4 MAIN ANGLE SENSOR DISAGREEMENT ....................................................................................................... 1-104 8-4 MAIN ANGLE SENSOR NOT DETECTING ANGLE CHANGE ......................................................................... 1-105 8-4 MAIN BOOM TRN ANGLE SW/SENSOR DISAGREEMENT ............................................................................ 1-108 8-4 MAIN TRN ANGLE SW FAILED ........................................................................................................................ 1-116 8-4 MAIN TRN LEN SW DISAGREEMENT ............................................................................................................. 1-118 8-4 TOWER ANGLE SENSOR DISAGREEMENT ................................................................................................... 1-143 8-4 TOWER LENGTH SENSOR DISAGREEMENT ................................................................................................. 1-144 8-4 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT .................................................................................. 1-145 8-4 TRN DUAL CAP BAD TRANSITION .................................................................................................................. 1-159 8-4 TRN DUAL CAP SWITCHES BAD .................................................................................................................... 1-160 8-4 TWR ANGL1 INVALID ANGLE .......................................................................................................................... 1-161 8-4 TWR ANGL2 INVALID ANGLE .......................................................................................................................... 1-161 8-4 TWR CYL ANGLE MOVEMENT WITHOUT CMD ............................................................................................. 1-162 8-4 TWR CYL ANGLE NOT DETECTING ANGLE CHANGE .................................................................................. 1-162 8-4 TWR CYL ANGLE SENSOR OUT OF RANGE HIGH ........................................................................................ 1-164 8-4 TWR CYL ANGLE SENSOR OUT OF RANGE LOW ......................................................................................... 1-164 8-4 TWR LENGTH MOVEMENT WITHOUT CMD ................................................................................................... 1-165 8-4 TWR LENGTH SENSOR NOT DETECTING LENGTH CHANGE ..................................................................... 1-166 8-4 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE HIGH ........................................................................ 1-167 8-4 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW ......................................................................... 1-168 8-4 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE HIGH ....................................................................... 1-169 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 CODE - MESSAGE PAGE NO. INTRODUCTION A-16 1250AJP 3128411 8-4 WRONG TWR TELE RESPONSE ..................................................................................................................... 1-174 8-5 LOAD PIN FORCE TOO LOW OVER MAIN ANGLE CHANGE ........................................................................ 1-95 8-5 LOAD PIN FORCE TOO LOW OVER MAIN LENGTH TRANSITION ................................................................ 1-95 8-5 LOAD PIN FORCE TOO LOW OVER TOWER ANGLE CHANGE .................................................................... 1-95 8-5 LOAD PIN FORCE VALUES NOT CHANGING ................................................................................................. 1-95 8-5 LOAD PIN HORIZONTAL FORCE OUT OF RANGE ........................................................................................ 1-95 8-5 LOAD PIN SENSOR FAULT ............................................................................................................................. 1-96 8-5 LOAD PIN VERTICAL FORCE OUT OF RANGE .............................................................................................. 1-96 8-5 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT ...................................................................... 1-96 8-5 NEW LOAD PIN DETECTED FAULT ................................................................................................................ 1-121 8-6 AXLE EXT STB OR OC ..................................................................................................................................... 1-35 8-6 AXLE EXT STG ................................................................................................................................................. 1-35 8-6 AXLE RET STB OR OC ..................................................................................................................................... 1-35 8-6 AXLE RET STG ................................................................................................................................................. 1-36 8-6 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT ................................................................................ 1-70 8-6 FRONT LEFT WHEEL BLOCKED ..................................................................................................................... 1-77 8-6 FRONT LEFT WHEEL SENSOR FAULT - CHECK MOUNTING ....................................................................... 1-78 8-6 FRONT LEFT WHEEL SENSOR OUT OF RANGE HIGH ................................................................................. 1-80 8-6 FRONT LEFT WHEEL SENSOR OUT OF RANGE LOW .................................................................................. 1-81 8-6 FRONT RIGHT WHEEL BLOCKED .................................................................................................................. 1-82 8-6 FRONT RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING .................................................................... 1-83 8-6 FRONT RIGHT WHEEL SENSOR OUT OF RANGE HIGH ............................................................................... 1-84 8-6 FRONT RIGHT WHEEL SENSOR OUT OF RANGE LOW ................................................................................ 1-85 8-6 LT FNT STEER LT STB OR OC ........................................................................................................................ 1-97 8-6 LT FNT STEER LT STG .................................................................................................................................... 1-98 8-6 LT FNT STEER RT STB OR OC ........................................................................................................................ 1-98 8-6 LT FNT STEER RT STG .................................................................................................................................... 1-99 8-6 LT REAR STEER LT STB OR OC ..................................................................................................................... 1-99 8-6 LT REAR STEER LT STG .................................................................................................................................. 1-99 8-6 LT REAR STEER RT STB OR OC ..................................................................................................................... 1-99 8-6 LT REAR STEER RT STG ................................................................................................................................. 1-100 8-6 REAR LEFT WHEEL BLOCKED ....................................................................................................................... 1-126 8-6 REAR LEFT WHEEL SENSOR FAULT - CHECK MOUNTING ......................................................................... 1-127 8-6 REAR LEFT WHEEL SENSOR OUT OF RANGE HIGH .................................................................................... 1-128 8-6 REAR LEFT WHEEL SENSOR OUT OF RANGE LOW ..................................................................................... 1-129 8-6 REAR RIGHT WHEEL BLOCKED ..................................................................................................................... 1-130 8-6 REAR RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING ....................................................................... 1-131 8-6 REAR RIGHT WHEEL SENSOR OUT OF RANGE HIGH ................................................................................. 1-132 8-6 REAR RIGHT WHEEL SENSOR OUT OF RANGE LOW .................................................................................. 1-133 8-6 RESTRICTED TO TRANSPORT - OSC AXLE PRESS SW DISAGREEMENT .................................................. 1-135 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 CODE - MESSAGE PAGE NO. INTRODUCTION 3128411 1250AJP A-17 8-6 RT REAR STEER LT STG ................................................................................................................................. 1-138 8-6 RT REAR STEER RT STB OR OC ..................................................................................................................... 1-139 8-6 RT REAR STEER RT STG ................................................................................................................................. 1-139 8-7 NEW MAIN ANGL1 SENSOR DETECTED ....................................................................................................... 1-121 8-7 NEW MAIN ANGL2 SENSOR DETECTED ....................................................................................................... 1-121 9-? 9-9 BLAM BACKUP COMMUNICATIONS LINK FAULTY ....................................................................................... 1-46 9-9 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED ................................................... 1-47 9-9 BLAM HIGH RES A/D FAILURE ........................................................................................................................ 1-53 9-9 BLAM SENSOR SUPPLY OUT OF RANGE HIGH ............................................................................................ 1-53 9-9 BLAM SENSOR SUPPLY OUT OF RANGE LOW ............................................................................................. 1-54 9-9 BOOM SENSORS NOT CALIBRATED ............................................................................................................. 1-58 9-9 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH ...................................................................................... 1-60 9-9 CHASSIS SENSOR SUPPLY OUT OF RANGE Low ........................................................................................ 1-61 9-9 CHASSIS TILT SENSOR GAIN OUT OF RANGE ............................................................................................. 1-61 9-9 CHASSIS TILT SENSOR NOT GAIN CALIBRATED ......................................................................................... 1-62 9-9 DRIVE CRACKPOINTS NOT CALIBRATED ...................................................................................................... 1-67 9-9 EEPROM FAILURE - CHECK ALL SETTINGS .................................................................................................. 1-69 9-9 ENVELOPE CONTROL DISABLED .................................................................................................................. 1-73 9-9 GROUND MODULE CONSTANT DATA UPDATE REQUIRED ......................................................................... 1-89 9-9 GROUND MODULE FAILURE HIGH SIDE DRIVER CUTOUT FAULTY ........................................................... 1-89 9-9 GROUND MODULE FAILURE HWFS CODE 1 ................................................................................................. 1-89 9-9 GROUND SENSOR REF VOLTAGE OUT OF RANGE .....................................................................................1-89 9-9 HIGH RESOLUTION A2D FAILURE-INTERRUPT LOST .................................................................................. 1-90 9-9 HIGH RESOLUTION A2D FAILURE-REINIT LIMIT ........................................................................................... 1-90 9-9 LENGTH SENSOR REF VOLTAGE HIGH ........................................................................................................ 1-94 9-9 LENGTH SENSOR REF VOLTAGE LOW ......................................................................................................... 1-94 9-9 LOAD PIN NOT CALIBRATED .......................................................................................................................... 1-95 9-9 MOMENT CONTROL DISABLED ..................................................................................................................... 1-120 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 CODE - MESSAGE PAGE NO. INTRODUCTION A-18 1250AJP 3128411 This Page Left Blank Intentionally SAFETY 3128411 1250AJP B-19 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 mainte- nance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance pro- gram 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 trouble- shooting are inserted at the appropriate point in the man- ual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine com- ponent parts. Your safety, and that of others, is the first consideration when engaging in the troubleshooting of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER troubleshooting, SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/ OPERATOR. B.2 HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pres- sures. 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 during electrical storms. Ensure that fuel cap is closed and secure at all other times. • Remove all rings, watches and jewelry when performing any troubleshooting. • Do not wear long hair unrestrained, or loose-fitting clothing and neckties which are apt to become caught on or entangled in equipment. • Observe and obey all warnings and cautions on machine and in service and operators manuals. • Keep oil, grease, water, etc. wiped from standing sur- faces and hand holds. • Use caution when checking a hot, pressurized coolant system. • Never work under an elevated boom until boom has been safely restrained from any movement by blocking or overhead sling, or boom safety prop has been engaged. • A machine that is damaged or malfunctioning should immediately be tagged and removed from service. • Repair any machine damage or malfunction before operating the machine. • Unless otherwise specified, perform any troubleshoot- ing procedure with the machine parked on a flat level surface, boom stowed, key switch off and key removed, park brake applied. • Battery should always be disconnected during replace- ment of electrical components. • Keep all support equipment and attachments stowed in their proper place. • Use only approved, nonflammable cleaning solvents. 20 1250AJP 3128411 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. 3128411 1250AJP 21 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION / PARAGRAPH PAGE NO. SECTION A - INTRODUCTION A.1 How To Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.3 Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.4 Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A.5 Ground Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A.6 Control Module Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 A.7 Critical Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 A.8 Service Fault Code Cross References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 SECTION B - TROUBLESHOOTING SAFETY PRECAUTIONS B.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19 B.2 Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19 B.3 Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1.1 AIR FILTER BYPASSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.2 ALTERNATOR POWER SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.3 AUX POWER OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.4 AUX POWER SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.5 AUX POWER SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.6 AXLE EXT STB OR OC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.7 AXLE EXT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.8 AXLE RET STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 1.9 AXLE RET STG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.10 BACKUP BLAM COMMUNICATIONS ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.11 BASKET DOWN OVERRIDE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.12 BASKET DOWN OVERRIDE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.13 BASKET DOWN OVERRIDE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.14 BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.15 BASKET DOWN SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.16 BASKET LEFT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.17 BASKET LEFT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 1.18 BASKET LEFT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1.19 BASKET LEVELING CRACKPOINT DOWN NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 1.20 BASKET LEVELING CRACKPOINT UP NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38 1.21 BASKET LEVELING OVERRIDE OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.22 BASKET LEVELING OVERRIDE ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.23 BASKET LEVELING SENSOR 1 SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.24 BASKET LEVELING SENSOR 1 SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . . . . . . . 1-39 1.25 BASKET LEVELING SENSOR 2 SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 1.26 BASKET LEVELING SENSOR 2 SHORT TO GROUND OR OPEN CIRCUIT . . . . . . . . . . . . . . . . 1-39 1.27 BASKET LEVELING SYSTEM TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39 22 1250AJP 3128411 TABLE OF CONTENTS (Continued) 1.28 BASKET LEVELING TILT REFERENCE 1 OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.29 BASKET LEVELING TILT REFERENCE 2 OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.30 BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . 1-41 1.31 BASKET LEVELING TILT SENSOR 2 COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . 1-43 1.32 BASKET LEVELING TILT SENSOR DIFFERENCE TOO GREAT. . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 1.33 BASKET RIGHT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 1.34 BASKET RIGHT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 1.35 BASKET RIGHT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.36 BASKET UP OVERRIDE OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.37 BASKET UP OVERRIDE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.38 BASKET UP OVERRIDE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.39 BASKET UP SHORT TO BATTERY OR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.40 BASKET UP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.41 BATTERY LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.42 BATTERY TOO HIGH - SYSTEM SHUT DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.43 BATTERY TOO LOW - SYSTEM SHUT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 1.44 BLAM BACKUP COMMUNICATIONS LINK FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46 1.45 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . 1-47 1.46 BLAM CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48 1.47 BLAM HIGH RES A/D FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 1.48 BLAM SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53 1.49 BLAM SENSOR SUPPLY OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 1.50 BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54 1.51 BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56 1.52 BOOM LENGTH SENSOR #1 OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57 1.53 BOOM LENGTH SENSOR #1 OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.54 BOOM LENGTH SENSOR #2 OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.55 BOOM LENGTH SENSOR #2 OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.56 BOOM PREVENTED - DRIVE SELECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.57 BOOM SENSORS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.58 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED. . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.59 CHASSIS CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58 1.60 CHASSIS SENSOR SUPPLY OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60 1.61 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61 1.62 CHASSIS TILT SENSOR GAIN OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61 1.63 CHASSIS TILT SENSOR NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.64 CHASSIS TILT SENSOR NOT GAIN CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.65 CHASSIS TILT SENSOR OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.66 COLD START ADVANCE SOLENOID OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.67 COLD START ADVANCE SOLENOID SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.68 COLD START ADVANCE SOLENOID SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.69 COOLANT TEMPERATURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.70 CYL ANGLE SENSOR/SW DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62 1.71 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63 SUBJECT - SECTION / PARAGRAPH PAGE NO. 3128411 1250AJP 23 TABLE OF CONTENTS (Continued) 1.72 D/S JOY. CENTER TAP BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64 1.73 D/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64 1.74 D/S JOY. OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64 1.75 DCAP LEN SW DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64 1.76 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL. . . . . . . . . . . . 1-67 1.77 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67 1.78 DRIVE CRACKPOINTS NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67 1.79 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68 1.80 DRIVE PREVENTED - ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68 1.81 DRIVE PREVENTED - BOOM SELECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68 1.82 DRIVE PREVENTED - TILTED & ABOVE ELEVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68 1.83 EEPROM FAILURE - CHECK ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 1.84 ELECTRIC PUMP OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 1.85 ELECTRIC PUMP SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 1.86 ELECTRIC PUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 1.87 ENGINE CONTROLLER CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69 1.88 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70 1.89 ENGINE TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70 1.90 ENVELOPE CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 1.91 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 1.92 EVERYTHING OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73 1.94 FOOTSWITCH SELECTED BEFORE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77 1.95 FRONT LEFT WHEEL BLOCKED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77 1.96 FRONT LEFT WHEEL SENSOR FAULT - CHECK MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78 1.97 FRONT LEFT WHEEL SENSOR OUT OF RANGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80 1.98 FRONT LEFT WHEEL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81 1.99 FRONT RIGHT WHEEL BLOCKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82 1.100 FRONT RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . 1-83 1.101 FRONT RIGHT WHEEL SENSOR OUT OF RANGE HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84 1.102 FRONT RIGHT WHEEL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85 1.103 FSW FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85 1.104 FSW INTERLOCK TRIPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86 1.105 FSW OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86 1.106 FUEL SENSOR SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 1.107 FUEL SENSOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 1.108 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER. . . . . . . . . . . 1-87 1.109 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER. . . . . . . . 1-87 1.110 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER . . . . . . 1-87 1.111 GEN SET/WELDER OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87 1.112 GEN SET/WELDER SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.113 GEN SET/WELDER SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.114 GENERATOR MOTION CUTOUT ACTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.115 GLOW PLUG OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 SUBJECT - SECTION / PARAGRAPH PAGE NO. 24 1250AJP 3128411 TABLE OF CONTENTS (Continued) 1.116 GLOW PLUG SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.117 GLOW PLUG SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.118 GROUND ALARM OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.119 GROUND ALARM SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.120 GROUND ALARM SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88 1.121 GROUND MODULE CONSTANT DATA UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89 1.122 GROUND MODULE FAILURE: HWFS CODE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89 1.123 GROUND MODULE FAILURE:HIGH SIDE DRIVER CUTOUT FAULTY. . . . . . . . . . . . . . . . . . . . . 1-89 1.124 GROUND SENSOR REF VOLTAGE OUT OF RANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89 1.125 HEAD TAIL LIGHT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89 1.126 HEAD TAIL LIGHT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89 1.127 HEAD TAIL LIGHT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.128 HIGH ENGINE TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.129 HIGH RESOLUTION A2D FAILURE-INTERRUPT LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.130 HIGH RESOLUTION A2D FAILURE-REINIT LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.131 HORN OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.132 HORN SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.133 HORN SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.134 HOUR METER SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.135 HOUR METER SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90 1.136 INVALID ANGLE SENSOR #1 MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.137 INVALID ANGLE SENSOR #2 MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.138 JIB DOWN OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.139 JIB DOWN SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.140 JIB DOWN SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.141 JIB LEFT OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91 1.142 JIB LEFT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.143 JIB LEFT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.144 JIB RIGHT OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.145 JIB RIGHT SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.146 JIB RIGHT SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.147 JIB SWING PREVENTED - IN 1000# MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.148 JIB UP OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.149 JIB UP SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.150 JIB UP SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.151 KEYSWITCH FAULTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92 1.152 L/S JOY. CENTER TAP BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.153 L/S JOY. OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.154 L/S JOY. OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.155 LEFT FORWARD DRIVE PUMP OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.156 LEFT FORWARD DRIVE PUMP SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.157 LEFT FORWARD DRIVE PUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.158 LEFT REVERSE DRIVE PUMP OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.159 LEFT REVERSE DRIVE PUMP SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 SUBJECT - SECTION / PARAGRAPH PAGE NO. 3128411 1250AJP 25 TABLE OF CONTENTS (Continued) 1.160 LEFT REVERSE DRIVE PUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93 1.161 LENGTH SENSOR REF VOLTAGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94 1.162 LENGTH SENSOR REF VOLTAGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94 1.163 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . 1-94 1.164 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH . . . . . . . . . . . . . . . . . . . . . 1-95 1.165 LOAD PIN FORCE TOO LOW OVER MAIN ANGLE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.166 LOAD PIN FORCE TOO LOW OVER MAIN LENGTH TRANSITION . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.167 LOAD PIN FORCE TOO LOW OVER TOWER ANGLE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.168 LOAD PIN FORCE VALUES NOT CHANGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.169 LOAD PIN HORIZONTAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.170 LOAD PIN NOT CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 1.171 LOAD PIN SENSOR FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.172 LOAD PIN VERTICAL FORCE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.173 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.174 LOAD SENSOR NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.175 LOAD SENSOR READING UNDER WEIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.176 LOW OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96 1.177 LT FNT STEER LT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 1.178 LT FNT STEER LT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 1.179 LT FNT STEER RT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 1.180 LT FNT STEER RT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 1.181 LT REAR STEER LT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 1.182 LT REAR STEER LT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 1.183 LT REAR STEER RT STB OR OC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99 1.184 LT REAR STEER RT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100 1.185 MAIN ANGL1 CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100 1.186 MAIN ANGL1 INVALID ANGLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101 1.187 MAIN ANGL2 CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102 1.188 MAIN ANGL2 INVALID ANGLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103 1.189 MAIN ANGLE MOVEMENT WITHOUT CMD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104 1.190 MAIN ANGLE SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104 1.191 MAIN ANGLE SENSOR NOT DETECTING ANGLE CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105 1.192 MAIN BOOM TRN ANGLE SW/SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108 1.193 MAIN DUMP OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.194 MAIN DUMP SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.195 MAIN DUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.196 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.197 MAIN IN OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.198 MAIN IN SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.199 MAIN IN SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.200 MAIN LIFT APU OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-109 1.201 MAIN LIFT APU SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.202 MAIN LIFT APU SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.203 MAIN LIFT ENABLE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 SUBJECT - SECTION / PARAGRAPH PAGE NO. 26 1250AJP 3128411 TABLE OF CONTENTS (Continued) 1.204 MAIN LIFT ENABLE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.205 MAIN LIFT ENABLE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.206 MAIN LIFT PILOT PRESSURE FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.207 MAIN LIFT PILOT PRESSURE SWITCH FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.208 MAIN LIFT PVG VALVE COMMAND IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 1.209 MAIN LIFT PVG VALVE COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111 1.210 MAIN LIFT PVG VALVE HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111 1.211 MAIN LIFT PVG VALVE INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112 1.212 MAIN LIFT PVG VALVE LOCATION IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112 1.213 MAIN LIFT PVG VALVE LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112 1.214 MAIN LIFT PVG VALVE OBSTRUCTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113 1.215 MAIN LIFT PVG VALVE PARAMETERS INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.216 MAIN LIFT PVG VALVE SENT UNRECOGNIZED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.217 MAIN LIFT PVG VALVE SETUP FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.218 MAIN LIFT PVG VALVE STUCK EXTENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.219 MAIN LIFT PVG VALVE STUCK NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.220 MAIN LIFT PVG VALVE STUCK RETRACTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114 1.221 MAIN LIFT PVG VALVE TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.222 MAIN LIFT PVG VALVE WIRING INCORRECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.223 MAIN OUT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.224 MAIN OUT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.225 MAIN OUT SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.226 MAIN TELE FLOW CONTROL OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115 1.227 MAIN TELE FLOW CONTROL SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-116 1.228 MAIN TELE FLOW CONTROL SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-116 1.229 MAIN TRN ANGLE SW FAILED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-116 1.230 MAIN TRN LEN SW DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-118 1.231 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS . . . . . . . . . . . . . . . . . . . . . . . . 1-120 1.232 MOMENT CONTROL DISABLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-120 1.233 NEW LOAD PIN DETECTED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.234 NEW MAIN ANGL1 SENSOR DETECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.235 NEW MAIN ANGL2 SENSOR DETECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.236 NO ALTERNATOR OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.237 NO MAIN LIFT PILOT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.238 OIL PRESSURE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121 1.239 OIL PRESSURE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 1.240 PARKING BRAKE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 1.241 PARKING BRAKE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 1.242 PARKING BRAKE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 1.243 PLATFORM CAN COMMUNICATIONS LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 1.244 PLATFORM CONTROL VALVE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 1.245 PLATFORM CONTROL VALVE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 1.246 PLATFORM CONTROL VALVE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 1.247 PLATFORM MODULE FAILURE: HWFS CODE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 SUBJECT - SECTION / PARAGRAPH PAGE NO. 3128411 1250AJP 27 TABLE OF CONTENTS (Continued) 1.248 PLATFORM MODULE SOFTWARE UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 1.249 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-124 1.250 PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-125 1.251 PUMP SWITCHES LOCKED - SELECTED BEFORE AUX POWER . . . . . . . . . . . . . . . . . . . . . . . . 1-125 1.252 PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH. . . . . . . . . . . . . . . . . . . . . . . 1-125 1.253 PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH . . . . . . . . . . . . . . . . . . . . . 1-125 1.254 PVG VALVE ENABLE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-125 1.255 PVG VALVE ENABLE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-126 1.256 PVG VALVE ENABLE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-126 1.257 REAR LEFT WHEEL BLOCKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-126 1.258 REAR LEFT WHEEL SENSOR FAULT - CHECK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-127 1.259 REAR LEFT WHEEL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-128 1.260 REAR LEFT WHEEL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-129 1.261 REAR RIGHT WHEEL BLOCKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-130 1.262 REAR RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131 1.263 REAR RIGHT WHEEL SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-132 1.264 REAR RIGHT WHEEL SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-133 1.265 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE STB OR OC. . . . . . . . . . . . . . . . . . . . 1-134 1.266 RESTRICTED TO TRANSPORT - OSC AXLE PRESS SW DISAGREEMENT . . . . . . . . . . . . . . . . 1-135 1.267 RESTRICTED TO TRANSPORT - PARKING BRAKE STB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-137 1.268 RIGHT FORWARD DRIVE PUMP OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-137 1.269 RIGHT FORWARD DRIVE PUMP SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-137 1.270 RIGHT FORWARD DRIVE PUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.271 RIGHT REVERSE DRIVE PUMP OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.272 RIGHT REVERSE DRIVE PUMP SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.273 RIGHT REVERSE DRIVE PUMP SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.274 RT FNT STEER LT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.275 RT FNT STEER LT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.276 RT FNT STEER RT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.277 RT FNT STEER RT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.278 RT REAR STEER LT STB OR OC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.279 RT REAR STEER LT STG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-138 1.280 RT REAR STEER RT STB OR OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139 1.281 RT REAR STEER RT STG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139 1.282 RUNNING AT CREEP - CREEP SWITCH OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-139 1.283 RUNNING AT CREEP - PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-140 1.284 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-140 1.285 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141 1.286 SPEED INPUT LOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141 1.287 SPEED SENSOR READING INVALID SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141 1.288 START SOLENOID OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141 1.289 START SOLENOID SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.290 START SOLENOID SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.291 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 SUBJECT - SECTION / PARAGRAPH PAGE NO. 28 1250AJP 3128411 TABLE OF CONTENTS (Continued) 1.292 STEER LOCKED - SELECTED BEFORE FOOTSWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.293 STEER SENSORS NOT CALIBRATED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.294 STEER SWITCHES FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.295 SWING LEFT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.296 SWING LEFT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.297 SWING RIGHT OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-142 1.298 SWING RIGHT SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.299 THROTTLE ACTUATOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.300 THROTTLE ACTUATOR OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.301 THROTTLE ACTUATOR SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.302 THROTTLE ACTUATOR SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.303 TOWER ANGLE SENSOR DISAGREEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-143 1.304 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED . . . . . . . . . . . . . . . . . . . . . . 1-144 1.305 TOWER LENGTH SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-144 1.306 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-145 1.307 TOWER LIFT APU VALVE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-147 1.308 TOWER LIFT APU VALVE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-147 1.309 TOWER LIFT APU VALVE SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.310 TOWER LIFT APU VALVE STUCK OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.311 TOWER LIFT ENABLE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.312 TOWER LIFT ENABLE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.313 TOWER LIFT ENABLE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.314 TOWER LIFT ENABLE STUCK OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.315 TOWER LIFT PVG VALVE COMMAND IMPROPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148 1.316 TOWER LIFT PVG VALVE COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-149 1.317 TOWER LIFT PVG VALVE HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-149 1.318 TOWER LIFT PVG VALVE INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150 1.319 TOWER LIFT PVG VALVE LOCATION IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150 1.320 TOWER LIFT PVG VALVE LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150 1.321 TOWER LIFT PVG VALVE OBSTRUCTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-151 1.322 TOWER LIFT PVG VALVE PARAMETERS INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.323 TOWER LIFT PVG VALVE SEND UNRECOGNIZED FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.324 TOWER LIFT PVG VALVE SETUP FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.325 TOWER LIFT PVG VALVE STUCK EXTENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.326 TOWER LIFT PVG VALVE STUCK NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.327 TOWER LIFT PVG VALVE STUCK RETRACTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152 1.328 TOWER LIFT PVG VALVE TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.329 TOWER LIFT PVG VALVE WIRING INCORRECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.330 TOWER TELE APU VALVE STUCK OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.331 TOWER TELE ENABLE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.332 TOWER TELE ENABLE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.333 TOWER TELE ENABLE SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-153 1.334 TOWER TELE ENABLE STUCK OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 1.335 TOWER TELESCOPE APU OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 SUBJECT - SECTION / PARAGRAPH PAGE NO. 3128411 1250AJP 29 TABLE OF CONTENTS (Continued) 1.336 TOWER TELESCOPE APU SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 1.337 TOWER TELESCOPE APU SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 1.338 TOWER TELESCOPE PVG VALVE COMMAND IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 1.339 TOWER TELESCOPE PVG VALVE COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-154 1.340 TOWER TELESCOPE PVG VALVE HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-155 1.341 TOWER TELESCOPE PVG VALVE INTERNAL FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-155 1.342 TOWER TELESCOPE PVG VALVE LOCATION IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-156 1.343 TOWER TELESCOPE PVG VALVE LOW VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-156 1.344 TOWER TELESCOPE PVG VALVE OBSTRUCTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-157 1.345 TOWER TELESCOPE PVG VALVE PARAMETERS INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . 1-157 1.346 TOWER TELESCOPE PVG VALVE SENT UNRECOGNIZED FAULT . . . . . . . . . . . . . . . . . . . . . . 1-158 1.347 TOWER TELESCOPE PVG VALVE SETUP FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158 1.348 TOWER TELESCOPE PVG VALVE STUCK EXTENDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158 1.349 TOWER TELESCOPE PVG VALVE STUCK NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158 1.350 TOWER TELESCOPE PVG VALVE STUCK RETRACTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158 1.351 TOWER TELESCOPE PVG VALVE TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158 1.352 TOWER TELESCOPE PVG VALVE WIRING INCORRECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-159 1.353 TRN DUAL CAP BAD TRANSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-159 1.354 TRN DUAL CAP SWITCHES BAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160 1.355 TWO SPEED OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160 1.356 TWO SPEED SHORT TO BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160 1.357 TWO SPEED SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-160 1.358 TWR ANGL1 INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161 1.359 TWR ANGL2 INVALID ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161 1.360 TWR CYL ANGLE MOVEMENT WITHOUT CMD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-162 1.361 TWR CYL ANGLE NOT DETECTING ANGLE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-162 1.362 TWR CYL ANGLE SENSOR OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-164 1.363 TWR CYL ANGLE SENSOR OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-164 1.364 TWR LENGTH MOVEMENT WITHOUT CMD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-165 1.365 TWR LENGTH SENSOR NOT DETECTING LENGTH CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-166 1.366 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-167 1.367 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-168 1.368 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-169 1.369 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-170 1.370 TWR TRN SW DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171 1.371 WAITING FOR FSW TO BE OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-172 1.372 WRONG ENGINE SELECTED - ECM PRESENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-172 1.373 WRONG MAIN LIFT RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-173 1.374 WRONG MAIN TELE RESPONSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-173 1.375 WRONG TWR LIFT RESPONSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-173 1.376 WRONG TWR TELE RESPONSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-174 1.377 COMMON STB OR OC PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-174 1.378 COMMON STG PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-175 SUBJECT - SECTION / PARAGRAPH PAGE NO. 30 1250AJP 3128411 TABLE OF CONTENTS (Continued) SECTION 2 - ELECTRICAL REFERENCE 2.1 Connector Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-209 2.2 BLAM Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-215 2.3 Chassis Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217 2.4 Ground Module Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-219 2.5 Platform Module Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-223 2.6 Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-227 2.7 Working with AMP Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-239 2.8 Working with Deutsch Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-244 SECTION 3 - HYDRAULIC REFERENCE SECTION 4 - JLG ANALYZER 4.1 To Connect the JLG Control System Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-261 4.2 Using the Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-261 4.3 Changing the Access Level of the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-270 4.4 Adjusting Parameters Using the Hand Held Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-271 4.5 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-271 4.6 Machine Orientation When Setting Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-282 4.7 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-282 SECTION 5 - CALIBRATIONS 5.1 Calibration Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-289 5.2 Calibrating Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-290 5.3 Calibrating Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-292 5.4 Calibrating Boom Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-296 5.5 Electronic Platform Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-299 5.6 Calibrating Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-302 5.7 Calibrating Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-307 5.8 Boom Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-309 SECTION 6 - MULTIMETER BASICS 6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-319 6.2 Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-321 SUBJECT - SECTION / PARAGRAPH PAGE NO. 3128411 1250AJP 31 TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. TITLE PAGE NO. A-1. Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A-2. Ground Module and Platform Fault (System Distress) Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A-3. Basic Electronic Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 2-1. Main Boom Angle and Length Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178 2-2. Dual Capacity / Transport Switch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179 2-3. Color Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-181 2-4. Platform Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-183 2-5. Boom Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-185 2-6. Engine Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-187 2-7. Main Valve Area Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-189 2-8. Ground Control Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-191 2-9. Chassis Area Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-193 2-10. Platform Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-195 2-11. Tower and Main Boom Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-197 2-12. Ground Control Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-199 2-13. BLAM Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-201 2-14. Chassis Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-203 2-15. Electrical Wiring (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-205 2-16. Electrical Wiring (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-207 2-17. Connector Assembly Figure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-240 2-18. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-240 2-19. Connector Assembly Figure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-241 2-20. Connector Assembly Figure 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-241 2-21. Connector Assembly Figure 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242 2-22. Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242 2-23. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-243 2-24. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-244 2-25. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-244 2-26. HD/HDP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-244 2-27. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-245 2-28. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-245 2-29. HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-245 3-1. Main Valve Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-247 3-2. Pumps Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-248 3-3. Platform Valve Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-249 3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-250 3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-251 3-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-252 3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-253 3-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-254 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-255 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-256 32 1250AJP 3128411 TABLE OF CONTENTS (Continued) LIST OF TABLES 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-257 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-258 3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-259 4-1. Ground Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-261 4-2. Platform Analyzer Connection Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-261 4-3. Analyzer Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-263 4-4. Analyzer Flow Chart - Personalities (Software Version 6.X to Present). . . . . . . . . . . . . . . . . . . . . 4-264 4-5. Analyzer Flow Chart - Machine Setup (Software Version 6.X to Present). . . . . . . . . . . . . . . . . . . 4-265 4-6. Analyzer Flow Chart - Calibrations (Software Version 6.X to Present) . . . . . . . . . . . . . . . . . . . . . 4-266 4-7. Analyzer Flow Chart - Diagnostics (Software Version 6.X to Present) - Sheet 1 of 3 . . . . . . . . . . 4-267 4-8. Analyzer Flow Chart - Diagnostics (Software Version 6.X to Present) - Sheet 2 of 3 . . . . . . . . . . 4-268 4-9. Analyzer Flow Chart - Diagnostics(Software Version 6.X to Present) - Sheet 3 of 3. . . . . . . . . . . 4-269 4-10. System Test Flow Chart - Platform Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-284 4-11. System Test Flow Chart - Ground Station Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-286 6-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-320 6-2. Resistance Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-320 6-3. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-321 6-4. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-321 6-5. Example Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-322 6-6. Example Continuity Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-323 TABLE NO. TITLE PAGE NO. 1-1 Common Deutz Engine Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70 2-1 Limit Switch States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-177 2-2 Main Boom Dual Capacity Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-178 2-3 Switch States / Boom Length Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-179 2-4 Platform Area Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-182 2-5 Main Valve Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-188 2-6 Chassis Area Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-192 2-7 Connector Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-209 2-8 X086 (J1) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-215 2-9 X087 (J2) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-215 2-10 X088 (J3) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-215 2-11 X089 (J4) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-216 2-12 X090 (J5) BLAM Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-216 2-13 X229 (J1) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217 2-14 X230 (J2) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217 2-15 X231 (J3) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-217 2-16 X232 (J4) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-218 2-17 X233 (J5) Chassis Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-218 FIGURE NO. TITLE PAGE NO. 3128411 1250AJP 33 TABLE OF CONTENTS (Continued) 2-18 X001 (J1) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-219 2-19 X002 (J2) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-219 2-20 X004 (J4) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-220 2-21 X007 (J7) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-221 2-22 X008 (J8) Ground Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-222 2-23 X165 (J1) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-223 2-24 X166 (J2) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-223 2-25 X167 (J5) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-224 2-26 X168 (J6) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-225 2-27 X169 (J7) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-225 2-28 X170 (J8) Platform Module Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-226 2-29 Connector Loading Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-227 4-1 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-272 4-2 Machine Personality Settings and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-277 4-3 System Test Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-287 5-1 Calibrations Listed by Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-289 5-2 Calibrations Listed by Service Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-289 TABLE NO. TITLE PAGE NO. 34 1250AJP 3128411 TABLE OF CONTENTS (Continued) This Page Left Blank Intentionally SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-35 SECTION 1. FAULT DICTIONARY AND SELECTED TROUBLESHOOTING For a cross-reference list of fault codes, see A.8 Service Fault Code Cross References on Pg. 9 1.1 AIR FILTER BYPASSED Air filter bypassed. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module. 1.2 ALTERNATOR POWER SHORT TO GROUND Alternator power short to ground. The alternator power output [X001.10] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.3 AUX POWER OPEN CIRCUIT Auxiliary power open circuit. There is an open circuit in the auxiliary power output [X001.13]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.4 AUX POWER SHORT TO BATTERY Auxiliary power short to battery. The auxiliary power output [X001.13] is shorted to battery voltage. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.5 AUX POWER SHORT TO GROUND Auxiliary power short to ground. The auxiliary power output [X001.13] is shorted to ground. See 1.378 COMMON STG PRO- CEDURE on Pg. 175. 1.6 AXLE EXT STB OR OC Axle extend short to battery or open circuit. The control system detected a short to battery or open circuit on the axle exten- sion valve output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.7 AXLE EXT STG Axle extend short to ground. The control system detected a short to ground on the axle extension valves output [X230.11] controlling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See 1.378 COMMON STG PROCE- DURE on Pg. 175. 1.8 AXLE RET STB OR OC 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. Flash Code: 4-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-36 1250AJP 3128411 1.9 AXLE RET STG Axle retract short to ground. The control system detected a short to ground on the axle retract valves output [X230.12] con- trolling the front axle extend solenoid [X206] and rear axle extend solenoid [X224]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.10 BACKUP BLAM COMMUNICATIONS ACTIVE Backup BLAM communications active. Notification that the serial backup communications link to the BLAM module is active. Look for 6-6 CAN fault codes in the fault log and troubleshoot those faults. 1.11 BASKET DOWN OVERRIDE OPEN CIRCUIT Basket down override open circuit. The ground module J2 platform level down override output [X002.7] is open. If the open is in or near the platform down solenoid [X137], the fault 1.14 BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 36 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.12 BASKET DOWN OVERRIDE SHORT TO BATTERY Basket down override short to battery. The ground module J2 platform level down override output [X002.7] is shorted to bat- tery. If there are no open wires, the fault 1.14 BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 36 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.13 BASKET DOWN OVERRIDE SHORT TO GROUND Basket down override short to ground. The ground module J2 platform level down override output [X002.7] is shorted to ground. If there are no open wires, the fault 1.15 BASKET DOWN SHORT TO GROUND on Pg. 36 should also be active. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.14 BASKET DOWN SHORT TO BATTERY OR OPEN CIRCUIT Basket down short to battery or open circuit. The platform module J7 platform level down output [X169.16] is shorted to bat- tery or open. If there are no open wires, the fault 1.12 BASKET DOWN OVERRIDE SHORT TO BATTERY on Pg. 36 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.15 BASKET DOWN SHORT TO GROUND Basket down short to ground. The platform module J7 platform level down output [X169.16] is shorted to ground. If there are no open wires, the fault 1.13 BASKET DOWN OVERRIDE SHORT TO GROUND on Pg. 36 should also be active. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.16 BASKET LEFT OPEN CIRCUIT Basket left open circuit. The platform module J7 platform rotate left output [X169.5] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.17 BASKET LEFT SHORT TO BATTERY 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. Flash Code: 8-6 Flash Code: 2-5 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-37 1.18 BASKET LEFT SHORT TO GROUND Basket left short to ground. The platform module J7 platform rotate left output [X169.5] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.19 BASKET LEVELING CRACKPOINT DOWN NOT CALIBRATED Basket leveling crackpoint down not calibrated. The control system detected there was no stored calibration data for the platform leveling down valve current crackpoint. This could be due to installing a new ground module that has not yet been calibrated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic plat- form leveling will be disabled. Platform leveling can still be performed manually, but the BASKET LEVELING SYSTEM TIME- OUT fault will still be enabled. Complete a level down crackpoint calibration, see 5.6 Calibrating Platform Level on Pg. 302 Flash Code: 3-4 Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.19.1 Run a system test Are there any basket leveling sensor faults? Yes Troubleshoot those faults first. No Go to step 1.19.2 1.19.2 Complete a level down crackpoint calibration, see 5.6 Calibrating Platform Level on Pg. 302. Did it complete successfully? Yes Troubleshooting complete No Go to step 1.19.3 1.19.3 Install a high pressure gauge on port M2 of the platform valve. Start engine. Activate level down to end of stroke. Does gauge read or adjust to about 2000 psi? Yes Go to step 1.19.4 No Keep machine in same condition. Go to step 1.19.5 . 1.19.4 Remove hose from platform valve port L1. - Cap port L1. Install a high pressure gauge on end of hose. Start engine. Activate level down. Does pres- sure on gauge read about 2000 psi? Yes Repair/replace level circuit check valve No Repair/replace level cylinder holding valve. 1.19.5 Install a high pressure gauge on port MP of the platform valve. Start engine. Activate level down to end of stroke. Does gauge read about 3400psi? Yes Go to step 1.19.8 No Go to step 1.19.6 1.19.6 Install a high pressure gauge on port mp1 of the main valve. Start engine. Activate level down to end of stroke. Does gauge read about 3400psi? Yes Unclog/repair/replace pressure filter at the plat- form and/or hose from main valve port P3 to plat- form valve port P. No Keep machine in same condition. Go to step 1.19.7. 1.19.7 Install a high pressure gauge on port MP1 of the main valve. start engine. Activate level down to end of stroke. Adjust high pressure relief to 3400psi. See Figure 3- 2. Pumps Layout on Pg. 248 for location. Can it be adjusted to proper pressure? Yes Inspect/repair/replace hydraulics between main valve and platform valve, including filter at plat- form valve. No Repair/replace function pump and/or high pres- sure relief 1.19.8 Start engine. Do the other platform functions operate? Yes Go to step 1.19.10 No Go to step 1.19.9 1.19.9 Turn off machine. Discon- nect platform dump sole- noid [X135]. Does the platform dump solenoid [X135] measure about 6.4 Ω? Yes Clean/repair/replace platform dump valve [X135] cartridge. No Replace platform dump solenoid [X135] 1.19.10 In the platform valve, swap cartridge common to level up solenoid [X136] and level down solenoid [X135] with the cartridge common to rotate right [X138] and rotate left [X139]. Does the crackpoint calibrate? Yes Repair/replace cartridge that was originally installed common to level up solenoid [X136] and level down solenoid [X135] No Go to step 1.19.11 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-38 1250AJP 3128411 1.20 BASKET LEVELING CRACKPOINT UP NOT CALIBRATED Basket leveling crackpoint up not calibrated. The control system detected there was no stored calibration data for the plat- form leveling up valve current crackpoint. This could be due to installing a new ground module that has not yet been cali- brated or prematurely escaping from a level down calibration. A default crackpoint will be assumed, but automatic platform leveling will be disabled. Platform leveling can still be performed manually, but the BASKET LEVELING SYSTEM TIMEOUT fault will still be enabled. Complete a level up crackpoint calibration, see 5.6 Calibrating Platform Level on Pg. 302 1.19.11 Cap platform valve port L2 and its hose. Install a high pressure gauge in port M2. Start engine. Operate level down to end of stroke. Adjust pressure of the platform level down relief for 2000psi. See Figure 3-3. Platform Valve Lay- out on Pg. 249 for location. Does gauge read the proper pressure? Yes Repair/replace platform level cylinder No Repair/replace platform level down relief Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.20.1 Run a system test Are there any basket leveling sensor faults? Yes Troubleshoot those faults first. No Go to step 1.20.2 1.20.2 Complete a level up crackpoint calibration, see 5.6 Calibrating Platform Level on Pg. 302. Did it complete successfully? Yes Troubleshooting complete No Go to step 1.20.3 1.20.3 Install a high pressure gauge on port M1 of the platform valve. Start engine. Activate level up to end of stroke. Does gauge read or adjust to about 3000 psi? Yes Go to step 1.20.4 No Keep machine in same condition. Go to step 1.20.5. 1.20.4 Remove hose from platform valve port L2. - Cap port L2. Install a high pressure gauge on end of hose. Start engine. Activate level down. Does pres- sure on gauge read about 3000 psi? Yes Repair/replace level circuit check valve No Repair/replace level cylinder holding valve. 1.20.5 Install a high pressure gauge on port MP of the platform valve. Start engine. Activate level down to end of stroke. Does gauge read about 3400psi? Yes Go to step 1.20.8 No Go to step 1.20.6 1.20.6 Install a high pressure gauge on port MP1 of the main valve. Start engine. Activate level down to end of stroke. Does gauge read about 3400psi? Yes Unclog/repair/replace pressure filter at the plat- form and/or hose from main valve port P3 to plat- form valve port P. No Keep machine in same condition. Go to step 1.20.7. 1.20.7 Install a high pressure gauge on port MP1 of the main valve. Start engine. Activate level down to end of stroke. Adjust high pressure relief to 3400psi. See Figure 3- 2. Pumps Layout on Pg. 248 for location. Can it be adjusted to proper pressure? Yes Inspect/repair/replace hydraulics between main valve and platform valve, including filter at plat- form valve. No Repair/replace function pump and/or high pres- sure relief 1.20.8 Start engine. Do the other platform functions operate? Yes Go to step 1.20.10 No Go to step 1.20.9 1.20.9 Turn off machine. Discon- nect platform dump sole- noid [X135]. Does the platform dump solenoid [X135] measure about 6.4 Ω? Yes Clean/repair/replace platform dump valve [X135] cartridge. No Replace platform dump solenoid [X135] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-39 1.21 BASKET LEVELING OVERRIDE OFF Basket leveling override off. This fault only applies to service access levels. Notification that the user has forced basket level- ing off. 1.22 BASKET LEVELING OVERRIDE ON Basket leveling override on. This fault only applies to service access levels. Notification that the user has forced basket level- ing on. 1.23 BASKET LEVELING SENSOR 1 SHORT TO BATTERY Basket leveling sensor 1 short to battery. The platform module J1 right platform level sensor communication terminal [X016.25] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.24 BASKET LEVELING SENSOR 1 SHORT TO GROUND OR OPEN CIRCUIT Basket leveling sensor 1 short to ground or open circuit. The platform module J1 right platform level sensor communication terminal [X016.25] is shorted to ground or open. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.25 BASKET LEVELING SENSOR 2 SHORT TO BATTERY Basket leveling sensor 2 short to battery. The platform module J1 left platform level sensor communication terminal [X016.26] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.26 BASKET LEVELING SENSOR 2 SHORT TO GROUND OR OPEN CIRCUIT Basket leveling sensor 2 short to ground or open circuit. The platform module J1 left platform level sensor communication terminal [X016.26] is shorted to ground or open. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.27 BASKET LEVELING SYSTEM TIMEOUT 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- 1.20.10 In the platform valve, swap cartridge common to level up solenoid [X136] and level down solenoid [X135] with the cartridge common to rotate right [X138] and rotate left [X139]. Does the crackpoint calibrate? Yes Repair/replace cartridge that was originally installed common to level up solenoid [X136] and level down solenoid [X135] No Go to step 1.20.11 1.20.11 Cap platform valve port L2 and its hose. Install a high pressure gauge in port M2. Start engine. Operate level up to end of stroke. Adjust pres- sure of the platform level down relief for 3000psi. See Figure 3-3. Platform Valve Lay- out on Pg. 249 for location. Does gauge read the proper pressure? Yes Repair/replace platform level cylinder No Repair/replace platform level up relief Flash Code: 8-3 Flash Code: 8-3 Flash Code: 8-3 Flash Code: 8-3 Flash Code: 8-3 Flash Code: 8-3 Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-40 1250AJP 3128411 able. This fault can happen when driving too fast over abrupt terrain changes because the basket leveling system cannot respond fast enough. Platform operations will be disabled. Note Pretest Instructions Test Result Corrective Action 1.27.1 Examine active faults Are there any other basket leveling faults? Yes Troubleshoot those first No Go to step 1.27.2 1.27.2 Does the fault only occur when driving over changing terrain? Yes Drive slower. If fault still occurs, go to step 1.27.3 No Go to step 1.27.3 1.27.3 Are the mounting blocks for both sensors properly assembled? -AND- Is the hardware tight? Yes Go to step 1.27.4 No Repair as needed 1.27.4 Disconnect platform level sensor #1 (Right) connec- tor [X150] Is the fault BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST now an active fault? Yes Go to step 1.27.5 No Connections are swapped. Make proper harness connections to sensors. 1.27.5 Does the platform move slowly or not at all when commanded? Yes Perform platform leveling calibration. See 5.6 Calibrating Platform Level on Pg. 302. If this does not fix problem go to step 1.27.6 No Go to step 1.27.6 1.27.6 Do the other platform functions operate? Yes Go to step 1.27.10 No Go to step 1.27.7 1.27.7 Install a high pressure gauge on port MP of the platform valve. Start engine. Activate level down to end of stroke. Does gauge read about 3400psi? Yes Go to step 1.27.9 No Go to step 1.27.8 1.27.8 Install a high pressure gauge on port MP1 of the main valve. Start engine. Activate level down to end of stroke. Adjust high pressure relief to 3400psi. See Figure 3- 2. Pumps Layout on Pg. 248 for location. Can it be adjusted to proper pressure? Yes Inspect/repair/replace hydraulics between main valve and platform valve, including filter at plat- form valve. No Repair/replace function pump and/or high pres- sure relief 1.27.9 Turn off machine. Discon- nect platform dump sole- noid [X135]. Does the platform dump solenoid [X135] measure about 6.4 Ω? Yes Clean/repair/replace platform dump valve [X135] cartridge. No Replace platform dump solenoid [X135] 1.27.10 Turn off machine. Discon- nect platform level UP [X136] and level DOWN [X137]. Do both solenoids measure 10.1Ω? Yes Go to step 1.27.11 No Replace platform level valve coil [X136] [X137] 1.27.11 Take car tridge from platform level valve [X136] [X137] and swap it with the one in the jib swing valve [X142] [X143] Does problem clear or move? Yes Replace cartridge originally in the platform level valve [X136] [X137]. No Go to step 1.27.12 1.27.12 Install a high pressure gauge on ports M1 and M2 of the platform valve. Start engine. Activate level down to end of stroke. Does pressure measure or adjust to about 2000 psi? Also, activate level up to end of stroke. Does pressure measure or adjust to about 2500 psi? Yes Repair/replace 75psi check valve and/or level cylinder assembly No Repair/replace relief valve that does not produce proper pressure. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-41 1.28 BASKET LEVELING TILT REFERENCE 1 OUT OF RANGE Basket leveling tilt reference 1 out of range. Platform J7, terminal 11 [X169.11] is reading outside of the expected range of 4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is present only in software before version P7.0. 1.29 BASKET LEVELING TILT REFERENCE 2 OUT OF RANGE Basket leveling tilt reference 2 out of range. Platform J7, terminal 12 [X169.12] is reading outside of the expected range of 4.9V to 5.1V. This terminal is not used and should not be connected. Check the wiring. An EMS cycle is required. This fault is present only in software before version P7.0. 1.30 BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST Basket leveling tilt sensor 1 communications lost. The control system lost serial communications with platform tilt angle sen- sor #1 (right). A power cycle is required. Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.28.1 Cycle power Is fault still present? Yes Go to step 1.28.2 No Troubleshooting complete 1.28.2 Inspect harness and at platform module J7. Is there a wire or short to terminal 11 [X169.11]? Yes Repair/replace harness No Reprogram/replace platform module Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.29.1 Cycle power Is fault still present? Yes Go to step 1.29.2 No Troubleshooting complete 1.29.2 Inspect harness and at platform module J7. Is there a wire or short to terminal 12 [X169.12]? Yes Repair/replace harness No Reprogram/replace platform module Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.30.1 Is harness from platform level sensor 1 [X150] plugged into the platform level passthru 1 [X162]? Also, are those connections in good condition? Yes Go to step 1.30.2 No Correct wiring 1.30.2 Check the faults. Is the fault BASKET LEVELING TILT SENSOR 2 COMMUNICATIONS LOST active? Yes Go to step 1.30.9 No Go to step 1.30.3 1.30.3 Plug platform level sensor 2 (left) [X148] into connector for platform level sensor 1 (right) [X150] Does the BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST fault clear? Yes Replace original platform level sensor 1 (RIGHT) [X150] No Go to step 1.30.4 1.30.4 Disconnect platform level sensor 1 [X150]. Turn on machine. Measure voltage between platform level sen- sor 1 pin1[X150.1.pin] and pin 3 [X150.3.pin]. Does it measure about 12VDC? Yes Go to step 1.30.5 No Go to step 1.30.7 1.30.5 Disconnect platform level sensor 1 [X150] and plat- form module J1 Is there continuity between platform level sen- sor 1 pin 2 [X150.2.pin] and platform module J1 socket 25 [X165.25.soc]? Yes Replace platform level sensor 1 [X150] No Go to step 1.30.6 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-42 1250AJP 3128411 1.30.6 Disconnect platform level passthru 1 [X162] and plat- form module J1 [X165] Is there continuity between platform level passthru 1 pin 2 [X162.2.pin] and platform module J1 socket 25 [X165.25.soc]? Yes Repair/replace harness between platform level passthru 1 [X162] and platform level sensor 1 [X150] No Repair/replace harness between platform level passthru 1 [X162] and platform module J1 [X165] 1.30.7 Disconnect platform mod- ule J2 [X166]. Ground meter. See Grounding on Pg. 319 for details. Turn on machine. Measure voltage between platform module J2 pin 32 [X166.32] and ground. Does it measure about 12VDC? Yes Go to step 1.30.8 No Replace platform module 1.30.8 Disconnect platform level passthru 1 [X162]. Turn on machine. Measure voltage between platform level passthru 1 pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Does it measure about 12VDC? Yes Repair/replace harness between platform level passthru 1 [X162] and platform level sensor 1 [X150] No Repair/replace harness between platform level passthru 1 [X162] and platform module J7 [X169] and/or J1 [X165] 1.30.9 Take the following measure- ment by backprobing. See Backprobing on Pg. 319 for details. Is there about 12 VDC between platform mod- ule J2 terminal 32 [X166.32] and platform module J7 terminal 21 [X169.21]? Yes Go to step 1.30.10 No Replace platform module 1.30.10 Turn on machine. Measure voltage between platform level sen- sor 1 pin 1 [X150.1.pin] and pin 3 [X150.3.pin]. Also, between platform level sensor 2 pin 1 [X148.1.pin] and pin 3 [X148.3.pin]. Do they measure about 12 VDC? Yes Go to step 1.30.12 No Go to step 1.30.11 1.30.11 Turn on machine. Discon- nect platform level passthru 1 [X162] and platform level passthru 2 [X163] Measure voltage between platform level passthru pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Also, measure voltage between platform level passthru 2 pin 1 [X163.1.pin] and pin 3 [X163.3.pin]. Do they measure about 12 VDC? Yes Repair/replace harness between the platform level sensor and platform level passthru connec- tor that did not have the proper voltage. No Repair/Replace harness between the platform level passthru connector +1 [X162] and 2 [X163] and the platform module connector J1 [X165] that did not have the proper voltage. 1.30.12 Disconnect platform level passthru 1 [X162] and plat- form level passthru 2 [X163]. Ground meter. Is there continuity between platform level passthru 1 pin 3 [X162.3.pin] and ground? Also, is there continuity between platform level passthru 2 pin 3 [X163.3.pin] and ground? Yes Go to step 1.30.13 No Repair/replace harness between platform mod- ule J7 [X169] and the connectors platform level passthru 1 [X162] and platform level passthru 2 [X163]. 1.30.13 Disconnect platform level sensor 1 [X150] and plat- form level sensor 2 [X148]. Ground meter. Is there continuity between platform level sen- sor 1 pin 3 [X150.3.pin] and ground. Also, is there continuity between platform level sensor 2 pin 3 [X148.3.pin] and ground. Yes Replace both platform level sensors No Repair/replace harness(es) that did not have con- tinuity. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-43 1.31 BASKET LEVELING TILT SENSOR 2 COMMUNICATIONS LOST Basket leveling tilt sensor 2 communications lost. The control system lost serial communications with platform tilt angle sen- sor #2 (Left). Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.31.1 Is harness from platform level sensor 2 [X148] plugged into the platform level passthru 2 [X163]? Also, are those connections in good condition? Yes Go to step 1.31.2 No Correct wiring 1.31.2 Check the faults. Is the fault BASKET LEVELING TILT SENSOR 1 COMMUNICATIONS LOST active? Yes Go to step 1.31.9 No Go to step 1.31.3 1.31.3 Plug platform level sensor 1 (right) [X150] into connec- tor for platform level sensor 2 (left) [X148] Does the BASKET LEVELING TILT SENSOR 2 COMMUNICATIONS LOST fault clear? Yes Replace original platform level sensor 2 (left) [X148] No Go to step 1.31.4 1.31.4 Disconnect platform level sensor 2 (left) [X148]. Turn on machine. Measure voltage between platform level sen- sor 2 pin1[X148.1.pin] and pin 3 [X148.3.pin]. Does it measure about 12VDC? Yes Go to step 1.31.5 No Go to step 1.31.7 1.31.5 Disconnect platform level sensor 2 (left) [X148] and platform module J1 Is there continuity between platform level sen- sor 1 pin 2 [X148.2.pin] and platform module J1 socket 26 [X165.26.soc]? Yes Replace platform level sensor 2 (left) [X148] No Go to step 1.31.6 1.31.6 Disconnect platform level passthru 2 [X163] and plat- form module J1 [X165] Is there continuity between platform level passthru 2 pin 5 [X163.5.pin] and platform module J1 socket 26 [X165.26.soc]? Yes Repair/replace harness between platform level passthru 2 [X163] and platform level sensor 2 (LEFT) [X148] No Repair/replace harness between platform level passthru 2 [X163] and platform module J1 [X165] 1.31.7 Disconnect platform mod- ule J2 [X166]. Ground meter. See Grounding on Pg. 319 for details. Turn on machine. Measure voltage between platform module J2 pin 32 [X166.32] and ground. Does it measure about 12VDC? Yes Go to step 1.31.8 No Replace platform module 1.31.8 Disconnect platform level passthru 1 [X162]. Turn on machine. Measure voltage between platform level passthru 1 pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. Does it measure about 12VDC? Yes Repair/replace harness between platform level passthru 1 [X162] and platform level sensor 1 [X150] No Repair/replace harness between platform level passthru 1 [X162] and platform module J7 [X169] and/or J1 [X165] 1.31.9 Take the following measure- ment by backprobing. See Backprobing on Pg. 319 for details. Is there about 12 VDC between platform mod- ule J2 terminal 32 [X166.32] and platform module J7 terminal 21 [X169.21]? Yes Go to step 1.31.10 No Replace platform module 1.31.10 Turn on machine. Measure voltage between platform level sen- sor 1 pin 1 [X150.1.pin] and pin 3 [X150.3.pin]. -AND- measure voltage between platform level sensor 2 pin 1 [X148.1.pin] and pin 3 [X148.3.pin]. Do they measure about 12 VDC? Yes Go to step 1.31.12 No Go to step 1.31.11 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-44 1250AJP 3128411 1.32 BASKET LEVELING TILT SENSOR DIFFERENCE TOO GREAT Basket leveling tilt sensor difference too great. The basket leveling tilt readings from platform tilt sensor #1 and #2 both appear to be good, but their measurements are not within 5.0° of each other. This value is programmable. A power cycle is required. 1.33 BASKET RIGHT OPEN CIRCUIT Basket right open circuit. The platform module J7 platform rotate right output [X169.6] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.34 BASKET RIGHT SHORT TO BATTERY 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. 1.31.11 Turn on machine. Discon- nect platform level passthru 1 [X162] and platform level passthru 2 [X163] Measure voltage between platform level passthru pin 1 [X162.1.pin] and pin 3 [X162.3.pin]. -AND- measure voltage between platform level passthru 2 pin 1 [X163.1.pin] and pin 3 [X163.3.pin]. Do they measure about 12 VDC? Yes Repair/Replace harness between the platform level sensor and platform level passthru connec- tor that did not have the proper voltage. No Repair/Replace harness between the platform level passthru connector 1 [X162] and 2 [X163] and the platform module connector J1 [X165] that did not have the proper voltage. 1.31.12 Disconnect platform level passthru 1 [X162] and plat- form level passthru 2 [X163]. Ground meter. Is there continuity between platform level passthru 1 pin 3 [X162.3.pin] and ground? -AND- Is there continuity between platform level passthru 2 pin 3 [X163.3.pin] and ground? Yes Go to step 1.31.13 No Repair/replace harness between platform mod- ule J7 [X169] and the connectors platform level passthru 1 [X162] and platform level passthru 2 [X163]. 1.31.13 Disconnect platform level sensor 1 [X150] and plat- form level sensor 2 [X148]. Ground meter. Is there continuity between platform level sen- sor 1 pin 3 [X150.3.pin] and ground. -AND- Is there continuity between platform level sensor 2 pin 3 [X148.3.pin] and ground. Yes Replace both platform level sensors No Repair/replace harness(es) that did not have con- tinuity. Flash Code: 8-3 Note Pretest Instructions Test Result Corrective Action 1.32.1 Are there any other basket leveling faults? Yes Troubleshoot them first No Go to step 1.32.2 1.32.2 Are both sensors mounted properly and securely? Yes Go to step 1.32.3 No Repair as needed 1.32.3 Disconnect platform level sensor #1 (Right) [X150] Turn on machine. Does the BASKET LEVEL- ING TILT SENSOR 1 COMMUNICATIONS LOST fault appear? Yes Go to step 1.32.4 No Wires to wrong sensor. Swap harness connec- tions and ensure they attach to the correct sensor. 1.32.4 Perform 5.6 Calibrating Platform Level on Pg. 302. (There is also helpful infor- mation in section 5.5 Elec- tronic Platform Leveling on Pg. 299.) Does it calibrate successfully? -AND- Does fault clear? Yes Troubleshooting complete No Replace both platform level sensors, #1 [X148] and #2 [X150] Flash Code: 3-4 Flash Code: 3-4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-45 1.35 BASKET RIGHT SHORT TO GROUND Basket right short to ground. The platform module J7 platform rotate right output [X169.6] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.36 BASKET UP OVERRIDE OPEN CIRCUIT Basket up override open circuit. The ground module J2 platform level up override output [X002.5] is open. If the open is in or near the platform up solenoid [X136], the fault 1.39 BASKET UP SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 45 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.37 BASKET UP OVERRIDE SHORT TO BATTERY Basket up override short to battery. The ground module J2 platform level up override output [X002.5] is shorted to battery. If there are no open wires, the fault 1.39 BASKET UP SHORT TO BATTERY OR OPEN CIRCUIT on Pg. 45 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.38 BASKET UP OVERRIDE SHORT TO GROUND Basket up override short to ground. The ground module J2 platform level up override output [X002.5] is shorted to ground. If there are no open wires, the fault 1.40 BASKET UP SHORT TO GROUND on Pg. 45 should also be active. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.39 BASKET UP SHORT TO BATTERY OR OPEN CIRCUIT Basket up short to battery or open circuit. The platform module J7 platform level up output [X169.15] is shorted to battery or open. If there are no open wires, the fault 1.37 BASKET UP OVERRIDE SHORT TO BATTERY on Pg. 45 should also be active. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.40 BASKET UP SHORT TO GROUND Basket up short to ground. The platform module J7 platform level up output [X169.15] is shorted to ground. If there are no open wires, the fault 1.38 BASKET UP OVERRIDE SHORT TO GROUND on Pg. 45 should also be active. See 1.378 COM- MON STG PROCEDURE on Pg. 175. 1.41 BATTERY LOW Battery low. A warning that the voltage at ground module J8 [X008.2] is below 11 volts. Remove any corrosion on battery ter- minals and battery cable terminals. Recharge or replace battery. 1.42 BATTERY TOO HIGH - SYSTEM SHUT DOWN Battery too high - system shut down. The voltage at ground module J8 [X008.2] is above 18.69 volts. The system will shut down. Check battery and battery connections or replace battery. 1.43 BATTERY TOO LOW - SYSTEM SHUT DOWN 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. Flash Code: 3-4 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 4-4 Flash Code: 4-4 Flash Code: 4-4 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-46 1250AJP 3128411 1.44 BLAM BACKUP COMMUNICATIONS LINK FAULTY BLAM backup communications link faulty. The ground module was not able to communicate with the BLAM during the star- tup test of the backup communications link. The BCS indicator will turn on and the machine will not leave transport position. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.44.1 Connect analyzer at ground module. Turn on machine. Does the analyzer turn on? Yes Keep test setup in place. Go to step 1.44.4 No Go to step 1.44.2 1.44.2 Take the following measure- ment by backprobing. See Backprobing on Pg. 319. Is there about 8.5 VDC between ground mod- ule J1 terminal 28 [X001.28] and terminal 31[X001.31]? Yes Go to step 1.44.3 No Reprogram/replace ground module 1.44.3 Disconnect ground module J1 [X001] Is there continuity between ground module J1 socket 31 [X001] and ground analyzer pin 4 [X013.4.pin]? Yes Repair/replace harness between ground module J1 socket 28 [X001.28.soc] and ground analyzer pin 1 [X013.1.pin] No Repair/replace harness between ground module J1 socket 31 [X001.31.soc] and ground analyzer pin 4 [X013.4.pin] 1.44.4 Connect analyzer at ground module. Turn on machine Does the analyzer start up and say "MENU: HELP: PRESS ENTER"? Yes Go to step 1.44.8 No Keep analyzer connected and machine on. Go to step 1.44.5 1.44.5 Connect analyzer at ground module. Turn on machine. Does the analyzer say, "CONNECT FAILURE"? Yes Go to step 1.44.6 No Go to step 1.44.8 1.44.6 Disconnect ground module J1 [X001] Is there continuity between ground module J1 socket 29 [X001.29.soc] and ground analyzer pin 2 [X013.2.pin]? -AND- Is there continuity between ground module J1 socket 30 [X001.30.soc] and ground analyzer pin 3 [X013.3.pin]? Yes Replace ground module No Go to step 1.44.7 1.44.7 Disconnect RS-232 passthru [X015] Is there continuity between RS-232 passthru pin 1 [X015.1.pin] and RS-232 passthru pin 2 [X015.2.pin]? Also, is there continuity between RS-232 passthru pin 5 [X015.5.pin] and RS-232 passthru pin 6 [X015.6.pin]? Yes Repair/replace harness between ground module J1 [X001] and RS-232 passthru [X015] No Repair/replace RS-232 backup relay assembly. 1.44.8 Disconnect RS-232 passthru [X015] Is there 160Ω ±15% between RS-234 passthru pin 4 [X015.4.pin] and pin 8 [X015.8.pin]? Yes Keep RS-232 passthru disconnected. Go to step 1.44.9 No Replace RS-232 backup relay 1.44.9 Turn off machine. Discon- nect RS-232 passthru [X015]. Turn on machine. About 4 seconds after machine is turned on does voltage measure about 8.5 VDC between RS-232 passthru socket 4 [X015.4.soc] and socket 8 [X015.8.soc]? Yes Go to step 1.44.12 No Keep connector disconnected. Go to step 1.44.10 1.44.10 Disconnect RS-232 passthru [X015] and ground module J2 Is there continuity between RS-232 passthru socket 4[X015.4.soc] and ground module J2 socket 45 [X002.45.soc]? Yes Keep connectors disconnected Go to step 1.44.11. No Repair/replace harness between RS-232 passthru [X015] and ground module J2 1.44.11 Disconnect RS-232 passthru [X015] and ground module J1 Is there continuity between RS-232 passthru socket 8[X015.8.soc] and ground module J1 socket 9 [X002.9.soc]? Yes Replace ground module No Repair/replace harness between RS-232 passthru [X015] and ground module J1 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-47 1.45 BLAM BACKUP COMMUNICATIONS LOST - HYDRAULICS SUSPENDED BLAM backup communications lost - hydraulics suspended. If the ground module loses CAN communications with the BLAM it will attempt to communicate via the RS-232 backup communications link. If the backup communications link cannot be established, all main boom, tower boom, jib, swing and drive functions are disabled, and this fault is logged. 1.44.12 Turn off machine. Discon- nect RS-232 passthru [X015]. Remove socket 4 with ORN/Red wire [X015.4.soc] and socket 8 with Black wire [X015.8.soc] from connec- tor body. Insert them onto the mating pin. Disconnect CAN line to ground module at the T-connection in MTB. Turn on machine. Ignore faults generated by the test setup. Is there continuity between RS- 232 passthru pin 1 [X015.1.pin] and pin 3 [X015.3.pin] -AND- Is there continuity between pin 5 [X015.5.pin] and pin 7 [X015.7.pin]? Yes Keep RS-232 passthru [X015] disconnected. Go to step 1.44.13 No Replace RS-232 backup relay and harness assembly 1.44.13 Turn off machine. Discon- nect RS-232 passthru [X015] and BLAM J5 [X090]. Is there continuity between RS-232 passthru socket 3 [X015.3.soc] and BLAM J5 socket 10 [X090.10.soc]? Yes Go to step 1.44.15 No Keep RS-232 passthru [X015] disconnected. Go to step 1.44.14. 1.44.14 Turn off machine. Discon- nect RS-232 passthru [X015] and RS-232 backup passthru [X059]. Is there continuity between RS-232 passthru socket 3 [X015.3.soc] and RS-232 backup passthru socket 1 [X059.1.soc]? Yes Repair/replace harness between RS-232 backup passthru socket 1 [X059.1.soc] and BLAM J5 socket 10 [X090.10.soc] No Repair/replace harness between RS-232 passthru socket 3 [X015.3.soc] and RS-232 backup passthru socket 1 [X059.1.soc] 1.44.15 Turn off machine. Discon- nect RS-232 passthru [X015] and BLAM J5 [X090]. Is there continuity between RS-232 passthru socket 7 [X015.3.soc] and BLAM J5 socket 11 [X090.11.soc]? Yes Keep BLAM J5 [X090] disconnected. Go to step 1.44.17 No Keep RS-232 passthru [X015] disconnected. Go to step 1.44.16 1.44.16 Turn off machine. Discon- nect RS-232 passthru [X015] and RS-232 backup passthru [X059]. Is there continuity RS-232 passthru socket 7 [X015.7.soc] and RS-232 backup passthru socket 2 [X059]? Yes Repair/replace harness between RS-232 backup passthru socket 2 [X059] and BLAM J5 socket 11 [X090.11.soc] No Repair/replace harness between RS-232 passthru socket 7 [X015.7.soc] and RS-232 backup passthru socket 2 [X059] 1.44.17 Disconnect ground module J1 [X001] and BLAM J5 [X090] Is there continuity between ground module J 1 socket 5 [X001.5.soc] and BLAM J5 socket 12 [X090.12.soc]? Yes Reprogram/replace BLAM No Keep BLAM disconnected. Go to step 1.44.18 1.44.18 Disconnect BLAM J5 [X090] and RS-232 backup passthru [X059] Is there continuity between RS-232 backup passthru pin 3 [X059.3.pin] and BLAM J5 socket 12 [X090.12.soc]? Yes Repair/replace harness between ground module J1 [X001] and BLAM J5 [X090] No Repair/replace harness between RS-232 backup passthru [X059] and BLAM J5 [X090] Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.45.1 Have all personnel been removed from basket and has it been lowered to transport position? Yes See 1.44 BLAM BACKUP COMMUNICATIONS LINK FAULTY on Pg. 46 No Call JLG for help. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-48 1250AJP 3128411 1.46 BLAM CAN COMMUNICATIONS LOST BLAM CAN communications lost. The system cannot communicate with the Boom Length Angle Module (BLAM). This may be due to wiring problems between the platform and chassis modules. Since the trunk of the CAN bus passes through the BLAM, other CAN faults are also likely active. If power is lost to the BLAM, then power will not be provided to the cylinder load pin and the CYLINDER LOAD PIN CAN COMMUNICATIONS LOST fault will also be active. Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.46.1 Check the fault log for other modules having lost com- munication (6-6 codes) Is the CYLINDER LOAD PIN CAN COMMUNI- CATIONS LOST fault active? Yes Go to step 1.46.2 No Go to step 1.46.5 1.46.2 Disconnect the BLAM mod- ule J1 connector [X086] Does the voltage between socket 5 and socket 4 of the BLAM module J1 connector [X086.5.soc X086.4.soc] measure 12VDC? Yes Go to step 1.46.5 No Go to step 1.46.3 1.46.3 Disconnect the 12 position BLAM passthru connector [X058] Does the voltage between socket 1 and socket 6 of the 12 position BLAM passthru connector [X058.1.soc X058.6.soc] measure 12VDC? Yes Repair/replace the YEL/RED 2-70-2 and/or BLACK wires between the Power or ground bus connector [X010 X009] and the 12 position BLAM passthru connector [X058] No Go to step 1.46.4 1.46.4 Does the voltage between any terminal of the MTB Power Bus [X010] and any terminal of the MTB ground bus [X009] measure 12VDC? Yes Repair the YEL/RED 2-70-2 and/or BLACK wires between the battery and terminal 5 and terminal 4 of the BLAM module J1 connector [X086.5 X086.4] No Check the connections, make sure the machine is turned on, and return to step 1.46.2 1.46.5 Does the CAN resistance between terminal 6 and terminal 7 of the BLAM module J1 con- nector [X086.6 X086.7] measure 60Ω and open circuit between terminal 6 and shield [X086.6] and open circuit between terminal 7 and shield [X086.7]? Yes Go to step 1.46.8 No Go to step 1.46.6 1.46.6 Disconnect the BLAM mod- ule J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X086.6.soc X086.7.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Go to step 1.46.26 No Go to step 1.46.7 1.46.7 Is the MAIN ANGL1 CAN COMMUNICATIONS LOST fault active in the fault log? Yes Go to step 1.46.13 to examine the CAN wiring between the ground module and BLAM module No Go to step 1.46.8 1.46.8 Disconnect the BLAM mod- ule J1 connector [X086] and the ground module J7 con- nector [X007] Is there CAN HI continuity between socket 6 of the BLAM module J1 connector [X086.6.soc] and socket 13 of the ground module J7 con- nector [X007.13.soc] and CAN LO continuity between socket 7 of the BLAM module J1 con- nector [X086.7.soc] and socket 24 of the ground module J7 connector [X007.24.soc]? Yes Go to step 1.46.9 No Go to step 1.46.10 1.46.9 View ANALYZER ⇒ DIAG- NOSTICS ⇒ VERSIONS ⇒ GROUND MODULE SOFT- WARE: Px.x and B.L.A. MODULE SOFTWARE: Px.x Are the BLAM and ground modules BOTH run- ning the current software version? Yes Replace the BLAM module. No Update all the software to the same version (latest available) SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-49 1.46.10 Disconnect the 12 position BLAM passthru connector [X058] and the ground mod- ule J7 connector [X007] Is there CAN HI continuity between socket 10 of the 12 position BLAM passthru connector [X058.10.soc] and socket 13 of the ground module J7 connector [X007.13.soc] and CAN LO continuity between socket 11 of the 12 position BLAM passthru connector [X058.11.soc] and socket 24 of the ground module J7 connector [X007.24.soc]? Yes Repair/Replace the harness between the BLAM module J1 connector [X086] and the 12 position BLAM passthru connector [X058] No Go to step 1.46.11 1.46.11 Disconnect the BLAM side of the 3 way CAN connector in the main terminal box [X269] and the ground mod- ule J7 connector [X007] Is there CAN HI continuity between pin A of the 3 way CAN connector [X269.A.pin] and socket 13 of the ground module J7 connector [X007.13.soc] and CAN LO continuity between pin B of the 3 way CAN connector [X269.B.pin] and socket 24 of the ground module J7 connector [X007.24.soc]? Yes Repair/Replace the harness between the 12 posi- tion BLAM passthru connector [X058] and the 3 way CAN connector in the main terminal box [X269] No Go to step 1.46.12 1.46.12 Disconnect the ground module side of the 3 way CAN connector in the main terminal box [X014] and the ground module J7 connec- tor [X007] Is there CAN HI continuity between socket A of the 3 way CAN connector [X014.A.soc] and socket 13 of the ground module J7 connector [X007.13.soc] and CAN LO continuity between socket B of the 3 way CAN connector [X269.B.soc] and socket 24 of the ground module J7 connector [X007.24.soc]? Yes Repair/Replace the 3 way CAN connector in the main terminal box [X014 X269 X270] No Repair/Replace the harness between the 3 way CAN connector in the main terminal box [X014] and the ground module J7 connector [X007] 1.46.13 Disconnect the main boom angle sensor 1 connector [X048] and the BLAM mod- ule J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X086.6.soc X086.7.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Replace main boom angle sensor 1 No Go to step 1.46.14 1.46.14 Disconnect the main boom angle sensor 2 connector [X049] and the BLAM mod- ule J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X086.6.soc X086.7.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Replace main boom angle sensor 2 No Go to step 1.46.15 1.46.15 Disconnect the ground module J7 connector [X007] and the BLAM mod- ule J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X086.6.soc X086.7.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Replace the ground module No Go to step 1.46.16 1.46.16 Disconnect the platform module J7 connector [X007] Does the CAN resistance between socket 31 and socket 30 of the platform module J7 con- nector [X169.31.soc X169.30.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Go to step 1.46.17 No Go to step 1.46.18 1.46.17 Disconnect the platform module J7 connector [X007] Does the CAN resistance between pin 31 and pin 30 of the platform module J7 connector [X169.31.pin X169.30.pin] measure 120Ω and open circuit between pin 31and shield [X169.32.pin] and open circuit between pin 30 and shield [X169.32.pin]? Yes Check the connections at the platform module J7 connector [X169] No Replace the platform module Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-50 1250AJP 3128411 1.46.18 Disconnect the ground module side of the 3 way CAN connector in the main terminal box [X014] and the BLAM module J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X086.6.soc X086.7.soc] measure 120Ω and open circuit between socket 6 and shield [X086.6.soc] and open circuit between socket 7 and shield [X086.7.soc]? Yes Repair/Replace the harness between the ground module side of the 3 way CAN connector in the main terminal box [X014] and the ground module J7 connector [X007] No Go to step 1.46.19 1.46.19 Disconnect the 12 position BLAM passthru connector [X058] Does the CAN resistance between socket 10 and socket 11 of the 12 position BLAM passthru connector [X058.10.soc X058.11.soc] measure 120Ω and open cir- cuit between socket 10 and socket 12 [X058.10.soc X058.12.soc] and open circuit between socket 11 and socket 12 [X058.11.soc X058.12.soc]? Yes Repair/Replace the harness between the BLAM module J1 connector [X086] and the 12 position BLAM passthru connector [X058] No Go to step 1.46.20 1.46.20 Disconnect the BLAM mod- ule side of the 3 way CAN connector in the main termi- nal box [X269] Does the CAN resistance between socket A and socket B of the BLAM module side of the 3 way CAN connector in the main terminal box [X269.A.soc X269.B.soc] measure 120Ω and open circuit between socket A and socket C [X269.A.soc X269.C.soc] and open circuit between socket B and socket C [X269.B.soc X269.C.soc]? Yes Repair/Replace the harness between the BLAM module side of the 3 way CAN connector in the main terminal box [X269] and the 12 position BLAM passthru connector [X058] No Go to step 1.46.21 1.46.21 Disconnect the platform module side of the 3 way CAN connector in the main terminal box [X270] Does the CAN resistance between socket A and socket B of the platform module side of the 3 way CAN connector in the main terminal box [X270.A.soc X270.B.soc] measure 120Ω and open circuit between socket A and socket C [X270.A.soc X270.C.soc] and open circuit between socket B and socket C [X270.B.soc X270.C.soc]? Yes Repair/Replace the 3 way CAN connector in the main terminal box [X014 X269 X270] No Go to step 1.46.22 1.46.22 Disconnect the 19 position main terminal box passthru connector [X043] Does the CAN resistance between socket 2 and socket 3 of the 19 position main terminal box passthru connector [X043.2.soc X043.3.soc] measure 120Ω and open circuit between socket 2 and socket 1 [X043.2.soc X043.1.soc] and open circuit between socket 3 and socket 1 [X043.3.soc X043.1.soc]? Yes Repair/Replace the harness between the 19 posi- tion main terminal box passthru connector [X043] and the platform module side of the 3 way CAN connector in the main terminal box [X270] No Go to step 1.46.23 1.46.23 Disconnect the 19 position tower boom passthru con- nector [X045] Does the CAN resistance between pin 2 and pin 3 of the 19 position tower boom passthru connector [X045.2.pin X045.3.pin] measure 120Ω and open circuit between pin 2 and pin 1 [X045.2.pin X045.1.pin] and open circuit between pin 3 and pin 1 [X045.3.pin X045.1.pin]? Yes Repair/Replace the harness between the 19 posi- tion tower boom passthru connector [X045] and the 19 position main terminal box passthru con- nector [X043] No Go to step 1.46.24 1.46.24 Disconnect the 19 position boom sensor passthru con- nector [X050] Does the CAN resistance between socket 2 and socket 3 of the 19 position boom sensor passthru connector [X050.2.soc X050.3.soc] measure 120Ω and open circuit between socket 2 and socket 1 [X050.2.soc X050.1.soc] and open circuit between socket 3 and socket 1 [X050.3.soc X050.1.soc]? Yes Repair/Replace the harness between the 19 posi- tion boom sensor passthru connector [X050] and the 19 position tower boom passthru con- nector [X045] No Go to step 1.46.25 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-51 1.46.25 Disconnect the 19 position platform control box passthru connector [X160] Does the CAN resistance between pin 2 and pin 3 of the 19 position platform control box passthru connector [X160.2.pin X160.3.pin] measure 120Ω and open circuit between pin 2 and pin 1 [X160.2.pin X160.1.pin] and open circuit between pin 3 and pin 1 [X160.3.pin X160.1.pin]? Yes Repair/Replace the harness between the 19 posi- tion platform control box passthru connector [X160] and the 19 position boom sensor passthru connector [X050] No Repair/Replace the harness between the platform module J7 connector [X169] and the 19 position platform control box passthru connector [X160] 1.46.26 Disconnect the BLAM mod- ule J4 connector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Go to step 1.46.27 No Go to step 1.46.28 1.46.27 Disconnect the BLAM mod- ule J4 connector [X089] Does the CAN resistance between pin 3 and pin 4 of the BLAM module J4 connector [X089.3.pin X089.4.pin] measure 120Ω and open circuit between pin 3 and shield [X089.3.pin X089.5.pin] and open circuit between pin 4 and shield [X089.4.pin X089.5.pin]? Yes Check the connections at the BLAM module J4 connector [X089] No Replace the BLAM module 1.46.28 Disconnect the load pin passthru connector[X060] located near the tower lift cylinder load pin and the BLAM module J4 connector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Go to step 1.46.29 No Go to step 1.46.30 1.46.29 Disconnect the load pin con- nector[X062] and the load pin passthru connec- tor[X060] located near the tower lift cylinder load pin Is there CAN HI continuity between socket D of the load pin connector [X062.D.soc] and socket 3 of the load pin passthru connec- tor[X060.3.soc] and CAN LO continuity between socket E of the load pin connector [X062.E.soc] and socket 4 of the load pin passthru connector[X060.4.soc] Yes Replace the load pin No Repair/Replace the harness between the load pin connector [X062.D X062.E] and the load pin passthru connector[X060.3 X060.4] 1.46.30 Disconnect the top swivel connector [X083] Does the CAN resistance between pin 1 and pin 2 of the top swivel connector [X083.1.pin X083.2.pin] measure 120Ω and open circuit between pin 1 and shield [X083.1.pin X083.3.pin] and open circuit between pin 2 and shield [X083.2.pin X083.3.pin]? Yes Go to step 1.46.31 No Go to step 1.46.38 to examine the CAN wiring in the swivel and chassis 1.46.31 Disconnect the 3 position deutz EMR2 chassis CAN connector [X084] Does the CAN resistance between pin A and pin B of the 3 position Deutz EMR2 Chassis CAN connector [X084.A.pin X084.B.pin] measure 120Ω and open circuit between pin A and pin C [X084.A.pin X084.C.pin] and open circuit between pin B and pin C [X084.B.pin X084.C.pin]? Yes Go to step 1.46.32 No Repair/Replace the harness between the 3 posi- tion Deutz EMR2 Chassis CAN connector [X084] and the top swivel connector [X083] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-52 1250AJP 3128411 1.46.32 Disconnect the engine mod- ule connector [X240] and the BLAM module J4 con- nector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Replace the engine module No Go to step 1.46.33 1.46.33 Disconnect the engine mod- ule can connector [X268] and the BLAM module J4 connector [X089] Does the CAN resistance between pin A and pin B of the engine module CAN connector [X268.A.pin X268.B.pin] measure 120Ω and open circuit between pin A and pin C [X268.A.pin X268.C.pin] and open circuit between pin B and pin C [X268.B.pin X268.C.pin]? Yes Go to step 1.46.34 No Repair/replace the harness between the engine module CAN connector [X268], the engine mod- ule connector [X240], and the 3 position deutz EMR2 chassis CAN connector [X084] 1.46.34 Disconnect the 3 position load pin CAN pass thru con- nector [X262] Does the CAN resistance between pin A and pin B of the 3 position load pin can pass thru connector [X262.A.pin X262.B.pin] measure 120Ω and open circuit between pin A and pin C [X262.A.pin X262.C.pin] and open circuit between pin B and pin C [X262.B.pin X262.C.pin]? Yes Go to step 1.46.35 No Repair/Replace the harness between the 3 posi- tion load pin can pass thru connector [X262] and the engine module CAN connector [X268] 1.46.35 Disconnect the tower lift PVG connector [X066] and the BLAM module J4 con- nector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Replace the tower lift PVG valve section No Go to step 1.46.36 1.46.36 Disconnect the tower tele PVG connector [X067] and the BLAM module J4 con- nector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Replace the tower tele PVG valve section No Go to step 1.46.37 1.46.37 Disconnect the main lift PVG connector [X065] and the BLAM module J4 connector [X089] Does the CAN resistance between socket 3 and socket 4 of the BLAM module J4 connec- tor [X089.3.soc X089.4.soc] measure 120Ω and open circuit between socket 3 and shield [X089.3.soc X089.5.soc] and open circuit between socket 4 and shield [X089.4.soc X089.5.soc]? Yes Replace the main lift PVG valve section No Repair/Replace the harness between the BLAM module J4 connector [X089], the tower lift PVG connector [X066], the tower tele PVG connector [X067], the main lift PVG connector [X065], and the 3 position load pin can pass thru connector [X262] 1.46.38 Disconnect the bottom swivel connector [X216] Does the CAN resistance between socket 1 and socket 2 of the bottom swivel connector [X216.1.soc X216.2.soc] measure 120Ω and 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]? Yes Go to step 1.46.39 No Repair/replace the slip ring connections in the swivel Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-53 1.47 BLAM HIGH RES A/D FAILURE BLAM high resolution analog to digital converter failure. A BLAM internal circuit to measure sensor output had a failure. A power cycle is required. 1.48 BLAM SENSOR SUPPLY OUT OF RANGE HIGH BLAM sensor supply out of range high. BLAM sensor power supply voltage for the boom angle sensors is above the expected range. A power cycle is required. 1.46.39 Disconnect the chassis module J1 connector [X229] Does the CAN resistance between socket 6 and socket 7 of the chassis module J1 con- nector [X229.6.soc X229.7.soc] measure 120Ω and open circuit between socket 6 and shield [X229.6.soc X229.8.soc] and open cir- cuit between socket 7 and shield [X229.7.soc X229.8.soc]? Yes Go to step 1.46.40 No Repair/Replace the harness between the Bottom Swivel connector [X216] and the chassis module J1 connector [X229] 1.46.40 Disconnect the chassis module J1 connector [X229] Is the jumper in place between socket 9 and socket 10 of the chassis module J1 connector [X229.9 X229.10](is there continuity) Yes Replace the chassis module No Replace the CAN jumper between socket 9 and socket 10 of the chassis module J1 connector Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.47.1 Cycle power. Check faults. Does fault continue to occur after cycling power? Yes Reprogram/replace BLAM No Troubleshooting complete Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.48.1 Cycle power Does fault clear? Yes Troubleshooting complete No Go to step 1.48.2 1.48.2 Ensure all optional power sources are de-energized, including welding and off- board power. Does fault clear? Yes Leave all optional power sources de-energized. Go to step 1.48.3. No Go to step 1.48.4 1.48.3 Ensure all optional power sources are de-energized, including welding and off- board power. Re-energize one source and re-check faults. Does fault re-appear? Yes Look for shorts in the harness for that system to harness at BLAM J3. No Go to "Test" box in this step. 1.48.4 Disconnect BLAM J3 [X088]. Turn on machine. Is there between 5.5 V and 4.5 volts measured between the following points on BLAM J3: pin 1 [X088.8.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]? Yes Go to step 1.48.5 No Replace BLAM 1.48.5 Disconnect BLAM J3 [X088]. Disconnect battery (+) terminal [X116] Is there a short between the battery (+) termi- nal [X116] and any of the following: BLAM J3, socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]? Yes Troubleshoot BLAM J3 [X088] harness wire with short No Reprogram/replace BLAM Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-54 1250AJP 3128411 1.49 BLAM SENSOR SUPPLY OUT OF RANGE LOW BLAM sensor supply out of range low. BLAM sensor power supply voltage for the boom angle sensors is below the expected range. A power cycle is required. 1.50 BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT Boom angle sensor #1 communications fault. The control system lost serial communications with tower angle sensor #1 (Right). Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.49.1 Cycle power Does fault clear? Yes Troubleshooting complete No Go to step 1.49.2 1.49.2 Disconnect BLAM J3 [X088]. Turn on machine. Is there between 5.5 V and 4.5 volts measured between the following points on BLAM J3: pin 1 [X088.8.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]? Yes Go to step 1.49.3 No Replace BLAM 1.49.3 Disconnect BLAM J3 [X088]. Disconnect battery ( - ) terminal [X117] Is there a short between the battery ( - ) termi- nal [X117] and any of the following: chassis module J3, socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]? Yes Troubleshoot BLAM J3 [X088] harness wire with short No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.50.1 Are there loose or damaged connections at the right tower boom angle sensor connector [X099]? Yes Repair any loose or damaged wires or connec- tors No Go to step 1.50.2 1.50.2 Does the fault log show BOOM ANGLE SEN- SOR #2 COMMUNICATIONS FAULT before a power cycle? Yes Go to step 1.50.4 No Go to step 1.50.3 1.50.3 Turn on machine. Discon- nect right tower boom angle sensor connector [X099] Is there 12VDC on right tower boom angle sen- sor connector socket 1 [X099.1.soc] and socket 3 [X099.3.soc]? Yes Leave connector disconnected. Go to step 1.50.8. No Go to step 1.50.4 1.50.4 Turn on machine. Back- probe between the 12-pin ground bus connector [X098] and 12-pin V-Batt+ bus connector [X097] by the BLAM. (See Section 6. Mul- timeter Basics on Pg. 319 for details on backprobing.) Is there 12VDC between 12-pin V-Batt+ bus connector[X097] and 12-pin ground bus con- nector [X098]? Yes Repair/replace 12-pin V-Batt+ bus connector [X097] and/or 12-pin ground bus connector [X098]. No Leave machine on. Go to step 1.50.5. 1.50.5 Turn on machine. Discon- nect 12-pin Deutsch con- nector [X058]. Is there 12VDC between 12-pin Deutsch socket 2 [X058.2soc] and socket 5 [X058.5.soc]? Yes Go to step 1.50.11 No Leave 12-pin Deutsch connector [X058] dicon- nected. Go to step 1.50.6. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-55 1.50.6 Disconnect 12-pin Deutsch connector [X058] and Power Down Relay [X011] Is there a short between 12-pin Deutsch con- nector socket 2 [X058.2.soc] and Power Down Relay socket 87 [X011.87.soc]? Yes Leave 12-pin Deutsch connector [X058] discon- nected. Go to step 1.50.7. No Repair/Replace harness between 12-pin Deutsch connector [X058], including the bus connector itself and the Power Down Relay [X011] 1.50.7 Disconnect 12-pin Deutsch connector [X058] and ground control module J3 [X008] Is there a short between 12-pin Deutsch con- nector socket 2 [X058.2.soc] and ground control module J3 socket 3 [X008.3.soc]? Yes Ensure both contacts of the 12-pin Deutsch con- nector socket 2 [X058.2] are seated properly in the connector bodies and that there is continuity between all pins. No Repair/replace harness and or connectors between 12-pin Deutsch connector [X058] and ground control module J3 socket 3 [X008.3] 1.50.8 Plug the tower boom angle sensor connector #2 (Left) [X100] into the #1 (right) sensor and the tower boom angle sensor #1 (Right) connector [X099] into the #2 (left) sensor. Read faults. Does the BOOM ANGLE SENSOR #2 COM- MUNICATIONS FAULT appear? Yes Replace sensor #1 No Go to step 1.50.9 1.50.9 Disconnect right tower boom angle sensor connec- tor [X099] and BLAM J2 [X087] Is there continuity between right angle sensor socket 2 [X099.2.soc] and BLAM J2 socket 8 [X087.8.soc]? Yes Go to step 1.50.11 No Leave the right angle sensor [X099] discon- nected. Go to step 1.50.10. 1.50.10 Disconnect the right angle sensor [X099] and tower angle sensor 1 passthru [X095] (See Figure 2-7. Main Valve Area Connectors on Pg. 189 for location). Is there continuity between right angle sensor socket 2 [X099.2.soc] and tower angle sensor 1 passthru [X095.2.soc]? Also, are the con- tacts free from damage? Yes Repair/replace harness between tower angle sensor 1 pass through [X095] and BLAM J2 [X087] No Repair/replace harness between right angle sen- sor socket 2 [X099.2.soc] and tower angle sen- sor 1 passthru - 4 position [X095] 1.50.11 Disconnect the #1 right side tower boom angle sensor passthru - 4 position [X095]. Turn on the machine. Is there 12VDC between the #1 right side tower boom angle sensor passthru pin 1 [X095.1.pin] and pin 3 [X095.3.pin]? Yes Leave the connector disconnected and machine on. Go to step 1.50.13. No Go to step 1.50.12 1.50.12 Disconnect battery busbar - 12 pos. [X097] and ground busbar - 12 pos. [X098] Is there 12VDC between battery busbar socket 5 [X097.5.soc] and ANY of the sockets in ground busbar [X098]? Yes Repair/replace harness and or connectors between #1 right side tower boom angle sensor passthru [X095] and the 12-pin V-Batt+ bus connector sockets [X097] and/or 12-pin ground bus connector sockets [X098]. No Repair/replace harness and or connectors between battery busbar - 12 pos. [X097] and 12- pin Deutsch connector socket 2 [X058.2.soc] and/or the ground busbar - 12 pos. [X098] and 12-pin Deutsch connector socket 5 [X058.5.soc] 1.50.13 Disconnect the #1 right side tower boom angle sensor [X099]. Turn on the machine. Is there 12VDC between the #1 right side tower boom angle sensor harness connector closest to the sensor socket 1 [X099.1.soc] and socket 3 [X099.3.soc]? Yes Leave the connector disconnected. Go to step 1.50.14. No Repair/replace the harness and or connectors between the #1 right side tower boom angle sen- sor [X099] and #1 right side tower boom angle sensor passthru [X095] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-56 1250AJP 3128411 1.51 BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT Boom angle sensor #2 communications fault. The control system lost serial communications with tower angle sensor #2 (Left). 1.50.14 Disconnect the #1 right side tower boom angle sensor [X099] and the BLAM con- nector J2 [X087] Is there continuity between #1 right side tower boom angle sensor socket 2 [X099.2.soc] and the BLAM connector J2 socket 8 [X087.8.soc]? Also, are the contacts free from damage? Yes Reprogram/replace the BLAM No Repair/replace harness and/or contacts as needed Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.51.1 Are there loose or damaged connections at the left tower boom angle sensor connector [X100]? Yes Repair any loose or damaged wires or connec- tors No Go to step 1.51.2 1.51.2 Does the fault log show BOOM ANGLE SEN- SOR #1 COMMUNICATIONS FAULT before a power cycle? Yes Go to step 1.51.4 No Go to step 1.51.3 1.51.3 Turn on machine. Discon- nect left tower boom angle sensor #2 connector [X100] Is there 12VDC on left tower boom angle sen- sor #2 connector socket 1 [X100.1.soc] and socket 3 [X100.3.soc]? Yes Leave connector disconnected. Go to step 1.51.8. No Go to step 1.51.4 1.51.4 Turn on machine. Back- probe between the 12-pin ground bus connector [X098] and 12-pin V-Batt+ bus connector [X097] by the BLAM. (See Backprobing on Pg. 319 for details on backprobing.) Is there 12VDC between 12-pin V-Batt+ bus connector[X097] and 12-pin ground bus con- nector [X098]? Yes Repair/replace 12-pin V-Batt+ bus connector [X097] and/or 12-pin ground bus connector [X098]. No Leave machine on. Go to step 1.51.5. 1.51.5 Turn on machine. Discon- nect 12-pin Deutsch con- nector [X058]. Is there 12VDC between 12-pin Deutsch socket 2 [X058.2soc] and socket 5 [X058.5.soc]? Yes Go to step 1.51.11 No Leave 12-pin Deutsch connector [X058] dicon- nected. Go to step 1.51.6. 1.51.6 Disconnect 12-pin Deutsch connector [X058] and Power Down Relay [X011] Is there a short between 12-pin Deutsch con- nector socket 2 [X058.2.soc] and Power Down Relay socket 87 [X011.87.soc]? Yes Leave 12-pin Deutsch connector [X058] discon- nected. Go to step 1.51.7. No Repair/Replace harness between 12-pin Deutsch connector [X058], including the bus connector itself and the Power Down Relay [X011] 1.51.7 Disconnect 12-pin Deutsch connector [X058] and ground control module J3 [X008] Is there a short between 12-pin Deutsch con- nector socket 2 [X058.2.soc] and ground control module J3 socket 3 [X008.3.soc]? Yes Ensure both contacts of the 12-pin Deutsch con- nector socket 2 [X058.2] are seated properly in the connector bodies and that there is continuity between all pins. No Repair/replace harness and or connectors between 12-pin Deutsch connector [X058] and ground control module J3 socket 3 [X008.3] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-57 1.52 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. 1.51.8 Plug the tower boom angle sensor connector #1 (Right) [X099] into the #2 (left) sensor and the tower boom angle sensor #2 (Left) connector [X100] into the #1 (right) sensor. Read faults. Does the BOOM ANGLE SENSOR #1 COM- MUNICATIONS FAULT appear? Yes Replace sensor #2 No Go to step 1.51.9 1.51.9 Disconnect tower boom angle sensor #2 (Left) con- nector [X100] and BLAM J2 [X087] Is there continuity between left angle sensor socket 2 [X100.2.soc] and BLAM J2 socket 8 [X087.8.soc]? Yes Go to step 1.51.11 No Leave the left angle sensor [X100] disconnected. Go to step 1.51.10. 1.51.10 Disconnect the left angle sensor [X100] and tower angle sensor 2 passthru [X096] (See Figure 2-7. Main Valve Area Connectors on Pg. 189 for location). Is there continuity between left angle sensor socket 2 [X100.2.soc] and tower angle sensor 2 passthru [X096.2.soc]? Also, are the con- tacts free from damage? Yes Repair/replace harness between tower angle sensor 2 pass through [X096] and BLAM J2 [X087] No Repair/replace harness between left angle sen- sor socket 2 [X100.2.soc] and tower angle sen- sor 2 passthru - 4 position [X096] 1.51.11 Disconnect the #2 left side tower boom angle sensor passthru - 4 position [X096]. Turn on the machine. Is there 12VDC between the #2 left side tower boom angle sensor passthru pin 1 [X096.1.pin] and pin 3 [X096.3.pin]? Yes Leave the connector disconnected and machine on. Go to step 1.51.13 No Go to step 1.51.12 1.51.12 Disconnect battery busbar - 12 pos. [X097] and ground busbar - 12 pos. [X098] Is there 12VDC between battery busbar socket 5 [X097.5.soc] and ANY of the sockets in ground busbar [X098]? Yes Repair/replace harness and or connectors between #2 left side tower boom angle sensor passthru [X096] and the 12-pin V-Batt+ bus connector sockets [X097] and/or 12-pin ground bus connector sockets [X098]. No Repair/replace harness and or connectors between battery busbar - 12 pos. [X097] and 12- pin Deutsch connector socket 2 [X058.2.soc] and/or the ground Busbar - 12 pos. [X098] and 12-pin Deutsch connector socket 5 [X058.5.soc] 1.51.13 Disconnect the #2 left side tower boom angle sensor [X100]. Turn on the machine. Is there 12VDC between the #2 left side tower boom angle sensor harness connector clos- est to the sensor socket 1 [X100.1.soc] and socket 3 [X100.3.soc]? Yes Leave the connector disconnected. Go to step 1.51.14 No Repair/replace the harness and or connectors between the #2 left side tower boom angle sen- sor [X100] and #2 left side tower boom angle sensor passthru [X096]. 1.51.14 Disconnect the #2 left side tower boom angle sensor [X100] and the BLAM con- nector J2 [X087] Is there continuity between #2 left side tower boom angle sensor socket 2 [X100.2.soc] and the BLAM connector J2 socket 9 [X087.9.soc]? Also, are the contacts free from damage? Yes Reprogram/replace the BLAM No Repair/replace harness and/or contacts as needed Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-58 1250AJP 3128411 1.53 BOOM LENGTH SENSOR #1 OUT OF RANGE LOW Tower boom length sensor #1 out of range low. The BLAM module J3 input [X088.8] for tower boom length sensor #1 (Top) is reading under 0.007 volts. See 1.367 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW on Pg. 168. 1.54 BOOM LENGTH SENSOR #2 OUT OF RANGE HIGH Tower boom length sensor #2 out of range high. The BLAM module J3 input [X088.11] for tower boom length sensor #2 (Bottom) is reading over 4.95 volts. See 1.368 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE HIGH on Pg. 169. 1.55 BOOM LENGTH SENSOR #2 OUT OF RANGE LOW Tower boom length sensor #2 out of range low. The BLAM module J3 input [X088.11] for tower boom length sensor #2 (Bot- tom) is reading under 0.007 volts. See 1.369 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE LOW on Pg. 170. 1.56 BOOM PREVENTED - DRIVE SELECTED Boom prevented - drive selected. Notification that ANALYZER ⇒ MACHINE SETUP ⇒ FUNCTION CUTOUT is set to BOOM CUTOUT and the machine is driving above elevation and a boom function is being attempted. Operate drive and boom sep- arately or change the machine setup. 1.57 BOOM SENSORS NOT CALIBRATED Boom sensors not calibrated. The Boom sensors require calibration. See 5.1 Calibration Instructions on Pg. 289, Table 5-2. Calibrations Listed by Service Action on Pg. 289 and 5.8 Boom Sensor Calibration on Pg. 309 for more details. The machine will be in electrical retrieval mode until in transport position. Then, tower path control, controlled angle, auto main lift, main lift up, and tower lift up will be disabled. 1.58 CAN DONGLE ATTACHED - HYDRAULICS NOT RESTRICTED CAN dongle attached - hydraulics not restricted. Notification the production dongle control tool is connected. 1.59 CHASSIS CAN COMMUNICATIONS LOST Chassis CAN communications lost. The system cannot communicate with the chassis module. This may be due to wiring problems between the chassis and ground module. Flash Code: 8-4 Flash Code: 8-4 Flash Code: 8-4 Flash Code: 2-5 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.57.1 Read active faults Are there any boom sensor faults? Yes Troubleshoot those faults first No Go to step 1.57.2 1.57.2 Perform boom sensor cali- bration. Does machine calibrate successfully? Yes Troubleshooting complete No Troubleshoot in accordance with calibration fault Flash Code: 2-5 Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.59.1 Check fault log for other modules having lost com- munication Have most modules lost communications? Yes See 1.93 EXCESSIVE CAN BUS COMMUNICA- TION ERRORS on Pg. 73 No Go to step 1.59.2 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-59 1.59.2 Is Chassis Power fuse [X267] blown? (Located by Aux Power Pump.) Yes Replace with 30A fuse. If it blows again immedi- ately, repair the short to ground on terminals 30 and/or 87a of Chassis Power Relay [X266.30 X266.87a]. It it blows again, but only after turning on the machine, go to step 1.59.17 No Go to step 1.59.3 1.59.3 Disconnect the chassis module J1 connector [X229]. Turn on machine Is there 11VDC or more between socket 5 and socket 4 of the chassis module J1 connector [X229.5.soc X229.4.soc]? Yes See 1.93 EXCESSIVE CAN BUS COMMUNICA- TION ERRORS on Pg. 73 fault step 1.93.3 No Keep machine on. Go to step 1.59.4 1.59.4 Disconnect the chassis module J1 connector [X229]. Turn on machine Is there zero VDC between socket 5 and socket 4 of the chassis module J1 connector [X229.5.soc X229.4.soc]? Yes Keep machine on. Go to step 1.59.6 No Go to step 1.59.5 1.59.5 Remove any corrosion on battery terminals and bat- tery cable terminals. Run machine to recharge battery. Does battery still exhibit low power? Yes Replace battery No Retry normal vehicle operation 1.59.6 Disconnect Lower Swivel connector [X216]. Turn on machine Is there 11VDC or more between socket 4 and socket 5 of the Lower Swivel connector [X216.4.soc X216.5.soc]? Yes Inspect/repair/replace harness between the Lower Swivel connector [X216] and the chassis module J1 connector [X229] No Go to step 1.59.7 1.59.7 Disconnect Upper Swivel connector [X083]. Turn on machine Is there 11VDC or more between socket 4 and socket 5 of the Upper Swivel connector [X083.4.soc X083.5.soc]? Yes Repair/replace swivel harness or replace Swivel No Go to step 1.59.8 1.59.8 Turn on machine Is there 11VDC or more at the Chassis Power relay terminal 87 [X266.87]? Yes Repair/replace harness between the Upper Swivel connector [X083] and the Chassis Power relay terminal 87 [X266.87] No Keep machine on. Go to step 1.59.9 1.59.9 Disconnect Chassis Power Relay [X266]. Turn on machine Is there about 12 VDC at the Chassis Power relay terminal 30 [X266.30]? Yes Go to step 1.59.12 No Go to step 1.59.10 1.59.10 Remove the Chassis Power Fuse from the holder [X267] Is there about 12 VDC at the relay side of the Chassis Power fuse holder [X267]? Yes Repair/replace harness between the Chassis Power fuse connector [X267] and the Chassis Power relay terminal 30 [X266.30] No Go to step 1.59.11 1.59.11 Remove the Chassis Power Fuse from the holder [X267] Is there about 12 VDC at the Auxiliary pump side of the Chassis Power fuse holder [X267]? Yes Replace the Chassis Power Fuse No Repair/replace harness between the Chassis Power fuse connector [X267] and the battery positive [X116] through the Auxiliary Pump Relay positive terminal [X108] 1.59.12 Disconnect Chassis Power Relay [X266]. Turn on machine. Is there about 12 VDC between socket 86 and socket 85 of the Chassis Power relay connec- tor [X266.86.soc X266.85.soc]? Yes Replace Chassis Power relay No Go to step 1.59.13 1.59.13 Disconnect the 2 position chassis power connector [X263]. Turn on machine Is there about 12 VDC between socket 2 and socket 1 of the 2 position chassis power con- nector [X263.2.soc X263.1.soc]? Yes Repair/replace harness between the 2 position chassis power connector [X263] and the chassis power relay connector [X266] No Go to step 1.59.14 1.59.14 Disconnect the 12 position BLAM passthru connector [X058]. Turn on machine Is there about 12 VDC at pin 3 of the 12 posi- tion BLAM passthru connector [X058.3.pin]? Yes Go to step 1.59.15 No Go to step 1.59.16 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-60 1250AJP 3128411 1.60 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. 1.59.15 Is there continuity between terminal 1 of the 2 position chassis power connector [X263.1] and the ground bus connector [X009]? Yes Repair/replace the YEL/RED 2-70-4 wire between the 2 position chassis power connector [X263.2] and the 12 position BLAM passthru connector [X058.3] No Repair/replace the Black wire/harness between the 2 position chassis power connector [X263.1] and the ground bus connector [X009] or battery negative [X117] 1.59.16 Do the faults BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT and BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT both show in the fault log before a power cycle? Yes See 1.50 BOOM ANGLE SENSOR #1 COMMU- NICATIONS FAULT on Pg. 54 to troubleshoot the power supply No Repair/replace harness between the 12 position BLAM passthru connector [X058] and the 12-pin V-Batt+ bus connector [X097] and/or the 12-pin ground bus connector [X098] 1.59.17 Disconnect chassis module J1 connector [X229] Is there a short to ground on socket 5 of chas- sis module J1 connector [X229.5.soc]? Yes Go to step 1.59.19 No Leave chassis module disconnected. Go to step 1.59.18 1.59.18 Disconnect chassis module J1 connector [X229] Is there a short between pin 4 and pin 5 of the chassis module J1 connector [X229.4.pin X229.5.pin]? Yes Replace the chassis module No Check the connections at the chassis module J1 connector [X229] 1.59.19 Disconnect Lower Swivel connector [X216] Is there a short between pin 4 and pin 5 of the Lower Swivel connector [X216.4.pin X216.5.pin]? Yes Repair/replace Chassis harness between the Lower Swivel connector [X216] and chassis module J1 connector [X229] No Go to step 1.59.20 1.59.20 Disconnect Upper Swivel connector [X083] Is there a short between pin 4 and pin 5 of the Upper Swivel connector [X083.4.pin X083.5.pin]? Yes Repair Swivel harness or replace Swivel No Go to step 1.59.21 1.59.21 Disconnect the chassis power relay connector [X266] Is there a short between socket 87 of the Chassis Power Relay connector [X266.87.soc] and socket 85 of the Chassis Power Relay connector [X266.85.soc] or the negative side of the battery [X117]? Yes Repair/replace harness between the chassis power relay connector [X266] and the Upper Swivel connector [X083] No Leave the chassis power relay connector discon- nected. Go to step 1.59.22 1.59.22 Disconnect the chassis power relay connector [X266] Is there a short between socket 30 of the Chassis Power Relay connector [X266.30.soc] and socket 85 of the Chassis Power Relay connector [X266.85.soc] or the negative side of the battery [X117]? Yes Repair/replace harness between the Chassis Power Relay [X266] and the Chassis Power Fuse [X267] No Replace Chassis Power Relay Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.60.1 Cycle power Does fault clear? Yes Troubleshooting complete No Go to step 1.60.2 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-61 1.61 CHASSIS SENSOR SUPPLY OUT OF RANGE LOW Chassis sensor supply out of range low. The supply voltage for chassis steer angle sensors is below the expected range. A power cycle is required. 1.62 CHASSIS TILT SENSOR GAIN OUT OF RANGE Chassis tilt sensor gain out of range. Chassis tilt sensor calibration information has been corrupted. This calibration data is programmed into the ground module during its manufacture, not in the field. 1.60.2 Ensure all optional power sources are de-energized, including welding and off- board power. Does fault clear? Yes Leave all optional power sources de-energized. Go to step 1.60.3. No Go to step 1.60.4 1.60.3 Ensure all optional power sources are de-energized, including welding and off- board power. Re-energize one source and re-check faults. Does fault re-appear? Yes Look for shorts in the harness for the system just energized to harness at chassis module J3. No Go to "Test" box in this step. Repeat until source of fault is found. 1.60.4 Disconnect chassis module J3 [X 23 1]. Tur n o n mac hi ne . Is there between 5.5 V and 4.5 volts measured between the following points on chassis module J3: pin 1 [X231.1.pin] to pin 3 [X231.3.pin]; pin 4 [X231.4.pin] to pin 6 [X231.6.pin]; pin 7 [X231.7.pin] to pin 9 [X231.9.pin]; pin 10 [X231.10.pin] to pin 12 [X231.12.pin]? Yes Go to step 1.60.5 No Replace chassis module 1.60.5 Disconnect chassis module J3 [X231]. Disconnect bat- tery (+) terminal [X116] Is there a short between the battery (+) termi- nal [X116] and any of the following: chassis module J3, socket 1 [X231.1.soc], socket 4 [X231.4.soc], socket 7 [X231.7.soc], or socket 10 [X231.10.soc]? Yes Troubleshoot chassis module J3 [X231] harness wire with short No Reprogram/replace chassis module Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.61.1 Cycle power Does fault clear? Yes Troubleshooting complete No Go to step 1.61.2 1.61.2 Disconnect chassis module J3 [X 23 1]. Tur n o n mac hi ne . Is there between 5.5 V and 4.5 volts measured between the following points on chassis module J3: pin 1 [X231.1.pin] to pin 3 [X231.3.pin]; pin 4 [X231.4.pin] to pin 6 [X231.6.pin]; pin 7 [X231.7.pin] to pin 9 [X231.9.pin]; pin 10 [X231.10.pin] to pin 12 [X231.12.pin]? Yes Go to step 1.61.3 No Replace chassis module 1.61.3 Disconnect chassis module J3 [X231]. Disconnect bat- tery - terminal [X117] Is there a short between the battery(-) terminal [X117] and any of the following: chassis mod- ule J3, socket 1 [X231.1.soc], socket 4 [X231.4.soc], socket 7 [X231.7.soc], or socket 10 [X231.10.soc]? Yes Troubleshoot chassis module J3 [X231] harness wire with short No Reprogram/replace chassis module Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.62.1 Cycle power Does fault clear? Yes Troubleshooting complete No Replace ground module Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-62 1250AJP 3128411 1.63 CHASSIS TILT SENSOR NOT CALIBRATED Chassis tilt sensor not calibrated. Notification that the chassis tilt sensor calibration information has been lost. Machine will indicate that it is tilted at all times. Perform tilt calibration. See 5.7 Calibrating Tilt Sensor on Pg. 307. 1.64 CHASSIS TILT SENSOR NOT GAIN CALIBRATED Chassis tilt sensor not gain calibrated. Chassis tilt sensor calibration information has been lost. Machine will indicate that it is tilted at all times. This calibration data is programmed into the ground module during its manufacture, not in the field. 1.65 CHASSIS TILT SENSOR OUT OF RANGE Chassis tilt sensor out of range. Chassis tilt sensor has indicated a tilt angle greater than 19° for more than 4 seconds. 1.66 COLD START ADVANCE SOLENOID OPEN CIRCUIT Cold start advance solenoid open circuit. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module. 1.67 COLD START ADVANCE SOLENOID SHORT TO BATTERY Cold start advance solenoid short to battery. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module. 1.68 COLD START ADVANCE SOLENOID SHORT TO GROUND Cold start advance solenoid short to ground. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module. 1.69 COOLANT TEMPERATURE SHORT TO GROUND Coolant temperature short to ground. This fault is only active for machines configured with older non-ECM Deutz engines. The engine coolant temperature input [X001.14] is shorted to ground. 1.70 CYL ANGLE SENSOR/SW DISAGREEMENT 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- Flash Code: 8-1 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.64.1 Cycle power Does fault clear? Yes Troubleshooting complete No Replace ground module Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.65.1 Put machine on level sur- face Did fault clear? Yes Normal operation. Troubleshooting complete. No Go to step 1.65.2 1.65.2 Perform Tilt calibration. See 5.7 Calibrating Tilt Sensor on Pg. 307. Did it calibrate successfully? Yes Troubleshooting complete No Replace ground module Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 4-3 Flash Code: 8-4 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-63 nications backup, the BLAM module also sets a digital output [X090.4] to the ground module [X007.22] high if the tower lift cylinder angle sensor raw reading is at or below the stored elevation point recorded during calibration. The ground module treats this digital input as a switch. This fault occurs when this digital input t to the ground module disagrees with the tower lift cylinder angle sensor [X092] data from the CAN bus. If CAN communications are operating properly, this probably means there is a problem with the digital signal line between the ground and BLAM modules. 1.71 CYLINDER LOAD PIN CAN COMMUNICATIONS LOST Cylinder load pin CAN communications lost. The system cannot communicate with the cylinder load pin. This may be due to wiring problems between the cylinder load pin and BLAM module. Note Pretest Instructions Test Result Corrective Action 1.70.1 Ensure the tower lift cylinder angle sensor [X092] is mounted properly, the keeper pin on cylinder pin is in tact and that the Pilot Adapter is installed. Is fault still present? Yes Go to step 1.70.2 No Troubleshooting complete. 1.70.2 Disconnect BLAM J5 [X090] and ground module J7 [X007] Is there continuity between BLAM J5 socket 4 [X090.4.soc] and ground module J7 socket 22 [X090.22.soc]? Yes Go to step 1.70.5 No Leave connectors disconnected. Go to step 1.70.3 1.70.3 Disconnect BLAM J5 [X090], ground module J7 [X007] and BLAM pump passthru [X106]. Is there continuity between BLAM J5 socket 4 [X090.4.soc] and pump passthru socket 5 [X106]? Yes Leave ground module J7 [X007] and BLAM pump passthru [X106] disconnected. Go to step 1.70.4 No Repair/replace harness between BLAM J5 [X090] and BLAM pump passthru [X106] 1.70.4 Disconnect ground module J7 [X007] and BLAM pump passthru [X106]. Is there continuity between ground module J7 socket 22 [X007.22.soc] and BLAM pump passthru pin 5 [X106.5.pin]? Yes Go to 1.70.5 No Repair/replace harness between ground module J7 [X007] and BLAM pump passthru [X106] 1.70.5 Perform 5.8 Boom Sensor Calibration on Pg. 309 Receive calibration failure message: CYL ANGL FAULT? Yes Replace Cylinder Angle sensor and recalibrate. No Retain calibration failure message if any. Go to step 1.70.6 1.70.6 Any other calibration failure message? Yes Troubleshoot in accordance with calibration fault No Troubleshooting complete Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.71.1 Is the EXCESSIVE CAN BUS COMMUNICA- TION ERRORS fault active in the fault log? Yes Troubleshoot 1.93 EXCESSIVE CAN BUS COM- MUNICATION ERRORS on Pg. 73 first No Go to step 1.71.2 1.71.2 Does the BLAM software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ B.L.A. MODULE SOFTWARE:? Yes See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Go to step 1.71.3 1.71.3 Disconnect the load pin con- nector [X062]. Turn on the machine Does the voltage between socket A and socket B of the load pin connector [X062.A.soc X062.B.soc] measure 12VDC? Yes Go to step 1.71.5 No Go to step 1.71.4 1.71.4 Backprobe terminal 1 and terminal 2 of the BLAM mod- ule J4 connector [X089.1 X089.2] Does the voltage between terminal 1 and ter- minal 2 of the BLAM module J4 connector [X089.1 X089.2] measure 12VDC? Yes Repair the WHITE and/or GREEN wires between terminal 1 and terminal 2 of the BLAM module J4 connector [X089.1 X089.2] and terminals A and B of the load pin connector [X062.A X062.B] No Replace the BLAM module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-64 1250AJP 3128411 1.72 D/S JOY. CENTER TAP BAD Drive/Steer joystick center tap bad. The drive joystick center tap input [X168.2] is not reading the correct voltage, +/- 10% from the reference voltage middle point. 1.73 D/S JOY. OUT OF RANGE HIGH Drive/Steer joystick out of range high. The drive joystick input [X168.3] is above the working voltage range. 1.74 D/S JOY. OUT OF RANGE LOW Drive/Steer joystick out of range low. The drive joystick input [X168.3] is below the working voltage range. 1.75 DCAP LEN SW DISAGREEMENT Dual Capacity Length Switch Disagreement. The two main boom dual capacity limit switches are reading the same state. As in Figure 2-2. Dual Capacity / Transport Switch Mounting on Pg. 179 and Table 2-3. Switch States / Boom Length Regions on Pg. 179, the dual capacity limit switches should always read opposite, except at the B/C transition. 1.71.5 Backprobe terminal 3, ter- minal 4, and terminal 5 of the BLAM module J4 connector [X089.3 X089.4 X089.5] Does the CAN resistance between terminal 3 and terminal 4 of the BLAM module J4 con- nector [X089.3 X089.4] measure 60Ω and open circuit between terminal 3 and shield on terminal 5 [X089.3 X089.5] and open circuit between terminal 4 and shield on terminal 5 [X089.4 X089.5]? Yes Go to step 1.71.6 No See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 1.71.6 Disconnect the load pin con- nector [X062] and the BLAM module J4 connector [X089]. Is there CAN HI continuity between socket D of the load pin connector [X062.D.soc] and socket 3 of the BLAM module J4 connector [X089.3.soc] and CAN LO continuity between socket E of the load pin connector [X062.E.soc] and socket 4 of the BLAM mod- ule J4 connector [X089.4.soc]? Yes Replace the load pin No Check the RED, BLACK, and Shield wires between the load pin connector [X062.D X062.E] and the BLAM module J4 connector [X089.3 X089.4] Flash Code: 2-2 Flash Code: 2-2 Flash Code: 2-2 Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.75.1 Access the dual capacity switches #1 [X052] and #2 [X053]. Are any of these switches stuck or frozen? Yes Clean/repair/replace as needed. No Keep access to the switches. Go to step 1.75.2 1.75.2 Access the dual capacity switches #1 [X052] and #2 [X053]. Fully retract the boom. Note the cams that the switch levers ride upon on the side of the fly boom. Are the switches and cam strips mounted so that the switch levers engage the entire length of cam? Also, are the switch levers mounted at 90° to housing as seen when not engaging a cam? Yes Keep access to the switches. Go to step 1.75.3 No Repair as needed 1.75.3 Access the dual capacity switches #1 [X052] and #2 [X053]. Are both switches off cam? Yes Check for mechanical failure of the boom tele- scope cylinder mechanism. No Keep access to switches. Keep machine on. Go to step 1.75.4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-65 1.75.4 Turn on machine and switch to 500 lb. mode. Ground the meter to clean, non-painted metal surface on boom. (See Section 6. Multimeter Basics on Pg. 319 for details on "grounding the meter".) Access black and white wires in the dual capacity switches #1 [X052] and #2 [X053]. Move boom such that switch #1 (top) is off cam and switch #2 (bottom) is on cam. Switch #1 should measure 12VDC on white and 12 VDC on black. Switch #2 should mea- sure 9VDC on white and 12 VDC on black. Move boom such that switch #1 (top) is on cam and switch #2 (bottom) is off cam. Switch #1 should measure 12VDC on white and 9 VDC on black. Switch #2 should mea- sure 12VDC on white and 1 2 V D C o n b la ck . D o switches respond correctly? Yes Keep machine on and switched to 500 lb. mode. Go to step 1.75.5 . No Keep access to switch wires, machine on and switched to 500 lb. mode. Go to step 1.75.6 . 1.75.5 Turn on machine and switch to 500 lb. mode. Ground the meter to clean, non-painted metal surface near MTB passthru - 21 position [X042] and ground control module. Take the following readings by backprobing the contact in question. (See Section 6. Multimeter Basics on Pg. 319 for back- probing details.) Move boom such that switch #1 (top) is off cam and switch #2 (bottom) is on cam. MTB passthru - 21 position contact B [X042.B] should measure 12VDC. Switch #1 should make ground control module J4 contact 18 [X004.18] measure 12 VDC. Switch #2 should make ground control module J4 con- tact 6 [X004.6] measure 9VDC. Move boom such that switch #1 (top) is on cam and switch #2 (bottom) is off cam. MTB passthru - 21 position contact B [X042.B] should mea- sure 12VDC. Switch #1 should make ground control module J4 contact 18 [X004.18] mea- sure 9 VDC. Switch #2 should make ground control module J4 contact 6 [X004.6] mea- sure 12VDC. Are voltages correct? Yes Reprogram/replace ground control module No Go to step 1.75.12 1.75.6 Access switch wire termi- nals. Disconnect dual capacity switch passthru - 3 position [X046] near left main rotary angle sensor [X049]. Turn on machine and switch to 500 lb. mode. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there continuity between switch #1 terminals 21 and 22? Yes Keep machine in same condition. Go to step 1.75.7 . No Replace switch dual capacity switch #1 1.75.7 Access terminals in dual capacity switches #1 [X052] and #2 [X053]. Dis- connect dual capacity switch passthru - 3 position [X046]. Turn on machine and switch to 500 lb. mode. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there continuity between switch #2 terminals 21 and 22? Yes Replace switch dual capacity switch #2 No Go to step 1.75.8 . 1.75.8 Access terminals in dual capacity switches #1 [X052] and #2 [X053]. Dis- connect dual capacity switch passthru - 3 position [X046]. Turn on machine and switch to 500 lb. mode. Move boom such that switch #1 is on cam and switch #2 is off cam. Is there continuity between switch #1 terminals 21 and 22? Yes Replace switch dual capacity switch #1 No Keep machine in same condition. Go to step 1.75.9 . Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-66 1250AJP 3128411 1.75.9 Access terminals in dual capacity switches #1 [X052] and #2 [X053]. Dis- connect dual capacity switch passthru - 3 position [X046]. Turn on machine and switch to 500 lb. mode. Move boom such that switch #1 is on cam and switch #2 is off cam. Is there continuity between switch #2 terminals 21 and 22? Yes Keep access switch terminals. Go to step 1.75.10 . No Replace switch dual capacity switch #2 1.75.10 Turn on machine. Access terminals in dual capacity switches #1 [X052] and #2 [X053]. Take the following readings by grounding meter near switches. Is there 12 VDC on switch #1 terminal 22 and on switch #2 terminal 21? Yes Keep machine on. Go to step 1.75.14 . No Keep machine on. Go to step 1.75.11 . 1.75.11 Turn on machine. Take the following readings by back- probing and grounding meter near connector. Is there 12 VDC on turntable passthru - 21 position contact B [X044.B]? Yes Keep machine on. Go to step 1.75.12 . No Keep machine on. Go to step 1.75.13 1.75.12 Turn on machine. Take the following readings by back- probing and grounding meter near connector. Is there 12 VDC on dual capacity switch passthru contact A [X046.A]? Yes Repair/replace harness between dual capacity switch passthru [X046] and any dual capacity switch that didn’t have the proper voltage in step 1.75.10 No Repair/replace harness between dual capacity switch passthru [X046] and turntable passthru - 21 position [X044] 1.75.13 Turn on machine. Take the following readings by back- probing and grounding meter near connector. Is there 12 VDC on MTB passthru - 21 position contact B [X042.B]? Yes Repair/replace harness between MTB passthru - 21 position [X042] and turntable passthru - 21 position [X044] No Repair/replace harness between MTB passthru - 21 position [X042] and Power Down Relay [X011] 1.75.14 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is on cam and switch #2 is off cam. Is there 12VDC on MTB passthru - 21 position contact M [X042.M]? Yes Keep machine in same condition. Go to step 1.75.15 No Repair/replace harness between MTB passthru - 21 position [X042] and turntable passthru - 21 position [X044] 1.75.15 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is on cam and switch #2 is off cam. Is there 12VDC on ground control module J4 contact 6 [X004.6]? Yes Keep machine in same condition. Go to step 1.75.16 . No Repair/replace harness between MTB passthru - 21 position [X042] and ground control module J4 [X004]. 1.75.16 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there 12VDC on turntable passthru - 21 position contact L [X044.L]? Yes Keep machine in same condition. Go to step 1.75.18 No Keep machine in same condition. Go to step 1.75.17 1.75.17 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there 12VDC on dual capacity switch passthru - 3 position contact B [X046.B]? Yes Repair/replace harness between turntable passthru - 21 position [X044] and dual capacity switch passthru - 3 position [X046] No Repair/replace harness between and dual capac- ity switch #1 and dual capacity switch passthru - 3 position [X046] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-67 1.76 DISCONNECT ANALYZER AND CYCLE EMS TO PERFORM BOOM RETRIEVAL Disconnect analyzer and cycle ems to perform boom retrieval. The ground module has detected that it needs to use the backup communications link to the BLAM module but an analyzer is connected. Remove the analyzer and cycle power. 1.77 DRIVE & BOOM PREVENTED - PLATFORM OVERLOADED Drive & boom prevented - platform overloaded. Only applies to machines configured with platform load sensing. Drive and boom functions will be prevented while the platform is overloaded. 1.78 DRIVE CRACKPOINTS NOT CALIBRATED Drive crackpoints not calibrated. The drive valves require a calibration that has not been performed. 1.75.18 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there 12VDC on MTB passthru - 21 position contact L [X042.L]? Yes Keep machine in same condition. Go to step 1.75.19 No Repair/replace harness between MTB passthru - 21 position [X042] and turntable passthru - 21 position [X044] 1.75.19 Turn on machine and switch to 500 lb. mode. Take the fol- lowing readings by back- probing and grounding meter near connector. Move boom such that switch #1 is off cam and switch #2 is on cam. Is there 12VDC on ground control module J4 contact 18 [X004.18]? Yes Reprogram/replace ground control module. No Repair/replace harness between MTB passthru - 21 position [X042] and ground control module J4 [X004]. Flash Code: 2-5 Flash Code: 8-2 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.78.1 Are there any Drive faults? Yes Troubleshoot those first No Go to step 1.78.2 1.78.2 Perform dive calibration. See 5.3 Calibrating Drive on Pg. 292. Did calibration complete successfully? Yes Troubleshooting complete No Go to step 1.78.3 1.78.3 Were there any calibration faults? Yes Troubleshoot all calibration faults No Go to step 1.78.4 1.78.4 Tee in a 1000 psi pressure gauge next to the pressure switch on the traction con- trol valve manifold While drive is activated in the transport posi- tion does the gauge read about 500 psi? Yes Replace the ground module No Go to step 1.78.5 1.78.5 Connect a 1000 psi pres- sure gauge to the MP port on the traction control valve manifold With the machine idling, can the pressure be adjusted with the adjacent charge relief valve so that the gauge reads 500psi? Yes Replace the axle lockout valve cartridge No Go to step 1.78.6 1.78.6 Disconnect, plug and cap all four drive hoses at the top of the swivel (ports 3, 4, 5, and 6). Tee in a gauge with the hoses at the charge (pres- sure) filter (on engine side). Plug open lines. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Reassemble, but keep gauge installed. Go to step 1.78.8. No Shut down, and reassemble, but keep gauge installed. Go to step 1.78.7. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-68 1250AJP 3128411 1.79 DRIVE LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH Drive locked - joystick moved before footswitch. Notification that drive was selected before and during footswitch signal [X007.15] closure. Can be reported during power-up sequence. Allow the joystick to return to neutral before activating the footswitch. This may also indicated a problem with the footswitch wiring. 1.80 DRIVE PREVENTED - ABOVE ELEVATION Drive prevented - above elevation. Notification that drive was selected while above elevation and drive cutout is configured to prevent drive. 1.81 DRIVE PREVENTED - BOOM SELECTED Drive prevented - boom selected. Notification that drive was selected while a boom function was selected and drive cutout is configured to prevent simultaneous drive & boom operation. 1.82 DRIVE PREVENTED - TILTED & ABOVE ELEVATION Drive prevented - tilted & above elevation. Notification that drive was selected while tilted and above elevation and tilt is con- figured to cutout drive. 1.78.7 Tee in a gauge with the hoses at the charge filter. Discon- nect the front drive pump charge pressure lines (ports Fa and Fe). A jumper hose between the fittings on the pump is required to prevent pump damage. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Repair/replace right side drive pump No Repair/replace left side drive pump. 1.78.8 Disconnect, plug and cap all four drive hoses at the bot- tom of the swivel (ports 3, 4, 5, and 6). Tee in a gauge with the hoses at the charge filter. Plug open lines. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Shut down, and reassemble, but keep gauge installed. Go to step 1.78.9. No Repair seals in swivel. 1.78.9 Disconnect hoses to trac- tion valve ports A3, a4, A5, A6, B3, B4, B5, and B6. Plug/cap open lines and ports. Tee a gauge in with the hoses at the charge filter. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Repair drive motor leakage or replace drive motor. No Repair/replace traction valve. Flash Code: 2-2 Flash Code: 2-5 Flash Code: 2-5 Flash Code: 2-5 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-69 1.83 EEPROM FAILURE - CHECK ALL SETTINGS EEPROM failure - check all settings. A critical failure occurred with the EEPROM. Personalities, machine configuration digits, etc. may be reset to default values and should be checked. A power cycle is required. This can occur if new software that adds a personality or other configurations, is downloaded to the machine. 1.84 ELECTRIC PUMP OPEN CIRCUIT Electric pump open circuit. This fault should never occur on properly configured machines. Reload ground module software or replace the ground module. 1.85 ELECTRIC PUMP SHORT TO BATTERY Electric pump short to battery. This fault should never occur on properly configured machines. Reload ground module soft- ware or replace the ground module. 1.86 ELECTRIC PUMP SHORT TO GROUND Electric pump short to ground. This fault should never occur on properly configured machines. Reload ground module soft- ware or replace the ground module. 1.87 ENGINE CONTROLLER CAN COMMUNICATIONS LOST Engine controller CAN communications lost. The ground module is not receiving CAN messages from the engine controller. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.83.1 Cycle power Does fault clear? Yes Troubleshooting complete No Reprogram/replace ground module Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.87.1 Is the EXCESSIVE CAN BUS COMMUNICA- TION ERRORS fault active in the fault log? Yes Troubleshoot 1.93 EXCESSIVE CAN BUS COM- MUNICATION ERRORS on Pg. 73 first No Go to step 1.87.2 1.87.2 Does the BLAM software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ B.L.A. MODULE SOFTWARE:? Yes See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Go to step 1.87.3 1.87.3 Disconnect the EMR2 ECU equipment connector [X240]. Turn on the machine Does the voltage between socket 14 and socket 1 of the EMR2 ECU equipment connec- tor [X240.14.soc X240.1.soc] measure 12VDC? Yes Go to step 1.87.5 No Go to step 1.87.4 1.87.4 Backprobe between any ter- minal of the MTB power bus connector [X010] and ter- minal 8 of the ground mod- ule J1 connector [X001.8] Does the voltage between any terminal of the MTB power bus connector [X010] and termi- nal 8 of the ground module J1 connector [X001.8] measure 12VDC? Yes Repair the YEL/RED 2-1-99 wire between he MTB power bus connector [X010] and terminal 14 of the EMR2 ECU equipment connector [X240.14] and/or the black wire between terminal 1 of the EMR2 ECU equipment connector [X240] and ter- minal 8 of the ground module J1 connector [X001.8] No 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 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-70 1250AJP 3128411 1.88 ENGINE SHUTDOWN - AXLE LOCKOUT VALVE FAULT Engine shutdown - axle lockout valve fault. The control system detected a short to battery or open circuit on the axle lockout valve and detects pressure on the pressure switch and the boom is out of transport position. Engine starting will be pre- vented while this fault is active. Use auxiliary power to lower the boom to transport. See 1.265 RESTRICTED TO TRANS- PORT - AXLE LOCKOUT VALVE STB OR OC on Pg. 134. 1.89 ENGINE TROUBLE CODE Engine trouble code. This fault text is followed by the engine’s specific fault code. This code could represent engine faults like low oil pressure warning, high coolant temperature warning, etc. See Table 1-1. Common Deutz Engine Fault Codes on Pg. 70 or consult the engine control module manual to interpret the engine specific fault code. 1.87.5 Backprobe terminal 12 and terminal 13 of the EMR2 ECU equipment connector [X240] Does the CAN resistance between terminal 12 and terminal 13 of the EMR2 ECU equipment connector [X240] measure 60Ω? Yes Go to step 1.87.6 No See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 1.87.6 Disconnect the EMR2 ECU equipment connector [X240] and the BLAM mod- ule J4 connector [X089]. See 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321. Is there CAN HI continuity between socket 12 of the EMR2 ECU equipment connector [X240.12.soc] and socket 3 of the BLAM module J4 connector [X089.3.soc] and CAN LO continuity between socket 13 of the EMR2 ECU equipment connector [X240.13.soc] and socket 4 of the BLAM module J4 connector [X089.4.soc]? Yes Replace the engine module No Go to step 1.87.7 1.87.7 Disconnect the EMR2 ECU equipment connector [X240] and the CAN pass thru for EMR2 - 3 position connector [X268]. See 6.2 Continuity Measurement Over Long Distances on Pg. 321. Is there CAN HI continuity between socket 12 of the EMR2 ECU equipment connector [X240.12.soc] and pin A of the CAN pass thru for EMR2 - 3 position connector [X268.A.pin] and CAN LO continuity between socket 13 of the EMR2 ECU equipment connector [X240.13.soc] and pin B of the CAN pass thru for EMR2 - 3 position connector [X268.B.pin]? Yes Replace the valve harness between the BLAM module J4 connector [X089] and the CAN pass thru for EMR2 - 3 position connector [X268] No Check the RED and BLACK wires between the EMR2 ECU equipment connector [X240.12 X240.13] and the CAN pass thru for EMR2 - 3 position connector [X268.A X268.B] Flash Code: 8-6 Flash Code: 4-3 Table 1-1. Common Deutz Engine Fault Codes Fault Code using JLG Analyzer Fault Code using Deutz SERDIA Fault Description Cause Results Troubleshooting Engine Troubleshooting Machine 190:8 1 Speed sensor Engine speed sen- sor failure OR Gap from sensor tip to ringgear too large OR Additional incorrect impulses received OR Wiring to sensor inter- rupted. Loss of engine speed signal will cause the engine to shut down or not start. Check distance from sensor to ringgear. Check for contamination on sensor end. Check wiring connection. Check sensor located at flywheel housing and replace if required. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-71 100:2 8 Oil Pressure Fault at corre- sponding sensor OR wiring connec- tion has a short cir- cuit or open circuit. The engine will con- tinue operating with the failure of either Oil Pressure or Coolant Tempera- ture sensors. How- ever with a failure of the sensor, the associated moni- toring function is de-activated Check relevant sen- sor replace if required. Check rel- evant wiring and connections between sensor and ECU. 110:2 9 Coolant tempera- ture 100:1 30 Oil Pressure warn- ing Engine Oil Pressure has fallen below acceptable value. Fault message occurs. Engine may also shutdown depending on JLG Machine program- ming Check engine oil level. Check oil pressure sensor and wiring. Check engine for other possible mechani- cal causes. The engine has a 12 second monitoring delay on startup, so proceed carefully not to cause further low oil pressure damage to engine on repeated start attempts Depending on Machine Program- ming the engine will either Shutdown OR only give a warning 110:0 31 Coolant Tempera- ture warning Engine Oil Tempera- ture has exceeded acceptable value. Fault message occurs. Engine may also shutdown depending on JLG Machine program- ming. Fault will dis- appear when Oil Temperature drops below preset recov- ery temperature. Check engine oil level. Check Oil temperature sen- sor and wiring. Check cooling sys- tem for leaks or contamination, etc. Depending on Machine Program- ming the engine will either Shutdown OR only give a warning 702:14 35 Overspeed warning (with thrust mode operation). Engine RPM was or is above maximum allowed rpm limit limit. "Thrust mode" function is active If engine exceeds maximum rpm set point (3300 rpm) the fuel rack is set to zero position until engine speed returns below acceptable recov- ery speed (2810 rpm). If condition per- sists: Check fuel rack. Check actua- tor and replace if required. Check wiring to actuator. Check engine speed sensor, ringgear teeth, etc. Check for external environmental con- ditions that could cause engine over- speed condition Table 1-1. Common Deutz Engine Fault Codes Fault Code using JLG Analyzer Fault Code using Deutz SERDIA Fault Description Cause Results Troubleshooting Engine Troubleshooting Machine SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-72 1250AJP 3128411 100:1 40 Oil pressure switch off Oil pressure below switch-off limit. Normally this would cause an Emer- gency stop of the engine. But EMR is not programmed to directly shutdown the engine in JLG machines. Only if the JLG machine is programmed to shutdown will this occur See Oil Pressure Warning info 110:0 41 Coolant tempera- ture switch-off Oil temperature has exceeded switch off limit Normally this would cause an Emer- gency stop of the engine. But EMR is not programmed to directly shutdown the engine in JLG machines. Only if the JLG machine is programmed to shutdown will this occur See Coolant Tem- perature Warning info 91:11 67 Error Hand Setp1 Loss of CAN bus input. Engine will only run at constant speed of 1835 rpm Check CAN con- nection and wiring connection entering engine ECU from machine. Check ECU for proper CAN bus data flow and correct program- ming. Check relevant wir- ing and connec- tions between machine and ECU for open or short circuit. Check Ter- minating resistor in machine wiring 898:2 68 Error CAN Setp1 743:12 70 CAN-Bus controller Controller for CAN- bus is faulty. Fault removal despite reinitializing contin- uously not possi- ble. Engine will shut- down or not restart OR Engine will only run at constant speed of 1835 rpm 743:9 71 CAN interface SAE J 1939 Overflow in input buffer or a trans- mission cannot be placed on the bus. 743:14 74 CAN Passive error Open or Short cir- cuit in wiring Engine will shut- down or not restart OR engine will only run at constant speed of 1835 rpm Check CAN con- nection and wiring connection entering engine ECU from machine. Table 1-1. Common Deutz Engine Fault Codes Fault Code using JLG Analyzer Fault Code using Deutz SERDIA Fault Description Cause Results Troubleshooting Engine Troubleshooting Machine SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-73 1.90 ENVELOPE CONTROL DISABLED Envelope control disabled. The user has forced envelope control off with the analyzer from access level 0. This can happen if calibration procedure is not followed properly. 1.91 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED 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. 1.92 EVERYTHING OK Everything OK. The "normal" help message when the analyzer is plugged into the platform. No troubleshooting is needed. 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS Excessive CAN bus communication errors. More than 500 bus off or more than 500 bus passive conditions have been detected by the ground module in the current power cycle. This could be due to faulty bus wiring or termination resistors, capacitance on the bus, or a module not communicating. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.90.1 Perform 5.8 Boom Sensor Calibration on Pg. 309 then cycle power. Did fault clear? Yes Troubleshooting complete No Reprogram/replace ground module Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.91.1 Is the platform stuck in the air? Yes Call JLG for help No Go to step 1.91.2 1.91.2 Perform boom sensor cali- bration Did calibration complete successfully? Yes Go to step 1.91.3 No Troubleshoot according to calibration fault 1.91.3 Perform Chassis Tilt calibra- tion Did calibration complete successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault Flash Code: 0-0 Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.93.1 Does the CAN resistance between terminal 13 and terminal 24 of the ground module J7 con- nector [X007.13 X007.24] measure 60Ω and open circuit between terminal 13 and shield [X007.18] and open circuit between terminal 24 and shield [X007.18]? Yes Go to step 1.93.2 No Go to step 1.93.29 to examine the CAN termina- tion 1.93.2 Does the platform software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ PLATFORM MODULE SOFTWARE:?? Yes Go to step 1.93.3 No Go to step 1.93.13 1.93.3 For help with this type of test see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 31 of the platform module J7 connector [X169.31] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 30 of the platform module J7 connector [X169.30] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.13 No Go to step 1.93.4 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-74 1250AJP 3128411 1.93.4 Is there CAN HI continuity between terminal 3 of the platform control box passthru - 19 posi- tion connector [X160.3] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 2 of the platform control box passthru - 19 position connector [X160.2] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the platform module J7 connector [X169] and the platform control box passthru - 19 position connector [X160] No Go to step 1.93.5 1.93.5 Is there CAN HI continuity between terminal 3 of the boom sensor passthru - 19 position connector [X050.3] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 2 of the boom sensor passthru - 19 position connec- tor [X050.2] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the platform control box passthru - 19 position connector [X160] and the boom sensor passthru - 19 position connector [X050] No Go to step 1.93.6 1.93.6 Is there CAN HI continuity between terminal 4 of the main boom angle sensor 2 (Left) con- nector [X049.4] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 5 of the main boom angle sensor 2 (Left) connector [X049.5] and terminal 24 of the ground mod- ule J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the main boom angle sensor 2 (Left) connector [X049] and the boom sensor passthru - 19 position connector [X050] No Go to step 1.93.7 1.93.7 Is there CAN HI continuity between terminal 4 of the main boom angle sensor 1 (Right) con- nector [X048.4] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 5 of the main boom angle sensor 1 connector [X048.5] and terminal 24 of the ground module J7 connec- tor [X007.24]? Yes Check the RED, BLACK, and Shield wires between the main boom angle sensor 1 (Right) connector [X048] and the boom sensor passthru - 19 position connector [X050] No Go to step 1.93.8 1.93.8 Is there CAN HI continuity between terminal 3 of the tower boom passthru - 19 position con- nector [X045.3] and terminal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between terminal 2 of the tower boom passthru - 19 position connector [X045.2] and terminal 24 of the ground mod- ule J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the tower boom passthru - 19 position connector [X045] and the boom sensor passthru - 19 position connector [X050] No Go to step 1.93.9 1.93.9 Is there CAN HI continuity between terminal 3 of the MTB pass thru - 19 position connector [X043.3] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 2 of the MTB pass thru - 19 position connector [X043.2] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the MTB pass thru - 19 position connec- tor [X043] and the tower boom passthru - 19 position connector [X045] No Go to step 1.93.10 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-75 1.93.10 Is there CAN HI continuity between terminal 3 of the MTB pass thru - 19 position connector [X043.3] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 2 of the MTB pass thru - 19 position connector [X043.2] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the MTB pass thru - 19 position connec- tor [X043] and the tower boom passthru - 19 position connector [X045] No Go to step 1.93.11 1.93.11 Is there CAN HI continuity between terminal A of the platform module side of the 3 way CAN connector in the main terminal box [X270.A] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal B of the platform module side of the 3 way CAN connector in the main terminal box [X270.B] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check the RED, BLACK, and Shield wires between the platform module side of the 3 way CAN connector in the main terminal box [X270] and the MTB pass thru - 19 position connector [X043] No Go to step 1.93.12 1.93.12 Is there CAN HI continuity between terminal A of the 3 way CAN connector [X014.A] and ter- minal 13 of the ground module J7 connector [X007.13] and CAN LO continuity between ter- minal B of the 3 way CAN connector [X269.B] and terminal 24 of the ground module J7 con- nector [X007.24]? Yes Repair/Replace the 3 way CAN connector in the main terminal box [X014 X269 X270] No Repair/Replace the harness between the 3 way CAN connector in the main terminal box [X014] and the ground module J7 connector [X007] 1.93.13 Is the MAIN ANGL1 CAN COMMUNICATIONS LOST fault active in the fault log? Yes Go to step 1.93.14 No Go to step 1.93.15 1.9 3. 14 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 4 of the main boom angle #1 connector [X048.4] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 5 of the main boom angle #1 connector [X048.5] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.15 No Check the RED, BLACK, and Shield wires be- tween the main boom angle #1 connector [X048] and the ground module J7 connector [X007]. See step 1.93.6 1.93.15 Is the MAIN ANGL2 CAN COMMUNICATIONS LOST fault active in the fault log? Yes Go to step 1.93.16 No Go to step 1.93.17 1.9 3. 16 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 4 of the main boom angle #2 connector [X049.4] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 5 of the main boom angle #2 connector [X049.5] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.17 No Check the RED, BLACK, and Shield wires be- tween the main boom angle #2 connector [X049] and the ground module J7 connector [X007]. See step 1.93.6 1.93.17 Does the BLAM software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ B.L.A. MODULE SOFTWARE:?? Yes Go to step 1.93.18 No Go to step 1.93.19 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-76 1250AJP 3128411 1.9 3. 18 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 6 of the BLAM module J1 connector [X086.6] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal 7 of the BLAM module J1 connector [X086.7] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.19 No Check the RED, BLACK, and Shield wires be- tween the BLAM module J1 connector [X086] and the ground module J7 connector [X007]. See step 1.46.8 of 1.46 BLAM CAN COMMUNI- CATIONS LOST on Pg. 48 1.93.19 Is the TOWER LIFT PVG VALVE COMMUNI- CATIONS fault active in the fault log? Yes Go to step 1.93.20 No Go to step 1.93.21 1.9 3. 20 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 4 of the tower lift PVG valve connector [X066.4] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal 1 of the tower lift PVG valve connector [X066.1] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.21 No Check the RED, BLACK, and Shield wires be- tween the tower lift PVG valve connector [X066] and the ground module J7 connector [X007]. See step 1.46.8 of 1.46 BLAM CAN COMMUNI- CATIONS LOST on Pg. 48 1.93.21 Is the TOWER TELESCOPE PVG VALVE COM- MUNICATIONS fault active in the fault log? Yes Go to step 1.93.22 No Go to step 1.93.23 1.9 3. 22 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 4 of the tower tele PVG valve connector [X067.4] and terminal 13 of the ground mod- ule J7 connector [X007.13] and CAN LO conti- nuity between terminal 1 of the tower tele PVG valve connector [X067.1] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.23 No Check the RED, BLACK, and Shield wires be- tween the tower tele PVG valve connector [X067] and the ground module J7 connector [X007]. See step 1.46.8 of 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 1.93.23 Is the MAIN LIFT PVG VALVE COMMUNICA- TIONS fault active in the fault log? Yes Go to step 1.93.24 No Go to step 1.93.25 1.9 3. 24 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 4 of the main lift PVG valve connector [X065.4] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal 1 of the main lift PVG valve connector [X065.1] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.25 No Check the RED, BLACK, and Shield wires be- tween the main lift PVG valve connector [X065] and the ground module J7 connector [X007]. See step 1.46.8 of 1.46 BLAM CAN COMMUNI- CATIONS LOST on Pg. 48 1.93.25 Is the ENGINE CONTROLLER CAN COMMU- NICATIONS LOST fault active in the fault log? Yes Go to step 1.93.26 No Go to step 1.93.27 1.9 3. 26 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 12 of the engine module connector [X240.12] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal 13 of the engine module connector [X240.13] and terminal 24 of the ground module J7 connector [X007.24]? Yes Go to step 1.93.27 No Check the RED, BLACK, and shield wires between the engine module connector [X240] and the ground module J7 connector [X007] 1.93.27 Does the Chassis software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ CHASSIS MODULE SOFTWARE:?? Yes Go to step 1.93.28 No Go to step 1.93.29 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-77 1.94 FOOTSWITCH SELECTED BEFORE START Footswitch selected before start. Notification that the footswitch was selected before starting the machine. Release the foot- switch before starting the machine. 1.95 FRONT LEFT WHEEL BLOCKED Front left wheel blocked. The control system is unable to steer the front left wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front left steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor. 1.9 3. 28 Fo r he lp wit h th is ty pe o f t est see 6.2 Continuity Mea- surement Over Long Dis- tances on Pg. 321 Is there CAN HI continuity between terminal 6 of the chassis module J1 connector [X229.6] and terminal 13 of the ground module J7 con- nector [X007.13] and CAN LO continuity between terminal 7 of the chassis module J1 connector [X229.7] and terminal 24 of the ground module J7 connector [X007.24]? Yes Check all CAN connections for moisture and bad connections No Check the RED, BLACK, and Shield wires between the chassis module J1 connector [X229], through the swivel [X083 X216] and the ground module J7 connector [X007] 1.93.29 Disconnect the platform module J7 connector [X167] Does the CAN resistance between pin 31 and pin 30 of the platform module J7 connector [X169.31.pin X169.30.pin] measure 120Ω? Yes Go to step 1.93.30 No Replace the platform module 1.93.30 Disconnect the chassis module J1 connector [X229] Does the CAN resistance between pin 6 and pin 10 of the chassis module J1 connector [X229.6.pin X229.10.pin] measure 120Ω? Yes Leave the chassis module disconnected and go to step 1.93.31 No Replace the chassis module 1.93.31 Disconnect the chassis module J1 connector [X229] Does the CAN resistance between socket 9 and socket 10 of the chassis module J1 con- nector [X229.9.soc X229.10.soc] measure 0Ω? Yes Go to step 1.93.32 No Repair/Replace the Chassis harness or CAN ter- mination jumper wire between socket 9 and socket 10 of the platform module J7 connector [X229.9.soc X229.10.soc] 1.93.32 Disconnect the Top Swivel connector [X083] Does the CAN resistance between socket 1 and socket 2 of the Top Swivel connector [X083.1.soc X083.2.soc] measure 120Ω? Yes Go to step 1.93.33 No Go to step 1.93.34 1.93.33 Disconnect the Bottom Swivel connector [X216] Does the CAN resistance between socket 1 and socket 2 of the Bottom Swivel connector [X216.1.soc X216.2.soc] measure 120Ω? Yes Repair the RED, BLACK, and/or Shield wires between the Bottom Swivel connector [X216] and the chassis module J1 connector [X229] No Replace the Swivel 1.93.34 Disconnect the BLAM mod- ule J1 connector [X086] Does the CAN resistance between socket 6 and socket 7 of the BLAM module J1 connec- tor [X087.6.soc X087.7.soc] measure 120Ω? Yes Repair the RED, BLACK, and/or Shield wires between the Top Swivel connector [X083] and the BLAM module J1 connector [X086] No Repair the RED, BLACK, and/or Shield wires between the ground module J7 connector [X007] and the BLAM module J1 connector [X086] Flash Code: 2-3 Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.95.1 Is the front left wheel kept from moving? Yes Free the wheel from any obstructions No Go to step 1.95.2 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-78 1250AJP 3128411 1.96 FRONT LEFT WHEEL SENSOR FAULT - CHECK MOUNTING Front left wheel sensor fault - check mounting. The control system detected the front left steer angle sensor value was below the mechanical minimum angle while the wheel was detected as blocked. The mechanical limitations on the maximum steer- ing angle depend on the axle extension. When fully retracted, the steering will be mechanically limited to about 25°. As the axle is extended, the mechanical limit will increase to about 45°, however the control system will maintain a 25° limit until the 1.95.2 Check the fault log for primary faults, LT FNT S TE ER LT S T B O R O C, LT F N T S TE ER LT S TG , LT FNT STEER RT STB OR OC, LT FNT STEER RT S TG, or an y st ee rin g angle sensor fault Yes If a primary fault is found, troubleshoot it before this fault No Go to step 1.95.3 1.95.3 Note that glow plug’s large power draw can aggravate existing problems with power distribution wiring and low battery power. Fre- quent starting can drain bat- tery when preheating. When engine coolant temperature is below 140°F (60°C), air temperature is below 59°F (15°C), and battery voltage is less than 11VDC before starting, does fault mainly occur within 30 seconds after starting engine? Yes Examine the battery condition and contacts within the Chassis power distribution wiring. Repair/replace as needed. No Go to step 1.95.4 1.95.4 Watch the angle sensor value on ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALI- BRATIONS ⇒ STEER ⇒ CALIBRATE? Press Enter to view raw value FRONT LT STEER VALUE = XX Do not press Enter. Steer completely left, pause, then completely right, pause. Does the value continuously and smoothly change while steering? Yes ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Go to step 1.95.5 No Repair/Replace the sensor and calibrate. 1.95.5 If the wheel will not steer in either direction, check the steer valve for a stuck spool. Yes Repair/Replace the valve No Go to step 1.95.6 1.95.6 Are there any bent, damaged, or seized steer- ing components? Yes Repair/Replace the component No Go to step 1.95.7 1.95.7 Ensure proper pressure with ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALIBRATIONS ⇒ STEER ⇒ FRONT LT STEER VALUE = XX. Install a 3000 psi gauge or higher on Front Steer Axle valve port MS1 and MS2 Adjust steer pressures on Front Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on g a u g e o n p o r t M S 1 . A dj u s t r e li e f n e x t t o p o r t t o 2000 psi ± 10% on port MS2. ESC out of cali- brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.95.8 1.95.8 Install a low pressure gauge (1000 psi) on main manifold MP1 and adjust to 450 psi ± 10% on load sense Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.95.9 1.95.9 Swap valve section with the one on the other side of machine. Does condition follow valve section to other side of machine? Yes Repair/replace valve section No Repair/replace front left steer cylinder and/or hoses. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-79 axle is fully extended, when the control system allows the full 45° of steering. The sensor may be mounted improperly or the sensor may be faulty. Note Pretest Instructions Test Result Corrective Action 1.96.1 Check faults Is the fault FRONT LEFT WHEEL BLOCKED present? Yes Troubleshoot that first No 1.96.2 1.96.2 Disconnect front left steer sensor [X203] Do the connectors have any loose, damaged, corroded contacts or moisture inside? Yes Repair as needed No Go to step 1.96.3 1.96.3 Is the front left wheel sensor X203] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sen- sor is properly tensioned. Yes Go to step 1.96.4 No Reinstall and recheck 1.96.4 Extend axles. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L FRONT WHEEL ANGL Monitor value while operating steering. Steer fully to the left, then fully to the right. Does the displayed angle ever climb above ±42.11? -OR- Does the value pause, jump or act errati- cally? Yes Repair/replace sensor and mounting as needed No Go to step 1.96.5 1.96.5 Swap front left wheel sensor [X203] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor fault? Yes Replace sensor originally at the front left wheel. No Go to step 1.96.6 1.96.6 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.96.7 1.96.7 Disconnect front left wheel sensor [X203] Turn on machine. Is there 5VDC between front left wheel sensor socket A [X203.A.soc] and socket C [X203.C.soc]? Yes Keep sensor disconnected. Go to step 1.96.8. No Go to step 1.96.10 1.96.8 Disconnect front left wheel sensor [X203] and chassis module J3 [X231] Is there continuity between front left wheel sensor socket B [X203.B.soc] and chassis module J3 socket 5 [X231.5.soc]? Yes Reprogram/replace ground module No Keep front left wheel sensor [X203] discon- nected. Go to step 1.96.9 1.96.9 Disconnect front left wheel sensor [X203] and front left steer passthru - 4 pos. [X202] Is there continuity between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin]? Yes Repair harness between front left steer passthru socket 2 [X202.2.soc] and chassis module J3 socket 5 [X231.5.soc] No Repair/replace harness between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin] 1.96.10 Disconnect front left steer passthru - 4 pos. [X202]. Turn on machine. Is there 5VDC between front left steer passthru socket 1 [X202.1.soc] and socket 3 [X202.3.soc]? Yes Repair/replace harness between front left steer passthru [X202] and front left wheel sensor [X203] No Go to step 1.96.11 1.96.11 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 4 [X231.4.pin] and pin 6 [X231.6.pin]? Yes Repair/Replace harness between front left steer passthru [X202] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-80 1250AJP 3128411 1.97 FRONT LEFT WHEEL SENSOR OUT OF RANGE HIGH Front left wheel sensor out of range high. The control system detected the front left steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.97.1 Is the front left steer angle sensor [X203] installed and connected properly? Yes Go to step 1.97.2 No Repair as needed 1.97.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L FRONT WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels? Yes Go to step 1.97.3 No Go to step 1.97.5 1.97.3 Swap front left wheel sensor [X203] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range high fault? Yes Replace sensor originally at the front left wheel. No Go to step 1.97.4 1.97.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.97.5 1.97.5 Disconnect front left wheel sensor [X203] Turn on machine. Is there 5VDC between front left wheel sensor socket A [X203.A.soc] and socket C [X203.C.soc]? Yes Keep sensor disconnected. Go to step 1.97.6. No Go to step 1.97.8 1.97.6 Disconnect front left wheel sensor [X203] and chassis module J3 [X231] Is there continuity between front left wheel sensor socket B [X203.B.soc] and chassis module J3 socket 5 [X231.5.soc]? Yes Reprogram/replace ground module No Keep front left wheel sensor [X203] discon- nected. Go to step 1.97.7 1.97.7 Disconnect front left wheel sensor [X203] and front left steer passthru - 4 pos. [X202] Is there continuity between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin]? Yes Repair harness between front left steer passthru socket 2 [X202.2.soc] and chassis module J3 socket 5 [X231.5.soc] No Repair/replace harness between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin] 1.97.8 Disconnect front left steer passthru - 4 pos. [X202]. Turn on machine. Is there 5VDC between front left steer passthru socket 1 [X202.1.soc] and socket 3 [X202.3.soc]? Yes Repair/replace harness between front left steer passthru [X202] and front left wheel sensor [X203] No Go to step 1.97.9 1.97.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 4 [X231.4.pin] and pin 6 [X231.6.pin]? Yes Repair/Replace harness between front left steer passthru [X202] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-81 1.98 FRONT LEFT WHEEL SENSOR OUT OF RANGE LOW Front left wheel sensor out of range low. The control system detected the front left steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.98.1 Is the front left steer angle sensor [X203] installed and connected properly? Yes Go to step 1.98.2 No Repair as needed 1.98.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L FRONT WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels? Yes Go to step 1.98.3 No Go to step 1.98.5 1.98.3 Swap front left wheel sensor [X203] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range low fault? Yes Replace sensor originally at the front left wheel. No Go to step 1.98.4 1.98.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.98.5 1.98.5 Disconnect front left wheel sensor [X203] Turn on machine. Is there 5VDC between front left wheel sensor socket A [X203.A.soc] and socket C [X203.C.soc]? Yes Keep sensor disconnected. Go to step 1.98.6. No Go to step 1.98.8 1.98.6 Disconnect front left wheel sensor [X203] and chassis module J3 [X231] Is there continuity between front left wheel sensor socket B [X203.B.soc] and chassis module J3 socket 5 [X231.5.soc]? Yes Reprogram/replace ground module No Keep front left wheel sensor [X203] discon- nected. Go to step 1.98.7 1.98.7 Disconnect front left wheel sensor [X203] and front left steer passthru - 4 pos. [X202] Is there continuity between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin]? Yes Repair harness between front left steer passthru socket 2 [X202.2.soc] and chassis module J3 socket 5 [X231.5.soc] No Repair/replace harness between front left wheel sensor socket B [X203.B.soc] and front left steer passthru pin 2 [X202.2.pin] 1.98.8 Disconnect front left steer passthru - 4 pos. [X202]. Turn on machine. Is there 5VDC between front left steer passthru socket 1 [X202.1.soc] and socket 3 [X202.3.soc]? Yes Repair/replace harness between front left steer passthru [X202] and front left wheel sensor [X203] No Go to step 1.98.9 1.98.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 4 [X231.4.pin] and pin 6 [X231.6.pin]? Yes Repair/Replace harness between front left steer passthru [X202] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-82 1250AJP 3128411 1.99 FRONT RIGHT WHEEL BLOCKED Front right wheel blocked. The control system is unable to steer the front right wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the front left steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem or a faulty angle sensor. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.99.1 Is the front right wheel kept from moving? Yes Free the wheel from any obstructions No Go to step 1.99.2 1.99.2 Check the fault log for primary faults, RT FNT STEER LT STB OR OC, RT FNT STEER LT STG, RT FNT STEER RT STB OR OC, RT FNT STEER RT STG, or any sensor value too high or too low Yes If a primary fault is found, troubleshoot it before this fault No Go to step 1.99.3 1.99.3 Note that glow plug’s large power draw can aggravate existing problems with power distribution wiring and low battery power. Fre- quent starting can drain bat- tery when preheating. When engine coolant temperature is below 140°F (60°C), air temperature is below 59°F (15°C), and battery voltage is less than 11VDC before starting, does fault mainly occur within 30 seconds after starting engine? Yes Examine the battery condition and contacts within the Chassis power distribution wiring. Repair/replace as needed. No Go to step 1.99.4 1.99.4 Watch the angle sensor value on ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALI- BRATIONS ⇒ STEER ⇒ CALIBRATE? Press Enter then right arrow to view FRONT RT STEER VALUE = XX Do not press Enter. Steer completely left, pause, then completely right, pause. Does the value continuously and smoothly change while steering? Yes ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Go to step 1.99.5 No Repair/Replace the sensor and calibrate. 1.99.5 If the wheel will not steer in either direction, check the steer valve for a stuck spool. Yes Repair/Replace the valve No Go to step 1.99.6 1.99.6 Are there any bent, damaged, or seized steer- ing components? Yes Repair/Replace the component No Go to step 1.99.7 1.99.7 Ensure proper pressure with ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALIBRATIONS ⇒ STEER ⇒ FRONT RT STEER VALUE = XX. Install a 3000 psi gauge or higher on Front Steer Axle valve port MS3 and MS4 Adjust steer pressures on Front Steer/Axle valve. Adjust proper cartridge for 2600 psi ± 10% on gauge on port MS3. Adjust proper cartridge for 2000 psi ± 10% on port MS4. ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.99.8 1.99.8 Install a low pressure gauge (1000 psi) on main manifold MP1 and adjust to 450 psi ± 10% on load sense Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.99.9 1.99.9 Swap valve section with the one on the other side of machine. Does condition follow valve section to other side of machine? Yes Repair/replace valve section No Repair/replace front left steer cylinder and/or hoses. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-83 1.100 FRONT RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING Front right wheel sensor fault - check mounting. The control system detected the front right steer angle sensor value was below the mechanical minimum angle while the wheel was detected as blocked. The sensor may be mounted improperly or the sensor may be faulty. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.100.1 Check faults Is the fault FRONT RIGHT WHEEL BLOCKED present? Yes Troubleshoot that first No Go to step 1.100.2 1.100.2 Disconnect front right steer sensor [X200] Do the connectors have any loose, damaged, corroded contacts or moisture inside? Yes Repair as needed No Go to step 1.100.3 1.100.3 Is the front right wheel sensor [X200] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sensor is properly tensioned. Yes Go to step 1.100.4 No Reinstall and recheck 1.100.4 Extend axles. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒R FRONT WHEEL ANGL Monitor value while operating steering. Steer fully to the left, then fully to the right. Does the displayed angle ever climb above ±42.11? -OR- Does the value pause, jump or act errati- cally? Yes Repair/replace sensor and mounting as needed No Go to step 1.100.5 1.100.5 Swap front right wheel sen- sor [X200] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor fault? Yes Replace sensor originally at the front right wheel. No Go to step 1.100.6 1.100.6 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.100.7 1.100.7 Disconnect front right wheel sensor [X200] Turn on machine. Is there 5VDC between front right wheel sensor socket A [X200.A.soc] and socket C [X200.C.soc]? Yes Keep sensor disconnected. Go to step 1.100.8. No Go to step 1.100.10 1.100.8 Disconnect front right wheel sensor [X200] and chassis module J3 [X231] Is there continuity between front left wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]? Yes Reprogram/replace ground module No Keep front right wheel sensor [X200] discon- nected. Go to step 1.100.9 1.100.9 Disconnect front right wheel sensor [X200] and front right steer passthru - 4 pos. [X201] Is there continuity between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]? Yes Repair harness between front right steer passthru socket 2 [X201.2.soc] and chassis module J3 socket 2 [X231.2.soc] No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin] 1.100.10 Disconnect front right steer passthru - 4 pos. [X201]. Turn on machine. Is there 5VDC between front right steer passthru socket 1 [X201.1.soc] and socket 3 [X201.3.soc]? Yes Repair/replace harness between front right steer passthru [X201] and front right wheel sensor [X200] No Go to step 1.100.11 1.100.11 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 1 [X231.1.pin] and pin 3 [X231.3.pin]? Yes Repair/Replace harness between front right steer passthru [X201] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-84 1250AJP 3128411 1.101 FRONT RIGHT WHEEL SENSOR OUT OF RANGE HIGH Front right wheel sensor out of range high. The control system detected the front right steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.101.1 Is the front right steer angle sensor [X200] installed and connected properly? Yes Go to step 1.101.2 No Repair as needed 1.101.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L FRONT WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the right front wheel angle more than 2° difference from other wheels? Yes Go to step 1.101.3 No Go to step 1.101.5 1.101.3 Swap front right wheel sen- sor [X200] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range high fault? Yes Replace sensor originally at the front right wheel. No Go to step 1.101.4 1.101.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.101.5 1.101.5 Disconnect front right wheel sensor [X200] Turn on machine. Is there 5VDC between front right wheel sensor socket A [X200.A.soc] and socket C [X200.C.soc]? Yes Keep sensor disconnected. Go to step 1.101.6. No Go to step 1.101.8 1.101.6 Disconnect front right wheel sensor [X200] and chassis module J3 [X231] Is there continuity between front right wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]? Yes Reprogram/replace ground module No Keep front right wheel sensor [X200] discon- nected. Go to step 1.101.7 1.101.7 Disconnect front right wheel sensor [X200] and front right steer passthru - 4 pos. [X201] Is there continuity between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]? Yes Repair harness between front right steer passthru socket 2 [X202.2.soc] and chassis module J3 socket 2 [X231.2.soc] No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin] 1.101.8 Disconnect front right steer passthru - 4 pos. [X201]. Turn on machine. Is there 5VDC between front right steer passthru socket 1 [X201.1.soc] and socket 3 [X201.3.soc]? Yes Repair/replace harness between front right steer passthru [X201] and front right wheel sensor [X201] No Go to step 1.101.9 1.101.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 1 [X231.1.pin] and pin 3 [X231.3.pin]? Yes Repair/Replace harness between front right steer passthru [X201] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-85 1.102 FRONT RIGHT WHEEL SENSOR OUT OF RANGE LOW Front right wheel sensor out of range low. The control system detected the front right steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection. 1.103 FSW FAULTY Footswitch faulty. The two footswitch inputs [X169.8 X007.15] have read the same state for more than one second. These signals should always be opposite. Check the footswitch and wiring for shorts or open circuits. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.102.1 Is the front right steer angle sensor [X200] installed and connected properly? Yes Go to step 1.102.2 No Repair as needed 1.102.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ R FRONT WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to R FRONT WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels? Yes Go to step 1.102.3 No Go to 1.102.5 1.102.3 Swap front right wheel sen- sor [X200] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range low fault? Yes Replace sensor originally at the front right wheel. No Go to step 1.102.4 1.102.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.102.5 1.102.5 Disconnect front right wheel sensor [X200] Turn on machine. Is there 5VDC between front right wheel sensor socket A [X200.A.soc] and socket C [X200.C.soc]? Yes Keep sensor disconnected. Go to step 1.102.6. No Go to step 1.102.8 1.102.6 Disconnect front right wheel sensor [X200] and chassis module J3 [X231] Is there continuity between front right wheel sensor socket B [X200.B.soc] and chassis module J3 socket 2 [X231.2.soc]? Yes Reprogram/replace ground module No Keep front right wheel sensor [X200] discon- nected. Go to step 1.102.7 1.102.7 Disconnect front right wheel sensor [X200] and front right steer passthru - 4 pos. [X201] Is there continuity between front right wheel sensor socket B [X200.B.soc] and front right steer passthru pin 2 [X201.2.pin]? Yes Repair harness between front right steer passthru socket 2 [X201.2.soc] and chassis module J3 socket 2 [X231.2.soc] No Repair/replace harness between front right wheel sensor socket B [X200.B.soc] and front left steer passthru pin 2 [X201.2.pin] 1.102.8 Disconnect front right steer passthru - 4 pos. [X201]. Turn on machine. Is there 5VDC between front right steer passthru socket 1 [X201.1.soc] and socket 3 [X202.3.soc]? Yes Repair/replace harness between front right steer passthru [X201] and front right wheel sensor [X200] No Go to step 1.102.9 1.102.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 1 [X231.1.pin] and pin 3 [X231.3.pin]? Yes Repair/Replace harness between front right steer passthru [X201] and chassis module J3 [X231] No Replace chassis module Flash Code: 2-1 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-86 1250AJP 3128411 1.104 FSW INTERLOCK TRIPPED Footswitch interlock tripped. Notification that the footswitch was closed for seven seconds with no function selected. Release the footswitch, close the footswitch again, then activate the desired function with seven seconds. 1.105 FSW OPEN Footswitch open. A drive or boom function has been selected but the platform footswitch[X152] is open. This could be caused by operator not depressing the footswitch before utilizing a machine control in the platform. Flash Code: 2-2 Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.105.1 Go to ANALYZER ⇒ DIAG- NOSTICS ⇒ SYSTEM ⇒ FOOTSWITCH INPUT PLAT- FORM Does the analyzer read OPEN? -AND- Does the analyzer read CLOSED with the footswitch depressed? Yes If fault is clear, this is normal operation. Otherwise reprogram/replace the ground module No Go to step 1.105.2 1.105.2 Locate platform passthru - 15 pos [X164]. Ground meter. See Grounding on Pg. 319 for details. Take the following reading by back- probing. See Backprobing on Pg. 319 for details. Turn on machine. Is there about 12 VDC on platform passthru terminal 8 [X164.8]? Yes Keep the test setup in same condition. Go to step 1.105.4 No Go to step 1.105.3 1.105.3 Ground meter. Take the fol- lowing measurement by backprobing. Turn on machine. Is there about 12 VDC on platform module J2 terminal 3 [X166.3]? Yes Repair/replace harness between platform mod- ule J2 terminal 3 [X166.3] and platform passthru terminal 8 [X164.8] No Replace platform module 1.105.4 Locate platform passthru [X164]. Ground meter. Take the following reading by backprobing. Turn on machine. Is there about 12 VDC on platform passthru terminal 7 [X164.7]? Yes Go to step 1.105.5 No Repair/replace footswitch 1.105.5 Disconnect platform passthru [X164] and plat- form module J7 [X169] Is there continuity between platform passthru pin 7 [X164.7.pin] and platform module J7 socket 8 [X169.8.soc]? Yes Go to step 1.105.6 No Repair/replace harness between platform passthru pin 7 [X164.7.pin] and platform module J7 socket 8 [X169.8.soc] 1.105.6 Locate platform control box passthru - 19 pos [X160]. Ground meter. Take the fol- lowing reading by backprob- ing. Turn on machine. Is there about 12 VDC on platform control box terminal 6 [X160.6]? Yes Repair/replace footswitch No Keep test setup in place. Go to step 1.105.7 1.105.7 Locate platform control box passthru - 19 pos [X160]. Ground meter. Take the fol- lowing reading by backprob- ing. Turn on machine. Depress footswitch. Is there about 12 VDC on platform control box terminal 6 [X160.6]? Yes Go to step 1.105.8 No Repair/replace footswitch 1.105.8 Disconnect ground module J7 [X007]. With a helper or an object, hold the foot- switch down. Ground the meter near the main terminal box. Take the following mea- surement by backprobing. Turn on machine. Is there about 12 VDC on ground module J7 terminal 15 [X007.15]? Yes Reprogram/replace platform module and/or ground module No Go to step 1.105.9 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-87 1.106 FUEL SENSOR SHORT TO BATTERY Fuel sensor short to battery. Indicates that the fuel sensor signal [X002.25] may be shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.107 FUEL SENSOR SHORT TO GROUND Fuel sensor short to ground. Indicates that the fuel sensor signal [X002.25] may be shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.108 FUNCTIONS LOCKED OUT - BLAM MODULE SOFTWARE VERSION IMPROPER Functions locked out - BLAM module software version improper. Notification that the functions have been locked out because the major version of the BLAM module software does not match the major version of the ground module software. Load the same version of software in the BLAM and ground modules. 1.109 FUNCTIONS LOCKED OUT - CHASSIS MODULE SOFTWARE VERSION IMPROPER Functions locked out - chassis module software version improper. Notification that the functions have been locked out because the major version of the chassis module software does not match the major version of the ground module software. Load the same version of software in the chassis and ground modules. 1.110 FUNCTIONS LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER Functions locked out - platform module software version improper. Notification that the functions have been locked out because the major version of the platform module software does not match the major version of the ground module soft- ware. Load the same version of software in the platform and ground modules. 1.111 GEN SET/WELDER OPEN CIRCUIT 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. 1.105.9 Disconnect ground module J7 [X007] and tower boom passthru - 19 pos [X045] Is there continuity between ground module J7 socket15 [X007.15.soc] to tower boom passthru socket 6 [X045.6.soc]? Yes Go to step 1.105.11 No Go to step 1.105.10 1.105.10 Disconnect ground module J7 [X007] and MTB passthru - 19 pos [X043] Is there continuity between ground module J7 socket 15 [X007.15.soc] and MTB passthru pin 6 [X043.6.pin]? Yes Repair/replace harness between MTB passthru socket 6 [X043.6.soc] and tower boom passthru socket 6 [X045.6.soc] No Repair/replace harness between ground module J7 socket 15 [X007.15.soc] and MTB passthru pin 6 [X043.6.pin] 1.105.11 Disconnect tower boom passthru - 19 pos [X045] and boom sensor passthru - 19 pos [X050] Is there continuity between tower boom passthru pin 6 [X045.6.pin] and boom sensor passthru pin 6 [X050.6.pin]? Yes Repair/replace harness between tower boom passthru socket 6 [X045.6.soc] and platform control box socket 6 [X160.6.soc] No Repair/replace harness between tower boom passthru pin 6 [X045.6.pin] and boom sensor passthru pin 6 [X050.6.pin] Flash Code: 4-3 Flash Code: 4-3 Flash Code: 2-5 Flash Code: 2-5 Flash Code: 2-5 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-88 1250AJP 3128411 1.112 GEN SET/WELDER SHORT TO BATTERY Generator set/welder short to battery. The output for the generator [X001.22] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.113 GEN SET/WELDER SHORT TO GROUND Generator set/welder short to ground. The output for the generator [X001.22] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.114 GENERATOR MOTION CUTOUT ACTIVE Generator motion cutout active. Notification that the generator motion cutout is configured and the machine is in platform mode with the generator active and a function was engaged. Do not engage functions while the generator is active or change the machine configuration. 1.115 GLOW PLUG OPEN CIRCUIT Glow plug open circuit. The glow plug / intake heater output [X001.12] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.116 GLOW PLUG SHORT TO BATTERY Glow plug short to battery. The glow plug / intake heater output [X001.12] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.117 GLOW PLUG SHORT TO GROUND Glow plug short to ground. The glow plug / intake heater output [X001.12] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.118 GROUND ALARM OPEN CIRCUIT Ground alarm open circuit. The ground alarm output [X002.27] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.119 GROUND ALARM 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 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. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 2-5 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-89 1.121 GROUND MODULE CONSTANT DATA UPDATE REQUIRED Ground module constant data update required. The ground module has old constant data that is not compatible with the current ground module software. The ground module constant data must be updated to a newer version. A power cycle is required. 1.122 GROUND MODULE FAILURE: HWFS CODE 1 Ground module failure: hardware failsafe code 1. The ground module V(low) FET has failed. A power cycle is required. 1.123 GROUND MODULE FAILURE:HIGH SIDE DRIVER CUTOUT FAULTY Ground module failure: high side driver cutout faulty. There is an internal problem with the ground module. 1.124 GROUND SENSOR REF VOLTAGE OUT OF RANGE Ground sensor reference voltage out of range. The ground module 7VDC reference voltage is out of acceptable range. This reference voltage is unused at this time. Possible causes of this fault include bad supply circuit in the module, or wires mis- takenly connected to the following pins on ground module J7 [X007]: J7-5, J7-16, J7-26, or J7-27. 1.125 HEAD TAIL LIGHT OPEN CIRCUIT Head tail light open circuit. The head and tail light output [X002.26] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.126 HEAD TAIL LIGHT SHORT TO BATTERY Head tail light short to battery. The head and tail light output [X002.26] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.121.1 Cycle power Does fault clear? Yes Troubleshooting complete No Reprogram/replace ground module Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.122.1 Cycle power Does fault clear? Yes Troubleshooting complete No Replace ground module Flash Code: 9-9 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.124.1 Are there any wires present in any of the fol- lowing terminals: ground module J7 terminal 5 [X007.5], terminal 16 [X007.16], terminal 26 [X007.26], or terminal 27 [X007.27]? Yes Make note of other faults then remove one wire. If any new faults appear or faults go away, use that information to find proper place for the wire. Repeat until all wires are placed correctly. No Go to step 1.124.2 1.124.2 Use backprobing for follow- ing measurement. See Backprobing on Pg. 319 for details. Is there 6.6VDC - 7.5VDC at the following ter- minals: ground module J7 terminal 5 [X007.5], terminal 16 [X007.16], terminal 26 [X007.26], or terminal 27 [X007.27]? Yes Reprogram/replace the ground module No Replace the ground module Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-90 1250AJP 3128411 1.127 HEAD TAIL LIGHT SHORT TO GROUND Head tail light short to ground. The head and tail light output [X002.26] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.128 HIGH ENGINE TEMP High engine temperature. This fault should only occur on machines configured with non-ECM engines. The engine tempera- ture is above 130°C. 1.129 HIGH RESOLUTION A2D FAILURE-INTERRUPT LOST High resolution analog to digital failure-interrupt lost. This fault should only occur with software versions prior to 7.0. There is an internal problem with the platform module. 1.130 HIGH RESOLUTION A2D FAILURE-REINIT LIMIT High resolution analog to digital failure - reinit limit. This fault should only occur with software versions prior to 7.0. There is an internal problem with the platform module. 1.131 HORN OPEN CIRCUIT Horn open circuit. The ground module horn output [X002.2] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.132 HORN SHORT TO BATTERY Horn short to battery. The ground module horn output [X002.2] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.133 HORN SHORT TO GROUND Horn short to ground. The ground module horn output [X002.2] is shorted to ground. See 1.378 COMMON STG PROCE- DURE on Pg. 175. 1.134 HOUR METER SHORT TO BATTERY 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 Hour meter short to ground. The hourmeter output [X004.12] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. Flash Code: 3-3 Flash Code: 4-3 Flash Code: 9-9 Flash Code: 9-9 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-91 1.136 INVALID ANGLE SENSOR #1 MODEL Invalid angle sensor #1 model. The tower angle sensor #1 (Right) is sending 10 bits of data instead of 11 bits of data. The sensor must be replaced. 1.137 INVALID ANGLE SENSOR #2 MODEL Invalid angle sensor #2 model. The tower angle sensor #2 (Left) is sending 10 bits of data instead of 11 bits of data. The sensor must be replaced. 1.138 JIB DOWN OPEN CIRCUIT Jib down open circuit. The jib down output [X169.26] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.139 JIB DOWN SHORT TO BATTERY Jib down short to battery. The jib down output [X169.26] is shorted to battery. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.140 JIB DOWN SHORT TO GROUND 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 Jib left open circuit. The jib swing left output [X169.28] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.136.1 Read fault log. Is INVALID ANGLE SENSOR #2 MODEL in log? Yes Replace both sensors. No Go to step 1.136.2 1.136.2 Plug the right tower boom angle sensor connector [X099] into the tower angle sensor #2 and the left tower boom angle sensor connec- tor [X100] into tower angle sensor #1 Is the message INVALID ANGLE SENSOR #2 MODEL gone and the message INVALID ANGLE SENSOR #2 MODEL in the fault stack? Yes Replace sensor #1 No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.137.1 Read fault log. Is INVALID ANGLE SENSOR #1 MODEL in log? Yes Replace both sensors. No Go to step 1.137.2 1.137.2 Plug the left tower boom angle sensor connector [X100] into the tower angle sensor #1 and the right tower boom angle sensor connector [X099] into tower angle sensor #2 Is the message INVALID ANGLE SENSOR #1 MODEL gone and the message INVALID ANGLE SENSOR #2 MODEL in the fault stack? Yes Replace sensor #2 No Reprogram/replace BLAM Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-92 1250AJP 3128411 1.142 JIB LEFT SHORT TO BATTERY Jib left short to battery. The jib swing left output [X169.28] is shorted to battery. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.143 JIB LEFT SHORT TO GROUND Jib left short to ground. The jib swing left output [X169.28] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.144 JIB RIGHT OPEN CIRCUIT Jib right open circuit. The jib swing right output [X169.27] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.145 JIB RIGHT SHORT TO BATTERY Jib right short to battery. The jib swing right output [X169.27] is shorted to battery. See 1.377 COMMON STB OR OC PRO- CEDURE on Pg. 174. 1.146 JIB RIGHT SHORT TO GROUND Jib right short to ground. The jib swing right output [X169.27] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.147 JIB SWING PREVENTED - IN 1000# MODE Jib swing prevented - in 1000 pound mode. Notification that the machine is in 1000# mode and the jib swing function was engaged. Swinging the jib is not allowed in 1000# mode. 1.148 JIB UP OPEN CIRCUIT Jib up open circuit. The jib up output [X169.25] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.149 JIB UP SHORT TO BATTERY Jib up short to battery. The jib up output [X169.25] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.150 JIB UP SHORT TO GROUND Jib up short to ground. The jib up output [X169.25] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.151 KEYSWITCH FAULTY Keyswitch faulty. Both platform [X007.2] and ground [X007.3] modes are selected simultaneously. This could be due to a bad keyswitch [X030], wiring, or bad diodes at the power down relay [X011]. Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 2-5 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 2-1 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-93 1.152 L/S JOY. CENTER TAP BAD Lift/Swing joystick center tap bad. The lift and/or swing joystick center tap inputs [X167.2 X167.5] are not reading the correct voltage, +/- 10% from the reference voltage middle point. 1.153 L/S JOY. OUT OF RANGE HIGH Lift/Swing joystick out of range high. The lift and/or swing joystick input [X167.3 X167.4] is above the working voltage range. 1.154 L/S JOY. OUT OF RANGE LOW Lift/Swing joystick out of range low. The lift and/or swing joystick input [X167.3 X167.4] is below the working voltage range. 1.155 LEFT FORWARD DRIVE PUMP OPEN CIRCUIT Left forward drive pump open circuit. The left forward drive pump output [X090.1] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.156 LEFT FORWARD DRIVE PUMP SHORT TO BATTERY Left forward drive pump short to battery. The left forward drive pump output [X090.1] is shorted to battery. See 1.377 COM- MON STB OR OC PROCEDURE on Pg. 174. 1.157 LEFT FORWARD DRIVE PUMP SHORT TO GROUND Left forward drive pump short to ground. The left forward drive pump output [X090.1] is shorted to ground. See 1.378 COM- MON STG PROCEDURE on Pg. 175. 1.158 LEFT REVERSE DRIVE PUMP OPEN CIRCUIT Left reverse drive pump open circuit. The left reverse drive pump output [X090.2] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.159 LEFT REVERSE DRIVE PUMP SHORT TO BATTERY Left reverse drive pump short to battery. The left reverse drive pump output [X090.2] is shorted to battery. See 1.377 COM- MON STB OR OC PROCEDURE on Pg. 174. 1.160 LEFT REVERSE DRIVE PUMP SHORT TO GROUND Left reverse drive pump short to ground. The left reverse drive pump output [X090.2] is shorted to ground. See 1.378 COM- MON STG PROCEDURE on Pg. 175. Flash Code: 2-3 Flash Code: 2-3 Flash Code: 2-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-94 1250AJP 3128411 1.161 LENGTH SENSOR REF VOLTAGE HIGH Length sensor reference voltage high. Supply voltage for the boom length sensors is above 5.5VDC. A power cycle is required. 1.162 LENGTH SENSOR REF VOLTAGE LOW Length sensor reference voltage low. Supply voltage for the boom length sensors is below 4.5VDC. A power cycle is required. 1.163 LIFT UP & TELE OUT PREVENTED - PLATFORM OVERLOADED 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. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.161.1 Cycle power Did fault clear? Yes Troubleshooting complete No Go to step 1.161.2 1.161.2 Disconnect all on-board and off-board optional power systems such as 110VAC and welders to keep them from energizing Did fault clear? Yes Isolate system by turing on each optional power system individually and checking fault. Then look for shorts between length sensor harness and faulty system harness. No Go to step 1.161.3 1.161.3 Disconnect BLAM J3 [X088]. Turn on machine. Is there between 5.5 VDC and 4.5 VDC mea- sured between all of the following points on BLAM J3: pin 1 [X088.1.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]? Yes Go to step 1.161.4 No Replace BLAM 1.161.4 Disconnect BLAM J3 [X088] and battery + termi- nal [X116]. Is there a short between the battery (+) termi- nal [X116] and any of the following: BLAM J3 socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]? Yes Troubleshoot BLAM J3 [X088] harness wire(s) with short No Reprogram/replace BLAM Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.162.1 Cycle power Did fault clear? Yes Troubleshooting complete No Go to step 1.161.3 1.162.2 Disconnect BLAM J3 [X088]. Turn on machine. Is there between 5.5 VDC and 4.5 VDC mea- sured between the following points on BLAM J3: pin 1 [X088.1.pin] to pin 3 [X088.3.pin]; pin 4 [X088.4.pin] to pin 6 [X088.6.pin]; pin 7 [X088.7.pin] to pin 9 [X088.9.pin]; pin 10 [X088.10.pin] to pin 12 [X088.12.pin]? Yes Go to step 1.161.4 No Replace BLAM 1.162.3 Disconnect BLAM J3 [X088]. Ground meter. See Grounding on Pg. 319 for details. Is there a short between ground and any of the following: BLAM J3 socket 1 [X088.1.soc], socket 4 [X088.4.soc], socket 7 [X088.7.soc], or socket 10 [X088.10.soc]? Yes Troubleshoot BLAM J3 [X088] harness wire(s) with short No Reprogram/replace BLAM Flash Code: 8-2 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-95 1.164 LIFT/SWING LOCKED - JOYSTICK MOVED BEFORE FOOTSWITCH Lift/swing locked - joystick moved before footswitch. Notification that the platform lift and/or swing joystick was not centered before the footswitch was closed. Lift and swing will be prevented. Close the footswitch before selecting any function or moving the joystick. This could also be due to faulty joystick not returning to center. 1.165 LOAD PIN FORCE TOO LOW OVER MAIN ANGLE CHANGE Load pin force too low over main angle change. Reported when the tower is above elevation and the force magnitude remains less than 5000 pounds for more than 45° net main lift movement and the main boom angle referenced to gravity is not between +15° and -15°. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.166 LOAD PIN FORCE TOO LOW OVER MAIN LENGTH TRANSITION Load pin force too low over main length transition. Reported when the tower is above elevation and the force magnitude remains less than 5000 pounds during main boom length transitions from C to A. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.167 LOAD PIN FORCE TOO LOW OVER TOWER ANGLE CHANGE Load pin force too low over tower angle change. Reported when the force magnitude remains less than 5000 pounds for more than 45° of net tower lift cylinder angle movement slower then 0.5 seconds. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.168 LOAD PIN FORCE VALUES NOT CHANGING Load pin force values not changing. Reported when tower lift is being commanded for at least 2 seconds, not lifting down below elevation and the load pin is not reporting changes in both the x and y force values of at least 100 pounds per 3° of tower lift cylinder angle change slower then 0.5 seconds. Except, if the greater tower inclinometer angle is between 15° and 50°, the y force check shall be ignored. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.169 LOAD PIN HORIZONTAL FORCE OUT OF RANGE Load pin horizontal force out of range. The X component of the load pin has been out of range, greater than +125,000 lbs or less than -125,000 lbs, for at least 1.0 second. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.170 LOAD PIN NOT CALIBRATED Load pin not calibrated. The tower lift cylinder load pin is not calibrated, or the calibration data has been removed because of a fault condition. Calibration could be invalidated by a rotated pin and cause this fault. Flash Code: 2-3 Flash Code: 8-5 Flash Code: 8-5 Flash Code: 8-5 Flash Code: 8-5 Flash Code: 8-5 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.170.1 Check faults Is CYLINDER LOAD PIN CAN COMMUNICA- TIONS LOST or LOAD PIN/TOWER LIFT CYL- INDER ANGLE DISAGREEMENT fault present? Yes Troubleshoot that fault first No Go to step 1.170.2 1.170.2 Is the load pin mounting hardware in good condition and secure, including the keeper pin and keeper pin bolt? Yes Go to step 1.170.3 No Repair as needed SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-96 1250AJP 3128411 1.171 LOAD PIN SENSOR FAULT Load pin sensor fault. This fault is reported when any load pin fault(s) other than the over range and under range faults are detected. Check the fault log for the specific fault: 1.165 LOAD PIN FORCE TOO LOW OVER MAIN ANGLE CHANGE on Pg. 95, 1.166 LOAD PIN FORCE TOO LOW OVER MAIN LENGTH TRANSITION on Pg. 95, 1.167 LOAD PIN FORCE TOO LOW OVER TOWER ANGLE CHANGE on Pg. 95, 1.168 LOAD PIN FORCE VALUES NOT CHANGING on Pg. 95, 1.170 LOAD PIN NOT CALIBRATED on Pg. 95, or 1.173 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT on Pg. 96. Refer to the troubleshooting for that fault. 1.172 LOAD PIN VERTICAL FORCE OUT OF RANGE Load pin vertical force out of range. The Y component of the load pin has been out of range, greater than +125,000 lbs or less than -125,000 lbs, for at least 1.0 second. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting. See 5.8 Boom Sensor Calibration on Pg. 309. 1.173 LOAD PIN/TOWER LIFT CYLINDER ANGLE DISAGREEMENT Load pin/tower lift cylinder angle disagreement. This fault is reported if the force magnitude is greater than 50000 lbs and the angle of the load pin force vector and the tower lift cylinder angle sensor reading disagree by 20° for 5 seconds. This fault also invalidates the current load pin calibration. There may be a problem with the load pin or its mounting or the tower cylin- der angle sensor or its wiring. Check for other load pin or cylinder angle faults in the fault log. See 5.8 Boom Sensor Calibra- tion on Pg. 309. 1.174 LOAD SENSOR NOT CALIBRATED Load sensor not calibrated. The load sense system (LSS) sensors require calibration. See the calibration procedure in the LSS manual for more details. 1.175 LOAD SENSOR READING UNDER WEIGHT Load sensor reading under weight. The load sensor is reading 20% or more under the calibrated zero point. This fault may occur if the basket is resting on the ground. Not reported during the 2 second power-up. 1.176 LOW OIL PRESSURE 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. 1.170.3 Perform 5.8 Boom Sensor Calibration on Pg. 309. Does it calibrate successfully? Yes Troubleshooting complete No Troubleshoot in accordance with calibration fault. Flash Code: 8-5 Flash Code: 8-5 Flash Code: 8-5 Flash Code: 8-2 Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.175.1 Safely ensure basket is not resting on anything. Does fault clear? Yes Troubleshooting complete No Go to step 1.175.2 1.175.2 Perform 5.8 Boom Sensor Calibration on Pg. 309. Does calibration complete successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault Flash Code: 4-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-97 1.177 LT FNT STEER LT STB OR OC Left front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chas- sis module left front steer left valve output [X233.4]. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.177.1 Connect analyzer and read fault log Does fault log shows other steer STB or OC faults. Yes Go to step 1.177.2 No Go to step 1.177.4 1.177.2 Disconnect chassis module J1 [X230] and battery nega- tive terminal [X117] Check for an open between chassis module J1 [X229] socket 4 [X229.4.soc] and the nega- tive battery terminal Yes Leave negative battery terminal disconnected. Go to step 1.177.8 No Go to step 1.177.3 1.177.3 Is there a bad connection at chassis module J5 connector [X233] or the left front steer left solenoid connector [X210]? Yes Re-connect connector No Go to step 1.177.4 1.177.4 Disconnect the left front steer left solenoid connector [X210]. Measure the sole- noid resistance. Is the solenoid resistance about 4.9 Ω? Yes Go to step 1.177.5 No Replace solenoid 1.177.5 Disconnect the left front steer left solenoid connector [X210] and chassis module J5 [X233]. Are all contacts good and is there continuity between left front steer left solenoid connector yellow wire and Chassis module J5 socket 4 [X233.4.soc]? Yes Leave solenoid connector and chassis module J5 disconnected. Go to step 1.177.6 No Repair/Replace harness 1.177.6 Disconnect positive battery terminal [X116], left front steer left solenoid [X210] and chassis module J5 [X233]. Is there a short between left front steer left solenoid [X210] YELLOW 9-1 wire and posi- tive battery terminal [X116]? Yes Repair/Replace harness No Go to step 1.177.7 1.177.7 Check black ground wire between terminal 5 of the bottom (chassis) swivel connector [X216.5.soc] and the left front steer left sole- noid connector [X210] Are there loose, bent, broken or corroded wires or contacts or moisture in the connec- tors? Yes Repair/Replace harness No Repair/Replace connector as needed. 1.177.8 Disconnect Upper Swivel connector [X083] and nega- tive battery terminal [X117]. Is there an open between socket 5 [X083.5.soc] and battery negative terminal [X117]? Yes Leave negative battery terminal disconnected. Go to step 1.177.10 No Leave negative battery terminal disconnected. Go to step 1.177.9 1.177.9 Disconnect negative battery terminal [X117] and Lower Swivel connector [X216]. Is there an open between negative battery ter- minal [X117] and Lower Swivel connector pin 5 [X216.5.pin]? Yes Replace swivel No Repair/replace harness to Chassis module. 1.177.10 Disconnect negative battery terminal [X117] Is there an open between Auxiliary Power Pump negative terminal and the negative bat- tery terminal [X117]. Yes Repair/replace harness between Auxiliary Power Pump negative terminal and negative battery ter- minal. No Repair/replace harness between Upper Swivel connector and Auxiliary Power Pump negative connector. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-98 1250AJP 3128411 1.178 LT FNT STEER LT STG Left front steer left short to ground. The control system detected a short to ground on the chassis module left front steer left valve output [X233.4]. 1.179 LT FNT STEER RT STB OR OC Left front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module left front steer left valve output [X233.3]. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.178.1 Disconnect the left front steer left solenoid connector [X210]. Is the solenoid about 4.9 Ω? Yes Leave the left front steer left solenoid [X210]dis- connected. Go to step 1.178.2 No Replace the solenoid 1.178.2 Disconnect chassis module connector J5 [X233] left front steer left solenoid con- nector [X210] and the Lower Swivel connector [X216] Is there a short between YELLOW 9-1 on the left front steer left solenoid connector [X210] and the Lower Swivel connector socket 5 [X216.5.soc]? Yes Repair/Replace harness No Check for loose, bent or corroded contacts or moisture in the connectors. Repair/Replace con- nector as needed. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.179.1 Connect analyzer and read fault log Does fault log shows other steer STB or OC faults. Yes Go to step 1.179.2 No Go to step 1.179.4 1.179.2 Disconnect chassis module J1 [X230] and battery nega- tive terminal [X117] Check for an open between chassis module J1 [X229] socket 4 [X229.4.soc] and the nega- tive battery terminal Yes Leave negative battery terminal disconnected. Go to step 1.179.8 No Go to step 1.179.3 1.179.3 Is there a bad connection at chassis module J5 connector [X233] or the left front steer right solenoid connector [X207]? Yes Re-connect connector No Go to step 1.179.4 1.179.4 Disconnect the left front steer right solenoid connec- tor [X207]. Measure the solenoid resistance. Is the solenoid resistance about 4.9 Ω? Yes Go to step 1.179.5 No Replace solenoid 1.179.5 Disconnect the left front steer right solenoid connec- tor [X207] and chassis module J5 [X233]. Are all contacts good and is there continuity between left front steer right solenoid connec- tor [X207] YELLOW wire and Chassis module J5 socket 4 [X233.4.soc]? Yes Leave solenoid connector and chassis module J5 disconnected. Go to step 1.179.6 No Repair/Replace harness 1.179.6 Disconnect positive battery terminal [X116], left front steer right solenoid [X207] and chassis module J5 [X233]. Is there a short between left front steer right solenoid [X207] YELLOW 9-1 wire and posi- tive battery terminal [X116]? Yes Repair/Replace harness No Go to step 1.179.7 1.179.7 Check black ground wire between terminal 5 of the bottom swivel connector [X216.5.soc] and the left front steer right solenoid connector [X207] Are there loose, bent, broken or corroded wires or contacts or moisture in the connec- tors? Yes Repair/Replace harness No Repair/Replace connector as needed. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-99 1.180 LT FNT STEER RT STG Left front steer right short to ground. The control system detected a short to ground on the chassis module left front steer right valve output [X233.3]. 1.181 LT REAR STEER LT STB OR OC Left rear steer left short to battery or open circuit. the control system detected a short to battery or open circuit on the chassis module left rear steer left valve output [X233.8]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.182 LT REAR STEER LT STG Left rear steer left short to ground. The control system detected a short to ground on the chassis module left rear steer left valve output [X233.8]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.183 LT REAR STEER RT STB OR OC 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. 1.179.8 Disconnect Upper Swivel connector [X083] and nega- tive battery terminal [X117]. Is there an open between socket 5 [X083.5.soc] and battery negative terminal [X117]? Yes Leave negative battery terminal disconnected. Go to step 1.179.10 No Leave negative battery terminal disconnected. Go to step 1.179.9 1.179.9 Disconnect negative battery terminal [X117] and Lower Swivel connector [X216]. Is there an open between negative battery ter- minal [X117] and Lower Swivel connector pin 5 [X216.5.pin]? Yes Replace swivel No Repair/replace harness to Chassis module. 1.179.10 Disconnect negative battery terminal [X117] Is there an open between Auxiliary Power Pump negative terminal and the negative bat- tery terminal [X117]. Yes Repair/replace harness between Auxiliary Power Pump negative terminal and negative battery ter- minal. No Repair/replace harness between Upper Swivel connector and Auxiliary Power Pump negative connector. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.180.1 Disconnect the left front steer right solenoid connec- tor [X207] Is the solenoid about 4.9 Ω? Yes Leave the left front steer right solenoid connector [X207] disconnected. Go to step No Replace solenoid 1.180.2 Disconnect the left front steer right solenoid connec- tor [X207], the chassis module J5 connector and the and the Lower Swivel connector [X216]. Is there a short between the left front steer right solenoid connector [X207] YELLOW 10- 1 wire and the Lower Swivel connector socket 5 [X216.5.soc]? Yes Repair/Replace harness No Check for loose, bent or corroded contacts or moisture in the connectors. Repair/Replace con- nector as needed. Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-100 1250AJP 3128411 1.184 LT REAR STEER RT STG Left rear steer right short to ground. The control system detected a short to ground on the chassis module left rear steer right valve output [X233.7]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.185 MAIN ANGL1 CAN COMMUNICATIONS LOST Main angle sensor 1 (right) CAN bus communications lost. The system cannot communicate with main angle sensor #1 (right). This may be due to wiring problems between main angle sensor #1 and ground module. Flash Code: 8-6 Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.185.1 Is the EXCESSIVE CAN BUS COMMUNICA- TION ERRORS fault active in the fault log? Yes Troubleshoot 1.93 EXCESSIVE CAN BUS COM- MUNICATION ERRORS on Pg. 73 first No Go to step 1.185.2 1.185.2 Does the BLAM software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ B.L.A. MODULE SOFTWARE: ?? Yes See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Go to step 1.185.3 1.185.3 Disconnect the main boom angle sensor 1 (right) con- nector [X048]. Turn on the machine Does the voltage between socket 2 and socket 3 of the main boom angle sensor 1 (right) con- nector [X048.2.soc X048.3.soc] measure more than 7 VDC? Yes Go to step 1.185.4 No Go to step 1.185.5 1.185.4 Ground meter and take the following measurement by backprobing. See Ground- ing and Backprobing on Pg. 319 for details. Use meter’s min/max feature or observe meter while turning on machine. Set up to measure voltage at ground module J2 terminal 10 [X002.10]. Turn on the machine. Does volt- age peak at 12 VDC? (This may need to be repeated several times to see voltage spike.) Yes Go to step 1.185.8 No Replace ground module 1.185.5 Disconnect the tower boom passthru - 21 position con- nector [X044]. Turn on the machine Does the voltage between socket J and socket E of the tower boom passthru connector [X044.J.soc X044.E.soc] measure more than 7 VDC? Yes Repair the RED/BLK and/or BLACK wires between the tower boom passthru connector [X044.J X044.E] and the main boom angle sen- sor 1 (right) connector [X048.2 X048.3] No Go to step 1.185.6 1.185.6 Disconnect the MTB pass thru - 21 position connector [X042]. Turn on the machine Does the voltage between pin J and pin E of the MTB pass thru connector [X042.J.pin X042.E.pin] measure more than 7 VDC? Yes Repair the RED/BLK and/or BLACK wires between the MTB pass thru connector [X042.J X042.E] and the tower boom passthru connector [X044.J X044.E] No Go to step 1.185.7 1.185.7 Ground meter and take the following measurement by backprobing. Turn on the machine. Does the voltage on terminal 10 of the ground module J2 connector [X002.10] measure more than 7VDC? Yes Repair the WHT/RED 57-10 wire between the MTB pass thru connector [X042.J] and the ground module J2 connector [X002.10] and/or the BLACK wire between the MTB pass thru con- nector and ground [X042.E] No Replace the ground module 1.185.8 Disconnect the main boom angle sensor 1 (right) con- nector [X048] Is there 60 Ω between main boom angle sen- sor 1 socket 4 and socket 5 [X048.4.soc X048.5.soc]? Yes Go to step 1.185.9 No See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-101 1.186 MAIN ANGL1 INVALID ANGLE Main angle sensor 1 (right) invalid angle. The right main boom angle sensor #1 is reading an angle less than 3° or greater than 177°. The control system is able to communicate with this sensor over the CAN bus, but the value returned from the sensor is outside of the allowed range. When fully stowed, the screen ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 1 ANGLE A/D: XXXX should show between 5 and 25. 1.185.9 Disconnect CAN 3 way - to platform [X270], CAN 3 way - to BLAM [X269] and ground module J7 Is there CAN HI continuity between CAN 3 way - to platform pin A [X270.A.pin] and socket 13 of the ground module J7 connector [X007.13.soc] also CAN LO continuity between CAN 3 way - to platform pin B [X270.B.pin] and socket 24 of the ground module J7 connector [X007.24.soc]? -AND- Is it open between CAN 3 way - to platform pin A [X270.A.pin] and CAN 3 way - to platform pin C [X270.C.pin]? -AND- Is it open between CAN 3 way - to platform pin B [X270.B.pin] and CAN 3 way - to platform pin C [X270.C.pin] Yes Go to step 1.185.10 No Repair/replace the RED, BLACK, and Shield wires, harness and/or CAN 3-way between the CAN 3 way - to platform pin A,B,C [X270.A.pin X270.B.pin X270.C.pin] and the ground module J7 connector [X007.13 X007.24 X007.18]. See step 1.93.14 of 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS on Pg. 73 1.185.10 Swap the right main boom angle sensor 1 with t he left main boom angle sensor 2, plugging the right harness plug [X048] into the left sen- sor [X049] Does this fault still occur? Yes Check the connections at the right main boom angle sensor 1 connector [X048] and see 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS on Pg. 73 No Repair/replace the sensor that was originally installed on the right [X048]. Re-calibration of the boom sensors will be necessary Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.186.1 Examine fault log Does the fault EXCESSIVE CAN BUS COMMU- NICATION ERRORS appear? Yes Trouble shot that fault first. No Go to step 1.186.2 1.186.2 Examine the coupling, clamps, rotary sensor, mounting blocks and the cross bolt in the main boom pivot pin for loose hardware or damage. Is there any? See Figure 2-5. Boom Area Con- nectors on Pg. 185 for details. Yes Repair as needed No Go to step 1.186.3 1.186.3 Retract and lower boom completely Is the timing mark for the sensor in the proper place? See Figure 2-5. Boom Area Connectors on Pg. 185 for details. Yes Go to step 1.186.4 No Re-align mark on shaft to the mark on the face near "R", for right side, on label. It is on the side opposite of the connector. See Figure 2-5. Boom Area Connectors on Pg. 185. Go to step 1.186.5. 1.186.4 Remove sensor coupler Is it between 2.6 and 2.8 inches? Yes Go to step 1.186.5 No Replace any coupler outside the given length 1.186.5 Perform boom calibration. Does it pass? Yes Troubleshooting complete No Go to step 1.186.6 1.186.6 Manually adjust angle sensor that failed cali- bration previous in step. Perform boom cali- bration. Does it pass? Yes Troubleshooting complete No Repeat this step. If a sensor cannot be adjusted or continually falls outside of calibration replace the sensor. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-102 1250AJP 3128411 1.187 MAIN ANGL2 CAN COMMUNICATIONS LOST Main angle sensor 2 CAN communications lost. The system cannot communicate with main angle sensor #2 (Left). This may be due to wiring problems between main angle sensor #2 and ground module. Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.187.1 Is the EXCESSIVE CAN BUS COMMUNICA- TION ERRORS fault active in the fault log? Yes Troubleshoot 1.93 EXCESSIVE CAN BUS COM- MUNICATION ERRORS on Pg. 73 first No Go to step 1.187.2 1.187.2 Does the BLAM software version show "??" in ANALYZER ⇒ DIAGNOSTICS ⇒ VERSIONS ⇒ B.L.A. MODULE SOFTWARE: ?? Yes See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Go to step 1.187.3 1.187.3 Disconnect the main boom angle sensor 2 (left) con- nector [X049]. Turn on the machine Does the voltage between socket 2 and socket 3 of the main boom angle sensor 2 (left) con- nector [X049.2.soc X049.3.soc] measure more than 7 VDC? Yes Go to step 1.187.4 No Go to step 1.187.5 1.187.4 Ground meter and take the following measurement by backprobing. See Ground- ing and Backprobing on Pg. 319 for details. Use meter’s min/max feature or observe meter while turning on machine. Set up to measure voltage at ground module J2 terminal 21 [X002.21]. Turn on the machine. Does volt- age peak at 12 VDC? (This may need to be repeated several times to see voltage spike.) Yes Go to step 1.187.8 No Replace ground module 1.187.5 Disconnect the tower boom passthru - 21 position con- nector [X044]. Turn on the machine Does the voltage between socket K and socket E of the tower boom passthru connector [X044.K.soc X044.E.soc] measure more than 7 VDC? Yes Repair the RED/BLK and/or BLACK wires between the tower boom passthru connector [X044.K X044.E] and the main boom angle sen- sor 2 (left) connector [X049.2 X049.3] No Go to step 1.187.6 1.187.6 Disconnect the MTB pass thru - 21 position connector [X042]. Turn on the machine Does the voltage between pin K and pin E of the MTB pass thru connector [X042.K.pin X042.E.pin] measure more than 7 VDC? Yes Repair the RED/BLK and/or BLACK wires between the MTB pass thru connector [X042.K X042.E] and the tower boom passthru connector [X044.K X044.E] No Go to step 1.187.7 1.187.7 Ground meter and take the following measurement by backprobing. Turn on the machine. Does the voltage on terminal 21 of the ground module J2 connector [X002.21] measure more than 7VDC? Yes Repair the WHT/RED 57-11 wire between the MTB pass thru connector [X042.K] and the ground module J2 connector [X002.21] and/or the BLACK wire between the MTB pass thru con- nector and ground [X042.E] No Replace the ground module 1.187.8 Disconnect the main boom angle sensor 2 (left) con- nector [X049] Is there 60 Ω between main boom angle sen- sor 2 socket 4 and socket 5 [X049.4.soc X049.5.soc]? Yes Go to step 1.187.9 No See 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-103 1.188 MAIN ANGL2 INVALID ANGLE Main angle sensor 2 (left) invalid angle. The left main boom angle sensor #2 is reading an angle less than 3° or greater than 177°. The control system is able to communicate with this sensor over the CAN bus, but the value returned from the sensor is outside of the allowed range. When fully stowed, the screen ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 2 ANGLE A/D: XXXX should show between 5 and 25. 1.187.9 Disconnect CAN 3 way - to platform [X270], CAN 3 way - to BLAM [X269] and ground module J7 Is there CAN HI continuity between CAN 3 way - to platform pin A [X270.A.pin] and socket 13 of the ground module J7 connector [X007.13.soc] also CAN LO continuity between CAN 3 way - to platform pin B [X270.B.pin] and socket 24 of the ground module J7 connector [X007.24.soc]? -AND- Is it open between CAN 3 way - to platform pin A [X270.A.pin] and CAN 3 way - to platform pin C [X270.C.pin]? -AND- Is it open between CAN 3 way - to platform pin B [X270.B.pin] and CAN 3 way - to platform pin C [X270.C.pin] Yes Go to step 1.187.10 No Repair/replace the RED, BLACK, and Shield wires, harness and/or CAN 3-way between the CAN 3 way - to platform pin A,B,C [X270.A.pin X270.B.pin X270.C.pin] and the ground module J7 connector [X007.13 X007.24 X007.18]. See step 1.93.14 of 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS on Pg. 73 1.187.10 Swap the right main boom angle sensor 1 with t he left main boom angle sensor 2, plugging the right harness plug [X048] into the left sen- sor [X049] Does this fault still occur? Yes Check the connections at the right main boom angle sensor 2 connector [X049] and see 1.93 EXCESSIVE CAN BUS COMMUNICATION ERRORS on Pg. 73 No Repair/replace the sensor that was originally installed on the left [X049]. Re-calibration of the boom sensors will be necessary Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.188.1 Examine fault log Does the fault EXCESSIVE CAN BUS COMMU- NICATION ERRORS appear? Yes Trouble shot that fault first. No Go to step 1.188.2 1.188.2 Examine the coupling, clamps, rotary sensor, mounting blocks and the cross bolt in the main boom pivot pin for loose hardware or damage. Is there any? See Figure 2-5. Boom Area Con- nectors on Pg. 185 for details. Yes Repair as needed No Go to step 1.188.3 1.188.3 Retract and lower boom completely Is the timing mark for the sensor in the proper place? See Figure 2-5. Boom Area Connectors on Pg. 185 for details. Yes Go to step 1.188.4 No Re-align mark on shaft to the mark on the face near "L", for left side, on label. It is on the same side as the connector. See Figure 2-5. Boom Area Connectors on Pg. 185. Go to step 1.186.5. 1.188.4 Remove sensor coupler Is it between 2.6 and 2.8 inches? Yes Go to step 1.188.5 No Replace any coupler outside the given length 1.188.5 Perform boom calibration. Does it pass? Yes Troubleshooting complete No Go to step 1.188.6 1.188.6 Manually adjust angle sensor that failed cali- bration previous in step. Perform boom cali- bration. Does it pass? Yes Troubleshooting complete No Repeat this step. If a sensor cannot be adjusted or continually falls outside of calibration replace sensor. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-104 1250AJP 3128411 1.189 MAIN ANGLE MOVEMENT WITHOUT CMD Main angle movement without command. The control system detected at least 2.5° of main angle movement in 0.5 seconds, while the main lift command was not being operated. This is most likely caused by a problem with the hydraulics. 1.190 MAIN ANGLE SENSOR DISAGREEMENT Main angle sensor disagreement. The BLAM detected a difference between the left and right main boom angle sensors. A difference greater than 3.0° was held for at least 2.0 seconds. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.189.1 Read fault log. Does the main lift PVG valve have one or more faults in the stack? Yes Repair main lift PVG valve in accordance with fault(s) in stack. No Go to step 1.189.2 1.189.2 Open main boom to maximum angle and return to fully closed. Does fault still occur? Yes Go to step 1.189.3 No Air was in cylinder. Troubleshooting complete. 1.189.3 Read fault log. Are there any 3-3 faults regarding main lift pilot pressure? Yes Repair machine in accordance with those fault(s) first. No Go to step 1.189.4 1.189.4 Are there visible hydraulic leaks? Yes Repair/replace as needed No Go to step 1.189.5 1.189.5 Are the main lift cylinder hydraulic connec- tions good? Yes Go to step 1.189.6 No Repair as needed 1.189.6 Swap cartridge from main lift enable valve [X082] to tower tele enable valve [X081]. Does this fault still occur? No Repair/replace main lift enable valve [X082] Yes Go to step 1.189.7 1.189.7 Rig wires from battery + and ground to reach the main lift enable valve [X082]. Raise main boom. Do not allow stripped area of wires to touch each other. Disconnect main lift enable connector [X082]. Energize main lift enable valve [X082] by touching wires from battery (+) and (-) wires to solenoid contacts. Does main boom move when solenoid is energized? Yes Keep machine in same condition. Go to step 1.189.8. No Repair/replace main cylinder 1.189.8 Ensure machine is set up the same as in step 1.189.7. Disconnect hose on port 2 from main lift enable valve [X082]. Disconnect main lift enable connector [X082]. Energize main lift enable valve [X082] by touching wires from battery (+) and (-) wires to solenoid contacts. Is there fluid flowing out of the hose? Yes Repair/replace main cylinder holding valve No Repack main cylinder piston seal Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.190.1 Check the fault log for primary faults, MAIN ANGL1 CAN COMMUNICATIONS LOST, MAIN ANGL1 INVALID ANGLE, MAIN ANGL2 CAN COMMUNICATIONS LOST, or MAIN ANGL2 INVALID ANGLE. Are any primary faults present? Yes Troubleshoot the primary fault before continuing No Go to step 1.190.2 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-105 1.191 MAIN ANGLE SENSOR NOT DETECTING ANGLE CHANGE Main angle sensor not detecting angle change. The control system did not detect at least 0.3° of movement within 6 sec- onds while the main lift function was commanded. This fault is not detected for main lift Up within 2° of the maximum angle or main lift Down within 2° of the minimum angle. This fault is most likely caused by a mechanical or hydraulic failure, prevent- ing the machine from responding. 1.190.2 Examine the couplings, rotary sensors, and mounting blocks. Is there any loose hardware or boom side to side movement on the pivot pin in excess of 0.375"? Yes Tighten any loose hardware and use thrust wash- ers to limit excess movement on the pin. For more information, see Figure 2-5. Boom Area Connec- tors on Pg. 185. No Go to step 1.190.3 1.190.3 In the transport position, are the left and right main angle sensors rotated to align with their corresponding timing marks? Yes Go to step 1.190.4 No Re-align. For more information, see Figure 2-5. Boom Area Connectors on Pg. 185. 1.190.4 Is each coupler’s length is between 2.6 and 2.8 inches? Yes Go to step 1.190.5 No Replace couplers. For more information, see Fig- ure 2-5. Boom Area Connectors on Pg. 185. 1.190.5 Perform a boom sensor cali- bration, see 5.8 Boom Sen- sor Calibration on Pg. 309 Did the calibration complete successfully? Yes Cycle power to clear the fault No Do not cycle power and Go to step 1.190.6 1.190.6 If power was cycled, go to step 1.190.5 Did the calibration fail with a MAIN ANGL1 FAULT or MAINANGL2 FAULT? (Note that ter- minal 10 of the ground module J2 connector [X002.10] must power the RIGHT main angle sensor and terminal 21 of the ground module J2 connector [X002.21] must power the LEFT main angle sensor.) Yes Adjust sensor #1 to read between 5° and 25° in ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOS- TICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 1 RAW ANGLE: XXX.X and sensor #2 between 155° and 175° in ANALYZER ⇒ ACCESS LEVEL 1 ⇒ DIAG- NOSTICS ⇒ BOOM SENSORS ⇒ MAIN LIFT 2 RAW ANGLE: XXX.X. Go to step 1.190.5. If a sen- sor cannot be adjusted into range or continually fails calibration, replace that main angle sensor and recalibrate No Follow the calibration instructions to calibrate the boom sensors Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.191.1 Read active faults Are there any faults with the main dump valve [X074], PVG enable valve [X086], or main lift enable valve [X082] Yes Troubleshoot them first. No Go to step 1.191.2 1.191.2 Are the main angle sensors securely mounted to the machine? Also does the pin attached to the main rotary angle sensors [X048] and [X049] have the cross bolt and nut secure? (See Figure 2-5. Boom Area Connectors on Pg. 185 for details.) Yes Go to step 1.191.3 No Repair as needed 1.191.3 View fault log Are any engine faults indicated? Yes Troubleshoot them first No Go to step 1.191.4 1.191.4 Are there any leaks between function pump, PVG main lift valve, and main lift cylinder? Yes Repair/replace as needed No Go to step 1.191.5 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-106 1250AJP 3128411 1.191.5 Install a high pressure gauge on the LS port on main valve block next to main lift PVG valve. turn on machine. Extend axles. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SER- VICE MODE ⇒ SET PRES- SURES ⇒ Enter code 14605 ⇒ SET PRES- SURES: MAIN LIFT ⇒ WARNING: MOVEMENT POSSIBLE. WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Observe pressure while operating main lift UP and main lift DOWN. Are both pressures between 2755psi and 3088 psi? If analyzer read "SERVICE FAILED" repair/replace main lift enable valve [X082] and recheck for fault. Yes Turn off machine. Go to step 1.191.6 No Record which pressure is not within range. Keep machine in same condition. Go to step 1.191.11 1.191.6 ANALYZER ⇒ DIAGNOS- TICS ⇒ SYSTEM ⇒ MAIN LIFT PILOT PRES.SW. Does analyzer indicate "CL" while operating main lift? Yes Repair/replace main lift cylinder No Go to step 1.191.7 1.191.7 Disconnect main lift enable valve solenoid [X082]. Mea- sure resistance across the solenoid. Does the solenoid measure approximately 8.7Ω? Yes Go to step 1.191.8 No Replace solenoid 1.191.8 Disconnect main lift enable valve solenoid [X082]. Ground meter. See Section 6. Multimeter Basics on Pg. 319 for details. Is there continuity between the black wire in the connector for the main lift enable valve solenoid [X082] and ground? Yes Go to step 1.191.9 No Repair/replace harness between main lift enable valve solenoid [X082] and ground including ground bus connector [X009]. 1.191.9 Disconnect main lift enable valve solenoid [X082]. Start machine. Fully stow boom, center turntable between rear wheels. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SER- VICE MODE ⇒ MAIN LIFT. Enter code 55050. WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage across main lift enable valve solenoid [X082] while operating boom lift. Only lift a few feet or operate it several sec- onds. Does the meter read about 12VDC? Yes Repair/replace main lift enable valve [X082]. Look for stuck spool, etc. No Keep machine in the same condition. Go to step 1.191.10 1.191.10 Ensure machine is in same condition as step 1.191.9 Pretest Instructions. Fully stow boom. Ground meter. Take the following measure- ment by backprobing. (See Section 6. Multimeter Basics on Pg. 319 for details.) WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage at ground control module J2 pin 23 [X002.23.pin] while operating boom lift. Only lift a few feet. Does the meter read about 12VDC? Yes Repair/replace harness between ground control module and main lift enable valve [X082]. No Reprogram/replace ground control module 1.191.11 Keep machine in same con- dition as step 1.191.5. Ensure the adjusting screw, just below the LS port, is turned fully clockwise. Are pressures between 2755psi and 3088 psi? Yes Turn off machine. Troubleshooting complete No Turn off machine. Go to step 1.191.12 1.191.12 Install a low pressure gauge to the "MP1" port on the main valve block. Start engine. The pressure can be adjusted using the adjustment screw under the low pressure relief adjustment cover nut on the function pump. Does the gauge read 450 psi or adjust to it? Yes Go to step 1.191.13 No Repair/replace function pump/low pressure relief Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-107 1.191.13 Swap cartridge in main dump valve [X074] with the one in the PVG enable valve[X068]. Does fault clear? Yes Replace cartridge originally in the main dump valve [X074] No Go to step 1.191.14 1.191.14 Disconnect main dump solenoid [X074]. Measure resistance across the solenoid. Does the solenoid measure approximately 7.2Ω? Yes Go to step 1.191.15 No Replace solenoid 1.191.15 Disconnect main dump solenoid [X074]. Ground meter. Is there continuity between the black wire in the connector for the main lift enable valve solenoid [X082] and ground? Yes Go to step 1.191.16 No Repair/replace harness to ground including MTB ground bus connector [X009] 1.191.16 Disconnect main dump solenoid [X074]. Start machine. Fully stow boom, center turntable between rear wheels. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SER- VICE MODE ⇒ MAIN LIFT. Enter code 55050. WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage across main dump solenoid [X074] while operating boom lift. Only lift a few feet or operate it several seconds. Does the meter read about 12 VDC? Yes Go to step 1.191.18 No Keep machine in same condition. Go to step 1.191.17 1.191.17 Ensure machine is in same condition as step 1.191.16 Pretest Instructions. Fully stow boom. Ground meter. Take the following measure- ment by backprobing. (See Section 6. Multimeter Basics on Pg. 319 for details.) WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage at ground control module J2 pin 13 [X002.13.pin] while operating boom lift. Only lift a few feet. Does the meter read about 12VDC? Yes Turn off machine. Repair/replace harness between ground control module J2 [X002] and main dump solenoid [X074] No Turn off machine. Replace ground control mod- ule. 1.191.18 Install a high pressure gauge at the "MP1" port on the main valve block. Remove coil for the main tele propor- tional valve [X072], but leave harness connected. Start engine. While activating main tele, observe pressure. Adjust pressure with the adjustment screw under the high pressure relief adjustment cover nut on the function pump. Does the pressure read or adjust to 3400 psi? Yes Keep machine in same condition. Go to step 1.191.19. No Repair/replace function pump or high pressure relief circuit on the function pump 1.191.19 Turn off machine. Discon- nect PVG enable [X068]. Measure resistance of PVG enable solenoid. Is resistance approximately 4.7 Ω? Yes Keep machine in same condition. Go to step 1.191.20. No Replace PVG enable solenoid [X068] 1.191.20 Swap cartridge from PVG enable valve [[X068] with the one in the main dump valve [X074] Does fault clear? Yes Replace PVG enable valve [X068] cartridge No Go to step 1.191.21 1.191.21 Turn off machine. Discon- nect PVG enable [X068]. Ground meter. (See Section 6. Multimeter Basics on Pg. 319 for details.) Is there continuity between the black wire in the connector of the PVG enable solenoid [X068] and ground? Yes Go to step 1.191.22 No Repair/replace harness to ground including MTB ground bus connector [X009] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-108 1250AJP 3128411 1.192 MAIN BOOM TRN ANGLE SW/SENSOR DISAGREEMENT Main boom transport angle switch and sensor disagreement. The main boom transport angle switch changed states outside of the +4/-8° tolerance window to the stored calibration point. This could indicate a problem with the main boom transport switch, the main boom angle sensor, or the calibration stored transport switch point. 1.191.22 Disconnect PVG enable [X068]. Start machine. Fully stow boom, center turntable between rear wheels. ANA- LYZER ⇒ ACCESS LEVEL 1 ⇒ SERVICE MODE ⇒ MAIN LIFT. Enter code 55050. WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage across PVG enable [X068] while operating boom lift momentarily. Only lift a few feet. Does the meter read about 12VDC? Yes Replace any main lift PVG valve [X074] shock valve that was not in specified range as recorded in step 1.191.5 No Keep machine in same condition. Go to step 1.191.23. 1.191.23 Ensure machine is in same condition as step 1.191.22 Pretest Instructions. Return boom to fully stowed posi- tion. Ground meter. Take the following readings by back- probing the contact in ques- tion. (See Section 6. Multimeter Basics on Pg. 319 for details.) WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. Measure voltage at ground control module J2 pin 31 [X002.31.pin] by backprobing while operating boom lift. Only lift a few feet. Does the meter read about 12VDC? Yes Turn off machine. Repair/replace harness between ground control module J2 [X002] and PVG enable [X068] No Turn off machine. Replace ground control mod- ule. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.192.1 Are the following faults present? MAIN TRANSPORT ANGLE SWITCH FAILED, main angle sensor faults Yes Troubleshoot those first No Go to step 1.192.2 1.192.2 Examine the coupling, rotary sensor, mount- ing blocks and the cross bolt in the main boom pivot pin for loose hardware or damage. See Figure 2-5. Boom Area Connectors on Pg. 185 for details. Is there any? Yes Repair as needed No Go to step 1.192.3 1.192.3 Retract and lower boom completely Is the timing mark for the sensor in the proper place? See Figure 2-5. Boom Area Connectors on Pg. 185 for details. Yes Go to step 1.192.4 No Re-align mark on shaft to the mark on the face near "R", for right side, on label. It is on the side opposite of the connector. Go to step 1.192.8 1.192.4 Remove sensor coupler Is it between 2.6 and 2.8 inches? Yes Go to step 1.192.5 No Replace any coupler outside the given length 1.192.5 Retract and lower boom completely Is there 0.075+/-0.030 inches clearance between the sensor mount and the main boom pivot doubler? Yes Go to step 1.192.6 No Adjust sensor mount to achieve proper distance. 1.192.6 Retract and lower boom completely Remove main transport angle switch [X051] mount. is the sensor flush +/- 0.015 inches with bottom of counterbore in sensor mount? Yes Do not re-install sensor mount. Go to step 1.192.7. No Adjust sensor to achieve proper distance. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-109 1.193 MAIN DUMP OPEN CIRCUIT Main dump open circuit. The main dump output [X002.13] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.194 MAIN DUMP SHORT TO BATTERY Main dump short to battery. The main dump output [X002.13] is shorted to battery. See 1.377 COMMON STB OR OC PRO- CEDURE on Pg. 174. 1.195 MAIN DUMP SHORT TO GROUND Main dump short to ground. The main dump output [X002.13] is shorted to ground. See 1.378 COMMON STG PROCE- DURE on Pg. 175. 1.196 MAIN ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED Main envelope encroached - hydraulics suspended. Notification that the system has detected a main envelope violation and suspended hydraulics to prevent further encroachment. Use the APU to telescope in or lift down inside the envelope. See 1.91 ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 73. 1.197 MAIN IN OPEN CIRCUIT Main telescope in open circuit. The main telescope in output [X002.4] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.198 MAIN IN SHORT TO BATTERY Main telescope in short to battery. The main telescope in output [X002.4] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.199 MAIN IN SHORT TO GROUND Main telescope in short to ground. The main telescope in output [X002.4] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.200 MAIN LIFT APU OPEN CIRCUIT 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. 1.192.7 Remove main transport angle switch [X051] mount and reconnect harness. Hold the mount and sensor to the metal sur- face of the boom. In ANALYZER ⇒ DIAGNOS- TICS ⇒ BOOM SWITCHES ⇒ MAIN LIFT ANGLE SWITCH, check the switch states. Is the NC Switch CLOSED and NO switch OPEN? Yes Go to step 1.192.8 No Go to 1.229 MAIN TRN ANGLE SW FAILED on Pg. 116 1.192.8 Perform boom calibration. Did calibration pass? Yes Troubleshooting complete No Repair according to calibration failure Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 0-0 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-110 1250AJP 3128411 1.201 MAIN LIFT APU SHORT TO BATTERY Main lift auxiliary power unit pilot valve short to battery. The main lift pilot valve output [X002.1] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.202 MAIN LIFT APU SHORT TO GROUND Main lift auxiliary power unit pilot valve short to ground. The main lift pilot valve output [X002.1] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.203 MAIN LIFT ENABLE OPEN CIRCUIT Main lift enable open circuit. The main lift enable valve output [X002.23] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.204 MAIN LIFT ENABLE SHORT TO BATTERY Main lift enable short to battery. The main lift enable valve output [X002.23] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.205 MAIN LIFT ENABLE SHORT TO GROUND Main lift enable short to ground. The main lift enable valve output [X002.23] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.206 MAIN LIFT PILOT PRESSURE FAILURE Main lift pilot pressure failure. Notification that the main lift pilot valve output [X002.1] is not engaged, but the main lift pilot pressure switch input [X001.21] is indicating pressure. The hydraulics will be suspended while this fault is active. This could be a problem with the main lift pilot pressure switch [X079], the switch wiring, wrong hydraulic connections, or residual pres- sure in the lift circuit. With the key on, engine off, check for the fault 1.207 MAIN LIFT PILOT PRESSURE SWITCH FAILURE on Pg. 110. 1.207 MAIN LIFT PILOT PRESSURE SWITCH FAILURE Main lift pilot pressure switch failure. Notification that the machine is not running and the machine is not in auxiliary power mode, but the main lift pilot pressure switch input [X001.21] is indicating pressure. This is likely due to a problem with the main lift pilot pressure switch [X079] or its wiring. 1.208 MAIN LIFT PVG VALVE COMMAND IMPROPER Main lift PVG valve command improper. Main lift PVG valve received an incorrect instruction from the CAN bus. This could be due to a CAN bus problem or a ground module problem. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.208.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.208.2 1.208.2 Cycle power. Does problem clear? Yes Troubleshooting complete No Reprogram/replace ground module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-111 1.209 MAIN LIFT PVG VALVE COMMUNICATIONS Main lift PVG valve communications. The main lift PVG valve is required to send it's status message every 100mS. If the sta- tus message from the PVG valve is not received within 500mS then this fault is issued. 1.210 MAIN LIFT PVG VALVE HIGH VOLTAGE Main lift PVG valve high voltage. Voltage powering the main lift PVG valve exceeded 32 VDC. Restore proper system voltage to clear fault. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.209.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.209.2 1.209.2 Disconnect main lift PVG - 4 pos. [X065]. Turn on machine. Measure voltage between main lift PVG con- nector socket 2 [X065.2.soc] and socket 3 [X065.3.soc]. Is it about 12 VDC? Yes Go to step 1.209.4 No Go to step 1.209.3 1.209.3 Disconnect main lift PVG - 4 pos. [X065] and ground module J2 [X002] Is there continuity between main lift PVG - 4 pos. socket 2 [X065.2.soc] and ground mod- ule J2 socket 11 [X002.11.soc]? Yes Repair harness between main lift PVG - 4 pos. [X065] and battery ground No Repair harness between main lift PVG - 4 pos. [X065] and ground module J2 1.209.4 Turn off machine. Discon- nect main lift PVG - 4 pos. [X065]. Measure resistance between main lift PVG socket 1 [X065.1.soc] and socket 4 [X065.4.soc]. Is it about 60Ω? Yes Replace main lift PVG valve [X065] actuator No Go to step 1.209.5 1.209.5 Turn off machine. Discon- nect main lift PVG - 4 pos. [X065] and BLAM J4 [X089]. Is there continuity between main lift PVG socket 1 [X065.1.soc] and BLAM J4 socket 4 [X089.4.soc]? AND Is there continuity between main lift PVG socket 4 [X065.4.soc] and BLAM J4 socket 3 [X089.3.soc]? Yes Replace main lift PVG valve [X065] actuator or see 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Repair harness between main lift PVG - 4 pos. [X065] and BLAM J4 [X089] Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.210.1 Ensure all off-board power connections, such as 110VAC, are disconnected. Ensure all on-board power systems are turned off, such as generators, welders, etc. Turn on machine and start engine. Is battery voltage about 12 VDC? -AND- Does charging and 12VDC electrical power generation sys- tem appear to be working properly? Yes Go to step 1.210.2 No Repair 12 VDC charging and electrical power generation system. 1.210.2 Turn off machine. Ensure all off-board power connec- tions, such as 110VAC, are disconnected. Ensure all on- board power systems are turned off, such as genera- tors, welders, etc. Turn off machine. Disconnect main lift PVG valve [X065] Are there any shorts between main lift PVG valve socket 2 [X065.2.soc] or socket 3 [X065.3.soc] and wiring for off-board power sources such as 110VAC, or on-board power sources such as welder or generator outputs, etc.? Note, main lift PVG valve socket 3 [X065.3.soc] to ground continuity is OK. Be sure to check for intermittent problems. Yes Repair shorts as needed No Transient condition likely set fault. If fault keeps occurring, go to step 1.210.3. 1.210.3 Measure voltage on the sec- ond main lift PVG valve con- nector[X259] using a spare harness exposing terminals 2 [X259.2] and 3 [X259.3], or use insulated alligator clips to those terminals. Observe 12VDC system voltage at the valve over an extended time under various operating conditions, for example, during engine start. See Min/Max on Pg. 319 for details. Is it per- forming properly? Yes Replace main lift PVG valve actuator [X065] No Repair as needed SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-112 1250AJP 3128411 1.211 MAIN LIFT PVG VALVE INTERNAL FAULT Main lift PVG valve internal fault. Hardware or software inside the main lift PVG valve caused an error. There are no service- able parts that cause this problem. 1.212 MAIN LIFT PVG VALVE LOCATION IMPROPER Main lift PVG valve location improper. Main lift PVG valve parameters entered into the incorrect valve. This could be due to a calibration or wiring problem. The valve harnesses have one wire in it that is labeled with a number. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.213 MAIN LIFT PVG VALVE LOW VOLTAGE Main lift PVG valve low voltage. Voltage powering the main lift PVG valve fell below about 10 VDC. Increase system voltage above 11 VDC to clear fault. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.211.1 Read faults Are there any 6-6 communication faults? Yes Troubleshoot those first No Go to step 1.211.2 1.211.2 Cycle machine power. Keep power off at least 20 seconds. Does fault still occur? Yes Replace main lift PVG valve actuator [X065] No Troubleshooting complete Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.212.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start off, then turn on, in order, LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Connect harnesses to the correct PVG valve according to wires listed above in description. Then calibrate boom valves and recheck. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.213.1 Are either of the faults MAIN LIFT PVG VALVE COMMUNICATIONS or BLAM CAN COMMU- NICATIONS LOST present? Yes Troubleshoot them first. No Go to step 1.213.2 1.213.2 Are the battery and battery connections good? Yes Go to step 1.213.3 No Repair/replace as needed 1.213.3 Turn on machine and start engine. Is battery voltage about 12 VDC and does system appear to be working properly? Yes Go to step 1.213.4 No Repair charging and 12 VDC electrical power generation system. 1.213.4 Disconnect main lift PVG valve connector [X065]. Turn on machine. Is there about 12 VDC between main lift PVG valve socket 2 [X065.2.soc] and socket 3 [X065.3.soc]? Yes Transient caused condition. If it occurs again troubleshoot charging and 12 VDC electrical power generation system. No Go to step 1.213.5 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-113 1.214 MAIN LIFT PVG VALVE OBSTRUCTED Main lift PVG valve obstructed. Main lift PVG valve spool is not free to move completely. This could be from contamination inside the valve or a blocked filter. 1.213.5 Take the following measure- ment by backprobing. See Backprobing on Pg. 319 for details. Turn on machine after setting up measure- ment. Is there about 12VDC between ground module J2 terminal 11 [X002.11] and any terminal on the MTB ground bus -12 pos. [X009]? Yes Repair/replace harness from main lift PVG valve [X065] to ground J2 [X002] and the MTB ground bus -12 pos. [X009]. No Go to step 1.213.6 1.213.6 Take the following measure- ment by backprobing. Turn on machine after setting up measurement. Is there about 12VDC between ground module J2 terminal 11 [X002.11] and ground module J8 terminal 1? Yes Repair harness between ground module J2 [X002] and MTB ground bus -12 pos. [X009] No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.214.1 Is there dirt in the hydraulic module part of the valve, especially around the spool? Yes Clean and repair as needed. Go to step 1.214.2 No Go to step 1.214.2 1.214.2 Is the filter at the main lift PVG valve [X065] pilot oil inlet blocked? Yes Clean and repair as needed. Go to step 1.214.3. No Go to step 1.214.3 1.214.3 Is the fault clear? Yes Go to step 1.214.5 No Go to step 1.214.4 1.214.4 Mark to identify the main lift PVG valve actuator [X065] using string, tape, etc. Swap it with an actuator that doesn’t have a fault. Perform 5.4 Calibrating Boom Valves on Pg. 296. Does fault move to new location of actua- tor? Yes Replace PVG valve actuator that was initially on the main lift PVG valve [X065]. Go to step 1.214.5 No Replace hydraulic module of main lift PVG valve [X065]. Go to step 1.214.5 1.214.5 Does the return filter have contamination in fil- ter media or housing? Yes Go to step 1.214.6 No Troubleshooting complete 1.214.6 Inspect all 4 hydraulic filters and housings and replace all 4 filters: output of function pump, platform filter (If filter is not external to platform valve it must be updated.), return filter and charge filter (for drive pump). Take note of filters/housings that have contamination. Cycle boom from fully lowered and retracted to fully extended and then back. Test hydraulic fluid. Does it test bad, appear cloudy, appear dark, smell burned or is otherwise abnormal? -OR- Was there any contamination in the filters or housings? Yes Replace all hydraulic fluid Go to step 1.214.7 No Go to step 1.214.7 1.214.7 Do machine hydraulics function properly? Yes Troubleshooting complete No Replace hydraulic components that are not func- tioning properly. Focus first on components upstream of any filters/housings with contamina- tion. Calibrate if necessary. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-114 1250AJP 3128411 1.215 MAIN LIFT PVG VALVE PARAMETERS INCORRECT Main lift PVG valve parameters incorrect. Programing parameters contained in the main lift PVG valve do not match those stored in the ground module. The valve needs to be calibrated. 1.216 MAIN LIFT PVG VALVE SENT UNRECOGNIZED FAULT Main lift PVG valve sent unrecognized fault. An error code sent by the main lift PVG valve was not recognized by the control system. 1.217 MAIN LIFT PVG VALVE SETUP FAULT Main lift PVG valve setup fault. Main lift PVG valve received programing parameter values that are not allowed. PVG setup is done over the CAN bus by the ground module. 1.218 MAIN LIFT PVG VALVE STUCK EXTENDED Main lift PVG valve stuck extended. The main lift PVG valve spool has moved out further than intended. Follow same proce- dure as 1.214 MAIN LIFT PVG VALVE OBSTRUCTED on Pg. 113. 1.219 MAIN LIFT PVG VALVE STUCK NEUTRAL Main lift PVG valve stuck neutral. The main lift PVG valve spool stuck outside of neutral position. This could be cause by dirt in the valve body or a PVG valve software issue. Follow same procedure as 1.214 MAIN LIFT PVG VALVE OBSTRUCTED on Pg. 113. 1.220 MAIN LIFT PVG VALVE STUCK RETRACTED 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. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.215.1 Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Did it pass calibration? Yes Troubleshooting complete. If fault is recurring replace main lift PVG valve [X065] actuator. No Replace main lift PVG valve [X065] actuator Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.216.1 Cycle machine power Operate main lift. Does fault occur again? Yes Replace main lift PVG valve [X065] actuator No Troubleshooting complete. If fault is recurring, replace main lift PVG valve [X065] actuator. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.217.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot other fault(s) first No Go to step 1.217.2 1.217.2 Perform 5.4 Calibrating Boom Valves on Pg. 296 Does the valve calibrate successfully? -AND- Does fault clear? Yes Troubleshooting complete. If fault is recurring, reprogram/replace ground module. No Reprogram/replace ground module Flash Code: 4-5 Flash Code: 4-5 Flash Code: 4-5 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-115 1.221 MAIN LIFT PVG VALVE TIMEOUT Main lift PVG valve timeout. Position instructions were not received by the main lift PVG valve within the allowed amount of time. 1.222 MAIN LIFT PVG VALVE WIRING INCORRECT Main lift PVG valve wiring incorrect. A different valve powered up during power up time for main lift PVG valve or the main lift PVG valve powered up outside of the allotted PVG valve power up time. This could be due to a calibration or wiring problem. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left (center of three) with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.223 MAIN OUT OPEN CIRCUIT Main telescope out open circuit. The main telescope out output [X002.16] is open. See 1.377 COMMON STB OR OC PRO- CEDURE on Pg. 174. 1.224 MAIN OUT SHORT TO BATTERY Main telescope out short to battery. The main telescope out output [X002.16] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.225 MAIN OUT SHORT TO GROUND Main telescope out short to ground. The main telescope out output [X002.16] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.226 MAIN TELE FLOW CONTROL OPEN CIRCUIT 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. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.221.1 Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot those faults first No Go to step 1.221.2 1.221.2 Disconnect main lift PVG valve [X065] Does MAIN LIFT PVG VALVE COMMUNICA- TIONS fault appear? Yes Replace main lift PVG valve [X065] actuator No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.222.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start all off, then turn on in this order: LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Go to step 1.222.2 1.222.2 Turn off machine. Discon- nect ignition on relay [X012] and main lift PVG valve [X065]. Is there a short between ignition on relay socket 30 [X012.30.soc]and main lift PVG valve socket 2 [X065.2.soc]? Yes Repair/replace harness between relay [X012] and main lift PVG valve [X065] No Connect harnesses to the correct PVG valve as in the description above. Then calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-116 1250AJP 3128411 1.227 MAIN TELE FLOW CONTROL SHORT TO BATTERY Main telescope flow control short to battery. The main telescope proportional valve output [X002.9] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.228 MAIN TELE FLOW CONTROL SHORT TO GROUND Main telescope flow control short to ground. The main telescope proportional valve output [X002.9] is shorted to ground. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.229 MAIN TRN ANGLE SW FAILED Main transport angle switch failed. The two main boom transport angle switch [X051] inputs at the ground control module are reading the same state. The normally closed (NC) and normally open (NO) switch inputs should always read opposite. In the Transport position the NC contacts are closed and the NO contacts are open. Switch states are visible in ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ MAIN LIFT ANGLE SWITCH Nx. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.229.1 Disconnect main boom transport angle switch [X051]. Turn on machine. Measure main boom transport angle switch voltage between socket 1 [X051.1.soc] and socket 3 [X051.3.soc]. Does it measure 12VDC? Yes Go to step 1.229.7 No Go to step 1.229.2 1.229.2 Turn on machine. Take fol- lowing measurement by backprobing. See Back- probing on Pg. 319 for details. Measure voltage between mtb pass thru - 21 position terminal B [X042.B] and terminal E [X042.E]. Is it about 12 VDC? Yes Go to step 1.229.4 No Go to step 1.229.3 1.229.3 Turn on machine. ground multimeter. See Grounding on Pg. 319 for details. Take the following measurement by backprobing. Measure voltage between MTB pass Thru - 21 position terminal B [X042.B] (backprobing) and ground. Is it about 12 VDC? Yes Repair/replace harness between MTB pass thru - 21 position pin E [X042.E.pin] and MTB ground bus [X009] No Repair/replace harness between MTB pass thru - 21 position pin B [X042.B.pin] and Power Down Relay [X011] 1.229.4 Turn on machine. Take the following measurement by backprobing. Measure voltage between turntable pass thru - 21 position terminal B [X044.B] and terminal E [X044.E]. Is it about 12 VDC? Yes Go to step 1.229.6 No Go to step 1.229.5 1.229.5 Turn on machine. Ground multimeter. Take the follow- ing measurement by back- probing. Measure voltage between turntable pass thru - 21 position terminal B [X044.B] (backprob- ing) and ground. Is it about 12 VDC? Yes Repair/replace harness between turntable pass thru - 21 position socket E [X044.E.soc] and MTB pass thru - 21 position pin E [X042.E.pin] No Repair/replace harness between turntable pass Thru - 21 position socket B [X044.B.soc] and MTB pass thru - 21 position pin B [X042.B.pin] 1.229.6 Disconnect main boom transport angle switch [X051]. Turn on machine. Ground multimeter. Measure main boom transport angle switch voltage between socket 1 [X051.1.soc] and Ground. Is it about 12 VDC? Yes Repair/replace harness between main boom transport angle switch socket 3 [X051.3.soc] and turntable pass thru - 21 position pin E [X044.E.soc] No 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] SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-117 1.229.7 Fully retract and lower the boom. Remove sensor from machine, but reconnect har- ness. Turn on machine. Ground meter by backprob- ing boom transport angle switch terminal 3 [X051.3]. Backprobe boom transport angle switch pin 2 [X051.2.pin] to measure voltage. Touch the sensor face (opposite of the wires) to a part of the boom. Does it measure about 12VDC? Yes Keep machine in same condition. Go to step 1.229.8. No Replace boom transport angle switch [X051] 1.229.8 Ensure machine is set up as in step 1.229.7, except do not ground meter. Hold sen- sor to a part of the boom. In ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ MAIN LIFT ANGLE SWITCH, check the switch states. Is the NC Switch CLOSED? Yes Keep machine in same condition. Go to step 1.229.12. No Keep machine in same condition. Go to step 1.229.9 1.229.9 Ensure machine is set up as in step 1.229.7 Backprobe MTB passthru - 21 position termi- nal R [X042.R] to measure voltage. Touch the sensor face (opposite of the wires) to a part of the boom. Does it measure about 12VDC? Yes Keep machine in same condition. Go to step 1.229.10. No Keep machine in same condition. Go to step 1.229.11 1.229.10 Ensure machine is set up as in step 1.229.7 Backprobe ground module J7 terminal 22 [X007.22] to measure voltage. Touch the sen- sor face (opposite of the wires) to a part of the boom. Does it measure about 12VDC? Yes Reprogram/replace ground module. No Repair/replace harness between ground module J7 socket 22 [X007.22.soc] and MTB passthru - 21 position pin R [X042.R.pin] 1.229.11 Ensure machine is set up as in step 1.229.7 Backprobe turntable passthru R [X044.R] to measure voltage. Touch the sensor face (opposite of the wires) to a part of the boom. Does it measure about 12VDC? Yes Repair/replace harness between turntable passthru socket R [X044.R.soc] and MTB passthru - 21position pin R [X042.R.pin] No Repair/replace harness between turntable passthru pin R [X044.R.pin] and boom transport angle switch socket 2 [X051.2.soc] 1.229.12 Ensure machine is set up as in step 1.229.7 with meter grounded. Backprobe boom transport angle switch ter- minal 4 [X051.4] to measure voltage while sensor is removed and away from metal. Does it measure about 12VDC? Yes Keep machine in same condition. Go to step 1.229.13. No Replace boom transport angle switch [X051] 1.229.13 Ensure machine is set up as in step 1.229.7, except do not ground meter. Hold sen- sor away from metal. In ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ MAIN LIFT ANGLE SWITCH, check the switch state. Is the NO Switch CLOSED? Yes Reprogram/replace ground control module. No Go to step 1.229.14 1.229.14 Ensure machine is set up as in step 1.229.7 Backprobe MTB passthru - 21 position termi- nal N [X042.N] to measure voltage. Touch the sensor to a part of the boom. Does it measure about 12VDC? Yes Keep machine in same condition. Go to step 1.229.15. No Keep machine in same condition. Go to step 1.229.16 1.229.15 Ensure machine is set up as in step 1.229.7 Backprobe ground module J7 terminal 11 [X007.11] to measure voltage. Touch the sen- sor to a part of the boom. Does it measure about 12VDC? Yes Reprogram/replace ground module. No Repair/replace harness between ground module J7 socket 11 [X007.11.soc] and MTB passthru - 21 position pin N [X042.N.pin] 1.229.16 Ensure machine is set up as in step 1.229.7 Backprobe turntable passthru terminal N [X044.N] to measure voltage. Touch the sen- sor to a part of the boom. Does it measure about 12VDC? Yes Repair/replace harness between turntable passthru socket N [X044.N.soc] and MTB passthru - 21 position pin N [X042.N.pin] No Repair/replace harness between turntable passthru pin N [X044.N.pin] and boom transport angle switch socket 4 [X051.4.soc] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-118 1250AJP 3128411 1.230 MAIN TRN LEN SW DISAGREEMENT Main Transport Length Switch Disagreement. The two main boom transport length switches are reading the same state. As in Figure 2-2. Dual Capacity / Transport Switch Mounting on Pg. 179 and Table 2-3. Switch States / Boom Length Regions on Pg. 179, the main boom transport length switches should always read opposite, except at the A/B and C/D transitions. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.230.1 Access the main boom transport switches #1 [X054] and #2 [X055] Are any of these switches stuck or frozen Yes Clean/repair/replace as needed No Keep access to the switches open. Go to step 1.230.2 1.230.2 Access the main boom transport switches #1 [X054] and #2 [X055]. Fully retract the boom. Note the cam strips that the switch levers ride upon on the side of the fly boom. Are the switches and cam strips mounted so that the switch levers engage the entire length of cam? Are the cams and switches securely mounted? Also, are the switch levers mounted at 90° to housing as seen when not engaging a cam? Yes Keep access to the switches open. Go to step 1.230.3 No Repair as needed 1.230.3 Access the main boom transport switches #1 [X054] and #2 [X055]. Fully retract the boom. Are both switches off cam? Yes Check for mechanical failure of the boom tele- scope cylinder mechanism No Keep access to the switches and the boom in the same position. Go to step 1.230.4. 1.230.4 On right side of boom access the main boom transport switches #1 [X054] interior terminals. Ground multimeter. Turn on machine. Measure voltage on main boom transport switch #1 (top) [X054] termi- nal 22 (white wire) and terminal 21 (black wire). Do they both measure about 12 volts? Yes Keep machine in same condition. Go to step 1.230.8. No Go to step 1.230.5 1.230.5 Fully retract main boom. Ground meter near tower boom passthru [X044]. Take the following measure- ment by backprobing. See Grounding and Backprobing on Pg. 319 for details. Turn on machine. Is there about 12 VDC on tower boom passthru socket B [X044.B.soc]. Yes Keep machine in same condition. Go to step 1.230.6 No Keep machine in same condition. Go to step 1.230.7 1.230.6 Fully retract main boom. Ground meter near main boom transport switch passthru [X047]. Take the following measurement by backprobing. Turn on machine. Is there about 12 VDC on main boom transport switch passthru pin A [X047.A.pin]? Yes Repair/replace switch wiring between main boom transport switches #1 and #2 (top and bottom) [X054] [X055] and main boom transport switch passthru [X047] No Repair/replace harness between main boom transport switch passthru pin A [X047.A.pin] and tower boom passthru socket B [X044.B.soc] 1.230.7 Fully retract main boom. Ground meter near MTB passthru - 21 position [X042]. Take the following measurement by backprob- ing. Turn on machine. Is there about 12 VDC on MTB passthru - 21 position socket B [X042.B.soc]? Yes Repair/replace harness between MTB passthru - 21 position socket B [X042.B.soc] and tower boom passthru socket B [X044.B.soc] No Repair/replace harness between MTB passthru - 21 position socket B [X042.B.soc] and Power Down Relay [X011] SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-119 1.230.8 On right side of boom access the main boom transport switches #1 [X054] interior terminals. Ground multimeter. See Grounding on Pg. 319 for details. Turn on machine. Fully retract the boom. Mea- sure voltage on main boom transport switch #2 (bottom) [X055]. Is there about 9 volts on terminal 22 (white wire)? Also, is there about 12 volts on terminal 21 (black wire)? Yes Keep machine in same condition. Go to step 1.230.9. No Replace switch 1.230.9 On right side of boom access the main boom transport switch #2 [X055] interior terminals. Ground multimeter. Turn on machine. From the fully retracted posi- tion, extend main boom approximately 6 ft. (2 m.) to get out of transport length. Measure voltage on main boom transport switch #1 (top) terminal 22 (white wire) [X054]. Is there about 12 volts? Measure voltage on terminal 21 (black wire) [X054]. Is there about 9 volts? Yes Keep machine in same condition. Go to step 1.230.10. No Replace switch 1.230.10 On right side of boom access the main boom transport switches #2 [X055] interior terminals. Ground multimeter. Turn on machine. From the fully retracted posi- tion, extend main boom approximately 6 ft. (2 m.) to get out of transport length. Measure voltage on main boom transport switch #2 (bottom) terminal 22 (black wire) [X055] and on terminal 21 (white wire). Is there about 12 volts in both places? Yes Keep machine in same condition. Go to step 1.230.11. No Replace switch 1.230.11 Read switch position in ANALYZER ⇒ DIAGNOS- TICS BOOM SWITCHES ⇒ MAIN BOOM LENGTH SWITCH NC Fully retract main boom. Does switch read, "CLOSED"? Also, extend boom about 6 ft. (2 m.) out of transport position. Does switch read "OPEN"? Yes Go to step 1.230.16 No Go to step 1.230.12 1.230.12 Fully retract main boom. Ground meter near tower boom passthru [X044]. Take the following measure- ment by backprobing. Turn on machine. Is there about 12 VDC on tower boom passthru socket S [X044.S.soc]? Yes Keep machine in same condition. Go to step 1.230.13. No Keep machine in same condition. Go to step 1.230.14. 1.230.13 Fully retract main boom. Ground meter near main boom transport switch passthru [X047]. Take the following measurement by backprobing. Turn on machine. Is there about 12 VDC on main boom transport switch passthru socket B [X047.B.soc]? Yes Repair/replace harness between main boom transport switch passthru socket B [X047.B.soc] and tower boom passthru socket S [X044.S.soc No Repair/replace switch wiring between main boom transport switch #1 (top) [X054] and main boom transport switch passthru [X047] 1.230.14 Fully retract main boom. Ground meter near MTB passthru - 21 position [X042]. Take the following measurement by backprob- ing. Turn on machine. Is there about 12 VDC on MTB passthru - 21 position pin S [X042.S.pin]? Yes Go to step 1.230.15 No Repair/replace harness between MTB passthru - 21 position pin S [X042.S.pin] and tower boom passthru socket S [X044.S.soc] 1.230.15 Fully retract main boom. Ground meter near MTB passthru - 21 position [X042]. Take the following measurement by backprob- ing. Turn on machine. Is there about 12 VDC on ground module J7 socket 12 [X007.12.soc]? Yes Inspect connection contacts. If OK, reprogram/ replace ground module. No Repair/replace harness between MTB passthru - 21 position pin S [X042.S.pin] and ground mod- ule J7 socket 12 [X007.12.soc] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-120 1250AJP 3128411 1.231 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS Model changed - hydraulics suspended - cycle emergency stop switch. Notification that the model number was changed using the analyzer. The hydraulics will be suspended until the power is cycled. 1.232 MOMENT CONTROL DISABLED Moment control disabled. The user has forced envelope control off with the analyzer from access level 0. 1.230.16 Turn on machine. Read switch position in ANA- LYZER ⇒ DIAGNOSTICS BOOM SWITCHES ⇒ MAIN BOOM LENGTH SWITCH NO Fully retract main boom. Does switch read, "OPEN"? Also, extend boom about 6 ft. (2 m.) out of transport position. Does switch read "CLOSED"? Yes Reprogram/replace ground module No Go to step 1.230.17 1.230.17 Extend boom about 6 ft. (2m.) from fully retracted. Ground meter near tower boom passthru [X044]. Take the following measure- ment by backprobing. See Grounding and Backprobing on Pg. 319 for details. Turn on machine. Is there about 12 VDC on tower boom passthru socket U [X044.S.soc]? Yes Keep machine in same condition. Go to step 1.230.19 No Keep machine in same condition. Go to step 1.230.18 1.230.18 Extend boom about 6 ft. (2m.) from fully retracted. Ground meter near main boom transport switch passthru [X047]. Take the following measurement by backprobing. Turn on machine. Is there about 12 VDC on main boom transport switch passthru socket C [X047.C.soc]? Yes Repair/replace harness between main boom transport switch passthru socket C [X047.C.soc] and tower boom passthru socket U [X044.U.soc] No Repair/replace switch wiring between main boom transport switch #2 (bottom) [X055] and main boom transport switch passthru [X047] 1.230.19 Extend boom about 6 ft. (2m.) from fully retracted. Ground meter near MTB passthru - 21 position [X042]. Take the following measurement by backprob- ing. Turn on machine. Is there about 12 VDC on MTB passthru - 21 position pin U [X042.U.pin]? Yes Keep machine in same condition. Go to step 1.230.20 No Repair/replace harness between MTB passthru - 21 position pin U [X042.U.pin] and tower boom passthru socket U [X044.U.soc] 1.230.20 Extend boom about 6 ft. (2m.) from fully retracted. Ground meter near MTB passthru - 21 position [X042]. Take the following measurement by backprob- ing. Turn on machine. Is there about 12 VDC on ground module J7 socket 12 [X007.12.soc]? Yes Inspect connection contacts. If OK, reprogram/ replace ground module. No Repair/replace harness between MTB passthru - 21 position pin S [X042.S.pin] and ground mod- ule J7 socket 12 [X007.12.soc] Flash Code: 2-5 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.232.1 Cycle power Does fault still occur? Yes Go to step 1.232.2 No Troubleshooting complete 1.232.2 Perform 5.8 Boom Sensor Calibration on Pg. 309 Does fault still occur? Yes Replace ground module No Troubleshooting complete Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-121 1.233 NEW LOAD PIN DETECTED FAULT New load pin detected fault. The load pin currently communicating on the CAN bus is not the same serial number pin as that stored in calibration information. APU mode will be active until a valid load pin calibration is performed. Perform a boom sen- sor calibration, see 5.8 Boom Sensor Calibration on Pg. 309. 1.234 NEW MAIN ANGL1 SENSOR DETECTED New main angle 1 sensor detected. The serial number for the current main angle sensor 1 is different from the one stored during previous calibration. 1.235 NEW MAIN ANGL2 SENSOR DETECTED New main angle 2 sensor detected. The serial number for the current main angle sensor 2 is different from the one stored during previous calibration. 1.236 NO ALTERNATOR OUTPUT No alternator output. Notification that the engine has been running for 15 seconds or more and the battery voltage is still below 11.5 volts. This probably indicates a problem with the alternator or its wiring. 1.237 NO MAIN LIFT PILOT PRESSURE No main lift pilot pressure. This fault will be set when the main lift pilot valve output [X002.1] is engaged, but the main lift pilot pressure switch input [X001.21] is not indicating pressure. This could be caused by a problem with the main lift pilot pres- sure switch [X079], its wiring, wrong hydraulic connections, or a hydraulic failure. 1.238 OIL PRESSURE SHORT TO BATTERY Oil pressure short to battery. This fault should only occur on machines configured with non-ECM engines. The engine oil pressure input [X001.15] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. Flash Code: 8-5 Flash Code: 8-7 Note Pretest Instructions Test Result Corrective Action 1.234.1 Disconnect main angle sen- sor 1 (right) [X048]. Check faults. Does the fault MAIN ANGL1 CAN COMMUNI- CATIONS LOST appear? Yes Go to step 1.234.2 No Harness connections to sensors are swapped. Connect harness to correct sensors. 1.234.2 Calibrate boom sensors Is calibration successful? Yes Troubleshooting complete No Troubleshoot in accordance with calibration fault Flash Code: 8-7 Note Pretest Instructions Test Result Corrective Action 1.235.1 Disconnect main angle sen- sor 2 (Left) [X049]. Check faults. Does the fault MAIN ANGL2 CAN COMMUNI- CATIONS LOST appear? Yes Go to step 1.235.2 No Harness connections to sensors are swapped. Connect harness to correct sensors. 1.235.2 Calibrate boom sensors Is calibration successfull? Yes Troubleshooting complete No Troubleshoot in accordance with calibration fault Flash Code: 4-3 Flash Code: 3-3 Flash Code: 4-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-122 1250AJP 3128411 1.239 OIL PRESSURE SHORT TO GROUND Oil pressure short to ground. This fault should only occur on machines configured with non-ECM engines. The engine oil pressure input [X001.15] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.240 PARKING BRAKE OPEN CIRCUIT Parking brake open circuit. The parking brake output [X001.23] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.241 PARKING BRAKE SHORT TO BATTERY Parking brake short to battery. The parking brake output [X001.23] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.242 PARKING BRAKE SHORT TO GROUND Parking brake short to ground. The parking brake output [X001.23] is shorted to ground. See 1.378 COMMON STG PRO- CEDURE on Pg. 175. 1.243 PLATFORM CAN COMMUNICATIONS LOST Platform CAN communications lost. The system cannot communicate with the platform module. This may be due to wiring problems between platform and ground modules. Flash Code: 4-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 6-6 Note Pretest Instructions Test Result Corrective Action 1.243.1 Check fault log for other modules having lost com- munication Have most modules lost communications? Yes See 1.93 EXCESSIVE CAN BUS COMMUNICA- TION ERRORS on Pg. 73 No Go to step 1.243.2 1.243.2 Disconnect the platform module J8 connector [X170]. Turn machine on in platform mode Is there 11VDC or more between socket 2 and socket 1 of the platform module J8 connector [X170.2.soc X170.1.soc]? Yes See 1.93 EXCESSIVE CAN BUS COMMUNICA- TION ERRORS on Pg. 73 fault step 1.93.3 No Keep machine on. Go to step 1.243.3 1.243.3 Disconnect the platform module J8 connector [X170]. Turn machine on in platform mode Is there zero VDC between socket 2 and socket 1 of the platform module J8 connector [X170.2.soc X170.1.soc]? Yes Keep machine on. Go to step 1.243.5 No Go to step 1.243.4 1.243.4 Remove any corrosion on battery terminals and bat- tery cable terminals. Run machine to recharge battery. Does battery still exhibit low power? Yes Replace battery No Retry normal vehicle operation 1.243.5 Turn machine on in platform mode. Backprobe to take the following measurement. See Backprobing on Pg. 319 for details. Is there 11VDC or more between terminal 12 and terminal 16 of the 19 position platform control box passthru connector [X160.12 X160.16]? Yes Repair/replace harness between the 19 position platform control box passthru connector [X160] and the platform module J8 connector [X170] No Go to step 1.243.6 1.243.6 Disconnect boom sensor passthru - 19 position con- nector [X050] Turn machine on in platform mode. Is there 11VDC or more between socket 12 and socket 16 of the boom sensor passthru - 19 position connector [X050.12.soc X050.16.soc]? Yes Repair/replace harness between the boom sen- sor passthru - 19 position connector [X050] and the 19 position platform control box passthru connector [X160] No Go to step 1.243.7 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-123 1.244 PLATFORM CONTROL VALVE OPEN CIRCUIT Platform control valve open circuit. The platform dump valve output [X002.3] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.245 PLATFORM CONTROL VALVE SHORT TO BATTERY Platform control valve short to battery. The platform dump valve output [X002.3] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.246 PLATFORM CONTROL VALVE SHORT TO GROUND Platform control valve short to ground. The platform dump valve output [X002.3] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.247 PLATFORM MODULE FAILURE: HWFS CODE 1 Platform module failure: hardware failsafe code 1. Platform module V(low) FET has failed. A power cycle is required. 1.248 PLATFORM MODULE SOFTWARE UPDATE REQUIRED Platform module software update required. The platform module software is a different major version than the ground mod- ule. Load new platform module software. 1.243.7 Disconnect boom sensor passthru - 19 position con- nector [X045] Turn machine on in platform mode. Is there 11VDC or more between socket 12 and socket 16 of the tower boom passthru - 19 position connector [X045.12 X045.16]? Yes Repair/replace harness between the tower boom passthru - 19 position connector [X045] and the boom sensor passthru - 19 position connector [X050] No Go to step 1.243.8 1.243.8 Take the following measure- ment by backprobing Turn machine on in platform mode. Is there 11VDC or more between pin 12 and pin 16 of the MTB pass thru - 19 position connector [X043.12.pin X043.16.pin]? Yes Repair/replace harness between the MTB pass thru - 19 position connector [X043] and the tower boom passthru - 19 position connector [X045] No Go to step 1.243.9 1.243.9 Take the following measure- ment by backprobing Turn machine on in platform mode. Is there 11VDC or more between pin 4 and pin 3 of the ground module J8 connector [X008.4 X008.3]? Yes Repair/replace harness between the ground module J8 connector [X008] and the MTB pass thru - 19 position connector [X043] No Go to step 1.243.10 1.243.10 Disconnect the ground module J8 connector [X008]. Turn machine on in platform mode Is there 11VDC or more between pin 4 and pin 3 of the ground module J8 connector [X008.4 X008.3]? Yes Repair/replace harness between the ground module J8 connector [X008] and the MTB pass thru - 19 position connector [X043] No Replace the ground module Flash Code: 3-4 Flash Code: 3-4 Flash Code: 3-4 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.247.1 Cycle power Does fault clear? Yes Troubleshooting complete No Replace platform module Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-124 1250AJP 3128411 1.249 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE Platform sensor reference voltage out of range. The platform module 7VDC reference voltage is out of acceptable range. This supply is used for the lift, swing, drive and pump controls. Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.249.1 Disconnect platform mod- ule J5 [X167] Is there about 2.5kΩ between platform mod- ule J5 socket 1 [X167.1.soc] and J5 socket 7 [X167.7.soc]? Yes Keep connector disconnected. Go to step 1.249.2. No Repair/replace Lift & Swing joystick assembly and/or wiring 1.249.2 Disconnect platform mod- ule J5 [X167] and J6 [X168] and hyd speed pot passthru - 6 pos [X199]. Turn on machine. Is there 6.6V - 7.5V between platform module J5 pin 1 [X167.1.pin] and J5 pin 7 [X167.7.pin]? Yes Keep J5 [X167] disconnected. Go to step 1.249.3. No Go to step 1.249.12 1.249.3 Disconnect platform mod- ule J5 [X167]. Ground multi- meter. See Grounding on Pg. 319 for details. Is there a short between platform module J5 socket 1 [X167.1.soc] and ground? Yes Repair/replace harness affecting Lift & Swing joystick wiring. No Go to step 1.249.4 1.249.4 Disconnect platform mod- ule J5 [X167]. Ground multi- meter. See Grounding on Pg. 319 for details. Turn on machine. Is there about 12 VDC between platform module J5 socket 1 [X167.1.soc] and ground? Yes Shor t to battery. Repair/replace harness affecting the Lift & Swing joystick wiring. No Go to step 1.249.5 1.249.5 Disconnect platform mod- ule J6 [X168] Is there about 5kΩ between platform module J6 socket 1 [X168.1.soc] and J6 socket 7 [X168.7.soc]? Yes Go to step 1.249.6 No Repair/replace Drive joystick and/or wiring 1.249.6 Disconnect platform mod- ule J6 [X168]. Ground multi- meter. See Grounding on Pg. 319 for details. Is there a short between platform module J6 socket 1 [X168.1.soc] and ground? Yes Short to ground. Repair/replace harness affect- ing Drive joystick assembly. No Go to step 1.249.7 1.249.7 Disconnect platform mod- ule J6 [X168]. Ground multi- meter. See Grounding on Pg. 319 for details. Turn on machine. Is there about 12 VDC between platform module J6 socket 1 [X168.1.soc] and ground? Yes Shor t to battery. Repair/replace harness affecting Drive joystick wiring. No Go to step 1.249.8 1.249.8 Disconnect hyd speed pot passthru - 6 pos. [X199] Measure resistance between hyd speed pot passthru socket 4 [X199.4.soc] and socket 5 [X199.5.soc]. Is there a short or open? Yes Repair/replace hyd speed pot passthru [X199] and or Speed Controller [X192] No Keep hyd speed pot passthru [X199] discon- nected. Go to step 1.249.9 1.249.9 Disconnect hyd speed pot passthru - 6 pos. [X199]. Measure resistance from hyd speed pot passthru pin 4 [X199.4.pin] and pin 5 [X199.5.pin]. Is there a short? Yes Keep hyd speed pot passthru [X199] discon- nected. Go to step 1.249.10 No Keep hyd speed pot passthru [X199] discon- nected. Go to step 1.249.11 1.249.10 Disconnect hyd speed pot passthru [X199] and plat- for m modu le J1 [X 165 ]. Measure resistance from platform module J1 socket 13 [X165.13.soc] and socket 34 [X165.34.soc]. Is there a short? Yes Repair/replace harness between hyd speed pot passthru [X199] pin 4 [X199.4.pin] and pin 6 [X199.6.pin] and platform module J1 [X 165] socket 13 [X165.13.soc] and socket 34 [X165.34.soc] No Short inside module. Replace platform module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-125 1.250 PUMP SWITCHES FAULTY - CHECK DIAGNOSTICS/BOOM Pump switches faulty - check diagnostics/boom. A ground control or platform control boom function switch (lower lift, tele- scope, platform level, platform rotate, jib, etc.) has both directions selected together. This may be caused by a problem with a switch or its wiring. Run ANALYZER ⇒ SYSTEM TEST from the ground controls and platform controls to find the specific switch. 1.251 PUMP SWITCHES LOCKED - SELECTED BEFORE AUX POWER Pump switches locked - selected before aux power. A ground function switch input (lower lift, telescope, platform level, plat- form rotate, jib) was selected before the ground auxiliary power switch input [X004.16]. The auxiliary power (enable) switch must be activated before the desired function switch. This also may be caused by a problem with a switch or its wiring. Run ANALYZER ⇒ SYSTEM TEST from the ground controls to find the specific switch. 1.252 PUMP SWITCHES LOCKED - SELECTED BEFORE FOOTSWITCH Pump switches locked - selected before footswitch. A platform boom function switch input (lower lift, telescope, basket level, basket rotate, jib) was selected before key switch or footswitch input [X169.8] closure. The footswitch must be activated before any function. This may be caused by a problem with a switch or its wiring. Run ANALYZER ⇒ SYSTEM TEST from the platform controls to find the specific switch. 1.253 PUMP SWITCHES LOCKED - SELECTED BEFORE START SWITCH Pump switches locked - selected before start switch. A ground control or platform control boom function switch (lower lift, telescope, platform level, platform rotate, jib, etc.) input was selected before the start switch input [X165.14 X004.4]. The start switch may only be activated when no function is commanded. This also may be caused by a problem with a switch or its wiring. Run ANALYZER ⇒ SYSTEM TEST from the ground controls and platform controls to find the specific switch. 1.254 PVG VALVE ENABLE OPEN CIRCUIT 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. 1.249.11 Disconnect hyd speed pot passthru [X199] Measure resistance between hyd speed pot passthru socket 3 [X199.3.soc] and socket 4 [X199.4.soc]. Is there a short? Yes Repair/replace Speed Controller [X192] No Keep hyd speed pot passthru [X199] discon- nected. Go to step 1.249.12 1.249.12 Disconnect hyd speed pot passthru [X199] Measure resistance between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin]. Is there a short? Yes Keep hyd speed pot passthru [X199] discon- nected. Go to step 1.249.13. No Reprogram/replace platform module 1.249.13 Disconnect hyd speed pot passthru [X199] and plat- form module J1 [X165] Measure resistance between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin]. Is there a short? Yes Repair/replace harness between hyd speed pot passthru pin 3[X199.3.pin] and pin 4 [X199.4.pin] No Short inside module. Replace platform module. Flash Code: 2-3 Flash Code: 2-3 Flash Code: 2-3 Flash Code: 2-3 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-126 1250AJP 3128411 1.255 PVG VALVE ENABLE SHORT TO BATTERY PVG valve enable short to battery. The PVG valve enable output [X002.31] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.256 PVG VALVE ENABLE SHORT TO GROUND PVG valve enable short to ground. The PVG valve enable output [X002.31] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.257 REAR LEFT WHEEL BLOCKED Rear left wheel blocked. The control system is unable to steer the rear left wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear left steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.257.1 Is the rear left wheel kept from moving? Yes Free the wheel from any obstructions No Go to step 1.257.2 1.257.2 Check the fault log for primary faults, LT REAR STEER LT STB OR OC, LT REAR STEER LT STG, LT REAR STEER RT STB OR OC, LT REAR STEER RT STG, or any steer angle sensor fault Yes If a primary fault is found, troubleshoot it before this fault No Go to step 1.257.3 1.257.3 Note that glow plug’s large power draw can aggravate existing problems with power distribution wiring and low battery power. Fre- quent starting can drain bat- tery when preheating. When engine coolant temperature is below 140°F (60°C), air temperature is below 59°F (15°C), and battery voltage is less than 11VDC before starting, does fault mainly occur within 30 seconds after starting engine? Yes Examine the battery condition and contacts within the Chassis power distribution wiring. Repair/replace as needed. No Go to step 1.257.4 1.257.4 Watch the angle sensor value on ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALI- BRATIONS ⇒ STEER ⇒ CALIBRATE? Press Enter to view raw value REAR LT STEER VALUE = XX Do not press Enter. Steer completely left, pause, then completely right, pause. Does the value continuously and smoothly change while steering? Yes ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Go to step 1.257.5 No Repair/Replace the sensor and calibrate. 1.257.5 If the wheel will not steer in either direction, check the steer valve for a stuck spool. Yes Repair/Replace the valve No Go to step 1.257.6 1.257.6 Are there any bent, damaged, or seized steer- ing components? Yes Repair/Replace the component No Go to step 1.257.7 1.257.7 Ensure proper pressure with ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALIBRATIONS ⇒ STEER ⇒ REAR LT STEER VALUE = XX. Install a 3000 psi gauge or higher on Rear Steer Axle valve port MS1 and MS2 Adjust steer pressures on Rear Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on g a u g e o n p o r t M S 1 . A dj u s t r e li e f n e x t t o p o r t t o 2000 psi ± 10% on port MS2. ESC out of cali- brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.257.8 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-127 1.258 REAR LEFT WHEEL SENSOR FAULT - CHECK MOUNTING Rear left wheel sensor fault - check mounting. The control system detected the rear left steer angle sensor value was below the mechanical minimum angle while the wheel was detected as blocked. The sensor may be mounted improperly or the sensor may be faulty. 1.257.8 Install a low pressure gauge (1000 psi) on main manifold MP1 and adjust to 450 psi ± 10% on load sense Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.257.9 1.257.9 Swap valve section with the one on the other side of machine. Does condition follow valve section to other side of machine? Yes Repair/replace valve section No Repair/replace rear left steer cylinder and/or hoses. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.258.1 Check faults Is the fault REAR LEFT WHEEL BLOCKED present? Yes Troubleshoot that first No 1.258.2 1.258.2 Disconnect rear left steer sensor [X238] Do the connectors have any loose, damaged, corroded contacts or moisture inside? Yes Repair as needed No Go to step 1.258.3 1.258.3 Is the rear left wheel sensor [X238] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sen- sor is properly tensioned. Yes Go to step 1.258.4 No Reinstall and recheck 1.258.4 Extend axles. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L REAR WHEEL ANGL Monitor value while operating steering. Steer fully to the left, then fully to the right. Does the displayed angle ever climb above ±42.11? -OR- Does the value pause, jump or act errati- cally? Yes Repair/replace sensor and mounting as needed No Go to step 1.258.5 1.258.5 Swap rear left wheel sensor [X238] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor fault? Yes Replace sensor originally at the rear left wheel. No Go to step 1.258.6 1.258.6 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.258.7 1.258.7 Disconnect rear left wheel sensor [X238] Turn on machine. Is there 5VDC between rear left wheel sensor socket A [X238.A.soc] and socket C [X238.C.soc]? Yes Keep sensor disconnected. Go to step 1.258.8. No Go to step 1.258.10 1.258.8 Disconnect rear left wheel sensor [X238] and chassis module J3 [X231] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and chassis mod- ule J3 socket 11 [X231.11.soc]? Yes Reprogram/replace ground module No Keep rear left wheel sensor [X238] disconnected. Go to step 1.258.9 1.258.9 Disconnect rear left wheel sensor [X238] and rear left steer passthru - 4 pos. [X237] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin]? Yes Repair harness between rear left steer passthru socket 2 [X238.2.soc] and chassis module J3 socket 11 [X231.11.soc] No Repair/replace harness between rear left wheel sensor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-128 1250AJP 3128411 1.259 REAR LEFT WHEEL SENSOR OUT OF RANGE HIGH Rear left wheel sensor out of range high. The control system detected the rear left steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem. 1.258.10 Disconnect rear left steer passthru - 4 pos. [X237]. Turn on machine. Is there 5VDC between rear left steer passthru socket 1 [X237.1.soc] and socket 3 [X237.3.soc]? Yes Repair/replace harness between rear left steer passthru [X237] and rear left wheel sensor [X238] No Go to step 1.258.11 1.258.11 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 10 [X231.10.pin] and pin 12 [X231.12.pin]? Yes Repair/Replace harness between rear left steer passthru [X237] and chassis module J3 [X231] No Replace chassis module Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.259.1 Is the rear left steer angle sensor [X238] installed and connected properly? Yes Go to step 1.259.2 No Repair as needed 1.259.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L REAR WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left rear wheel angle more than 2° difference from other wheels? Yes Go to step 1.259.3 No Go to step 1.259.5 1.259.3 Swap rear left wheel sensor [X238] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range high fault? Yes Replace sensor originally at the rear left wheel. No Go to step 1.259.4 1.259.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.259.5 1.259.5 Disconnect rear left wheel sensor [X238] Turn on machine. Is there 5VDC between rear left wheel sensor socket A [X238.A.soc] and socket C [X238.C.soc]? Yes Keep sensor disconnected. Go to step 1.259.6. No Go to step 1.259.8 1.259.6 Disconnect rear left wheel sensor [X238] and chassis module J3 [X231] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and chassis mod- ule J3 socket 11 [X231.11.soc]? Yes Reprogram/replace ground module No Keep rear left wheel sensor [X238] disconnected. Go to step 1.259.7 1.259.7 Disconnect rear left wheel sensor [X238] and rear left steer passthru - 4 pos. [X237] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin]? Yes Repair harness between rear left steer passthru socket 2 [X237.2.soc] and chassis module J3 socket 11 [X231.11.soc] No Repair/replace harness between rear left wheel sensor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin] 1.259.8 Disconnect rear left steer passthru - 4 pos. [X237]. Turn on machine. Is there 5VDC between rear left steer passthru socket 1 [X237.1.soc] and socket 3 [X237.3.soc]? Yes Repair/replace harness between rear left steer passthru [X237] and rear left wheel sensor [X238] No Go to step 1.259.9 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-129 1.260 REAR LEFT WHEEL SENSOR OUT OF RANGE LOW Rear left wheel sensor out of range low. The control system detected the rear left steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection. 1.259.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 10 [X231.10.pin] and pin 12 [X231.12.pin]? Yes Repair/Replace harness between rear left steer passthru [X237] and chassis module J3 [X231] No Replace chassis module Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.260.1 Is the rear left steer angle sensor [X238] installed and connected properly? Yes Go to step 1.260.2 No Repair as needed 1.260.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ L REAR WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They should be within 2 °. Return to L REAR WHEEL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels? Yes Go to step 1.260.3 No Go to step 1.260.5 1.260.3 Swap rear left wheel sensor [X238] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range low fault? Yes Replace sensor originally at the front left wheel. No Go to step 1.260.4 1.260.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.260.5 1.260.5 Disconnect rear left wheel sensor [X238] Turn on machine. Is there 5VDC between rear left wheel sensor socket A [X238.A.soc] and socket C [X238.C.soc]? Yes Keep sensor disconnected. Go to step 1.260.6. No Go to step 1.260.8 1.260.6 Disconnect rear left wheel sensor [X238] and chassis module J3 [X231] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and chassis mod- ule J3 socket 11 [X231.11.soc]? Yes Reprogram/replace ground module No Keep rear left wheel sensor [X238] disconnected. Go to step 1.260.7 1.260.7 Disconnect rear left wheel sensor [X238] and rear left steer passthru - 4 pos. [X237] Is there continuity between rear left wheel sen- sor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin]? Yes Repair harness between rear left steer passthru socket 2 [X2.237.soc] and chassis module J3 socket 11 [X231.11.soc] No Repair/replace harness between rear left wheel sensor socket B [X238.B.soc] and rear left steer passthru pin 2 [X237.2.pin] 1.260.8 Disconnect rear left steer passthru - 4 pos. [X237]. Turn on machine. Is there 5VDC between rear left steer passthru socket 1 [X237.1.soc] and socket 3 [X237.3.soc]? Yes Repair/replace harness between rear left steer passthru [X237] and rear left wheel sensor [X237] No Go to step 1.260.9 1.260.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 10 [X231.10.pin] and pin 12 [X231.12.pin]? Yes Repair/Replace harness between rear left steer passthru [X237] and chassis module J3 [X231] No Replace chassis module Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-130 1250AJP 3128411 1.261 REAR RIGHT WHEEL BLOCKED Rear right wheel blocked. The control system is unable to steer the rear right wheel. Steering was commanded for at least 1.3 seconds without sensing an appropriate change in angle from the rear right steer angle sensor. This could be caused by a mechanical blockage, a hydraulic problem, or a faulty angle sensor. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.261.1 Is the right rear wheel kept from moving? Yes Free the wheel from any obstructions No Go to step 1.261.2 1.261.2 Check the fault log for primary faults, RT REAR STEER LT STB OR OC, RT REAR STEER LT STG, RT REAR STEER RT STB OR OC, RT REAR STEER RT STG, or any steer angle sen- sor fault Yes If a primary fault is found, troubleshoot it before this fault No Go to step 1.261.3 1.261.3 Note that glow plug’s large power draw can aggravate existing problems with power distribution wiring and low battery power. Fre- quent starting can drain bat- tery when preheating. When engine coolant temperature is below 140°F (60°C), air temperature is below 59°F (15°C), and battery voltage is less than 11VDC before starting, does fault mainly occur within 30 seconds after starting engine? Yes Examine the battery condition and contacts within the Chassis power distribution wiring. Repair/replace as needed. No Go to step 1.261.4 1.261.4 Watch the angle sensor value on ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALI- BRATIONS ⇒ STEER ⇒ CALIBRATE? Press Enter to view raw value REAR RT STEER VALUE = XX Do not press Enter. Steer completely left, pause, then completely right, pause. Does the value continuously and smoothly change while steering? Yes ESC out of calibrate mode. Cycle E-stop switch to clear failed calibration message. Go to step 1.261.5 No Repair/Replace the sensor and calibrate. 1.261.5 If the wheel will not steer in either direction, check the steer valve for a stuck spool. Yes Repair/Replace the valve No Go to step 1.261.6 1.261.6 Are there any bent, damaged, or seized steer- ing components? Yes Repair/Replace the component No Go to step 1.261.7 1.261.7 Ensure proper pressure with ANALYZER ⇒ ACCESS LEVEL 1 ⇒ CALIBRATIONS ⇒ STEER ⇒ REAR RT STEER VALUE = XX. Install a 3000 psi gauge or higher on Rear Steer Axle valve port MS1 and MS2 Adjust steer pressures on Rear Steer/Axle valve. Adjust relief next to port to 2600 psi ± 10% on g a u g e o n p o r t M S 1 . A dj u s t r e li e f n e x t t o p o r t t o 2000 psi ± 10% on port MS2. ESC out of cali- brate mode. Cycle E-stop switch to clear failed calibration message. Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.261.8 1.261.8 Install a low pressure gauge (1000 psi) on main manifold MP1 and adjust to 450 psi ± 10% on load sense Is condition clear? Yes Troubleshooting complete No Do not remove gauges. Go to step 1.261.9 1.261.9 Swap valve section with the one on the other side of machine. Does condition follow valve section to other side of machine? Yes Repair/replace valve section No Repair/replace front left steer cylinder and/or hoses. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-131 1.262 REAR RIGHT WHEEL SENSOR FAULT - CHECK MOUNTING Rear right wheel sensor fault - check mounting. The control system detected the rear right steer angle sensor value was below the mechanical minimum angle while the wheel was detected as blocked. The sensor may be mounted improperly or the sensor may be faulty. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.262.1 Check faults Is the fault REAR RIGHT WHEEL BLOCKED present? Yes Troubleshoot that first No 1.262.2 1.262.2 Disconnect rear right steer sensor [X239] Do the connectors have any loose, damaged, corroded contacts or moisture inside? Yes Repair as needed No Go to step 1.262.3 1.262.3 Is the rear right wheel sensor [X239] in tact and properly installed? This includes checking that the sensor pin will turn the sensor and the sensor is properly tensioned. Yes Go to step 1.262.4 No Reinstall and recheck 1.262.4 Extend axles. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ R REAR WHEEL ANGL Monitor value while operating steering. Steer fully to the left, then fully to the right. Does the displayed angle ever climb above ±42.11? -OR- Does the value pause, jump or act errati- cally? Yes Repair/replace sensor and mounting as needed No Go to step 1.262.5 1.262.5 Swap rear right wheel sen- sor [X239] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor fault? Yes Replace sensor originally at the rear right wheel. No Go to step 1.262.6 1.262.6 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.262.7 1.262.7 Disconnect rear right wheel sensor [X239] Turn on machine. Is there 5VDC between rear right wheel sensor socket A [X239.A.soc] and socket C [X239.C.soc]? Yes Keep sensor disconnected. Go to step 1.262.8. No Go to step 1.262.10 1.262.8 Disconnect rear right wheel sensor [X239] and chassis module J3 [X231] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and chassis module J3 socket 8 [X231.8.soc]? Yes Reprogram/replace ground module No Keep rear right wheel sensor [X239] discon- nected. Go to step 1.262.9 1.262.9 Disconnect rear right wheel sensor [X239] and rear right steer passthru - 4 pos. [X236] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin]? Yes Repair harness between rear right steer passthru socket 2 [X236.2.soc] and chassis module J3 socket 8 [X231.8.soc] No Repair/replace harness between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin] 1.262.10 Disconnect rear left steer passthru - 4 pos. [X237]. Turn on machine. Is there 5VDC between rear right steer passthru socket 1 [X236.1.soc] and socket 3 [X236.3.soc]? Yes Repair/replace harness between rear left steer passthru [X237] and rear left wheel sensor [X238] No Go to step 1.262.11 1.262.11 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 10 [X231.10.pin] and pin 12 [X231.12.pin]? Yes Repair/Replace harness between rear right steer passthru [X236] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-132 1250AJP 3128411 1.263 REAR RIGHT WHEEL SENSOR OUT OF RANGE HIGH Rear right wheel sensor out of range high. The control system detected the rear right steer angle sensor value was above the electrical maximum. This may be due to a short to battery or a wiring problem. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.263.1 Is the rear right steer angle sensor [X239] installed and connected properly? Yes Go to step 1.263.2 No Repair as needed 1.263.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ R REAR WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They s h o u l d be w i t h in 2 ° . Re t u r n t o R RE A R W H E EL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the right rear wheel angle more than 2° difference from other wheels? Yes Go to step 1.263.3 No Go to step 1.263.5 1.263.3 Swap rear right wheel sen- sor [X239] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range high fault? Yes Replace sensor originally at the rear right wheel. No Go to step 1.263.4 1.263.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.263.5 1.263.5 Disconnect rear right wheel sensor [X239] Turn on machine. Is there 5VDC between rear right wheel sensor socket A [X239.A.soc] and socket C [X239.C.soc]? Yes Keep sensor disconnected. Go to step 1.263.6. No Go to step 1.263.8 1.263.6 Disconnect rear right wheel sensor [X239] and chassis module J3 [X231] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and chassis module J3 socket 8 [X231.8.soc]? Yes Reprogram/replace ground module No Keep rear right wheel sensor [X239] discon- nected. Go to step 1.263.7 1.263.7 Disconnect rear right wheel sensor [X239] and rear left steer passthru - 4 pos. [X236] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin]? Yes Repair harness between rear right steer passthru socket 2 [X236.2.soc] and chassis module J3 socket 8 [X231.8.soc] No Repair/replace harness between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin] 1.263.8 Disconnect rear right steer passthru - 4 pos. [X236]. Turn on machine. Is there 5VDC between rear right steer passthru socket 1 [X237.1.soc] and socket 3 [X236.3.soc]? Yes Repair/replace harness between rear right steer passthru [X236] and rear right wheel sensor [X239] No Go to step 1.263.9 1.263.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 7 [X231.7.pin] and pin 9 [X231.9.pin]? Yes Repair/Replace harness between rear right steer passthru [X236] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-133 1.264 REAR RIGHT WHEEL SENSOR OUT OF RANGE LOW Rear right wheel sensor out of range low. The control system detected the rear right steer angle sensor value was below the electrical minimum. This may be due to an open circuit or a poor connection. Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action 1.264.1 Is the rear right steer angle sensor [X239] installed and connected properly? Yes Go to step 1.264.2 No Repair as needed 1.264.2 Extend axles. Enable crab steering mode. Go to ANA- LYZER ⇒ DIAGNOSTICS ⇒ DRIVE ⇒ R REAR WHEEL ANGL. Observe angle while operating steering. Steer fully to the left. Check all wheel angles. They s h o u l d be w i t h in 2 ° . Re t u r n t o R RE A R W H E EL ANGL analyzer screen. Steer to right about two seconds while monitoring the value. Repeat checks. Repeat process for entire swing of wheel. Did the value, while steering, pause, jump or act erratically? -OR- Was the left front wheel angle more than 2° difference from other wheels? Yes Go to step 1.264.3 No Go to step 1.264.5 1.264.3 Swap rear right wheel sen- sor [X239] with a sensor that doesn’t have a fault. Check faults. Does the new location now have a wheel sensor out of range low fault? Yes Replace sensor originally at the rear right wheel. No Go to step 1.264.4 1.264.4 Calibrate steering. Does fault clear? Yes Troubleshooting complete No Go to step 1.264.5 1.264.5 Disconnect rear right wheel sensor [X239] Turn on machine. Is there 5VDC between rear right wheel sensor socket A [X239.A.soc] and socket C [X239.C.soc]? Yes Keep sensor disconnected. Go to step 1.264.6. No Go to step 1.264.8 1.264.6 Disconnect rear right wheel sensor [X239] and chassis module J3 [X231] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and chassis module J3 socket 8 [X231.8.soc]? Yes Reprogram/replace ground module No Keep rear right wheel sensor [X239] discon- nected. Go to step 1.264.7 1.264.7 Disconnect rear right wheel sensor [X239] and rear right steer passthru - 4 pos. [X236] Is there continuity between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin]? Yes Repair harness between rear right steer passthru socket 2 [X2.236.soc] and chassis module J3 socket 8 [X231.8.soc] No Repair/replace harness between rear right wheel sensor socket B [X239.B.soc] and rear right steer passthru pin 2 [X236.2.pin] 1.264.8 Disconnect rear right steer passthru - 4 pos. [X236]. Turn on machine. Is there 5VDC between rear right steer passthru socket 1 [X236.1.soc] and socket 3 [X236.3.soc]? Yes Repair/replace harness between rear right steer passthru [X236] and rear right wheel sensor [X239] No Go to step 1.264.9 1.264.9 Disconnect chassis module J3. Turn on machine. Is there 5VDC between chassis module J3 pin 7 [X231.10.pin] and pin 9 [X231.9.pin]? Yes Repair/Replace harness between rear right steer passthru [X236] and chassis module J3 [X231] No Replace chassis module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-134 1250AJP 3128411 1.265 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE STB OR OC Restricted to transport - Axle lockout valve short to battery or open circuit. The control system detected a short to battery or an open circuit on the PWM output for the Axle Lockout valve. Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action 1.265.1 Is the resistance of the axle lockout valve sole- noid [X212] 6.2Ω Yes Go to step 1.265.2 No Replace the axle lockout valve solenoid 1.265.2 Disconnect the axle lockout valve solenoid DIN connec- tor [X212] Does the voltage between the positive battery terminal [X116] and terminal 2 of the Axle Lockout valve solenoid DIN connector [X212.2.soc] measure 12VDC? Yes Go to step 1.265.10 No Go to step 1.265.3 1.265.3 Does the voltage between the positive battery terminal [X116] and terminal 2 of the chassis module J4 connector [X232.2.pin] measure 12VDC? Yes Repair/replace the black wire between terminal 2 of the axle lockout valve solenoid DIN connector [X212.2.soc] and terminal 2 of the chassis mod- ule J4 connector [X232.2.soc] No Go to step 1.265.4 1.265.4 Does the voltage between the positive battery terminal [X116] and terminal 4 of the chassis module J1 connector [X229.4] measure 12VDC? Yes Replace the chassis module No Go to step 1.265.5 1.265.5 Does the voltage between the positive battery terminal [X116] and terminal 5 of the chassis (bottom) swivel connector [X216.5] measure 12VDC? Yes Repair/Replace the black wire between terminal 5 of the chassis (bottom) swivel connector [X216.5] and terminal 4 of the chassis module J1 connector [X229.4] No Go to step 1.265.6 1.265.6 Does the voltage between the positive battery terminal [X116] and terminal 5 of the Turntable (top) Swivel connector [X083.5] measure 12VDC? Yes Replace the Collector Ring and swivel harness No Go to step 1.265.7 1.265.7 Does the voltage between the positive battery terminal [X116] and any terminal of the 12 position MTB ground buss connector [X009] measure 12VDC? Yes Replace the valve harness No Go to step 1.265.8 1.265.8 Does the voltage between the positive battery terminal [X116] and terminal 3 of the ground module J8 connector [X008.3] measure 12VDC? Yes Repair/Replace the Black wire between terminal 3 of the ground module J8 connector [X008.3] and the MTB ground buss connector [X009] No Go to step 1.265.9 1.265.9 Does the voltage between the positive battery terminal [X116] and terminal 1 of the ground module J8 connector [X008.1] measure 12VDC? Yes Replace the ground module No Repair/Replace the Black wire from the battery 1.265.10 Disconnect the axle lockout valve solenoid DIN connec- tor [X212] Does the voltage on terminal 1 of the axle lock- out valve solenoid DIN connector [X212.1.soc] measure 12VDC? Yes Go to step 1.265.11 No Go to step 1.265.15 1.265.11 Remove terminal 8 of the chassis (bottom) swivel connector [X216.8] Does the voltage on terminal 1 of the axle lock- out valve solenoid DIN connector [X212.1.soc] measure 12VDC? Yes Repair/replace the ORANGE 60-2 wire between terminal 1 of the axle lockout valve solenoid con- nector [212.1] and terminal 8 of the chassis (bot- tom) swivel connector [X216.8] No Go to step 1.265.12 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-135 1.266 RESTRICTED TO TRANSPORT - OSC AXLE PRESS SW DISAGREEMENT Restricted to transport - Oscillating axle pressure switch disagreement. The control system detected hydraulic pressure at the oscillating axle lockout pressure switch while the oscillating axle lockout valve solenoid was not being energized or did not detect pressure while the solenoid was energized. These fault conditions were detected for at least 5 seconds. This fault is ignored if the engine speed is under 1200 RPM. Only when driving in transport position should the oscillating axle lockout valve solenoid be energized, closing the oscillating axle lockout pressure switch and unlocking the oscillating axle cylinders. When out of transport position, drive/steer, tower lift up, main lift up, and main telescope out are prevented. This fault will be 1.265.12 Remove terminal 8 of the turntable (top) swivel con- nector [X083.8] Does the voltage on terminal 1 of the axle lock- out valve solenoid DIN connector [X212.1.soc] measure 12VDC? Yes Replace the collector ring and swivel harness No Go to step 1.265.13 1.265.13 Remove terminal 4 of the 12 position BLAM-Valve har- ness passthru connector [X058.4] Does the voltage on terminal 1 of the axle lock- out valve solenoid DIN connector [X212.1.soc] measure 12VDC? Yes Repair/Replace the ORANGE 60-1 wire between terminal 4 of the 12 position BLAM-Valve harness passthru connector [X058.4] and terminal 8 of the Turntable (top) swivel connector [X083.8] No Go to step 1.265.14 1.265.14 Remove terminal 3 of the BLAM module J5 connector [X090.3] Does the voltage on terminal 1 of the axle lock- out valve solenoid DIN connector [X212.1.soc] measure 12VDC? Yes Repair/Replace the ORANGE 60-1 wire between terminal 3 of the BLAM module J5 connector [X090.3] and terminal 4 of the 12 position BLAM- Valve harness passthru connector [X058.4] No Replace the BLAM module 1.265.15 Remove terminal 8 of the chassis (bottom) swivel connector [X216.8] and dis- connect the axle lockout valve solenoid DIN connec- tor [X212] Is there continuity between terminal 8 of the chassis (bottom) swivel connector [X216.8.pin] and terminal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]? Yes Go to step 1.265.16 No Repair/replace the ORANGE 60-2 wire between terminal 1 of the axle lockout valve solenoid con- nector [212.1] and terminal 8 of the chassis (bot- tom) swivel connector [X216.8] 1.265.16 Remove terminal 8 of the Turntable (top) swivel con- nector [X083.8] and discon- nect the axle lockout valve solenoid DIN connector [X212] Is there continuity between terminal 8 of the Turntable (top) swivel connector [X083.8] and terminal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]? Yes Go to step 1.265.17 No Replace the Collector Ring and swivel harness 1.265.17 Remove terminal 4 of the 12 position BLAM-Valve har- ness passthru connector [X058.4] and disconnect the axle lockout valve solenoid DIN connector [X212] Is there continuity between terminal 4 of the 12 position BLAM-Valve harness passthru con- nector [X058.4] and disconnect the axle lock- out valve solenoid DIN connector [X212] and terminal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]? Yes Go to step 1.265.18 No Repair/Replace the ORANGE 60-1 wire between terminal 4 of the 12 position BLAM-Valve harness passthru connector [X058.4] and terminal 8 of the Turntable (top) swivel connector [X083.8] 1.265.18 Remove terminal 3 of the BLAM module J5 connector [X090.3] and disconnect the axle lockout valve solenoid DIN connector [X212] Is there continuity between terminal 3 of the BLAM module J5 connector [X090.3] and ter- minal 1 of the axle lockout valve solenoid DIN connector [X212.1.soc]? Yes Replace the BLAM module No Repair/Replace the ORANGE 60-1 wire between terminal 3 of the BLAM module J5 connector [X090.3] and terminal 4 of the 12 position BLAM- Valve harness passthru connector [X058.4] Flash Code: 8-6 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-136 1250AJP 3128411 active until an EMS cycle, the engine will be stopped if out of transport and pressure is indicated with this fault, and engine starting will be prevented while out of transport and pressure is indicated by this switch. Note Pretest Instructions Test Result Corrective Action 1.266.1 Is the primary fault, RESTRICTED TO TRANS- PORT - AXLE LOCKOUT VALVE STB OR OC present in the fault log? Yes Troubleshoot any primary faults first No Go to step 1.266.2 1.266.2 With the machine idling, does ANALYZER ⇒ DIAGNOSTICS ⇒ SYSTEM ⇒ OSCILATING AXLE PRES. SW. read CLOSED? Yes Go to step 1.266.14 No Go to step 1.266.3 1.266.3 While drive is activated in the transport posi- tion does ANALYZER ⇒ DIAGNOSTICS ⇒ SYSTEM ⇒ OSCILATING AXLE PRES. SW. read CLOSED? Yes Go to step 1.266.4 No Go to step 1.266.5 1.266.4 While drive is activated in the elevated position does ANALYZER ⇒ DIAGNOSTICS ⇒ SYS- TEM ⇒ OSCILATING AXLE PRES. SW. read OPEN? Yes Perform drive calibration. See 5.3 Calibrating Drive on Pg. 292. No Check the fault log. Troubleshoot any 3-3 codes in the fault log first 1.266.5 Tee in a 1000 psi pressure gauge next to the pressure switch on the traction con- trol valve manifold While drive is activated in the transport posi- tion does the gauge read above 200 psi? Yes Go to step 1.266.11 No Go to step 1.266.6 1.266.6 Connect a 1000 psi pres- sure gauge to the MP port on the traction control valve manifold With the machine idling, can the pressure be adjusted with the adjacent charge relief valve so that the gauge reads 500psi? Yes Replace the axle lockout valve cartridge No Go to step 1.266.7 1.266.7 Disconnect, plug and cap all four drive hoses at the top of the swivel (ports 3, 4, 5, and 6). Tee a gauge in with the hoses at the charge (pres- sure) filter (on engine side). Plug open lines. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Reassemble, but keep gauge installed. Go to step 1.266.9. No Shut down, and reassemble, but keep gauge installed. Go to step 1.266.8. 1.266.8 Tee a gauge in with the hoses at the charge filter. Discon- nect the front drive pump charge pressure lines (ports Fa and Fe). A jumper hose between the fittings on the pump is required to prevent pump damage. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Repair/replace right side drive pump No Repair/replace left side drive pump. 1.266.9 Disconnect, plug and cap all four drive hoses at the bot- tom of the swivel (ports 3, 4, 5, and 6). Tee a gauge in with the hoses at the charge filter. Plug open lines. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Shut down, and reassemble, but keep gauge installed. Go to step 1.266.10. No Repair seals in swivel. 1.266.10 Disconnect hoses to trac- tion valve ports A3, a4, A5, A6, B3, B4, B5, and B6. Plug/cap open lines and ports. Tee a gauge in with the hoses at the charge filter. Start engine and let it idle. Ensure hydraulic oil has been warmed up. Does the gauge read about 500psi? Yes Repair drive motor leakage or replace. No Repair/replace traction valve. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-137 1.267 RESTRICTED TO TRANSPORT - PARKING BRAKE STB Restricted to transport - parking brake short to battery. The parking brake output [X001.23] is shorted to battery so the boom cannot go above the transport position. See 1.241 PARKING BRAKE SHORT TO BATTERY on Pg. 122. 1.268 RIGHT FORWARD DRIVE PUMP OPEN CIRCUIT Right forward drive pump open circuit. The right forward drive pump output [X087.1] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.269 RIGHT FORWARD DRIVE PUMP SHORT TO BATTERY Right forward drive pump short to battery. The right forward drive pump output [X087.1] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.266.11 Does the voltage at the axle lockout pressure switch connector YEL/RED 2-1-7 wire [X213.1.soc] measure 12VDC? Yes Go to step 1.266.12 No Check YEL/RED 2-1-7 wire for breaks between the axle lockout pressure switch [X213] and ter- minal 1 of the Chassis module J4 connector [X232.1] 1.266.12 While drive is activated in the transport posi- tion, does the voltage at the axle lockout pres- sure switch connector ORN/RED 49-107 wire [X213.3] measure 12VDC? Yes Go to step 1.266.13 No Replace the axle lockout pressure switch 1.266.13 While drive is activated in the transport posi- tion, does the voltage at terminal 7 of the chas- sis module J2 connector ORN/RED 49-107 wire [X230.7.soc] measure 12VDC? Yes Replace the chassis module No Check ORN/RED 49-107 wire for breaks between the axle lockout pressure switch [X213] and ter- minal 7 of the Chassis module J2 connector [X230.7] 1.266.14 Plumb a 1000 psi pressure gauge to the pressure switch port on the traction control valve manifold With the machine idling, does the gauge read any pressure? Yes Go to step 1.266.15 No Go to step 1.266.16 1.266.15 Remove the axle lockout valve solenoid from the valve. Tee in a 1000 psi pres- sure gauge next to the pres- sure switch on the traction control valve manifold With the machine idling, does the gauge read any pressure? Yes Replace the axle lockout valve cartridge No Go to 1.265 RESTRICTED TO TRANSPORT - AXLE LOCKOUT VALVE STB OR OC 1.266.16 Disconnect the axle lockout pressure switch DIN con- nector [X213] With the machine idling, does ANALYZER ⇒ DIAGNOSTICS ⇒ SYSTEM ⇒ OSCILATING AXLE PRES. SW. read CLOSED? Yes Go to step 1.266.17 No Replace the axle lockout pressure switch 1.266.17 Remove socket 7 from the chassis module J2 connec- tor [X230.7.soc] With the machine idling, does ANALYZER ⇒ DIAGNOSTICS ⇒ SYSTEM ⇒ OSCILATING AXLE PRES. SW. read CLOSED? Yes Replace the chassis module No Check the ORN/RED 49-107 wire for shorts between the axle lockout pressure switch [X213] and terminal 7 of the Chassis module J2 connec- tor [X230.7] Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-138 1250AJP 3128411 1.270 RIGHT FORWARD DRIVE PUMP SHORT TO GROUND Right forward drive pump short to ground. The right forward drive pump output [X087.1] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.271 RIGHT REVERSE DRIVE PUMP OPEN CIRCUIT Right reverse drive pump open circuit. The right reverse drive pump output [X087.12] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.272 RIGHT REVERSE DRIVE PUMP SHORT TO BATTERY Right reverse drive pump short to battery. The right reverse drive pump output [X087.12] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.273 RIGHT REVERSE DRIVE PUMP SHORT TO GROUND Right reverse drive pump short to ground. The right reverse drive pump output [X087.12] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.274 RT FNT STEER LT STB OR OC Right front steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right front steer left valve output [X233.2]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.275 RT FNT STEER LT STG Right front steer left short to ground. The control system detected a short to ground on the chassis module right front steer left valve output [X233.2]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.276 RT FNT STEER RT STB OR OC Right front steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right front steer right valve output [X233.1]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.277 RT FNT STEER RT STG Right front steer right short to ground. The control system detected a short to ground on the chassis module right front steer right valve output [X233.1]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.278 RT REAR STEER LT STB OR OC Right rear steer left short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right rear steer left valve output [233.6]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.279 RT REAR STEER LT STG 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. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 Flash Code: 8-6 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-139 1.280 RT REAR STEER RT STB OR OC Right rear steer right short to battery or open circuit. The control system detected a short to battery or open circuit on the chassis module right rear steer right valve output [233.5]. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.281 RT REAR STEER RT STG Right rear steer right short to ground. The control system detected a short to ground on the chassis module right rear steer right valve output [233.5]. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.282 RUNNING AT CREEP - CREEP SWITCH OPEN Running at creep - creep switch open. All function speeds are limited to creep because the creep switch is open. This switch is part of the hydraulic speed potentiometer operated by a knob on the platform console. The creep indicator will light when in creep mode or blink in super creep mode. Circumstances that cause the machine to automatically enter creep/super creep mode include encroachment of the operating envelope limit by tower or main boom, platform leveling fault, throttle actuator failure, stowed basket, software version faults, boom sensor failures, hydraulic warm-up mode, and hydraulic or electrical retrieval mode. Flash Code: 8-6 Flash Code: 8-6 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.282.1 Are any of the circumstances that cause creep or super creep mode automatically present? Yes Clear any condition present No Go to step 1.282.2 1.282.2 Rotate function speed con- trol knob fully CCW until it clicks. Is creep light on? Yes Go to step 1.282.7 No Go to step 1.282.3 1.282.3 Watch creep light while turning on machine from both the platform. Is creep light on for the lamp check? Yes Go to step 1.282.4 No Replace LED light panel with light that is bad. 1.282.4 Disconnect hyd speed pot passthru - 6 pos. [X199]. Ground meter. See Ground- ing on Pg. 319 for details. Turn on machine. Is there about 12VDC at hyd speed pot passthru socket 3 [X199.3.soc]? Yes Keep hyd speed pot passthru - 6 pos. [X199] dis- connected. Go to step 1.282.6 No Keep hyd speed pot passthru - 6 pos. [X199] dis- connected. Go to step 1.282.5 1.282.5 Disconnect hyd speed pot passthru - 6 pos. [X199] and platform module J1 [X165] Is there continuity between hyd speed pot passthru socket 3 [X199.3.soc] and platform module J1 socket 18 [X165.18.soc]? Yes Replace platform module No Replace/repair harness between hyd speed pot passthru socket 3 [X199.3.soc] and platform module J1 socket 18 [X165.18.soc] 1.282.6 Disconnect hyd speed pot passthru - 6 pos. [X199] and platform module J1 [X165] Is there continuity between hyd speed pot passthru pin 2 [X199.2.pin] and platform module J1socket 32 [X165.32.soc]? Yes Repair/replace hyd speed pot and/or harness [X199] No Repair/replace harness between hyd speed pot passthru pin 2 [X199.2.pin] and platform module J1socket 32 [X165.32.soc] 1.282.7 Turn on machine. Rotate function speed control knob CW 1/4 turn to 9 o’clock position. Does creep light turn off? Yes Keep machine in same condition. Go to step 1.282.8 No Go to step 1.282.9 1.282.8 Turn on machine. Rotate function speed control knob CW 1/4 turn to 9 o’clock position. Does fault message clear? Yes Normal operation. Troubleshooting complete. No Reprogram/replace ground module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-140 1250AJP 3128411 1.283 RUNNING AT CREEP - PLATFORM OVERLOADED Running at creep - platform overloaded. Reported when the platform is overloaded, causing the machine to be in creep mode. Only displayed when the load sensor machine configuration is set to WARN ONLY. 1.284 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION Running at creep - tilted and above elevation. All boom function speeds are limited to creep because the machine is tilted and above elevation. The machine is "Tilted" if the chassis is greater than 5.0° in any direction, or 3.0° to the side when the tower angle is greater than 60°. If Tilt calibration has not been performed after the ground module or the main terminal box has been removed or replaced the machine will also indicate it is tilted. The machine is "Above Elevation" if either the tower boom or main boom is above elevation. The tower boom is above elevation if it is greater than +2.0° from the turntable. If one sensor has failed the tower boom is above elevation if the good sensor indicates greater than +8.4° from the turntable. This resets at +5.9°. The main boom is above elevation if it is greater than +2.0° from the tower boom. This resets at 0.0°. If there is a main boom angle sensor failure the main boom is above elevation as indicated by the main boom transport angle switch. 1.282.9 Rotate function speed con- trol knob CW 1/4 turn to 9 o’clock position. Discon- nect hyd speed pot passthru - 6 pos. [X199]. Is there a short between hyd speed pot passthru socket 2 [X199.2.soc] and pin 3 [X199.3.pin]? Yes Repair/replace function speed control and/or har- ness to hyd speed pot passthru - 6 pos. [X199] No Go to step 1.282.10 1.282.10 Disconnect hyd speed pot passthru - 6 pos. [X199] and platform module J1 [X165] Is there a short between platform module J1 socket 32 [X165.32.soc] and socket 18 [X165.18.soc]? Yes Repair/replace harness between platform mod- ule J1 socket 32 [X165.32.soc] and socket 18 [X165.18.soc] No Keep hyd speed pot passthru - 6 pos. [X199] dis- connected. Go to step 1.282.11 1.282.11 Disconnect hyd speed pot passthru - 6 pos. [X199].Ground meter. Turn on machine. Is there about 12 VDC on hyd speed pot passthru pin 2 [X199.2.pin]? Yes Repair/replace harness between hyd speed pot passthru pin 2 [X199.2.pin] No Reprogram/replace platform module Flash Code: 8-2 Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.284.1 Return machine to Trans- port position and level ground Is fault still active? Yes Go to step 1.284.2 No Troubleshooting complete 1.284.2 Are there any boom sensor or Chassis tilt sen- sor faults? Yes Troubleshoot those faults No Go to step 1.284.3 1.284.3 Return machine to Trans- port position and level ground. ANALYZER ⇒ DIAGNOSTICS ⇒ TRANS- PORT DATA Does TOWER LIFT and MAIN LIFT read STOWED? Yes Go to step 1.284.4 No Perform 5.8 Boom Sensor Calibration on Pg. 309 1.284.4 Is the Tilt indicator on? Yes Perform 5.7 Calibrating Tilt Sensor on Pg. 307 No Repair/reprogram ground module Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-141 1.285 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION Running at cutback - out of transport position. Drive speed is limited to programmed maximum because the vehicle is out of transport position. Maximum drive speed is set in the Personality of the machine. Transport position is defined as main boom retracted to less than 4’ and parallel to tower boom, and the tower boom retracted and down to within 2.0° of the turntable. 1.286 SPEED INPUT LOST Speed input lost. This fault should only occur on machines configured with non-ECM engines. Notification that there is no engine speed detected on the engine flywheel speed sensor input [X001.16], but the oil pressure input [X001.15] reads above 8 PSI for more than 3 seconds. 1.287 SPEED SENSOR READING INVALID SPEED Speed sensor reading invalid speed. This fault should only occur on machines configured with non-ECM engines. Notifica- tion that the engine flywheel speed sensor input [X001.16] is indicating a speed that greater than 4000 RPM or approxi- mately 8875 Hz. 1.288 START SOLENOID OPEN CIRCUIT 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. Flash Code: 0-0 Note Pretest Instructions Test Result Corrective Action 1.285.1 Read faults Are there any tower angle sensor, tower length sensor, main (boom) angle sensor, dual capacity switch or transport length switch faults? Yes Troubleshoot those faults first No Go to step 1.285.2 1.285.2 Return machine to transport position Did fault clear? Yes Troubleshooting Complete No Go to step 1.285.3 1.285.3 ANALYZER ⇒ DIAGNOS- TICS ⇒ TRANSPORT DATA ⇒ TRANSPORT MODE Does it read OUT OF TRANSPORT? Yes Go to step 1.285.4 No Reprogram/replace ground module 1.285.4 ANALYZER ⇒ DIAGNOS- TICS ⇒ TRANSPORT DATA ⇒ TOWER LIFT STATUS Does it read STOWED, or can the tower boom be lowered to make it read STOWED? Yes Keep analyzer connected. Go to step 1.285.5 No Calibrate boom sensors 1.285.5 ANALYZER ⇒ DIAGNOS- TICS ⇒ TRANSPORT DATA ⇒ TOWER TELESCOPE STATUS Does it read RETRACTED, or can the main boom be moved within the transport position envelope to make it read RETRACTED? Yes Keep analyzer connected. Go to step 1.285.6 No Calibrate boom sensors 1.285.6 ANALYZER ⇒ DIAGNOS- TICS ⇒ TRANSPORT DATA ⇒ MAIN LIFT STATUS Does it read STOWED, or can the main boom be lowered to make it read STOWED? Yes Keep analyzer connected. Go to step 1.285.7 No Calibrate boom sensors 1.285.7 ANALYZER ⇒ DIAGNOS- TICS ⇒ TRANSPORT DATA ⇒ MAIN TELESCOPE STA- TUS Does it read RETRACTED, or can the main boom be moved within the transport position envelope to make it read RETRACTED? Yes Normal operation. Troubleshooting complete. No Calibrate boom sensors Flash Code: 5-5 Flash Code: 5-5 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-142 1250AJP 3128411 1.289 START SOLENOID SHORT TO BATTERY Start solenoid short to battery. The engine start solenoid output [X001.11] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.290 START SOLENOID SHORT TO GROUND Start solenoid short to ground. The engine start solenoid output [X001.11] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.291 START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH Start switch locked - selected before keyswitch. The start switch input [X004.4] was selected at startup. The engine start switch [X026] is likely stuck or the wiring is shorted. 1.292 STEER LOCKED - SELECTED BEFORE FOOTSWITCH Steer locked - selected before footswitch. Notification that one of the platform steer inputs [X168.5 X168.6] was selected before the footswitch was closed. Steering will be prevented. Close the footswitch before steering. This could also be due to a faulty steer switch [X176] or wiring. 1.293 STEER SENSORS NOT CALIBRATED Steer sensors not calibrated. The steering sensors require calibration. This fault can happen if calibration is incorrect or a new chassis module has been installed and steering calibration is not done. 1.294 STEER SWITCHES FAULTY Steer switches faulty. Notification that both left and right steer switch inputs [X168.5 X168.6] are active at the same time. This could be due to a faulty steer switch [X176] or wiring. 1.295 SWING LEFT OPEN CIRCUIT Swing left open circuit. The swing left valve output [X002.34] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.296 SWING LEFT 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 Swing right open circuit. The swing right valve output [X002.35] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 2-3 Flash Code: 2-2 Flash Code: 9-9 Note Pretest Instructions Test Result Corrective Action 1.293.1 Perform 5.2 Calibrating Steer on Pg. 290. Does calibration complete successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault Flash Code: 2-2 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-143 1.298 SWING RIGHT SHORT TO BATTERY Swing right short to battery. The swing right valve output [X002.35] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.299 THROTTLE ACTUATOR FAILURE Throttle actuator failure. This fault should only occur on machines configured with non-ECM engines. The engine is over- speeding, reading over 3050 RPM. This probably indicates the throttle actuator has failed. 1.300 THROTTLE ACTUATOR OPEN CIRCUIT Throttle actuator open circuit. This fault should only occur on machines configured with non-ECM engines. The engine throt- tle actuator output [X001.1] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.301 THROTTLE ACTUATOR SHORT TO BATTERY Throttle actuator short to battery. This fault should only occur on machines configured with non-ECM engines. The engine throttle actuator output [X001.1] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.302 THROTTLE ACTUATOR SHORT TO GROUND Throttle actuator short to ground. This fault should only occur on machines configured with non-ECM engines. The engine throttle actuator output [X001.1] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.303 TOWER ANGLE SENSOR DISAGREEMENT Tower angle sensor disagreement. The control system detected a difference between the #1 (Right) [X099] and #2 (Left) [X100] tower boom angle sensors. A difference greater than 1.5° was held for at least 2.0 seconds. A power cycle is required. Flash Code: 3-3 Flash Code: 4-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.303.1 Read fault log Are any of the following faults active on the machine? TWR ANGL1 (or 2) INVALID ANGLE or INVALID ANGLE SENSOR #1 (or 2) MODEL o r B OOM ANG LE S ENS OR #1 (o r 2 ) C OMM U- NICATIONS FAULT Yes Troubleshoot them first No Go to step 1.303.2 1.303.2 Access tower boom angle sensor #1 (Right) [X099] Check they aren’t swapped by unplugging tower boom angle sensor #1 (Right) [X099]. Does the BOOM ANGLE SENSOR #1 COM- MUNICATIONS FAULT show? Yes Go to step 1.303.3 No Plug sensor harnesses into correct sensors 1.303.3 Fully retract and lower boom. ANALYZER ⇒ DIAG- NOSTICS ⇒ BOOM SEN- SORS ⇒ TOWER ANGLE # SENSOR Are both sensor angles approximately -4.3 ± 1.5°? Yes Go to step 1.303.4 No Replace sensor out of specified range 1.303.4 Calibrate boom Did boom calibrate successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-144 1250AJP 3128411 1.304 TOWER ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED Tower envelope encroached - hydraulics suspended. The system has detected a tower envelope violation and suspended hydraulics to prevent further encroachment. Use the APU to telescope in or lift down inside the envelope. See 1.91 ENVE- LOPE ENCROACHED - HYDRAULICS SUSPENDED on Pg. 73. 1.305 TOWER LENGTH SENSOR DISAGREEMENT Tower length sensor disagreement. The control system detected a difference between the #1 (top) and #2 (bottom) tower boom length sensors. A difference greater than 2.0“was held for at least 2.0 seconds. The lengths are visible in ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 1 SENSOR and TOWER LENGTH 2 SENSOR. Flash Code: 0-0 Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.305.1 Read fault log with analyzer Are there any tower length sensor value out of range faults? Yes Troubleshoot, fix and clear them first No Go to step 1.305.2 1.305.2 Examine the cables, tower boom length sen- sors #1 [X093] and #2 [X094], and mount- ing blocks. Is there any visible damage, loose hardware, kinked or stuck cables, etc.? Or, are there any corroded or wet electrical connec- tions? Yes Tighten any loose hardware. Clean, repair or replace any bad connections. Repair/replace damaged items. Do not disassemble length sen- sor. No Go to step 1.305.3 1.305.3 Disconnect cable at sensor #1 (top) [X093]. If sensor #1 (top) [X093] is unplugged at the top tower boom length sensor connector [X093], message TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW should show in the fault log. If sensor 2 shows, the wires are swapped. Are the wires swapped? Yes Connect the top tower boom length sensor con- nector [X093] to sensor #1 (top) and the bottom tower boom length sensor connector [X094] to sensor #2 (bottom) No Go to step 1.305.4 1.305.4 Fully lower tower. Check this by looking for marks on the tower boom from the wear pads to be hidden. ANA- LYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS TOWER LENGTH 1 and TOWER LENGTH 2 should read approximately 305 inches. Do they? Yes Keep tower lowered and analyzer reading boom sensors. Go to step 1.305.9 No Note sensor(s) with bad reading. Go to step 1.305.5 1.305.5 Is the sensor with bad reading sensor #1? Yes Go to step 1.305.6 No Go to step 1.305.10 1.305.6 Turn on machine. Discon- nect tower boom length sen- sor #1 [X093]. Measure voltage from socket A[X093].A.soc] to socket B [X093.B.soc]. Does voltage read 5VDC? Yes Go to step 1.305.8 No Go to step 1.305.7 1.305.7 Turn on machine. Discon- nect BLAM J3 [X088]. Measure voltage from pin 7 [X088.7.pin] to pin 9 [X088.9.pin]. Does voltage read about 5VDC? Yes Repair/replace harness between tower boom length sensor #1 [X093] and BLAM J3 [X088] No Replace BLAM 1.305.8 Disconnect tower boom length sensor #1 [X093]. Disconnect BLAM J3 [X088]. Is there continuity from tower boom length sensor #1 socket C [X093.C.soc] socket C to BLAM J3 socket 8 [X088.8.soc]? Yes Go to step 1.305.9 No Repair/replace harness between tower boom length sensor #1 [X093] and BLAM J3 [X088] 1.305.9 Remove tower boom length sensor #1 (top) [X093]. Measure resistance from pin A [X093.A.pin] to pin C [X093.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.305.13 No Replace tower boom length sensor #1 [X093] SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-145 1.306 TOWER LENGTH SWITCH/SENSOR DISAGREEMENT Tower length switch/sensor disagreement. The tower length switch did not change states by 306.4 inches while retracting or by 315.4 inches while extending. Measured by tower length sensor #1. The calibrated switch point can be viewed in ANA- LYZ ER ⇒ ACCESS LEVEL 1 ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER TRIP POINT LENGTH. The length is visible in ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 1 SENSOR. The normally closed tower length switch should be closed when the tower is telescoped in to transport position and the limit switch arm is off the cam. The length switch state is visible in ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ TOWER TELESCOPE SWITCH NC. This could be caused by a sticking switch and may be an intermittent fault. 1.305.10 Turn on machine. Discon- nect tower boom length sen- sor #2 [X094]. Measure voltage from socket A [X094.A.soc] to socket B [X094.B.soc]. Does voltage read 5VDC? Yes Go to step 1.305.12 No Go to step 1.305.11 1.305.11 Turn on machine. Discon- nect BLAM J3 [X088]. Measure voltage from pin 4 [X088.4.pin] to pin 6 [X088.6.pin]. Does voltage read 5VDC? Yes Repair/replace harness between tower boom length sensor #2 [X094] and BLAM J3 [X088] No Replace BLAM 1.305.12 Disconnect tower boom length sensor #2 [X094]. Disconnect BLAM J3 [X088]. Is there continuity from tower boom length sensor #2 pin C [X094.C.soc] to BLAM J3 socket 8 [X088.8.soc]? Yes Go to step 1.305.13 No Repair/replace harness between tower boom length sensor #2 [X094] and BLAM J3 [X088] 1.305.13 Remove tower boom length sensor #2 (bottom) [X094]. Measure resistance from pin A [X094.A.pin] to pin C [X094.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.305.14 No Replace tower boom length sensor #2 [X094] 1.305.14 Perform a boom sensor Calibration, see 5.8 Boom Sensor Calibration on Pg. 309. Did fault clear? Yes Troubleshooting complete No Replace sensor causing failure Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.306.1 Check the fault log for primary faults, TOWER LENGTH SENSOR DISAGREEMENT, TWR LENGTH SENSOR NOT DETECTING LENGTH CHANGE, TWR LENGTH SENSOR ONE VALUE OUT OF RANGE HIGH, TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW, or TWR TRN SW DISAGREEMENT Yes Troubleshoot the primary fault before continuing No Go to step 1.306.2 1.306.2 Verify that the tower length limit switch [X056] is operating smoothly and in the transport position the switch arm is oriented at 90 degrees from the switch body Yes Go to step 1.306.3 No Repair, lubricate, or replace the switch 1.306.3 Is there any loose hardware on the length sen- sors [X093 X094], length switch [X056], mounting points, or cable mounts Yes Tighten any loose hardware No Go to step 1.306.4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-146 1250AJP 3128411 1.306.4 Check circuit connections at the tower boom transport length switch [X056], 6 position Mate-N-Lok connector in the main terminal box [X017], ground module J7 connector [X007], right & left tower boom length sensor [X093, X094], and BLAM module J3 connec- tor [X088]. Are there any loose terminals or moisture or corrosion? Yes Clean or replace any bad connections No Go to step 1.306.5 1.306.5 Check the tower boom transport length switch power. Terminal 14 and 22 of the tower boom transport switch [X056.14 X056.22] should measure 12VDC. Yes Go to step 1.306.8 No Go to step 1.306.6 1.306.6 In the transport position, terminal 1 of the 6 position Mate-N-Lok connector in the main terminal box [X017.1] should measure 12VDC. Yes Repair/Replace the white wire between the switch and the 6 position Mate-N-Lok connector in the main terminal box [X017.1] No Go to step 1.306.7 1.306.7 In the transport position, terminal 29 of the ground module J7 connector [X007.29] should measure 12VDC. Yes Repair/Replace the YEL/RED 2-60 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.1] and terminal 29 of the ground module J7 connector [X007.29] No Repair/Replace the ground module 1.306.8 In the transport position, does terminal 13 of the tower boom transport switch [X056.13] measure 12VDC? Yes Repair/Replace the tower boom transport length switch No Go to step 1.306.9 1.306.9 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 13 of the tower boom transport switch [X056.13] should measure 12VDC Yes Go to step 1.306.13 No Go to step 1.306.10 1.306.10 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 6 of the 6 position Mate-N-Lok connector in the main terminal box [X017.6] should measure 12VDC Yes Repair/Replace the red wire between the switch and the 6 position Mate-N-Lok connector in the main terminal box [X017.6] No Go to step 1.306.11 1.306.11 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 35 of the ground module J7 connector [X007.35] should measure 12VDC Yes Repair/Replace the ORN/RED 49-65 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.6] and terminal 35 of the ground module J7 connector [X007.35] No Go to step 1.306.12 1.306.12 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm Check that ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ TOWER TELESCOPE SWITCH NO: CLOSED is displayed. Yes Go to step 1.306.13 No Replace the ground module 1.306.13 In the transport position, terminal 21 of the tower boom transport switch [X056.21] should measure 12VDC Yes Go to step 1.306.14 No Repair/Replace the tower boom transport length switch 1.306.14 In the transport position, terminal 2 of the 6 position Mate-N-Lok connector in the main terminal box [X017.2] should measure 12VDC Yes Go to step 1.306.15 No Repair/Replace the black wire between the switch and terminal 2 of the 6 position Mate-N- Lok connector in the main terminal box [X017.2] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-147 1.307 TOWER LIFT APU VALVE OPEN CIRCUIT Tower lift auxiliary power unit pilot valve open circuit. The tower lift pilot valve output [X002.12] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.308 TOWER LIFT APU VALVE SHORT TO BATTERY 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. 1.306.15 In the transport position, terminal 11 of the ground module J7 connector [X007.11] should measure 12VDC Yes Go to step 1.306.16 No Repair/Replace the ORN/RED 49-64 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.2] and terminal 11 of the ground module J7 connector [X007.11] 1.306.16 Check that ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ TOWER TELESCOPE SWITCH NC: CLOSED is displayed. No Replace the ground module Yes Go to step 1.306.17 1.306.17 Recalibrate, see 5.8 Boom Sensor Calibration on Pg. 309 Does recalibration clear this fault? No Go to step 1.306.18 Yes Troubleshooting complete 1.306.18 Does ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SENSORS ⇒ TOWER LENGTH 1 SENSOR read about 305" when in transport position? Yes Recycle the EMS switch, then go to step 1.306.17 No Go to step 1.306.19 1.306.19 Disconnect the BLAM mod- ule J3 connector [X088] Does the resistance between terminals 7 and 9 of the BLAM module J3 connector [X088.7.soc and X088.9.soc] measure 5k Ω? Yes Go to step 1.306.21 No Go to step 1.306.20 1.306.20 Disconnect the right tower length sensor connector [X093] Does the resistance between terminals A and B of the right tower length sensor connector [X093.A.pin and X093.B.pin] measure 5k Ω? Yes Repair/replace the red and black wires between the right tower length sensor [X093] and the BLAM module J3 connector [X088] No Repair/replace the right tower length sensor 1.306.21 Disconnect the BLAM mod- ule J3 connector [X088] Does the resistance between terminals 10 and 12 of the BLAM module J3 connector [X088.10 and X088.12] measure 5k Ω? Yes Go to step 1.306.23 No Go to step 1.306.22 1.306.22 Disconnect the left tower length sensor connector [X094] Does the resistance between terminals A and B of the left tower length sensor connector [X094.A.pin and X094.B.pin] measure 5k Ω? Yes Repair/replace the Orange and Black wires between the left tower length sensor [X094] and the BLAM module J3 connector [X088] No Repair/replace the left tower length sensor 1.306.23 Does the voltage between terminals A and B of the right tower length sensor connector [X093] measure 5VDC? Yes Possible Causes: Faulty sensor, Faulty BLAM module No Go to step 1.306.24 1.306.24 Disconnect the BLAM mod- ule J3 connector [X088] Does the voltage between terminals 7 and 9 of the BLAM module J3 connector [X088.7.pin and X088.9.pin] measure 5VDC? Yes Possible Causes: Faulty sensor, Faulty BLAM module No Possible Causes: Faulty BLAM module Flash Code: 3-3 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-148 1250AJP 3128411 1.309 TOWER LIFT APU VALVE SHORT TO GROUND Tower lift auxiliary power unit pilot valve short to ground. The tower lift pilot valve output [X002.12] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.310 TOWER LIFT APU VALVE STUCK OPEN Tower lift auxiliary power unit pilot valve stuck open. This fault is detected at the end of a tower lift down command. The con- troller keeps the tower lift enable valve [X080] on with the tower lift PVG valve [X066] off and looks for tower angle sensor movement. If movement is detected, the tower lift pilot valve [X075] is likely stuck open. 1.311 TOWER LIFT ENABLE OPEN CIRCUIT Tower lift enable open circuit. The tower lift enable output [X002.33] is open. See 1.377 COMMON STB OR OC PROCE- DURE on Pg. 174. 1.312 TOWER LIFT ENABLE SHORT TO BATTERY Tower lift enable short to battery. The tower lift enable output [X002.33] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.313 TOWER LIFT ENABLE SHORT TO GROUND Tower lift enable short to ground. The tower lift enable output [X002.33] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.314 TOWER LIFT ENABLE STUCK OPEN Tower lift enable stuck open. Fault is detected when a tower lift up is engaged. The controller keeps the tower lift enable valve [X080] off and engages the tower lift PVG valve [X066] and looks for tower angle sensor movement. If movement is detected, the tower lift enable valve is likely stuck open. 1.315 TOWER LIFT PVG VALVE COMMAND IMPROPER Tower lift PVG valve command improper. Tower lift PVG valve received an incorrect instruction from the CAN bus. This could be due to a CAN bus problem or a ground module problem. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.315.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.315.2 1.315.2 Cycle power. Does problem clear? Yes Troubleshooting complete No Reprogram/replace ground module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-149 1.316 TOWER LIFT PVG VALVE COMMUNICATIONS Tower lift PVG valve communications. The tower lift PVG valve is required to send it's status message every 100mS. If the sta- tus message from the PVG valve is not received within 500mS then this fault is issued. 1.317 TOWER LIFT PVG VALVE HIGH VOLTAGE Tower lift PVG valve high voltage. Voltage powering the tower lift PVG valve exceeded 32 VDC. Restore proper system volt- age to clear fault. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.316.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.316.2 1.316.2 Disconnect tower lift PVG - 4 pos. [X066]. Turn on machine. Measure voltage between tower lift PVG con- nector socket 2 [X066.2.soc] and socket 3 [X066.3.soc]. Is it about 12 VDC? Yes Go to step 1.316.4 No Go to step 1.316.3 1.316.3 Disconnect tower lift PVG - 4 pos. [X066] and ground module J2 [X002] Is there continuity between tower lift PVG - 4 pos. socket 2 [X066.2.soc] and ground mod- ule J1 socket 3 [X001.3.soc]? Yes Repair harness between tower lift PVG - 4 pos. [X066] and battery ground No Repair harness between tower lift PVG - 4 pos. [X066] and ground module J1 1.316.4 Turn off machine. Discon- nect tower lift PVG - 4 pos. [X066]. Measure resistance between tower lift PVG socket 1 [X066.1.soc] and socket 4 [X066.4.soc]. Is it about 60Ω? Yes Replace tower lift PVG valve [X066] actuator No Go to step 1.316.5 1.316.5 Turn off machine. Discon- nect tower lift PVG - 4 pos. [X066] and BLAM J4 [X089]. Is there continuity between tower lift PVG socket 1 [X066.1.soc] and BLAM J4 socket 4 [X089.4.soc]? - AND - Is there continuity between tower lift PVG socket 4 [X066.4.soc] and BLAM J4 socket 3 [X089.3.soc]? Yes Replace tower lift PVG valve [X066] actuator or see 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Repair harness between tower lift PVG - 4 pos. [X066] and BLAM J4 [X089] Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.317.1 Ensure all off-board power connections, such as 110VAC, are disconnected. Ensure all on-board power systems are turned off, such as generators, welders, etc. Turn on machine and start engine. Is battery voltage about 12 VDC? -AND- Does charging and 12VDC electrical power generation sys- tem appear to be working properly? Yes Go to step 1.317.2 No Repair 12 VDC charging and electrical power generation system. 1.317.2 Turn off machine. Ensure all off-board power connec- tions, such as 110VAC, are disconnected. Ensure all on- board power systems are turned off, such as genera- tors, welders, etc. Turn off machine. Disconnect tower lift PVG valve [X066] Are there any shorts between tower lift PVG valve socket 2 [X066.2.soc] or socket 3 [X066.3.soc] and wiring for off-board power sources such as 110VAC, or on-board power sources such as welder or generator outputs, etc.? Note, tower lift PVG valve socket 3 [X066.3.soc] to ground continuity is OK. Be sure to check for intermittent problems. Yes Repair shorts as needed No Transient condition likely set fault. If fault keeps occurring, go to step 1.317.3. 1.317.3 Measure voltage on the sec- ond tower lift PVG valve con- nector[X260] using a spare harness exposing terminal 2 [X260.2] and 3 [X260.3], or use insulated alligator clips to those terminals. Observe 12VDC system voltage at the valve over an extended time under various operating conditions, for example, during engine start. See Min/Max on Pg. 319 for details. Is it per- forming properly? Yes Replace tower lift PVG valve actuator [X066] No Repair as needed SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-150 1250AJP 3128411 1.318 TOWER LIFT PVG VALVE INTERNAL FAULT Tower lift PVG valve internal fault. Hardware or software inside the tower lift PVG valve caused an error. There are no service- able parts that cause this problem. 1.319 TOWER LIFT PVG VALVE LOCATION IMPROPER Tower lift PVG valve location improper. Tower lift PVG valve parameters entered into the incorrect valve. This could be due to a calibration or wiring problem. The valve harnesses have one wire in it that is labeled with a number. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.320 TOWER LIFT PVG VALVE LOW VOLTAGE Tower lift PVG valve low voltage. Voltage powering the tower lift PVG valve fell below about 10 VDC. Increase system voltage above 11 VDC to clear fault. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.318.1 Read faults Are there any 6-6 communication faults? Yes Troubleshoot those first No Go to step 1.318.2 1.318.2 Cycle machine power. Keep power off at least 20 seconds. Does fault still occur? Yes Replace tower lift PVG valve actuator [X066] No Troubleshooting complete Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.319.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start off, then turn on, in order, LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Connect harnesses to the correct PVG valve according to wires listed above in description. Then calibrate boom valves and recheck. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.320.1 Are either of the faults TOWER LIFT PVG VALVE COMMUNICATIONS or BLAM CAN COMMUNICATIONS LOST present? Yes Troubleshoot them first. No Go to step 1.320.2 1.320.2 Are the battery and battery connections good? Yes Go to step 1.320.3 No Repair/replace as needed 1.320.3 Turn on machine and start engine. Is battery voltage about 12 VDC and does system appear to be working properly? Yes Go to step 1.320.4 No Repair charging and 12 VDC electrical power generation system. 1.320.4 Disconnect tower lift PVG valve connector [X066]. Turn on machine. Is there about 12 VDC between tower lift PVG valve socket 2 [X066.2.soc] and socket 3 [X066.3.soc]? Yes Transient caused condition. If it occurs again troubleshoot charging and 12 VDC electrical power generation system. No Go to step 1.320.5 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-151 1.321 TOWER LIFT PVG VALVE OBSTRUCTED Tower lift PVG valve obstructed. Tower lift PVG valve spool is not free to move completely. This could be from contamination inside the valve or a blocked filter. 1.320.5 Take the following measure- ment by backprobing. See Backprobing on Pg. 319 for details. Turn on machine after setting up measure- ment. Is there about 12VDC between ground module J1 terminal 3 [X001.3] and any terminal on the MTB ground bus -12 pos. [X009]? Yes Repair/replace harness from tower lift PVG valve [X066] to ground J1 [X001] and the MTB ground bus -12 pos. [X009]. No Go to step 1.320.6 1.320.6 Take the following measure- ment by backprobing. Turn on machine after setting up measurement. Is there about 12VDC between ground module J1 terminal 3 [X002.3] and ground module J8 terminal 1? Yes Repair harness between ground module J1 [X001] and MTB ground bus -12 pos. [X009] No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.321.1 Is there dirt in the hydraulic module part of the valve, especially around the spool? Yes Clean and repair as needed. Go to step 1.321.2 No Go to step 1.321.2 1.321.2 Is the filter at the tower lift PVG valve [X066] pilot oil inlet blocked? Yes Clean and repair as needed. Go to step 1.321.3. No Go to step 1.321.3 1.321.3 Is the fault clear? Yes Go to step 1.321.5 No Go to step 1.321.4 1.321.4 Mark to identify the tower lift PVG valve actuator [X066] using string, tape, etc. Swap it with an actuator that doesn’t have a fault. Perform 5.4 Calibrating Boom Valves on Pg. 296. Does fault move to new location of actua- tor? Yes Replace PVG valve actuator that was initially on the tower lift PVG valve [X066]. Go to step 1.321.5 No Replace hydraulic module of tower lift PVG valve [X066]. Go to step 1.321.5 1.321.5 Does the return filter have contamination in fil- ter media or housing? Yes Go to step 1.321.6 No Troubleshooting complete 1.321.6 Inspect all 4 hydraulic filters and housings and replace all 4 filters: output of function pump, platform filter (If filter is not external to platform valve it must be updated.), return filter and charge filter (for drive pump). Take note of filters/housings that have contamination. Cycle boom from fully lowered and retracted to fully extended and then back. Test hydraulic fluid. Does it test bad, appear cloudy, appear dark, smell burned or is otherwise abnormal? -OR- Was there any contamination in the filters or housings? Yes Replace all hydraulic fluid Go to step 1.321.7 No Go to step 1.321.7 1.321.7 Do machine hydraulics function properly? Yes Troubleshooting complete No Replace hydraulic components that are not func- tioning properly. Focus first on components upstream of any filters/housings with contamina- tion. Calibrate if necessary. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-152 1250AJP 3128411 1.322 TOWER LIFT PVG VALVE PARAMETERS INCORRECT Tower lift PVG valve parameters incorrect. Programing parameters contained in the tower lift PVG valve do not match those stored in the ground module. The valve needs to be calibrated. 1.323 TOWER LIFT PVG VALVE SEND UNRECOGNIZED FAULT Tower lift PVG valve send unrecognized fault. An error code sent by the tower lift PVG valve was not recognized by the con- trol system. 1.324 TOWER LIFT PVG VALVE SETUP FAULT Tower lift PVG valve setup fault. Tower lift PVG valve received programing parameter values that are not allowed. PVG setup is done over the CAN bus by the ground module. 1.325 TOWER LIFT PVG VALVE STUCK EXTENDED Tower lift PVG valve stuck extended. The tower lift PVG valve spool has moved out further than intended. Follow same proce- dure as 1.321 TOWER LIFT PVG VALVE OBSTRUCTED on Pg. 151. 1.326 TOWER LIFT PVG VALVE STUCK NEUTRAL Tower lift PVG valve stuck neutral. The tower lift PVG valve spool stuck outside of neutral position. This could be caused by dirt in the valve body or a PVG valve software issue. Follow same procedure as 1.321 TOWER LIFT PVG VALVE OBSTRUCTED on Pg. 151. 1.327 TOWER LIFT PVG VALVE STUCK RETRACTED 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. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.322.1 Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Did it pass calibration? Yes Troubleshooting complete. If fault is recurring replace tower lift PVG valve [X066] actuator. No Replace tower lift PVG valve [X066] actuator Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.323.1 Cycle machine power Operate main lift. Does fault occur again? Yes Replace tower lift PVG valve [X066] actuator No Troubleshooting complete. If fault is recurring, replace tower lift PVG valve [X066] actuator. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.324.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot other fault(s) first No Go to step 1.324.2 1.324.2 Perform 5.4 Calibrating Boom Valves on Pg. 296 Does the valve calibrate successfully? -AND- Does fault clear? Yes Troubleshooting complete. If fault is recurring, reprogram/replace ground module. No Reprogram/replace ground module Flash Code: 4-5 Flash Code: 4-5 Flash Code: 4-5 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-153 1.328 TOWER LIFT PVG VALVE TIMEOUT Tower lift PVG valve timeout. Position instructions were not received by the tower lift PVG valve within the allowed amount of time. 1.329 TOWER LIFT PVG VALVE WIRING INCORRECT Tower lift PVG valve wiring incorrect. A different valve powered up during power up time for tower lift PVG valve or the tower lift PVG valve powered up outside of the allotted PVG valve power up time. This could be due to a calibration or wiring prob- lem. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left (center of three) with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.330 TOWER TELE APU VALVE STUCK OPEN Tower telescope auxiliary power unit pilot valve stuck open. This fault is detected at the end of a tower lift down command. The controller keeps the tower tele enable valve [X081] on with the tower tele PVG valve [X067] off and looks for tower length sensor movement. If movement is detected, the tower tele pilot valve [X076] is likely stuck open. 1.331 TOWER TELE ENABLE OPEN CIRCUIT Tower telescope enable open circuit. The tower telescope enable valve output [X001.6] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.332 TOWER TELE ENABLE SHORT TO BATTERY Tower telescope enable short to battery. The tower telescope enable valve output [X001.6] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.333 TOWER TELE ENABLE SHORT TO GROUND 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. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.328.1 Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot those faults first No Go to step 1.328.2 1.328.2 Disconnect tower lift PVG valve [X066] Does TOWER LIFT PVG VALVE COMMUNI- CATIONS fault appear? Yes Replace tower lift PVG valve [X066] actuator No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.329.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start all off, then turn on in this order: LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Go to step 1.329.2 1.329.2 Turn off machine. Discon- nect Ignition On Relay [X012] and tower lift PVG valve [X066]. Is there a short between Ignition On Relay socket 30 [X012.30.soc]and tower lift PVG valve socket 2 [X066.2.soc]? Yes Repair/replace harness between Relay [X012] and tower lift PVG valve [X066]. No Connect harnesses to the correct PVG valve as in the description above. Then calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-154 1250AJP 3128411 1.334 TOWER TELE ENABLE STUCK OPEN Tower telescope enable stuck open. This fault is detected when a tower lift up is engaged. The controller keeps the tower tele enable valve [X081] off and engages the tower tele PVG valve [X067] and looks for tower length sensor movement. If movement is detected, the tower tele enable valve is likely stuck open. 1.335 TOWER TELESCOPE APU OPEN CIRCUIT Tower telescope auxiliary power unit pilot valve open circuit. The tower telescope pilot valve output [X002.32] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.336 TOWER TELESCOPE APU SHORT TO BATTERY Tower telescope auxiliary power unit pilot valve short to battery. The tower telescope pilot valve output [X002.32] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.337 TOWER TELESCOPE APU SHORT TO GROUND Tower telescope auxiliary power unit pilot valve short to ground. The tower telescope pilot valve output [X002.32] is shorted to ground. See 1.378 COMMON STG PROCEDURE on Pg. 175. 1.338 TOWER TELESCOPE PVG VALVE COMMAND IMPROPER Tower telescope PVG valve command improper. Tower telescope PVG valve received an incorrect instruction from the CAN bus. This could be due to a CAN bus problem or a ground module problem. 1.339 TOWER TELESCOPE PVG VALVE COMMUNICATIONS Tower telescope PVG valve communications. The tower telescope PVG valve is required to send it's status message every 100mS. If the status message from the PVG valve is not received within 500mS then this fault is issued. Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.338.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.338.2 1.338.2 Cycle power. Does problem clear? Yes Troubleshooting complete No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.339.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS present? Yes Troubleshoot that fault first No Go to step 1.339.2 1.339.2 Disconnect tower tele PVG - 4 pos. [X067]. Turn on machine. Measure voltage between tower tele PVG con- nector socket 2 [X067.2.soc] and socket 3 [X067.3.soc]. Is it about 12 VDC? Yes Go to step 1.339.4 No Go to step 1.339.3 1.339.3 Disconnect tower tele PVG - 4 pos. [X067] and ground module J2 [X002] Is there continuity between tower tele PVG - 4 pos. socket 2 [X067.2.soc] and ground mod- ule J1 socket? [X001.?.soc]? Yes Repair harness between tower tele PVG - 4 pos. [X067] and battery ground No Repair harness between tower tele PVG - 4 pos. [X067] and ground module J1 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-155 1.340 TOWER TELESCOPE PVG VALVE HIGH VOLTAGE Tower telescope PVG valve high voltage. Voltage powering the tower telescope PVG valve exceeded 32 VDC. Restore proper system voltage to clear fault. 1.341 TOWER TELESCOPE PVG VALVE INTERNAL FAULT Tower telescope PVG valve internal fault. Hardware or software inside the tower telescope PVG valve caused an error. There are no serviceable parts that cause this problem. 1.339.4 Turn off machine. Discon- nect tower tele PVG - 4 pos. [X067]. Measure resistance between tower tele PVG socket 1 [X067.1.soc] and socket 4 [X067.4.soc]. Is it about 60Ω? Yes Replace tower tele PVG valve [X067] actuator No Go to step 1.339.5 1.339.5 Turn off machine. Discon- nect tower tele PVG - 4 pos. [X067] and BLAM J4 [X089]. Is there continuity between tower tele PVG socket 1 [X067.1.soc] and BLAM J4 socket 4 [X089.4.soc]? - AND - Is there continuity between tower tele PVG socket 4 [X067.4.soc] and BLAM J4 socket 3 [X089.3.soc]? Yes Replace tower tele PVG valve [X067] actuator or see 1.46 BLAM CAN COMMUNICATIONS LOST on Pg. 48 No Repair harness between tower tele PVG - 4 pos. [X067] and BLAM J4 [X089] Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.340.1 Ensure all off-board power connections, such as 110VAC, are disconnected. Ensure all on-board power systems are turned off, such as generators, welders, etc. Turn on machine and start engine. Is battery voltage about 12 VDC? -AND- Does charging and 12VDC electrical power generation sys- tem appear to be working properly? Yes Go to step 1.340.2 No Repair 12 VDC charging and electrical power generation system. 1.340.2 Turn off machine. Ensure all off-board power connec- tions, such as 110VAC, are disconnected. Ensure all on- board power systems are turned off, such as genera- tors, welders, etc. Turn off machine. Disconnect tower tele PVG valve [X067] Are there any shorts between tower tele PVG valve socket 2 [X067.2.soc] or socket 3 [X067.3.soc] and wiring for off-board power sources such as 110VAC, or on-board power sources such as welder or generator outputs, etc.? Note, tower tele PVG valve socket 3 [X067.3.soc] to ground continuity is OK. Be sure to check for intermittent problems. Yes Repair shorts as needed No Transient condition likely set fault. If fault keeps occurring, go to step 1.340.3. 1.340.3 Measure voltage on the sec- ond tower tele PVG valve connector[X261] using a spare harness exposing ter- minal 2 [X261.2] and 3 [X261.3], or use insulated alligator clips to those termi- nals. Observe 12VDC system voltage at the valve over an extended time under various operating conditions, for example, during engine start. See Min/Max on Pg. 319 for details. Is it per- forming properly? Yes Replace tower tele PVG valve actuator [X067] No Repair as needed Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.341.1 Read faults Are there any 6-6 communication faults? Yes Troubleshoot those first No Go to step 1.341.2 1.341.2 Cycle machine power. Keep power off at least 20 seconds. Does fault still occur? Yes Replace tower tele PVG valve actuator [X067] No Troubleshooting complete Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-156 1250AJP 3128411 1.342 TOWER TELESCOPE PVG VALVE LOCATION IMPROPER Tower telescope PVG valve location improper. Tower telescope PVG valve parameters entered into the incorrect valve. This could be due to a calibration or wiring problem. The valve harnesses have one wire in it that is labeled with a number. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.343 TOWER TELESCOPE PVG VALVE LOW VOLTAGE Tower telescope PVG valve low voltage. Voltage powering the tower telescope PVG valve fell below about 10 VDC. Increase system voltage above 11 VDC to clear fault. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.342.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start off, then turn on, in order, LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Connect harnesses to the correct PVG valve according to wires listed above in description. Then calibrate boom valves and recheck. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.343.1 Are either of the faults TOWER TELESCOPE PVG VALVE COMMUNICATIONS or BLAM CAN COMMUNICATIONS LOST present? Yes Troubleshoot them first. No Go to step 1.343.2 1.343.2 Are the battery and battery connections good? Yes Go to step 1.343.3 No Repair/replace as needed 1.343.3 Turn on machine and start engine. Is battery voltage about 12 VDC and does system appear to be working properly? Yes Go to step 1.343.4 No Repair charging and 12 VDC electrical power generation system. 1.343.4 Disconnect tower tele PVG valve connector [X067]. Turn on machine. Is there about 12 VDC between tower tele PVG valve socket 2 [X067.2.soc] and socket 3 [X067.3.soc]? Yes Transient caused condition. If it occurs again troubleshoot charging and 12 VDC electrical power generation system. No Go to step 1.343.5 1.343.5 Take the following measure- ment by backprobing. See Backprobing on Pg. 319 for details. Turn on machine after setting up measure- ment. Is there about 12VDC between ground module J1 terminal 3 [X001.3] and any terminal on the MTB ground bus -12 pos. [X009]? Yes Repair/replace harness from tower tele PVG valve [X067] to ground J1 [X001] and the MTB ground bus -12 pos. [X009]. No Go to step 1.343.6 1.343.6 Take the following measure- ment by backprobing. Turn on machine after setting up measurement. Is there about 12VDC between ground module J1 terminal 3 [X001.3] and ground module J8 terminal 1? Yes Repair harness between ground module J1 [X001] and MTB ground bus -12 pos. [X009] No Reprogram/replace ground module SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-157 1.344 TOWER TELESCOPE PVG VALVE OBSTRUCTED Tower telescope PVG valve obstructed. Tower telescope PVG valve spool is not free to move completely. This could be from contamination inside the valve or a blocked filter. 1.345 TOWER TELESCOPE PVG VALVE PARAMETERS INCORRECT Tower telescope PVG valve parameters incorrect. Programing parameters contained in the tower telescope PVG valve do not match those stored in the ground module. The valve needs to be calibrated. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.344.1 Is there dirt in the hydraulic module part of the valve, especially around the spool? Yes Clean and repair as needed. Go to step 1.344.2 No Go to step 1.344.2 1.344.2 Is the filter at the tower tele PVG valve [X067] pilot oil inlet blocked? Yes Clean and repair as needed. Go to step 1.344.3. No Go to step 1.344.3 1.344.3 Is the fault clear? Yes Go to step 1.344.5 No Go to step 1.344.4 1.344.4 Mark to identify the tower tele PVG valve actuator [X067] using string, tape, etc. Swap it with an actuator that doesn’t have a fault. Perform 5.4 Calibrating Boom Valves on Pg. 296. Does fault move to new location of actua- tor? Yes Replace PVG valve actuator that was initially on the tower tele PVG valve [X067]. Go to step 1.344.5 No Replace hydraulic module of tower tele PVG valve [X067]. Go to step 1.344.5 1.344.5 Does the return filter have contamination in fil- ter media or housing? Yes Go to step 1.344.6 No Troubleshooting complete 1.344.6 Inspect all 4 hydraulic filters and housings and replace all 4 filters: output of function pump, platform filter (If filter is not external to platform valve it must be updated.), return filter and charge filter (for drive pump). Take note of filters/housings that have contamination. Cycle boom from fully lowered and retracted to fully extended and then back. Test hydraulic fluid. Does it test bad, appear cloudy, appear dark, smell burned or is otherwise abnormal? -OR- Was there any contamination in the filters or housings? Yes Replace all hydraulic fluid Go to step 1.344.7 No Go to step 1.344.7 1.344.7 Do machine hydraulics function properly? Yes Troubleshooting complete No Replace hydraulic components that are not func- tioning properly. Focus first on components upstream of any filters/housings with contamina- tion. Calibrate if necessary. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.345.1 Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Did it pass calibration? Yes Troubleshooting complete. If fault is recurring replace tower tele PVG valve [X067] actuator. No Replace tower tele PVG valve [X067] actuator SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-158 1250AJP 3128411 1.346 TOWER TELESCOPE PVG VALVE SENT UNRECOGNIZED FAULT Tower telescope PVG valve sent unrecognized fault. An error code sent by the tower telescope PVG valve was not recog- nized by the control system. 1.347 TOWER TELESCOPE PVG VALVE SETUP FAULT Tower telescope PVG valve setup fault. Tower telescope PVG valve received programing parameter values that are not allowed. PVG setup is done over the CAN bus by the ground module. 1.348 TOWER TELESCOPE PVG VALVE STUCK EXTENDED Tower telescope PVG valve stuck extended. The tower telescope PVG valve spool has moved out further than intended. Fol- low same procedure as 1.344 TOWER TELESCOPE PVG VALVE OBSTRUCTED on Pg. 157. 1.349 TOWER TELESCOPE PVG VALVE STUCK NEUTRAL Tower telescope PVG valve stuck neutral. The tower telescope PVG valve spool stuck outside of neutral position. This could be cause by dirt in the valve body or a PVG valve software issue. Follow same procedure as 1.344 TOWER TELESCOPE PVG VALVE OBSTRUCTED on Pg. 157. 1.350 TOWER TELESCOPE PVG VALVE STUCK RETRACTED Tower telescope PVG valve stuck retracted. Tower telescope PVG valve spool did not move in the required time. Follow same procedure as 1.344 TOWER TELESCOPE PVG VALVE OBSTRUCTED on Pg. 157. 1.351 TOWER TELESCOPE PVG VALVE TIMEOUT Tower telescope PVG valve timeout. Position instructions were not received by the tower telescope PVG valve within the allowed amount of time. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.346.1 Cycle machine power Operate main lift. Does fault occur again? Yes Replace tower tele PVG valve [X067] actuator No Troubleshooting complete. If fault is recurring, replace tower tele PVG valve [X067] actuator. Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.347.1 Check faults Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot other fault(s) first No Go to step 1.347.2 1.347.2 Perform 5.4 Calibrating Boom Valves on Pg. 296 Does the valve calibrate successfully? -AND- Does fault clear? Yes Troubleshooting complete. If fault is recurring, reprogram/replace ground module. No Reprogram/replace ground module Flash Code: 4-5 Flash Code: 4-5 Flash Code: 4-5 Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.351.1 Is EXCESSIVE CAN BUS COMMUNICATION ERRORS or other CAN bus communication error faults present? Yes Troubleshoot those faults first No Go to step 1.351.2 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-159 1.352 TOWER TELESCOPE PVG VALVE WIRING INCORRECT Tower telescope PVG valve wiring incorrect. A different valve powered up during power up time for tower tele PVG valve or the tower tele PVG valve powered up outside of the allotted PVG valve power up time. This could be due to a calibration or wiring problem. The valves are located as follows: main lift at lower left with wire TAN 55-50, tower lift at top left (center of three) with wire TAN 55-51, tower tele at top right with wire BROWN 55-50. 1.353 TRN DUAL CAP BAD TRANSITION Transport or Dual Capacity Bad Transition. The control system detected that the main boom length switches did not transi- tion in the correct sequence based on the telescope command, as in Table 2-3. Switch States / Boom Length Regions on Pg. 179 and Figure 2-2. Dual Capacity / Transport Switch Mounting on Pg. 179. If in the 1000# mode of operation, the main tele- scope function will be disabled. This could be caused by incorrect wiring to the main boom transport or dual capacity switches or a hydraulic problem preventing the boom from telescoping in the direction commanded. 1.351.2 Disconnect tower tele PVG valve [X067] Does TOWER TELESCOPE PVG VALVE COM- MUNICATIONS fault appear? Yes Replace tower tele PVG valve [X067] actuator No Reprogram/replace ground module Flash Code: 4-5 Note Pretest Instructions Test Result Corrective Action 1.352.1 Open hood covering the main valve body. Locate the LED’s on the PVG valves. Turn on the machine while watching the LED’s. Do they start all off, then turn on in this order: LEFT, CENTER, then RIGHT? Yes Calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. No Go to step 1.222.2 1.352.2 Turn off machine. Discon- nect Ignition On Relay [X012] and tower tele PVG valve [X067]. Is there a short between Ignition On Relay socket 30 [X012.30.soc]and tower tele PVG valve socket 2 [X067.2.soc]? Yes Repair/replace harness between Relay [X012] and tower tele PVG valve [X067] No Connect harnesses to the correct PVG valve as in the description above. Then calibrate boom valves. See 5.4 Calibrating Boom Valves on Pg. 296 for details. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.353.1 Are there any faults for the DCAP Length Switches [X052] & [X053], main boom trans- port switches [X054] & [X055], MAIN IN... - OR- MAIN OUT...? Yes Troubleshoot them first No Go to step 1.353.2 1.353.2 Operate main boom telescope IN and OUT. Is the response correct? Yes Go to step 1.353.5 No Go to step 1.353.3 1.353.3 Does the hosing between the main valve - main tele section and main tele cylinder match the schematic in Figure 3-12. Hydraulic Sche- matic - Boom Control - Sheet 1 of 2 on Pg. 258? Yes Go to step 1.353.4 No Correct hosing as needed 1.353.4 Disconnect main tele retract [X073] connector Does the fault MAIN IN OPEN CIRCUIT appear? Yes Repair/replace main tele cylinder holding valve No Harnesses for main tele retract [X073] and main tele extend [X071] are swapped. Correct them. Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-160 1250AJP 3128411 1.354 TRN DUAL CAP SWITCHES BAD Transport or dual capacity switches bad. The main length transport switches are reporting “A/D”, but the dual capacity length switches are reporting a disagreement. See Table 2-3. Switch States / Boom Length Regions and Figure 2-1. Main Boom Angle and Length Zones on Pg. 178. The dual capacity length switches should only report a disagreement while passing between the B and C regions. The main boom allowable functions for angle regions 1,2,7 and 8 will follow Dual Capacity Zones D1,D2,D7 and D8 respectively. For angle regions 3 and 4 the allowable functions will follow Dual Capacity Zone D3 and for angle regions 5 and 6 the allowable functions will follow Dual Capacity Zone D6. If the tower boom is recognized as being in transport position then main boom lift down will be allowed. 1.355 TWO SPEED OPEN CIRCUIT Two speed open circuit. The two speed valve output [X001.20] is open. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.356 TWO SPEED SHORT TO BATTERY Two speed short to battery. The two speed valve output [X001.20] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.357 TWO SPEED SHORT TO GROUND 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. 1.353.5 Access DCAP Length Switches [X052] & [X053] and main boom transport switches [X054] & [X055]. Switch to 500 lb. mode. Are the switches free to move? Also, are the switch levers mounted at 90° to housing as seen when not engaging a cam? Also, are the switches and cam strips mounted so that the switch levers engage the entire length of cam? Also, are the strips mounted such that they match Figure 2-2. Dual Capacity / Transport Switch Mounting on Pg. 179. Yes Ensure the dual capacity switch passthru [X046] and main boom transport switch passthru [X047] connections are not swapped. Also, ensure wiring of switches is correct. No Repair as needed Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.354.1 Is the fault DCAP LEN SW DISAGREEMENT present? Yes Go to 1.75 DCAP LEN SW DISAGREEMENT on Pg. 64. If instructed to replace module DO NOT. Go to step 1.354.2 instead. No Go to step 1.354.2 1.354.2 Is the fault MAIN TRN LEN SW DISAGREE- MENT present? Yes Go to 1.230 MAIN TRN LEN SW DISAGREE- MENT on Pg. 118 No Go to step 1.354.3 1.354.3 Go to 1.75 DCAP LEN SW DISAGREEMENT on Pg. 64. If instructed to replace module, DO NOT. Did fault clear? Yes Done troubleshooting No Go to 1.230 MAIN TRN LEN SW DISAGREE- MENT on Pg. 118 Flash Code: 3-3 Flash Code: 3-3 Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-161 1.358 TWR ANGL1 INVALID ANGLE Tower angle 1 (right side) invalid angle. Tower boom angle sensor #1 (Right) is reporting an invalid angle, over +85° or less than -30°. 1.359 TWR ANGL2 INVALID ANGLE Tower angle 2 (left) invalid angle. Tower boom angle sensor #2 (Left) is reporting an invalid angle, over +85° or less than - 30°. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.358.1 Read fault log Are any of the following faults active on the machine? BOOM ANGLE SENSOR #1 (or 2) COMMUNICATIONS FAULT Yes Troubleshoot them first No Go to step 1.358.2 1.358.2 Access tower boom angle sensor 1 (Right) [X099] and 2 (Left) [X100] Is there any lose mounting hardware, etc.? Yes Repair as needed No Keep access to tower boom angle sensor #1 (Right) [X099] open. Go to step 1.358.3 1.358.3 Access tower boom angle sensor #1 (Right) [X099] Check the sensors aren’t swapped by unplug- ging tower boom angle sensor #1 (Right) [X099]. Does the BOOM ANGLE SENSOR #1 COMMUNICATIONS FAULT show? Yes Go to step 1.358.4 No Ensure harnesses go to correct sensor, tower boom angle sensor #1 (Right) [X099] with Red, 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. 1.358.4 Fully retract and lower boom. ANALYZER ⇒ DIAG- NOSTICS ⇒ BOOM SEN- SORS ⇒ TOWER ANGLE 1 (and 2) SENSOR Are both sensor angles approximately -4.3° ± 1.5°? Yes Go to step 1.358.5 No Replace sensor out of specified range 1.358.5 Calibrate boom sensors. See 5.8 Boom Sensor Cali- bration on Pg. 309. Did boom calibrate successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.359.1 Read fault log Are any of the following faults active on the machine? BOOM ANGLE SENSOR #2 (or 1) COMMUNICATIONS FAULT Yes Troubleshoot them first No Go to step 1.359.2 1.359.2 Access tower boom angle sensor 1 (Right) [X099] and 2 (Left) [X100] Is there any lose mounting hardware, etc.? Yes Repair as needed No Keep access to tower boom angle sensor #2 (Left) [X100] open. Go to step 1.359.3 1.359.3 Access tower boom angle sensor #2 (Left) [X100] Check the sensors aren’t swapped by unplug- ging tower boom angle sensor #2 (Left) [X100]. Does the BOOM ANGLE SENSOR #2 COMMUNICATIONS FAULT show? Yes Go to step 1.359.4 No Ensure harnesses go to correct sensor, tower boom angle sensor #1 (Right) [X099] with Red, 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. SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-162 1250AJP 3128411 1.360 TWR CYL ANGLE MOVEMENT WITHOUT CMD Tower cylinder angle movement without command. The control system detected greater than 2.5° of tower angle movement in 0.5 seconds, while the tower lift command was not being operated. This is most likely caused by a problem with the hydraulics. 1.361 TWR CYL ANGLE NOT DETECTING ANGLE CHANGE 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 1.359.4 Fully retract and lower boom. ANALYZER ⇒ DIAG- NOSTICS ⇒ BOOM SEN- SORS ⇒ TOWER ANGLE 1 (and 2) SENSOR Are both sensor angles approximately -4.3° ± 1.5°? Yes Go to step 1.359.5 No Replace sensor out of specified range 1.359.5 Calibrate boom sensors. See 5.8 Boom Sensor Cali- bration on Pg. 309. Did boom calibrate successfully? Yes Troubleshooting complete No Troubleshoot according to calibration fault Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.360.1 Read fault log. Does the tower lift PVG valve have any faults in the stack? Yes Repair tower lift PVG valve in accordance with faults in stack. No Go to step 1.360.2 1.360.2 Open tower boom to maximum angle and return to fully closed. Does fault still occur? Yes Go to step 1.360.3 No Air was in cylinder. Troubleshooting complete. 1.360.3 Are there visible hydraulic leaks? Yes Repair/replace as needed No Go to step 1.360.4 1.360.4 Are the tower lift cylinder hydraulic connec- tions correct? Yes Go to step 1.360.5 No Repair as needed 1.360.5 Swap main lift enable valve [X082] cartridge with tower lift enable valve [X080] car- tridge. Does this fault still occur? No Repair/replace cartridge originally in tower lift enable valve [X080] Yes Go to step 1.360.6 1.360.6 Rig wires from battery (+) [X116] and battery ( - ) [X117] to reach the tower lift enable valve [X080]. Do not allow uninsulated area of wires to touch other con- ductors. Raise tower boom. Disconnect tower lift enable solenoid [X080]. Energize tower lift enable solenoid [X080] by touching wires from battery (+) and (-) wires to solenoid contacts. Does tower boom move when solenoid is energized? Yes Remove wires from solenoid. Keep the rest of the test setup in place. Go to step 1.360.7 No Repair/replace tower lift cylinder 1.360.7 Ensure machine is set up the same as in step 1.360.6. Disconnect hose on port 2 from tower lift enable valve [X080]. Disconnect tower lift enable solenoid [X080]. Energize tower lift enable solenoid [X080] by touching wires from battery (+) and (-) wires to solenoid contacts. Is there fluid flowing out of the hose continuously? Yes Repair/replace tower lift cylinder holding valve No Repack tower lift cylinder piston seal Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-163 tower lift down angles less than 3°. This fault is most likely caused by a mechanical or hydraulic failure, preventing the machine from responding. Before troubleshooting, warm up the oil to operating temperature. Note Pretest Instructions Test Result Corrective Action 1.361.1 Examine the electrical connections at the tower cylinder angle sensor [X092] and BLAM module J3 connector [X088]. Is there any loose connections or moisture or corrosion? Yes Clean or replace any bad connections No Go to step 1.361.2 1.361.2 Is the tower angle sensor properly mounted to the machine? Yes Go to step 1.361.3 No Remount the sensor 1.361.3 Connect a 1000 psi pres- sure gauge to MP1 on the main valve manifold With the machine idling, does the gauge read about 300 psi? Yes Go to step 1.361.4 No Adjust the outside relief on the function pump till gauge reads 300 psi. If adjustment does not cor- rect the pressure, replace the control valve on the function pump 1.361.4 Connect a 5000 psi pres- sure gauge to MP1 on the main valve manifold. Remove the solenoid from the main tele proportional valve While activating main telescope in, does the gauge read 3400 psi? Yes Go to step 1.361.6 No Adjust the inside relief on the function pump till the gauge reads 3400 psi while activating the function. If adjustment does not correct the pres- sure, go to step 1.361.5 1.361.5 Swap the main dump car- tridge with the PVG enable cartridge. Connect a 5000 psi pressure gauge to MP1 on the main valve manifold. Remove the solenoid from the main tele proportional valve While activating main telescope in, does the gauge read 3400 psi? Yes Replace the cartridge originally from the main dump valve No Replace the control valve on the function pump 1.361.6 Connect a 5000 psi pres- sure gauge to LS on the main valve manifold. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SERVICE MODE ⇒ SET PRESSURES ⇒ CODE(146005) ⇒ TWR LIFT? ⇒ ENTER While activating tower lift UP, does the gauge read 2755 to 3088 psi AND while activating tower lift DOWN, does the gauge read 2755 to 3088? Yes Go to step 1.361.7 No Replace the tower lift PVG Section 1.361.7 Connect a 5000 psi pres- sure gauge to LS on the main valve manifold. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SERVICE MODE ⇒ SET PRESSURES ⇒ CODE(146005) ⇒ TWR TELE? ⇒ ENTER While activating tower tele Out, does the gauge read 2537 to 2871 psi AND while activating tower tele IN, does the gauge read 2537 to 2871? Yes Go to step 1.361.8 No Replace the tower tele PVG Section 1.361.8 Swap the tower lift enable valve cartridge with the main lift enable valve cartridge Will the tower now lift and is the fault cleared? Yes Replace the valve cartridge originally from the tower lift enable No Go to step 1.361.9 1.361.9 Swap the tower tele enable valve cartridge with the main lift enable valve cartridge Will the tower now lift and tele and is the fault cleared? Yes Replace the valve cartridge originally from the tower tele enable No Go to step 1.361.10 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-164 1250AJP 3128411 1.362 TWR CYL ANGLE SENSOR OUT OF RANGE HIGH Tower cylinder angle sensor out of range high. The tower lift cylinder angle sensor [X092] is reading over 23484 A/D counts (4.46 volts). 1.363 TWR CYL ANGLE SENSOR OUT OF RANGE LOW Tower cylinder angle sensor out of range low. The tower lift cylinder angle sensor [X092] is reading less than 3949 A/D counts (0.75 volts). 1.361.10 While activating tower lift, does the tower boom move? Yes Replace tower cylinder angle sensor No Possible Causes: Faulty counterbalance valve, faulty tower lift or tele cylinder Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.362.1 Is there any loose mounting hardware? Also, is the sensor not mounted properly? Yes Repair as needed No Go to step 1.362.2 1.362.2 Disconnect tower lift cyl angle sensor [X092] and BLAM J3 [X088]. Ground meter. See Grounding on Pg. 319 for details. Turn on machine. Is there any voltage between tower lift cyl angle sensor pin B [X092.B.pin] (Blue wire) and ground? Yes Repair/replace harness and/or blue wire between tower lift cyl angle sensor [X092] and BLAM J3 [X088] No Go to step 1.362.3 1.362.3 Disconnect tower lift cyl angle sensor [X092]. Turn on machine. Is there 5 VDC between tower lift cyl angle sen- sor pin A[X092.A.pin] (Red wire) and pin C [X092.C.pin] (Black wire)? Yes Replace sensor No Go to step 1.362.4 1.362.4 Turn on machine. Take the following measurement by backprobing. (See Back- probing on Pg. 319 for details.) Is there about 5 VDC between BLAM J3 pin 4 [X088.4.pin] and pin 6 [X088.6.pin]? No Replace BLAM Yes Repair/replace harness between BLAM J3 [X088] and tower lift cyl angle sensor [X092] Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.363.1 Is there any loose mounting hardware? Also, is the sensor not mounted properly? Yes Repair as needed No Go to step 1.363.2 1.363.2 Disconnect tower lift cyl angle sensor [X092] and BLAM J3 [X088] Is there any damage, moisture or corrosion in the connections? Yes Clean/repair as needed No Keep connectors disconnected. Go to step 1.363.3. 1.363.3 Disconnect tower lift cyl angle sensor [X092], BLAM J3 [X088]. Ground meter. See Grounding on Pg. 319 for details. Is there a short between ground and the blue wire on either tower lift cyl angle sensor pin B [X092.B.pin] -OR- between ground and the blue wire at BLAM J3 socket 5 [X088.5.soc]? Yes Repair blue wire (including associated contacts) or replace harness between tower lift cyl angle sensor [X092], BLAM J3 [X088]. Also repair short/replace harness in the battery harness - side [X117]. No Keep connectors disconnected. Go to step 1.363.4. 1.363.4 Disconnect tower lift cyl angle sensor [X092] and BLAM J3 [X088]. Is there continuity between tower lift cyl angle sensor pin B [X092.B.pin] and BLAM J3 pin 5 [X088.5.pin] Yes Go to step 1.363.5 No Repair blue wire (including contacts) or replace harness between tower lift cyl angle sensor [X092] and BLAM J3 [X088] Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-165 1.364 TWR LENGTH MOVEMENT WITHOUT CMD Tower length movement without command. The control system detected at least 4.0“of tower length movement in 0.8 sec- onds, while the tower telescope command was not being operated. This is most likely caused by a problem with the hydrau- lics. 1.363.5 Disconnect tower lift cyl angle sensor [X092]. Turn on machine. Is there 5 VDC between tower lift cyl angle sen- sor pin A[X092.A.pin] (Red wire) and pin C [X092.C.pin] (Black wire)? Yes Replace sensor No Go to step 1.363.6 1.363.6 Turn on machine. Take the following measurement by backprobing. (See Back- probing on Pg. 319 for details.) Is there about 5 VDC between BLAM J3 pin 4 [X088.4.pin] and pin 6 [X088.6.pin]? No Replace BLAM Yes Repair/replace harness between BLAM J3 [X088] and tower lift cyl angle sensor [X092] Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.364.1 Read fault log. Does the tower tele PVG valve have one or more faults in the stack? Yes Repair tower tele PVG valve in accordance with fault(s) in stack. No Go to step 1.364.2 1.364.2 Telescope main boom to maximum length and return to fully retracted. Does fault still occur? Yes Go to step 1.364.3 No Air was in cylinder. Troubleshooting complete. 1.364.3 Are there visible hydraulic leaks? Yes Repair/replace as needed No Go to step 1.364.4 1.364.4 Are the tower tele cylinder hydraulic connec- tions correct? Yes Go to step 1.364.5 No Repair as needed 1.364.5 Swap main lift enable valve [X082] cartridge with tower tele enable valve [X081]. Does this fault still occur? No Repair/replace cartridge originally in tower tele enable valve [X081] Yes Go to step 1.364.6 1.364.6 Rig wires from battery (+) [X116] and battery ( - ) [X117] to reach the tower tele enable valve [X081]. Do not allow stripped area of wires to touch each other. Raise and extend main boom. Disconnect tower tele enable valve [X081] connector. Energize tower tele enable valve [X081] by touching wires from battery (+) [X116] and ( - ) [X117] wires to solenoid con- tacts. Does main boom retract when solenoid is energized? Yes Keep machine in same condition. Go to step 1.364.7 No Repair/replace tower tele cylinder 1.364.7 Ensure machine is set up the same as in step 1.364.6. Disconnect hose on port 2 from tower tele enable valve [X081]. Is there fluid flowing continuously out of the hose? Yes Repair/replace tower tele cylinder holding valve No Repack tower tele cylinder piston seal Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-166 1250AJP 3128411 1.365 TWR LENGTH SENSOR NOT DETECTING LENGTH CHANGE Tower length sensor not detecting length change. The control system did not detect at least 0.3“of movement within 3 sec- onds while the tower telescope function was commanded. This fault is not detected for tower telescope within 5" of the max- imum or minimum mechanical length. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.365.1 Check fault log Are there any other tower length sensor or tower tele PVG or tower tele enable faults? Yes Troubleshoot them first No Go to step 1.365.2 1.365.2 Examine the electrical connections at the tower boom length sensor [X093] and BLAM module J3 connector [X088]. Are there any loose connections, moisture or corrosion? Yes Clean or replace any bad connections No Go to step 1.365.3 1.365.3 Are the tower boom length sensors #1 (Top) [X093] and #2 (bottom) [X094] properly mounted to the machine. -AND- Are the sen- sor cables free to move with boom? Yes Go to step 1.365.4 No Remount/repair any affected sensor 1.365.4 Connect a 1000 psi pres- sure gauge to MP1 on the main valve manifold With the machine idling, does the gauge read 400 - 450 psi? Yes Go to step 1.365.5 No Adjust the low pressure relief on the function pump till gauge reads 450 psi. See Figure 3-2. Pumps Layout on Pg. 248 for location. If adjust- ment does not correct the pressure, replace the control valve on the function pump. 1.365.5 Connect a 5000 psi pres- sure gauge to MP1 on the main valve manifold. Remove the solenoid from the main tele proportional valve. While activating main telescope in, does the gauge read 3400 psi? Yes Go to step 1.365.8 No Adjust the high pressure relief on the function pump till the gauge reads 3400 psi while activat- ing the function. See Figure 3-2. Pumps Layout on Pg. 248 for location. If adjustment does not correct the pressure, go to step 1.365.6. 1.365.6 Disconnect main dump valve solenoid [X074] Does the solenoid measure 7.2 Ω? Yes Go to step 1.365.7 No Replace solenoid 1.365.7 Swap the main dump enable valve [X074] cartridge with the main lift enable valve [X082] cartridge. Connect a 5000 psi pressure gauge to MP1 on the main valve man- ifold. Remove the solenoid from the main tele propor- tional valve, but keep sole- noid connected to the harness. While activating main telescope in, does the gauge read 3400 psi? Yes Replace the cartridge originally from the main dump valve No Replace the control valve on the function pump 1.365.8 Disconnect PVG enable valve connector [X068] Does the solenoid measure 7.2 Ω? Yes Go to 1.365.9 No Replace PVG enable valve solenoid [X081] 1.365.9 Swap the PVG enable valve [X068] cartridge with the main lift enable valve [X082] cartridge. Does fault clear? Yes Replace cartridge originally in PVG enable valve [X081] No Go to step 1.365.10 SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-167 1.366 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE HIGH Tower length sensor 1 (top) value out of range high. The BLAM module is reading a value above 675.4" for the calibrated tower boom length sensor #1 (top). This sensor should always read between 299.4" and 675.4". This could be caused by a mechanical problem with the sensor or cable, the sensor ground wire being broken, or a sensor failure. 1.365.10 Connect a 5000 psi pres- sure gauge to LS on the main valve manifold. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SERVICE MODE ⇒ SET PRESSURES ⇒ CODE(14605) ⇒ TWR LIFT? ⇒ WARNING MOVE- MENT POSSIBLE WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. While activating tower lift UP, does the gauge read 2755 to 3088 psi? -AND- While activat- ing tower lift DOWN, does the gauge read 2755 to 3088? Yes Go to step 1.365.11 No Replace the tower lift PVG Section 1.365.11 Connect a 5000 psi pres- sure gauge to LS on the main valve manifold. ANALYZER ⇒ ACCESS LEVEL 1 ⇒ SERVICE MODE ⇒ SET PRESSURES ⇒ CODE(14605) ⇒ TWR TELE? ⇒ WARNING MOVE- MENT POSSIBLE WHEN THE STABILITY CONTROL IS OFF, THE MACHINE WILL TIP IF USED INCORRECTLY. While activating tower tele OUT, AND while activating tower tele IN, does the gauge read 2537 to 2871? Yes Go to step 1.365.12 No Replace the tower tele PVG section 1.365.12 Disconnect tower tele enable valve connector [X081] Does it measure 4.8 Ω? Yes Go to step 1.365.13 No Replace tower tele enable valve solenoid [X081] 1.365.13 Swap the tower tele enable valve cartridge with the main lift enable valve cartridge Will the tower now extend and is the fault cleared? Yes Replace the valve cartridge originally from the tower tele enable No Go to step 1.365.14 1.365.14 Raise tower. Disconnect hose from port 2 of the tower tele enable valve [X081] Does fluid flow out of hose continuously? Yes Repair/replace tower tele holding valve No Repack tower tele cylinder Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.366.1 Is the tower boom length sensor #1 (top) [X093] securely mounted to the machine and is cable free to move? Yes Go to step 1.366.2 No Repair as needed 1.366.2 Disconnect tower boom length sensor #1 (top) [X093] Does the tower boom length sensor #1 (top) connector [X093] have moisture, damage or corrosion? Yes Repair as needed No Keep tower boom length sensor #1 (top) [X093] disconnected. Go to step 1.366.3 1.366.3 Turn on machine. Discon- nect tower boom length sen- sor #1 (top) [X093] Is there about 5VDC between tower boom length sensor #1 (top) socket A [X093.A.soc] and socket B [X093.B.soc]? Yes Go to step 1.366.5. No Keep machine in same state. Go to step 1.366.4 1.366.4 Turn on machine. Discon- nect BLAM J 3 [X088] Is there about 5VDC between BLAM J 3 pin 7 [X088.7.pin] and pin 9 [X088.7.pin]? Yes Repair/replace harness between BLAM J3 [X088] and tower boom length sensor #1 (top) [X093] No Replace BLAM Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-168 1250AJP 3128411 1.367 TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW Tower length sensor 1 (top) value out of range low. The BLAM module is reading a value below 299.4" for the calibrated tower boom length sensor #1 (top) [X093]. This sensor should always read between 299.4" and 675.4". This could be caused by a mechanical problem with the sensor or cable, a disconnected or broken sensor cable clip, the sensor power and/or signal wire being broken, or sensor failure. 1.366.5 Unclip sensor #1 cable from boom. Observe resis- tance between tower boom length sensor 1 (Top) pin A [X093.A.pin] and pin C [X093.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.366.6 No Replace tower boom length sensor #1 (top) [X093] 1.366.6 Disconnect tower boom length sensor #1 (top) [X093] and BLAM module J3 connector [X088]. Is there a short between the Blue wire in tower boom length sensor #1 (top) socket C [X093.C.soc] and socket A [X093.A.soc] - OR- between tower boom length sensor #1 (top) socket C [X093.C.soc] and battery posi- tive [X116]? Yes Repair short or replace harness between tower boom length sensor #1 (top) socket C [X093.C.soc] and socket A [X093.A.soc] or BLAM module J3 connector socket 8 [X088.8.soc] to battery positive [X116] No Leave tower boom length sensor #1 (top) [X093] and BLAM module J3 [X088] disconnected. Go to step 1.366.7 1.366.7 Disconnect tower boom length sensor #1 (top) [X093] and BLAM module J3 connector [X088]. Is there continuity between tower boom length sensor #1 (top) socket C [X093.C.soc] and BLAM module J3 socket 8 [X088.8.soc]? Yes Go to step 1.366.8 No Repair/replace harness between tower boom length sensor #1 (top) [X093] and BLAM module J3 connector [X088]. 1.366.8 Disconnect tower boom length sensor #1 (top) [X093] and BLAM module J3 connector [X088] Is there continuity between tower boom length sensor #1 (top) socket B [X093.B.soc] and BLAM module J3 connector socket 9 [X088.9.soc]? Yes Leave tower boom length sensor #1 (top) [X093] disconnected. Go to step 1.366.9 No Repair/replace harness between tower boom length sensor #1 (top) socket B [X093.B.soc] and BLAM module J3 connector socket 9 [X088.9.soc] 1.366.9 Turn on machine. Discon- nect tower boom length sen- sor #1 (top) [X093] Does the fault become inactive -AND- the fault TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW appear? Yes Replace tower boom length sensor #1 (top) [X093] No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.367.1 Is the tower boom length sensor #1 (top) [X093] securely mounted to the machine, is cable free to move and is it connected cor- rectly? Yes Go to step 1.367.2 No Repair as needed 1.367.2 Disconnect tower boom length sensor #1 (top) [X093] Does the tower boom length sensor #1 (top) connector [X093] have moisture, damage or corrosion? Yes Repair as needed No Keep tower boom length sensor #1 (top) [X093] disconnected and machine on. Go to step 1.367.3 1.367.3 Disconnect tower boom length sensor #1 (top) [X093]. Turn on machine. Is there about 5VDC between tower boom length sensor #1 (top) socket A [X093.A.soc] and socket B [X093.B.soc]? Yes Leave machine on. Go to step1.367.5 No Go to step 1.367.4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-169 1.368 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE HIGH Tower length sensor 2 (bottom) value out of range high. The BLAM module is reading a value above 675.4" for the calibrated tower length sensor #2 (bottom). This sensor should always read between 299.4" and 675.4". This could be caused by a mechanical problem with the sensor or cable, the sensor ground wire being broken, or a sensor failure. 1.367.4 Disconnect BLAM J3 X088]. Turn on machine. I s there about 5VDC between BLAM J3 pin 7 [X088.7.pin] and pin 9 [X088.9.pin]? Yes Repair/replace harness between BLAM J3 [X088] and tower boom length sensor #1 (top) [X093] No Replace BLAM 1.367.5 Unclip sensor #1 cable from boom. Observe resis- tance between tower boom length sensor 1 (Top) pin A [X093.A.pin] and pin C [X093.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.367.6 No Replace tower boom length sensor #1 (top) [X093] 1.367.6 Disconnect tower boom length sensor #1 (top) [X093] and BLAM J3 [X088] Is there a short between tower boom length sensor #1 (top) socket C [X093.C.soc] or BLAM J3 socket 8 [X088.8.soc] to battery negative [X117]? Yes Repair/Replace harness between tower boom length sensor #1 (top) socket C [X093.C.soc], BLAM J3 socket 8 [X088.8.soc] and battery neg- ative [X117] No Leave tower boom length sensor #1 (top) [X093] and BLAM J3 [X088] disconnected. Go to step 1.367.7 1.367.7 Disconnect tower boom length sensor #1 (top) [X093] and BLAM J3 [X088] Is there continuity between tower boom length sensor #1 (top) socket C [X093.C.soc] and BLAM J3 socket 8 [X088.8.soc]? Yes Go to step 1.367.8 No Repair/Replace harness between tower boom length sensor #1 (top) socket C [X093.C.soc], BLAM J3 socket 8 [X088.8.soc]. 1.367.8 Disconnect tower boom length sensor #1 (top) [X093] and BLAM J3 [X088] Is there a short between tower boom length sensor #1 (top) socket C [X093.C.soc] and socket B [X093.B.soc]? Yes Repair/Replace harness between tower boom length sensor #1 (top) socket C [X093.C.soc] and socket B [X093.B.soc] No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.368.1 Is the tower boom length sensor #2 (bottom) [X094] securely mounted to the machine and is cable free to move? Yes Go to step 1.368.2 No Repair as needed 1.368.2 Disconnect tower boom length sensor #2 (top) [X094] Does the tower boom length sensor #2 (bot- tom) connector [X094] have moisture, dam- age or corrosion? Yes Repair as needed No Keep tower boom length sensor #2 (bottom) [X094] disconnected. Go to step 1.368.3 1.368.3 Turn on machine. Discon- nect tower boom length sen- sor #2 (bottom) [X094] Is there about 5VDC between tower boom length sensor #2 (bottom) socket A [X094.A.soc] and socket B [X094.B.soc]? Yes Go to step 1.368.5. No Keep machine in same state. Go to step 1.368.4 1.368.4 Turn on machine. Discon- nect BLAM J 3 [X088] Is there about 5VDC between BLAM J 3 socket 7 [X088.7.pin] and pin 9 [X088.9.pin]? Yes Repair/replace harness between BLAM J3 [X088] and tower boom length sensor #2 (bot- tom) [X094] No Replace BLAM Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-170 1250AJP 3128411 1.369 TWR LENGTH SENSOR TWO VALUE OUT OF RANGE LOW Tower length sensor 2 (bottom) value out of range low. The BLAM module is reading a value below 299.4" for the calibrated tower boom length sensor #2 (bottom) [X094]. This sensor should always read between 299.4" and 675.4". This could be caused by a mechanical problem with the sensor or cable, a disconnected or broken sensor cable clip, the sensor power and/or signal wire being broken, or sensor failure. 1.368.5 Unclip sensor #2 cable from boom. Observe resis- tance between tower boom length sensor #2 (bottom) pin A [X094.A.pin] and pin C [X094.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.368.6 No Replace tower boom length sensor #2 (bottom) [X094] 1.368.6 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM module J3 connector [X088]. Is there a short between the Blue wire in tower boom length sensor #2 (bottom) [X094] socket C [X094.C.socket] and socket A [X094.A.socket] -OR- between tower boom length sensor #2 (bottom) socket C [X094.C.socket] and battery positive [X116]? Yes Repair short or replace harness between tower boom length sensor #2 (bottom) socket C [X094.C.socket] and socket A [X094.A.socket] or BLAM module J3 connector socket 8 [X088.8.soc] to battery positive [X116] No Leave tower boom length sensor #2 (bottom) [X094] and BLAM module J3 [X088] discon- nected. Go to step 1.368.7 1.368.7 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM module J3 connector [X088]. Is there continuity between tower boom length sensor #2 (bottom) socket C [X094.C.socket] and BLAM module J3 socket 8 [X088.8.soc]? Yes Go to step 1.368.8 No Repair/replace harness between tower boom length sensor #2 (bottom) [X094] and BLAM module J3 connector [X088]. 1.368.8 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM module J3 connector [X088] Is there continuity between tower boom length sensor #2 (bottom) socket B [X094.B.socket] and BLAM module J3 con- nector socket 9 [X088.9.soc]? Yes Leave tower boom length sensor #2 (bottom) [X094] disconnected. Go to step 1.368.9. No Repair/replace harness between tower boom length sensor #2 (bottom) socket B [X094.B.socket] and BLAM module J3 connec- tor socket 9 [X088.9.soc] 1.368.9 Turn on machine. Discon- nect tower boom length sen- sor #2 (bottom) [X094] Does the fault become inactive -AND- the fault TWR LENGTH SENSOR ONE VALUE OUT OF RANGE LOW appear? Yes Replace tower boom length sensor #2 (bottom) [X094] No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.369.1 Is the tower boom length sensor #2 (bottom) [X094] securely mounted to the machine, is cable free to move and is it connected cor- rectly? Yes Go to step 1.369.2 No Repair as needed 1.369.2 Disconnect tower boom length sensor #2 (bottom) [X094] Does the tower boom length sensor #2 (bot- tom) [X094] have moisture, damage or corro- sion? Yes Repair as needed No Keep tower boom length sensor #2 (bottom) [X094] disconnected and machine on. Go to step 1.369.3 1.369.3 Disconnect tower boom length sensor #2 (bottom) [X094]. Turn on machine. Is there about 5VDC between tower boom length sensor #2 (bottom) socket A [X094.A.soc] and socket B [X094.B.soc]? Yes Leave machine on. Go to step1.369.5 No Go to step 1.369.4 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-171 1.370 TWR TRN SW DISAGREEMENT Tower transport switch disagreement. The two tower boom transport length switch inputs are reading the same state. The normally closed (NC) and normally open (NO) switch inputs should always read opposite. In the transport position the NC switch should be CLOSED and the NO switch should be OPEN. Switch states are visible in ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ TOWER TELESCOPE SWITCH Nx 1.369.4 Disconnect BLAM J3 X088]. Turn on machine. Is there about 5VDC between BLAM J3 pin 10 [X088.10.pin] and pin 12 [X088.12.pin]? Yes Repair/replace harness between BLAM J3 [X088] and tower boom length sensor #2 (top) [X094] No Replace BLAM 1.369.5 Unclip sensor #2 (bottom) [X094] cable from boom. Observe resistance between tower boom length sensor 1 (Top) pin A [X094.A.pin] and pin C [X094.C.pin]. Have second person slowly walk cable out and back completely. The sensor cable extends 400 inches (33’ 4"). (Do not allow cable to retract in an uncontrolled or rapid manner. This will break the sensor.) Does resistance change smoothly and consistently up to 5000 Ω ± 500 Ω and back? Yes Go to step 1.369.6 No Replace tower boom length sensor #2 (bottom) [X094] 1.369.6 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM J3 [X088] Is there a short between tower boom length sensor #2 (bottom) socket C [X094.C.soc] or BLAM J3 socket 11 [X088.11.soc] to battery negative [X117]? Yes Repair/Replace harness between tower boom length sensor #2 (bottom) socket C [X094.C.soc], BLAM J3 socket 11 [X088.11.soc] and battery negative [X117] No Leave tower boom length sensor #2 (bottom) [X094] and BLAM J3 [X088] disconnected. Go to step 1.369.7 1.369.7 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM J3 [X088] Is there continuity between tower boom length sensor #2 (bottom) socket C [X094.C.soc] and BLAM J3 socket 11 [X088.11.soc]? Yes Go to step 1.369.8 No Repair/Replace harness between tower boom length sensor #2 (bottom) socket C [X094.C.soc], BLAM J3 socket 11 [X088.11.soc]. 1.369.8 Disconnect tower boom length sensor #2 (bottom) [X094] and BLAM J3 [X088] Is there a short between tower boom length sensor #2 (bottom) socket C [X094.C.soc] and socket B [X094.B.soc]? Yes Repair/Replace harness between tower boom length sensor #2 (bottom) socket C [X094.C.soc] and socket B [X094.B.soc] No Reprogram/replace BLAM Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.370.1 Check the tower boom transport length switch power. Terminal 14 and 22 of the tower boom transport switch [X056.22] should measure 12VDC. Yes Go to step 1.370.4 No Go to step 1.370.2 1.370.2 In the transport position, terminal 1 of the 6 position Mate-N-Lok connector in the main terminal box [X017.1] should measure 12VDC. Yes Repair/Replace the white wire between the switch and the 6 position Mate-N-Lok connector in the main terminal box [X017.1] No Go to step 1.370.3 1.370.3 In the transport position, terminal 29 of the ground module J7 connector [X007.29] should measure 12VDC. Yes Repair/Replace the YEL/RED 2-60 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.1] and terminal 29 of the ground module J7 connector [X007.29] No Repair/Replace the ground module Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-172 1250AJP 3128411 1.371 WAITING FOR FSW TO BE OPEN Waiting for footswitch to be open. Notification that the platform footswitch input [X169.8] was open when the platform mode was selected. This indicates that the footswitch [X152] was engaged before platform power-on and may be blocked or stuck. This can also be reported during the power-up sequence. The footswitch or its wiring may be faulty. 1.372 WRONG ENGINE SELECTED - ECM PRESENT 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. 1.370.4 In the transport position, does terminal 13 of the tower boom transport switch [X056.13] measure 12VDC? Yes Repair/Replace the tower boom transport length switch No Go to step 1.370.5 1.370.5 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 13 of the tower boom transport switch [X056.13] should measure 12VDC Yes Go to step 1.370.9 No Go to step 1.370.6 1.370.6 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 6 of the 6 position Mate-N-Lok connector in the main terminal box [X017.6] should measure 12VDC Yes Repair/Replace the red wire between the switch and the 6 position Mate-N-Lok connector in the main terminal box [X017.6] No Go to step 1.370.7 1.370.7 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm In the transport position, terminal 35 of the ground module J7 connector [X007.35] should measure 12VDC Yes Repair/Replace the ORN/RED 49-65 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.6] and terminal 35 of the ground module J7 connector [X007.35] No Go to step 1.370.8 1.370.8 Manually close the tower boom transport length switch by rotating and hold- ing the switch arm Check that ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES⇒ TOWER TELESCOPE SWITCH NO: CLOSED is displayed. Yes Go to step 1.370.9 No Repair/Replace the ground module 1.370.9 In the transport position, terminal 21 of the tower boom transport switch [X056.21] should measure 12VDC Yes Go to step 1.370.10 No Repair/Replace the tower boom transport length switch 1.370.10 In the transport position, terminal 2 of the 6 position Mate-N-Lok connector in the main terminal box [X017.2] should measure 12VDC Yes Repair/Replace the black wire between the switch and the 6 position Mate-N-Lok connector in the main terminal box [X017.2] No Go to step 1.370.11 1.370.11 In the transport position, terminal 11 of the ground module J7 connector [X007.11] should measure 12VDC Yes Repair/Replace the ORN/RED 49-64 wire between the 6 position Mate-N-Lok connector in the main terminal box [X017.2] and terminal 11 of the ground module J7 connector [X007.11] No Go to step 1.370.12 1.370.12 Check that ANALYZER ⇒ DIAGNOSTICS ⇒ BOOM SWITCHES ⇒ TOWER TELESCOPE SWITCH NC: CLOSED is displayed. No Repair/Replace the ground module Flash Code: 2-2 Flash Code: 4-3 Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-173 1.373 WRONG MAIN LIFT RESPONSE Wrong main lift response. While the main lift was being commanded in one direction, the control system detected at least 2.5° of main angle movement in 3 seconds in the wrong direction. This is most likely caused by a problem with the hydrau- lics. The system will revert to the hydraulic retrieval mode of operation. 1.374 WRONG MAIN TELE RESPONSE Wrong main telescope response. Refer to 1.353 TRN DUAL CAP BAD TRANSITION on Pg. 159 for troubleshooting. 1.375 WRONG TWR LIFT RESPONSE Wrong tower lift response. While the tower lift was being commanded in one direction, the control system detected at least 2.5° of tower angle movement in 3 seconds in the wrong direction. This is most likely caused by a problem with the hydrau- lics. The system will revert to the hydraulic retrieval mode of operation. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.373.1 Are there any main lift PVG valve or main lift pilot valve faults? Yes Troubleshoot those first No Go to step 1.373.2 1.373.2 Are there any hydraulic leaks, especially between the main Lift PVG valve [X065] the main lift enable valve [X082] and the main lift cylinder? Yes Repair as needed No Go to step 1.373.3 1.373.3 Do the hydraulic connections match the sche- matic in Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 on Pg. 258, espe- cially between main lift PVG valve [X065] the main lift enable valve [X082] and the main lift cylinder? Yes Go to step 1.373.4 No Repair as needed 1.373.4 Raise main boom. Discon- nect the hose on the #2 port of the main lift enable valve [X082]. Does fluid continue to flow from the hose? Yes Repair/replace main cylinder holding valve No Repack main cylinder Flash Code: 8-4 Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.375.1 Are there any tower lift PVG valve or tower lift APU valve faults? Yes Troubleshoot those first No Go to step 1.375.2 1.375.2 Are there any hydraulic leaks, especially between the tower lift PVG valve [X066] the tower lift enable valve [X080] and the tower lift cylinder? Yes Repair as needed No Go to step 1.375.3 1.375.3 Do the hydraulic connections match the sche- matic in Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 on Pg. 258, espe- cially between tower lift PVG valve [X066] the tower lift enable valve [X080] and the tower lift cylinder? Yes Go to step 1.375.4 No Repair as needed 1.375.4 Raise tower boom. Discon- nect the hose on the #2 port of the tower lift enable valve [X080]. Does fluid continue to flow from the hose? Yes Repair/replace tower cylinder holding valve No Repack main cylinder SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-174 1250AJP 3128411 1.376 WRONG TWR TELE RESPONSE Wrong tower telescope response. While the tower telescope was being commanded in one direction, the control system detected at least 4.0" of tower length movement in 2 seconds in the wrong direction. This is most likely caused by a problem with the hydraulics. The system will revert to the hydraulic retrieval mode of operation. 1.377 COMMON STB OR OC PROCEDURE Common short to battery or open circuit procedure. A module input or output pin has been shorted to battery or the circuit has an open in it. All driver faults are detected in a similar manner. Open circuit faults are detected when the analog feedback reads too high and the output is commanded off. Short to battery is detected when the analog feedback reads Vbat and the output is commanded off. See the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting to battery voltage. This procedure applies to a number of faults, so it leaves the determination of specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate module, such as the main boom angle sensors and PVG valves. When opening any electrical connection, inspect the connectors for moisture inside the connector, and pins that are loose, damaged or cor- roded. Several examples are given starting at 1.177 LT FNT STEER LT STB OR OC on Pg. 97. Flash Code: 8-4 Note Pretest Instructions Test Result Corrective Action 1.376.1 Are there any tower telescope PVG valve or tower telescope APU valve faults? Yes Troubleshoot those first No Go to step 1.376.2 1.376.2 Are there any hydraulic leaks, especially between the tower tele. PVG valve [X067] the tower tele enable valve [X081] and the main lift cylinder? Yes Repair as needed No Go to step 1.376.3 1.376.3 Do the hydraulic connections match the sche- matic in Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 on Pg. 258, espe- cially between tower tele PVG valve [X067] the tower tele enable valve [X081] and the tower telescope cylinder? Yes Go to step 1.376.4 No Repair as needed 1.376.4 Raise tower boom. Discon- nect the hose on the #2 port of the tower tele enable valve [X081]. Does fluid continue to flow from the hose? Yes Repair/replace main cylinder holding valve No Repack main cylinder Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action 1.377.1 Are other STB/OC faults in the fault log? Yes Check for an open at a point in circuit common to this fault and the others. No Go to step 1.377.2 1.377.2 Find component on sche- matic and on the machine. Is the component good? Check the compo- nent resistance. Resistances of coils are given in Section 2. Electrical Reference on Pg. 177. Other loads or sensors should be neither short nor open. Some values are given on the sche- matics. For details on what some switch posi- tions mean see Table 2-1. Limit Switch States on Pg. 177. Also, inspect the connector for pins that are damaged, loose pushed out, etc. Pass Go to step 1.377.3 Fail Repair as needed SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 3128411 1250AJP 1-175 1.378 COMMON STG PROCEDURE Common short to ground procedure. A module input or output pin has been shorted to ground. All driver faults are detected in a similar manner. Short to ground is detected when the analog feedback reads low and the output is commanded on. See the fault description for the component or module pin identification. Frequently, this is due to a failed component shorting ground. This procedure applies to a number of faults so it leaves the determination of specific troubleshooting steps to the technician. However, it provides guidance to create those steps. Use of the machine schematics is required. Note that power for a particular component does not necessarily come directly from the battery. For example, the platform module power and ground circuits use the ground module, but the platform lighting does not. Some components are effectively a separate module, such as the main boom angle sensors and PVG valves. When opening any electrical connection, inspect the con- nectors for moisture inside the connector, and pins that are loose, damaged or corroded. Several examples are given start- ing at 1.178 LT FNT STEER LT STG on Pg. 98. 1.377.3 Find component power con- tacts. Is the component power good? Turn on machine and check the harness connector contacts for power. Not all components are powered by 12VDC. Pass Go to step 1.377.4 Fail Follow power connections back to source check- ing for power or continuity. Typically, the failure isn’t too close to the battery ground terminal because then so many things wouldn’t work, this fault would not be detected. Repair as needed 1.377.4 Is the signal wire good? Check the signal wire between the component and the signal input/ output on the module. Signal lists start with section 2.2 BLAM Module Connector Pinouts on Pg. 215. The information is also on the schematics. There should only be con ti nui ty between the component and the proper pin on the module in accordance with the schematic. There should not be shorts between the wire and battery + or - terminals, etc. Isolate har- ness sections that may have a problem by dis- connecting connectors as needed. Be sure to check for pins that are damaged, loose or pushed out of the connector, etc. Pass Go to step 1.377.5 Fail Repair as needed 1.377.5 Are the other wires good? Check wire from the component in question ground connection to the nearest major component. It should have continuity to the module, swivel or bus con- nector in accordance with the schematic. Pass Recheck measurements or try troubleshooting a different fault. If the component and wiring are good, reprogram/replace the associated module. Fail Repair as needed Flash Code: 3-3 Note Pretest Instructions Test Result Corrective Action 1.378.1 Find component on sche- matic and on the machine. Is the component good? Check the compo- nent resistance. Resistances of coils are given in Section 2. Electrical Reference on Pg. 177. Other loads or sensors should be neither short nor open. Also, inspect the connector for pins that are damaged, loose or pushed out, etc. Pass Go to step 1.378.3 Fail Repair as needed 1.378.2 Find component power con- tacts. Is the component power good? Turn on machine and check the harness connector contacts for power. Not all components are powered by 12VDC. Pass Go to step 1.377.4 Fail Follow power connections back to source check- ing for power or continuity. Typically, the failure isn’t too close to the battery ground terminal because then so many things wouldn’t work, this fault would not be detected. Repair as needed Note Pretest Instructions Test Result Corrective Action SECTION 1 - FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-176 1250AJP 3128411 1.378.3 Is the signal wire good? Check the signal wire between the component and the signal input/ output on the module. Signal lists start with section 2.2 BLAM Module Connector Pinouts on Pg. 215. The information is also on the schematics. There should only be continuity between the component and the proper pin on the module in accordance with the schematic. There should not be shorts between the wire and battery + or - terminals, etc. Isolate har- ness sections that may have a problem by dis- connecting connectors as needed. Be sure to include checking for pins that are damaged, loose or pushed out of the connector. Pass Go to step 1.378.4 Fail Repair as needed 1.378.4 Are the other wires good? If it does not go to ground, check other wire from the component in question connection to the nearest major component. It should have continuity to the module, swivel, bus or other connector in accordance with the schematic. Pass Recheck measurements or try troubleshooting a different fault. If the component and wiring are good, reprogram/replace the associated module. Fail Repair as needed Note Pretest Instructions Test Result Corrective Action SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-177 SECTION 2. ELECTRICAL REFERENCE Limit Switch States Table 2-1. Limit Switch States Connector Switch Normally Open or Closed Reference State X051 Main Boom Transport Angle Prox 1-4 NC, 2-3 NO 2-3 Closed = Transport X052 Dual Capacity 1 NC See Table 2-3. Switch States / Boom Length Regions on Pg. 179 X053 Dual Capacity 2 NC See Table 2-3. Switch States / Boom Length Regions on Pg. 179 X054 Main Boom Transport Length 1 NC See Table 2-3. Switch States / Boom Length Regions on Pg. 179 X055 Main Boom Transport Length 2 NC See Table 2-3. Switch States / Boom Length Regions on Pg. 179 X056 Tower Boom Transport Length 21-22 NC, 13-14 NO 21-22 Closed = Transport X079 Main Lift Pilot Pressure NO Closed = Pressure > 200psi X146 Jib Stow NC Open = Stowed (Jib > 70° Right) X147 Jib Center NC Open = Jib Centered ±5° X204 RF Axle Extension NC Closed = Extended X205 LF Axle Extension NC Closed = Extended X213 Osc Axle Lockout Pressure NO Closed = Pressure > 200psi X216 Drive Orientation NO Open = Normal Orientation X225 LR Axle Extension NC Closed = Extended X226 RR Axle Extension NC Closed = Extended SECTION 2 - ELECTRICAL REFERENCE 2-178 1250AJP 3128411 Boom Angle Regions Figure 2-1. Main Boom Angle and Length Zones Table 2-2. Main Boom Dual Capacity Zones Functions A B C D 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 A B C D L e n g t h R e g io n s +55 +53 +50 0 -40 -43 -45 1 2 3 4 5 6 7 8 Angle Regions SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-179 Figure 2-2. Dual Capacity / Transport Switch Mounting Table 2-3. Switch States / Boom Length Regions Switch Off Cam = Switch Closed, On Cam = Switch Open Dual Cap. Switch #1 Off Cam Off Cam Off Cam Disagree On Cam On Cam On Cam Disagree Disagree Dual Cap. Switch #2 On Cam On Cam On Cam Disagree Off Cam Off Cam Off Cam Disagree Disagree Control System Conclusion of Dual Cap Switches B/A B/A B/A Disagree C/D C/D C/D Disagree Disagree Main Transport Switch #1 Off Cam Disagree On Cam On Cam On Cam Disagree Off Cam Off Cam Disagree Main Transport Switch #2 On Cam Disagree Off Cam Off Cam Off Cam Disagree On Cam On Cam Disagree Control System Conclusion of Main Transport Switches A/D Disagree B/C B/C B/C Disagree A/D A/D Disagree Control System Conclusion of Main Boom Length A A/B B B/C C C/D D Switch Fault Switch Fault A/D B/C A/D D C B A (Left Side of Boom) TRANSPORT (Right Side of Boom) Dual Cap. Switch #1 (Top) Dual Cap. Switch #2 (Bottom) Main Transport Switch #2 (Bottom) Main Transport Switch #1 (Top) SECTION 2 - ELECTRICAL REFERENCE 2-180 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-181 Color Key Figure 2-3. Color Key PLATFORM CONTROL AREA BOOM AREA ENGINE SIDE AREA MAIN VALVE AREA GROUND CONTROL BOX AREA CHASSIS AREA SECTION 2 - ELECTRICAL REFERENCE 2-182 1250AJP 3128411 Platform Area Solenoids Table 2-4. Platform Area Solenoids Connector Function Nominal Resistance (Ohms) X135 Platform Dump 6.4 X136 Level Up 10.1 X137 Level Down 10.1 X138 Rotate Right 10.1 X139 Rotate Left 10.1 X140 Jig Swing Right 10.1 X141 Jib Swing Left 10.1 X142 Jib Up 10.1 X143 Jib Down 10.1 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-183 Platform Area Connectors Figure 2-4. Platform Area Connectors PLATFORM CONTROL AREA 1705744 A 1705745 B 1702938 1705170 A 1702565 A 1705171 A 17 18 19 20 21 J1 J4 J2 J3 22 56 7 981013 14 12 11 1516 12 3 4 1. Power/Emergency Stop 2. Engine Start / Aux Power 3. Capacity Select 4. Drive Orientation Override 5. Drive/Steer 6. Main Boom Telescope 7. Lights 8. Jib Lift 9. Soft Touch Override 10. Jib Swing 11. Tower Boom Lift (1250 Only) 12. Soft Touch Indicator 13. Platform Rotate 14. Jib Stow Override 15. Function Speed Control 16. Main Lift / Swing 17. Drive Speed / Torque Select 18. Steer Select 19. Platform Level Override 20. Axle Extend / Retract 21. Horn 22. Indicator Panel X197 X198 X192 X196 X189 X195 X194 X188 X193 X190 X191 X182 X183 X187 X186 X185 X184 X179 X180 X181 X177 X178 X175 X176 X174 VALVE ROTATED FOR CLARITY X135 X153 X154 X155 X152 X136 X137 X138 X139 X141 X143 X142 X140 LEVEL UP LEVEL DOWN ROTATE RIGHT ROTATE LEFT JIB SWING LEFT JIB DOWN JIB UP JIB SWING RIGHT PLATFORM DUMP SECTION 2 - ELECTRICAL REFERENCE 2-184 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-185 Boom Area Connectors Figure 2-5. Boom Area Connectors BOOM AREA X099 X100 X093 X094 X056 X048 X049 X147 X146 X150 X148 X054 X052 X053 X055 X105 (NEAR SIDE) (FAR SIDE) X104 TOWER TRANSPORT SWITCH X060 X062 X092 TOWER LIFT CYL ANGLE SENSOR TOWER BOOM LENGTH SENSOR #2 TOWER BOOM ANGLE SENSOR #1 RIGHT TOWER BOOM ANGLE SENSOR #2 LEFT JIB POSITION SWITCH JIB STOW SWITCH PLATFORM LEVEL SENSOR RIGHT PLATFORM LEVEL SENSOR LEFT MAIN BOOM TRANSPORT SWITCH #1 DUAL CAPACITY SWITCH #1 DUAL CAPACITY SWITCH #2 MAIN ROTARY ANGLE SENSOR RIGHT MAIN ROTARY ANGLE SENSOR LEFT WASHER WASHER Pivot Pin Cross Bolt MAIN BOOM TRANSPORT SWITCH #2 TOWER BOOM LENGTH SENSOR #1 X044 (21 pos.) X045 (19 pos.) X046 (Blue/Black wire) X047 (Blue wire) TAI LL IG HT TAI LL IG HT Align timing marks on shaft with timing marks at labeled letters (L or R). Each sensor must correspond with side of boom on which it is mounted. Measurement surfac e Initial adjustment: Use trunnion keeper shims to adjust sensor mount bar to be flush ±0.060 (1.52mm) with main boom pivot pin as shown Slide coupling onto mount until it bottoms out. Torque clamp screw to 0.8 in-lbs. (0.9 Nm) If space is available, install (1) thrust washer on each side of the boom assembly between the tower fly boom section and the main boom section. If space only allows for the use of (1) washer, install it on the side of the boom angle switch (Left side). MAIN BOOM TRANSPORT ANGLE SWITCH X051 X050 (to Platform) SECTION 2 - ELECTRICAL REFERENCE 2-186 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-187 Engine Area Connectors Figure 2-6. Engine Area Connectors ENGINE SIDE AREA THESE VIEWS SHOWN FOR CLARITY X250 X251 7500W GENERATOR X120 X121 X118 X119 X113 X241 X103 X24 0 STARTER RIGHT DRIVE FWD LEFT DRIVE FWD RIGHT DRIVE REV LEFT DRIVE REV SECTION 2 - ELECTRICAL REFERENCE 2-188 1250AJP 3128411 Main Valve Area Solenoids Table 2-5. Main Valve Area Solenoids Connector Function Nominal Resistance (Ohms) X068 PVG Enable 7.2 X069 Swing Right 5.2 X070 Swing left 5.2 X071 Main Tele Extend 4.7 X072 Main Tele Propor tional 4.7 X073 Main Tele Retract 4.7 X074 Main Dump 7.2 X075 Tower Lift Pilot 8.7 X0 76 To we r Te le Pi lo t 8 .7 X077 Main Lift Pilot 8.7 X080 Tower Lift Enable 4.8 X 08 1 Tow er Tel e E n ab le 4.8 X082 Main Lift Enable 4.8 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-189 Main Valve Area Connectors Figure 2-7. Main Valve Area Connectors MAIN VALVE AREA X090 X088 X107 X 057 X102 X089 X087 X086 J1 J3 J4 X091 ANALYZER CONNECTION X090 X088 X089 X087 X086 X082 X063 X081 X066 X260 X261 X068 X071 X073 X072 X067 X070 X069 X059 X077 X079 X078 X076 X075 X110 X116 X117 X080 MAIN LIFT ENABLE TOWER LIFT ENABLE TOWER TELE. ENABLE TOWER LIFT PVG PVG ENABLE MAIN TELE EXTEND MAIN TELE RETRACT MAIN DUMP MAIN TELE PROPORTIONAL TOWER TELE PVG SWING LEFT SWING RIGHT MAIN LIFT PILOT PRESSURE SWITCH OIL TEMP TOWER TELE PILOT TOWER LIFT PILOT B.L.A.M. MODULE X065 MAIN LIFT PVG J2 J5 AUX PUMP X097 BATTERY BUSSBAR X098 X095 TOWER SENSOR 1 PASSTHRU (4 POS.) X096 TOWER SENSOR 2 PASSTHRU (4 POS.) LOCATION APPROXIMATE GROUND BUSSBAR X058 X083 X263 X084 X268* X074 * X268 has cable going into valve harness X259 X262 SECTION 2 - ELECTRICAL REFERENCE 2-190 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-191 Ground Control Connectors Figure 2-8. Ground Control Connectors GROUND CONTROL BOX AREA X010 X009 X001 X008 X007 X042 X043 X016 X004 X012 X011 X002 X003 X023 X270 CAN to Platform X014 CAN to Ground Module X2 69 C AN to BLAM X024 X025 X022 X021 X020 X019 X018 X029 X026 X030 X028 SECTION 2 - ELECTRICAL REFERENCE 2-192 1250AJP 3128411 Chassis Area Solenoids Table 2-6. Chassis Area Solenoids Connector Function Nominal Resistance (Ohms) X206 Front Axles Extend 4.9 X207 Front Left Steer Right 4.9 X208 Front Right Steer Right 4.9 X209 Front Axles Retract 4.9 X210 Front Left Steer Left 4.9 X211 Front Right Steer Left 4.9 X212 Axle Lockout Solenoid 6.2 X214 2 Speed Solenoid 6.2 X215 Brake Release Solenoid 6.3 X219 Rear Right Steer Left 4.9 X220 Rear Left Steer left 4.9 X221 Rear Axles Retract 4.9 X222 Rear Right Steer Right 4.9 X223 Rear Left Steer Right 4.9 X224 Rear Axles Extend 4.9 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-193 Chassis Area Connectors Figure 2-9. Chassis Area Connectors CHASSIS AREA VALVES TURNED FOR CLARITY CHASSIS MODULE FRONT STEER VALVE REAR STEER VALVE TRACTION CONTROL VALVE AXLE LIMIT SWITCHES (FRONT) AXLE LIMIT SWITCHES (REAR) J1 J3 J4 ANALYZER CONNECTION X231 X233 X235 X229 X232 X230 X225 X238 X083 X212 X216 X213 X215 X222 X223 X224 X219 X220 X221 X239 X226 X214 X209 X210 X211 X206 X207 X208 X204 X200 X205 X203 J5 J2 REAR LEFT STEER LEFT FRONT LEFT STEER LEFT AXLE LOCKOUT BRAKE RELEASE AXLE LOCKOUT PRESSURE SWITCH 2 SPEED REAR LEFT STEER RIGHT FRONT LEFT STEER RIGHT REAR RIGHT STEER LEFT FRONT RIGHT STEER LEFT REAR RIGHT STEER RIGHT FRONT RIGHT STEER RIGHT RETRACT RETRACT REAR RIGHT STEER ANGLE FRONT RIGHT STEER ANGLE REAR LEFT STEER ANGLE FRONT LEFT STEER ANGLE REAR LEFT AXLE SWITCH FRONT LEFT AXLE SWITCH REAR REAR AXLE SWITCH FRONT REAR AXLE SWITCH EXTEND EXTEND SECTION 2 - ELECTRICAL REFERENCE 2-194 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-195 Platform Electrical Schematic Figure 2-10. Platform Electrical Schematic A B C D E F G H 12345678 G H E F C D A B 87654321 PLATFORM SCH. Ref. 1870197C 12 DEU TSCH 19 P OS. TWIS T LOC K IN M TB. = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = TERMINAL STRIP IN PLATFORM BOX = 15 POS. AMP MATE-N-LOCK CONNECT OR (KK2 ON HARNESS DW G.) = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.) TO BLAM 12 POS CONNECTOR (TH RU VALVE HARNESS) TO BLAM THRU ENGINE HARNESS TO CHASSIS A DEUTSCH 21 POS. TWIST LOCK IN MTB. ] ] = 6 POS. MATE-N-LOC IN MTB LEVEL JIB UP DOWN RIGHT LEFT DOWN UP ROTATE RED BLACK BLACK RED PLATFORM WORK LIGHTS ALARM FUEL GAGE FULL 3/4 1/2 1/4 MAIN TELE IN OUT ROTATE RIGHT LEFT LEVEL UP DOWN JIB UP UP DOWN DOWN EMS PTF TO MTB PTF EMS GND MODE GND EMS GND FROM GND MODULE CAN LO CAN HI START SWITCH AUX POW ER CRAB STEER COORDINATED STEER TWO SPEED ENGINE SPEED SOFT TOUCH OVERIDE HEAD/TAIL LIGHTS HORN FOOTSWITCH CREEP GENERATOR TILT AUTO LEVEL SYSTEM FOOTSWITCH/ENABLE CREEP BROKEN CABLE OVERLOAD 226KG/500# CAPACITY 453KG/1000# CAPACITY AXLE SET GENERATOR ON SOFT TOUCH GLOW PLUG BOOM CONTROL SYSTEM DRIVE ORIENTATION LEFT RIGHT PUMP TOWER POTENTIOMETER LIFT JIB SWING ANALYZER POWER ANALYZER RECEIVE ANALYZER TRANSMIT ANALYZER GROUND STEER LEFT RIGHT J1 (WHITE) BRN/WHT 47-13 YEL/RED 2-21 ORN/RED 49-15 RED/YEL 54-3-1 WHT/YEL 39-1 GRAY 23-3 GRAY 24-3 PINK 25-3-2 PINK 26-3-2 BLUE 27-3 BLUE 28-3 SWING LIFT DRIVE BLU/ORN 52-12 BLUE 27-1 BLUE 28-1 PINK 26-1 PINK 25-1 GRAY 23-1 GRAY 24-1 BROWN 14-1 BROWN 13-1 J2 (GRAY) J5 (WHITE) J6 (BLACK) output PLATFORM EMS CAN SHIELD 5 6 7 8 9 10 11 12 33 34 35 13 32 18 1 2 3 4 16 17 20 21 22 23 24 14 15 28 27 31 29 30 J8 (BLACK) J7 (BLACK) 19 5 6 15 16 25 26 27 28 29 2 31 30 32 3 1 8 19 18 9 1 2 35 23 24 22 25 16 9 7 21 18 19 14 30 13 10 8 15 11 12 6 17 33 26 28 29 6 5 6 4 2 1 3 7 Ref.V WIPER GND 20 27 BLK/WHT (12) BLU/ORN 52-11 YEL/RED 2-3(16) YEL/RED 2-2(12) ORANGE (12) RED (18) BLACK (18) SHIELD ORANGE (18) YEL/BLK (18) 15 13 YEL/RED 2-5 ORN/BLK (18) 10 3 2 1 4 YELLOW (18) 16 12 11 BLU/BLK (18) WHT/YEL 48-1 BRN/ORN 53-1 WHT/YEL 48-5 BLU/ORN 52-1 RED (18) BLACK (18) YEL/RED 2-3-1 YEL/RED 2-30-1 BLACK (12) YEL/RED 2-1- 2 (12) RED GREEN WHITE BLACK/SHIELD 1 2 3 4 HOLE PLUG HOLE PLUG HOLE PLUG 14 17 19 4 6 5 3 2 YEL/RED 2-10 RED/WHT 55-30 RED/WHT 55-31 BLACK ORN/RED 49-11 ORN 55-46 ORN/RED 49-40 GREEN BLU/ORN 52-4 20 AMP C.B. ORN/RED 49-1000 YELLOW 55-16 YELLOW 55-17 ORN/RED 49-101 ORN/RED 49-42 BRN/WHT 47-4 BRN/WHT 47-3 BRN/WHT 47-2 BRN/WHT 47-1 BLACK 18 5K 5K 5 1 4 2 3 7 GRAY 23-3 GRAY 24-3 PINK 25-3-3 PINK 26-3-3 BLUE 27-3 BLUE 28-3 WHITE 60-3 WHITE 59-3 BLACK WHITE 60-3 WHITE 59-3 BLACK 8 9 10 11 19 20 12 4 33 1 2 3 7 21 1 2 3 BRN/BLK (18) BRAIDED SHIELD ORN/RED 49-12 21 PINK 26-3-3 PINK 25-3-3 PINK 26-3-1 PINK 25-3-1 6 7 RED/WHT 50-2-1 RED/WHT 50-2-3 5 PLATFORM DUMP 9 7 5 RED WHITE BLACK RED WHITE BLACK 25 26 19 ORN/RED 49-10 14 YEL/RED 2-11 YEL/RED 2-11 13 YEL/RED 2-11-1 1 YEL/RED 2-11-2 1 ORN/RED 49-11 2 ORN/RED 49-12 2 17 32 BASKET LEVEL SENSOR #1 BASKET LEVEL SENSOR #2 MOUNTED ON LEFT SIDE OF BOOM MOUNTED ON RIGHT SIDE OF BOOM AXLE SET RET EXT YEL/WHT 43-1 YEL/WHT 44-1 RED/YEL 54-1 500# 1000# CAPACITY 1 2 3 6 1 2 3 4 5 6 1 2 3 4 6 3 2 4 1 SYSTEM DISTRESS J3 J2 J1 5 6 J4 BLACK BRN/WHT 47-12 BRN/WHT 47-10 RED/YEL 54-2 ORN/RED 49-3 WHT/YEL 48-6 ORN/RED 49-100 BLU/ORN 52-4-1 ORANGE 55-51 ORN/RED 49-92 ORN/RED 49-91 ORN/RED 49-90 ORN/RED 49-89 LEFT RIGHT DRIVE ORIENTATION OVERIDE JIB STOW 2 34 1 4 3 5 WHITE 59-1 YEL/RED 2-10-14 WHITE 60-1 JIB SWING ORANGE 55-50 YEL/RED 2-16 YEL/RED 2-16-1 YEL/RED 2-16 -2 YEL/RED 2-16-3 WHITE 59-60 BLACK (12) BLACK (12) RED (12) BLACK WHITE ORN/RED 49-70 YEL/RED 2-16-2 WHITE (10) BLACK (10) GREEN (10) 5 5 4 RED/YEL 54-3 BLU/ORN 52-3 20 BROWN (18) RED/BLK BLUE (18) JIB INLINE LIM IT SWITCH JIB STOW LIMIT SWITCH SOFT TOUCH LIMIT SWITCHS 1 2 BLU/ORN 52-4 BLU/ORN 52-3 ORN/RED 49-69 3 7 8 BLACK ORN/RED 49-4 8 YEL/RED 2-37 15 11 10 9 8 ORN/RED 49-63 YEL/RED 2-12-2 ORN/RED 49-68 1 2 3 RED BLUE BLACK BRN/BLK (18) BRAIDED SHIELD 4 5 6 ORANGE YELLOW BLACK YEL/RED 2-12-1 ORN/RED 49-80 ORN/RED 49-81 10 11 12 13 14 22 23 24 34 35 6 RED/WHT 50-2-3 TAN 5 -1 TAN 6 -1 31 WHITEBLACK 4 ORN/RED 49-67 5 WHITE BLACK 6 YEL/RED 2-36 14 8 SEE SHEET 2 18 9 7 5 8 15 13 10 3 2 1 4 6 16 12 11 14 17 19 8 8 V BAT. V REF. X199 X185 X189 X176 X178 X188 X195 X180 X192 X196 X175 X186 X194 X177 X177 X198 X193 X184 X181 X165 X169 X155 X172 X161 X162 X163 X136 X137 X139 X138 X142 X143 X140 X141 X152 X197 X144 X145 X146 X147 X153 X179 X160 X161 X164 X173 X017 X043 X042 X050 X109 X154 X167 X168 X174 X171 X190 X191 X182 X183 X187 X166 SECTION 2 - ELECTRICAL REFERENCE 2-196 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-197 Tower and Main Boom Electrical Schematic Figure 2-11. Tower and Main Boom Electrical Schematic A B C D E F G H 12345678 G H E F C D A B 87654321 STROBE LIGHT BLK/WHT (12) ORANGE (12) RED (18) BLACK (18) SHIELD ORANGE (18) 18 YEL/BLK(18) BLU/ORN 52-1115 13 ORN/BLK(18) 10 3 2 1 4 6 6 YELLOW (18) 16 12 11 BLU/BLK HOLE PLUG HOLE PLUG HOLE PLUG 19 17 14 2 1 8BLACK (12) BLACK (12) RED (12) BLK/WHT (12) ORANGE (12) RED (18) BLACK (18) SHIELD ORANGE (18) YEL/BLK(18) 15 13 ORN/BLK (18) 10 3 2 1 4 YELLOW (18) 16 12 11 BLU/BLK HOLE PLUG HOLE PLUG HOLE PLUG 14 17 19 18 9 BLACK (12) BLACK (12) RED (12) RED/BLK ORANGE (18) YELLOW BLU/BLK HOLE PLUG HOLE PLUG HOLE PLUG BLACK (12) RED (12) BLK/WHT (12) ORANGE (12) YEL/BLK(18) ORN/BLK(18) RED/BLK ORN/RED 49-122 ORN/RED 49-123 #1 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF BOOM (TOP SWITCH). THIS SWIT CH IS IN THE N.C. POSITION WHEN THE MAIN BOOM IS FULLY RETRACTED. #2 DUAL CAPACITY LIMIT SWITCH, MOUNTED ON LEFT SIDE OF BOOM (BOTTOM SWITCH). THIS SWITCH IS OPEN WHEN THE MAIN BOOM IS FULLY RETRACTED. #1 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT SIDE OF MAIN BOOM (TOP SWITCH) THIS SWITCH IS IN THE N.C. POSITION WHEN THE MAIN BOOM IS FULLY RETRACTED. #2 MAIN BOOM TRANSPORT LIMIT SWITCH, MOUNTED ON THE RIGHT SIDE OF MAIN BOOM (BOTTOM SWITCH) THIS SWITCH IS OPEN WHEN THE MAIN BOOM IS FULLY RETRACTED. MAIN BOOM TRANS PORT ANGLE LIMIT SWITCH 13 14 21 22 MAIN BOOM ANGLE LIMIT SWITCH BLACK (CAN H) GRAY (CAN L) BROWN (SHIELD) WHITE (POWER) BLUE (GROUND) BLACK (CAN H) GRAY (CAN L) BROWN (SHIELD) WHITE (POWER) BLUE (GROUND) #1 RIGHT SIDE MAIN BOOM ANGLE SE NSOR #2 LEFT SIDE MAIN BOOM ANGLE SENSOR BROWN BLUE E S U L B M J K RED BLACK SHIELD RED WHITE BLACK B A C ORN/RED 49-120 YEL/RED 2-70-8 ORN/RED 49-121 RED WHITE BLACK B A C ORN/RED 49-130 YEL/RED 2-70-7 ORN/RED 49-131 WHT RED BLK BLK WHT 2221 21 22 WHT RED BLK BLK WHT 22 21 21 22 4 5 1 2 3 4 5 1 2 3 E S U L B M J K D G R N HOLE PLUG HOLE PLUG H P V W X N R G BLUE (18) 5 BROWN (18) 7 RED/BLK (18) 9 RED BLACK SHIELD BROWN (18) 5 BLUE (18) 7 8 6 YEL/RED 2-70-5 YELLOW RED/BLK BLACK (14) 1 2 3 18 16 15 13 12 11 10 9 8 7 5 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3 2 1 WHITE BLACK RED ]1] ]2] ]6] TOWER BOOM TRANSPORT LIMIT SWITCH 13 14 21 22 D BLK/WHT (12) ORANGE (12) RED (18) BLACK (18) SHIELD ORANGE (18) YEL/BLK(18) ORN/BLK (18) YELLOW (18) BLU/BLK BLACK (12) BLACK (12) RED (12) RED/BLK BROWN (18) BLUE (18) TOWER & MAIN BOOM SCH. YEL/RED 2-70-5 MAIN BOOM TRANSPORT ANGLE PROXIMITY SENSOR BLUE (22) 3 BLACK E BLK (22) 2 ORN/RED 49-122 R WHT (22) 4 ORN/RED 49-123 N BRN (22) 1 YEL/RED 2-70-9 B B N R WHICHEVER IS PRESENT (EARLY MACHINES HAD LIMIT SWITCH) SEE SHEET 1 12 DEUTSCH 19 POS. TWIST LOCK IN MTB. = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = 21 POSITION DEUTSCH CO NNECTOR IN PLATFORM BOX = TERMINAL STRIP IN PLATFORM BOX = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.) = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.) TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) TO BLAM THRU ENGINE HARNESS TO CHASSIS A DEUTSCH 21 POS. TWI ST LOCK IN MTB. ] ] = 6 POS. MATE-N-LOC I N MTB Ref. 1870197C X160 X050 X160 X161 X164 X173 X017 X043 X042 X045 X044 X056 X048 X049 X052 X053 X054 X055 X046 X047 X051 X051 X057 SECTION 2 - ELECTRICAL REFERENCE 2-198 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-199 Ground Control Electrical Schematic Figure 2-12. Ground Control Electrical Schematic 12345678 G H E F C D A B 87654321 A B C D E F G H ALARM MAIN TELE IN OUT ROTATE RIGHT LEFT LEVEL UP DOWN JIB UP DOWN MTB MODE OUTPUT MAIN LIFT SWING START SWITCH AUX POW ER LEFT RIGHT DOWN UP ENGINE LOW OIL PRESSURE ENGINE HIGH TEMPERATURE NO CHARGE GROUND CONTROL BOX HOURMETER OUT IN TOWER TELE. PILOT LEFT RIGHT MAIN DUMP TELE. FLOW CONTROL 17 2 13 31 9 8 4 24 7 30 6 18 17 5 4 16 19 8 23 33 35 34 20 9 10 21 25 32 12 29 28 26 15 13 1 14 2 27 3 31 16 1 12 32 11 35 34 19 14 30 27 15 29 26 18 24 28 25 6 HEAD/TAIL LIGHT FUEL SENSOR (SIGNAL) SENSOR (GROUND) J4 (BLUE) 29 12 13 22 7 21 26 27 35 2 1 6 32 33 34 15 3 14 9 30 21 31 10 12 17 6 27 35 25 7 13 24 18 5 8 28 FOOTSWITCH MTB MODE SELECT MTB EMS 2 3 4 1 MTB EMS input GND FROM BATTERY GND TO PLATFORM MTB EMS TO PLATFORM TO BATTERY NEG. J2 (GRAY) J7 (BLACK) J1 (WHITE) HORN OUTPUT HORN GND BLACK BLU/ORN 52-2 RED/WHT 50-1 BROWN 55-60 BROWN 13-3 BROWN 14-3 BROWN 55-10 WHITE 22-3 WHITE 21-3 BLU/ORN 52-10 BLACK BRN/WHT 47-12 BRN/ORN 53-2 BLU/ORN 52-5 BROWN 13-2 BROWN 14-2 GRAY 24-2 GRAY 23-2 PINK 25-2 PINK 26-2 WHT/YEL 48-1 BRN/ORN 53-2 BLUE 27-2 BLUE 28-2 TAN 3 -2 TAN 4 -2 WHITE 22-2 WHITE 21-2 BRN/WHT 47-11-1 BRN/WHT 47-5-1 BRN/WHT 47-6-1 BRN/WHT 47-8-1 BLACK BLACK (10) BLACK (12) YEL/RED 2-1-2(12) YEL/RED 2-30 YEL/RED 2-30-1 2-40-1 ALL WIRES ARE 18 GA. UNLESS NOTED OTHERWISE. BLACK ANALYZER POWER ANALYZER RECEIVE ANALYZER TRANSMIT ANALYZER GROUND RED GREEN WHITE BLACK/SHIELD 1 2 3 4 28 18 5 24 31 YEL/RED 2-21 RED 1-2 (6) B+ 12 VDC BATTERY 30 15 14 11 8 25 9 17 16 BATTERY CABLE (1 GA.) 30 AMP 22 34 19 32 29 11 1 2 33 4 16 23 26 ORN/RED 49-103 WHT/YEL 39-1-1 ORN/RED 49-100 RED/YEL 54-2-1 RED/YEL 54-3-1 ORN/RED 49-101 AXLES SET PLATFORM OVERLOAD 500# CAP 1000# CAP 86 85 87 30 87a 86 85 87 30 87a 2 4 1 3 B1 B2 YEL/RED 2-2 (12) YEL/RED 2-5 YEL/RED 2-30-4 YEL/RED 20-70-1 YEL/RED 2-4 (12) YEL/RED 2-1 (12) YEL/RED 2-70 (14) YEL/RED 2-4-1 BLACK BLACK IGN. ON RELAY POWER DOWN RELAY YEL/RED 2-30 YEL/RED 2-3-1 YEL/RED 2-1-1(12) YEL/RED 2-1-3 (12) RED BLACK SHIELD CAN HI CAN LO CAN SHIELD A B C A B C RED(18) BLACK SHIELD 3 2 1 CB A SHEILD BLACK RED YEL/RED 2-60 ORN/RED 49-64 ORN/RED 49-65 13 10 16 12 11 YEL/RED 2-6-2 5 7 3 RED/WHT 50-2-1 PINK 26-3-1 PINK 25-3-1 5 7 9 4 MOMENT CONTROL TEST BOOM SYSTEM CONTROL YEL/RED 2-3-2 YEL/RED 2-2-1 TAN 55- 22 TAN 55-32 MAIN LIFT PILOT BLACK (14) 6 YEL/RED 2-40-11 ]1] ]2] ]6] GROUND CONTROL SCH. YEL/RED POWER AUXILIARY PUMP MOTOR M 10 21 22 20 4 8 3 1 275 6 10 9 19 1 2 3 BLACK BLACK RED WHITE GREEN RED WHITE GREEN WHITE GREEN BLACK RED WHITE GREEN RED WHITE GREEN 5 9 1 8 12 4 13 14 GLOW PLUGS WHT/YEL 48-6 JIB SWING LEFT RIGHT WHITE 60-2 WHITE 59-2 TOWER LIFT DOWN UP TAN 5 -2 TAN 6 -2 ORN/RED 49-121 ORN/RED 49-120 BRN/ORN 53-3 CANNOT BE USED CANNOT BE USED WHT/RED 57-10 WHT/RED 57-11 TO BLAM TO BLAM 7 8 RED/WHT 50-2 PVG ENABLE 23 33 MAIN LIFT ENABLE TAN 55- 21 TAN 55-31 TOWER LIFT ENABLE TOWER LIFT PILOT BROWN 55-50 TAN 55-50 15 ORN/RED 49-301 RS 232 BACK-UP RELAY 20 23 ORANGE 55-47 ORANGE 55-45 6 7 TOWER TELE. ENABLE BROWN 55-1 HYD OIL TEMP. SENDOR BRN/WHT 48-1 BLACK (14) TAN 55-23 MAIN LIFT PILOT PRESSURE 10 11 12 22 11 ORN/RED 49-200 5 3 TAN 55-51 TOWER LIFT POWER 18 5 YEL/RED 2-70-2 (14) YEL/RED 2-70 -3 (14) 4 BLACK (16) BLACK (16) BLACK (14) BLACK (14) 6 5 5 4 20 V REF. V BAT. 2 1 TO BLAM 9 ORN/RED 49-102 J8 (BLACK) J E K U S N R M L ORN/RED 49-130 ORN/RED 49-131 ORN/RED 49-123 ORN/RED 49-122 1 GA 86 85 87 30 87a BLU/ORN 52-12 B+ FUSIBLE LINK RECTIFER REGULATOR ALTERNATOR STATOR SENSING AND SWITCHING CIRCUITS WHT/YEL 48-12(12) D+ sol. RED 1-1(10) STARTER MOTOR SOL. STARTER MOTOR BRN/WHT 47-8 WHT/YEL 48-3 DEUTZ ENGINE BLACK (16) 1 2 10 11 12 13 14 MTB TO EMR2 ENGINE CONTROL ENGINE OIL PRESSURE COOLANT TEMPERATURE EMR ACTUATOR ENGINE SPEED CAMSHAFT CHARGE AIR PRESSURE 8 9 13 12 23 4 25 24 22 21 20 14 15 17 19 GRD (SPEED) SPEED GRD(TempAll) GRD (ACD2) ADC5(TEMP1) +5Vref(ADC2) ADC2 +5Vref(ADC4) ADC4 GND (ADC4) ActorOut ActorOut RackMea sCom RackMea sRef 18 RackMea sSignal ADC7(TEMP3) EMR2 ENGINE CONTROL TO ENGINE 2 1 2 1 1 2 3 4 1 2 3 1 2 3 4 5 YEL/RED 2-1-99 ORN/RED 49-198 ORN/RED 49-199 BLACK 0-1 A K L B DEUTZ DIANOSTICS PLUG YEL/RED 2-1-98 WHT/YEL 48-3 WHT/YEL 48-9 GENERATOR 86 85 87 30 87a 86 85 87 30 87a 7500 W GENERATOR 86 86 85 85 87 87 2 30 30 87a 87a RED RED YELLOW BLU/ORN 52-6 YEL/RED 2-20 C A B GENERATOR CONTROL BOX RED 1-3 (12) BLACK (14) 14 GA. FUSE LINK 2500W CHASSIS POWER CHASSIS POWER 2500W GENERATOR 5 AMP 30 AMP BRN/WHT 47-20 BLACK RED 1-1 (12) RED SHIELD BLACK RED SHIELD BLACK B A C B A C TO BOOM LENGTH ANGLE MODULE B YEL/RED 2-70-5 (14) BLACK (16) J8-3 30 29 BLACK BLACK 12 DEUTSCH 19 POS. TWIST LOCK IN MTB. = 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = TERMINAL STRIP IN PLATFORM BOX = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNE SS DWG.) = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.) TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) TO B LAM T HRU ENG INE H ARN ESS TO CHASSIS A DEUTSCH 21 POS. TWIST LOCK IN MTB. ] ] = 6 P OS. M ATE-N -LOC IN M TB WHT/YEL 48-9 WHT/YEL 48-13 (8) IN HEAD GLOW PLUG NOTE: ENGINE WILL ONLY HAVE INTAKE HEATERS OR GLOW PLUGS NOT BOTH. INTAKE HEATERS sol. WHT/YEL 48-10 (10) WHT/YEL 48 -11 (10) DISTRIBUTION RELAY RELAY HARNESS YEL/RED 2-70-5 YEL/RED 2-70-6 1 SWING MAIN TELE. Ref. 1870197C X024 X021 X025 X026 X022 X020 X018 X023 X019 X028 X035 X034 X036 X033 X040 XO32 X038 X031 X037 X039 X004 X002 X008 X001 X007 X064 X074 X068 X072 X082 X080 X077 X075 X076 X066.2 X065.2 X067.2 X101 X063 X107 X058 X030 X011 X106.5 X014 X270 X269 X058 X161 X164 X173 X017 X043 X042 X083 X106 X058 X058 X083 X079 X078 X081 X010 X029 X027 X012 X124 X240 X241 X122 X257 X256 X126 X016 X015 X059 X013 X108 X110 X127 X267 X248 X246 X266 X263 X247 X116 X117 X084 X268 X112 X113 X125 X111 X242 X009 X069 X070 X073 X071 = 19 POS ITION D EUTSCH CONNE CTOR IN P LATFORM BOX X160 SECTION 2 - ELECTRICAL REFERENCE 2-200 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-201 BLAM Electrical Schematic Figure 2-13. BLAM Electrical Schematic A B C D E F G H 87654321 G H E F C D A B 12345678 4 BRN/BLK BRN/BLK 1 2 5 9 10 11 12 6 5 2 1 ORANGE 8-3 ORANGE 8-2 J5 ORANGE 8-3 ORANGE 8-2 3 4 12 11 9 8 1 2 3 4 YEL/RED 2-82 ORN/RED 49-112 BLACK BRN/BLK J2 ORANGE YELLOW BLACK BRN/BLK 1 2 6 7 8 9 12 5 4 3 J1 1 2 3 4 YEL/RED 2-81 ORN/RED 49-111 BLACK BRN/BLK RED BLUE BLACK BRN/BLK RED WHITE BLACK RED WHITE BLACK 2 3 1 2 3 #1 RIGHT SI DE TOWER BOO M ANGLE SENSOR SERIAL OUTPUT ORANGE 7-3 ORANGE 7-2 ORANGE 7-2 ORANGE 7-3 LEFT FORWARD DRIVE PUMP LEFT REVERSE DRIVE PUMP RIGHT FORWARD DRIVE PUMP RIGHT REVERSE DRIVE PUMP ANALYZER POWER ANALYZER RECEIVE ANALYZER TRANSMIT ANALYZER GROUND RED GREEN WHITE BLACK/SHIELD 1 2 3 4 CAN HI CAN LO CAN SHIELD RED BLACK SHIELD 10 11 12 1 2 3 3 2 2 87 3 4 1 6 YEL/RED 2-70-2 (14) BLACK (14) ORANGE 60-1 4 YEL/RED 2-70-3 (14) YEL/RED 2-70-4 (14) YEL/RED 2-70-4 (14) 8 BLACK (14) ORANGE 55-47 ORANGE 55-45 5 6 7 5 BLACK 5 (16) J4 1 2 3 4 5 LIFT CYL. PIN SLIP RING CONNECTOR TO CHASSIS BOOM LENGTH ANGLE MODULE V-BAT + GND - BLACK GRAY GRAY BROWN 6 4 5 1 A 2 B 3 D 4 E 5 1 23 4 1 2 3 4 12 3 4 WHITE GREEN RED BLACK BRN/BLK ORN/RED 49-102 GRAY 24-2 GRAY 23-2 TOWER LIFT PVG TOWER TELE. PVG MAIN LIFT PVG BLACK TAN 55-51 BLACK BROWN 55-50 BLACK TAN 55-50 BLACK TAN 55 -51 BLACK BROWN 55-50 BLACK TAN 55-50 ORN/RED 49-102 GRAY 24-2 GRAY 23-2 8 7 9 1 2 6 7 8 9 12 5 4 3 J3 GREEN 11 10 ORN/RED C A C B B B A C A RED BLUE BLACK RED BLUE BLACK ORANGE YELLOW BLACK TOWER BOOM LIFT CYL. ANGLE SENSOR TOWER BOOM LENGTH SENSOR #1 T OP TOWER BOOM LENGTH SENSOR #2 BOTTOM BRN/BLK BRN/BLK 6 7 8 4 ORN/RED 49-200 RED GREEN WHITE BLACK/SHIELD RED GREEN WHITE BLACK/SHIELD 1 2 3 A B TO ENGINE MODULE 5 6 2 9 DEUTSCH 3 PO S. CONNECTOR DEUTSCH 3 PO S. CONNECTOR DEUTSCH 3 P OS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR DEUTSCH 12 POS. CONNECTOR CHASSIS POWER RELAY HARNESS CHASSIS POWER RELAY ORN/RED 49-200 TO MTB J7-22 CAN HI CAN LO CAN SHIELD 11 10 1 5V REF. V BAT. 3 2 1 ROTATE LEFT ROTATE RIGHT (LOAD PIN PUSH TO TEST NOT USED AT THIS TIME) J2-11 J2-8 J1-3 AUX POWER PUMP MOTOR BLAM SCH. 12 POS. GND CONNE CTOR IN MTB TO MTB 12 POS. GND CONNECTOR IN MTB TO MTB 12 POS. GND CONNECTOR IN MTB TO MTB J1-20TO MTB J1-23TO MTB C RED BLACK SHIELD A B C RED SHIELD BLACK FROM ENGINE MODULE V BAT. 12 DEUTSCH 19 POS. TWIST LOCK IN MTB. = 19 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = 21 POSITION DEUTSCH CONNECTOR IN PLATFORM BOX = TERMINAL STRIP IN PLATFORM BOX = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK2 ON HARNESS DWG.) = 15 POS. AMP MATE-N-LOCK CONNECTOR (KK1 ON HARNESS DWG.) TO BLAM 12 POS CONNECTOR (THRU VALVE HARNESS) TO B LAM THRU ENG INE H ARN ESS TO CHASSIS A DEUTSCH 21 POS. TWIST LOCK IN MTB. ] ] = 6 POS. MATE-N-LOC IN MTB Ref. 1870197C X059 X092 X093 X094 X058 X058 X058 X263 X266 X058 X084 X058 X058 X110 X058 X083 X009 X009 X009 X098 X097 X086 X088 X090 X087 X096 X100 X095 X099 X089 X091 X121 X119 X118 X120 X106 X066 X067 X065 X062 X268 X060 X160 X161 X164 X173 X017 X043 X042 X083 X106 X058 SECTION 2 - ELECTRICAL REFERENCE 2-202 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-203 Chassis Electrical Schematic Figure 2-14. Chassis Electrical Schematic A B C D E F G H 87654321 G H E F C D A B 12345678 DRIVE ORIENTATION SWITCH TWO SPD VALVE BRAKE VALVE RIGHT FRONT STEER RIGHT RIGHT FRONT STEER LEFT LEFT FRONT STEER RIGHT LEFT FRONT STEER LEFT RIGHT REAR STEER RIGHT RIGHT REAR STEER LEFT LEFT REAR STEER RIGH T LEFT REAR STEER LEFT 1 RED RED 2 BLACK BLACK 3 SHIELD SHIELD 4 YEL/BLK 14G A RED 14GA 5 BLK 14GA BLACK 14GA 6 ORANGE 55-47 YELLOW (16) 7 ORANGE 55-45 ORANGE (16) 8 ORANGE 60-2 VIOLET 9 10 11 YEL/RED BLACK 12 ORN/RED 49-106 BLACK 1 2 3 4 5 6 7 8 9 10 11 12 1 23456789 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 BLACK BLACK WHITE WHITE BLACK BLACK WHITE WHITE LEFT FRONT AXLE EXTEND LIMIT SWITCH RIGHT FRONT AXLE EXTEND LIMIT SWITCH LEFT REAR AXLE EXTEND LIMIT SWITCH RIGHT REAR AXLE EXTEND LIMIT SWITCH OSC. AXLE LOCK-O UT VALVE YEL/WHT 39-2 YEL/WHT 43-1 YEL/WHT 44-1 FRONT AXLE EXTEND REAR AXLE EXTEND REAR AXLE RETRACT FRONT AXLE RETRACT YEL/RED 2-1-3 YEL/RED 2-1-2 1 2 3 4 5 6 YEL/WHT 40-2 ORN/RED ORN/RED YEL/RED 2-1- 7 BLACK YEL/WHT 39-2-43-1 YEL/WHT 40-2-44-1 ORN/RED 49-105 ORN/RED 49-104 ORN/RED 49-106 ORN/RED 49-107 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 RED WHITE BLACK BLACK RED WHITE BLACK BLACK RED WHITE BLACK BLACK RED WHITE BLACK BLACK BRN/BLK BRN/BLK BRN/BLK BRN/BLK RED BLUE BLACK BRN/BLK RED BLUE BLACK BRN/BLK RED BLUE BLACK BRN/BLK RED BLUE BLACK BRN/BLK A B C A B C A B C A B C RIGHT FRONT STEER SENSOR LEFT FRONT STEER SENSOR RIGHT REAR STEER SENSOR LEFT REAR STEER SENSOR 6 PIN BUSS CONNECTOR OSC. AXLE LOCK-O UT PRESSURE SWITCH BLACK 14GA YEL/RED 2-1-1 (14GA) J2 BLACK J5 RUST J3 GREEN J1 GRAY J4 GRAY YELLOW 10-2 YELLOW 9-2 YELLOW 10-1 YELLOW 9-1 YELLOW 12-2 YELLOW 11-2 YELLOW 12-1 YELLOW 11-1 RED GROUND WHITE BLACK BLACK YEL/RED 2-1-5 RED BLACK SHIELD YEL/RED 2-1-6 CHASSIS SCH. 1 2 3 4 Chassis Analyzer Connection Ref. 1870197C X230 X205 X204 X225 X226 X206 X224 X221 X209 X233 X208 X211 X207 X210 X222 X219 X223 X220 X235 X229 X216 X212 X215 X214 X231 X213 X232 X227 X201 X200 X202 X203 X236 X239 X237 X238 SECTION 2 - ELECTRICAL REFERENCE 2-204 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-205 Electrical Wiring Sheet 1 Figure 2-15. Electrical Wiring (Sheet 1 of 2) FUEL LEVEL SENSOR LIGHTS RELAY HORN AUX PUMP AUX POWER RELAY A LARM MAIN CONTROL VALVE SWIVEL #1 TOWER BOOM ANGLE SENSOR (RIGHT) #2 TOWER BOOM ANGLE SENSOR (LEFT) B.L.A.M. MODULE ANALYZER CONNECTION MAIN LIFT ENABLE VALVE TOWER LIFT/TELE ENABLE VALVES TOWER BOOM LENGTH SENSOR #2 (BOTTOM) TOWER LIFT CYL ANGLE SENSOR HEADLIGHTS TAILLIGHTS HYDRAULIC PUMPS 2500W GENERATOR TOWER LIFT CYL PIVOT PIN GENERATOR RELAY GENERATOR CONTROL BOX ENGINE CONTROL (DEUTZ EMR2) STARTER ENGINE HARNESS (DEUTZ) 7500W GENERATOR CONTROL BOX TOWER BOOM LENGTH SENSOR #1 (TOP) 7500W GENERATOR PLATFORM BOX 7500W GENERATOR RELAYS 7500W SKYPOWER GENERATOR GLOW PLUG RELAY START RELAY OIL PRESSURE SWITCH TEMP SWITCH ENGINE SPEED SENSOR CHARGE PRESSURE OIL PRESSURE THROTTLE ACTUATOR AIR FILTER PRESSURE SWITCH ALTERNATOR J1 J4 J3 J5 J2 TO CHASSIS POWER RELAY J5 J6 J7 J2 J2 J1 J8 J3 J1 J8 PLATFORM LEVEL SENSOR (LEFT) PLATFORM LEVEL SENSOR (RIGHT) DIAGNOSTIC ANALYZER PLATFORM CONTROL VALVE PLATFORM CONTROL BOX GROUND CONTROL BOX JIB STOW SWITCH JIB POSITION SWITCH FOOTSWITCH MAIN BOOM TRANSPORT SWITCHES MAIN BOOM DUAL CAPACITY SWITCHES MAIN BOOM ANGLE SWITCH TOWER BOOM LENGTH SWITCH #1 RIGHT #2 LEFT MAIN ROTARY ANGLE SENSOR GENERATOR SWITCH J4 J7 PLATFORM WORK LIGHTS PLATFORM FLOODLIGHTS X001 X007 X008 X002 X004 X022 X087 X078 X077 X088 X079 X099 X090 X080 X093 X083 X268 X091 X081 X094 X095 X096 X089 X101 X102 X103 X104 X105 X106 X107 X108 X109 X110 X111X111 X262 X112X112 X121 X127 X128 X129 X130 X131 X132 X133 X134 X136 X137 X138 X 139 X140 X141 X142 X143 X144 X145 X146 X147 X148 X150 X152 X153 X154 X155 X156 X157 X158 X160 X162 X163 X164 X165 X166 X167 X168 X169 X170 X171 X172 X173 X174 X175 X176 X177 X178 X179 X180 X181 X182 X183 X184 X185 X186 X187 X188 X189 X190 X191 X192 X193 X194 X195 X196 X197 X198 X199 X120 X119 X118 X097 X086 X098 X092 X263 X084 X264 X265 X240 X241 X243 X244 X245 X246 X247 X248 X249 X250 X251 X252 X253 X254 X255 X082 X100 X021 X009 X011 X067 X260 X261 X069 X068 X070 X071 X072 X073 X074 X075 X076 X010 X012 X013 X023 X028 X030 X031 X032 X033 X034 X037 X038 X050 X051 X052 X054 X053 X056 X057 X058 X059 X060 X061 X062 X063 X064 X065 X259 X066 X040 X047 X048 X049 X045 X043 X042 X044 X046 X035 X036 X025 X024 X026 X029 X027 X269 X014 X270 X039 X016 X015 X017 X018 X020 X019 X055 X123 X124 X122 X242 X125 X126 X258 X113 X256 X257 SECTION 2 - ELECTRICAL REFERENCE 2-206 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-207 Electrical Wiring Sheet 2 Figure 2-16. Electrical Wiring (Sheet 2 of 2) STEER ANGLE SENSOR AXLE POWER TRACK AXLE POWER TRACK AXLE LIMIT SWITCH AXLE LIMIT SWITCH STEER VALVE TRACTION VALVE STEER ANGLE SENSOR Front J2 J5 J1 J3 J4 SWIVEL DIAGNOSTIC CONNECTION TO ANALYZER CHASSIS MODULE AXLE LIMIT SWITCH AXLE LIMIT SWITCH STEER A NGLE SENSOR AXLE POWER TRACK AXLE POWER TRACK STEER A NGLE SENSOR STEER VALVE AUX PUMP AUX POWER RELAY START RELAY STARTER BATTERY CABLE CONNECTIONS + Rear CHASSIS POWER RELAY X200 X201 X202 X203 X204 X205 X206 X207 X208 X209 X210 X211 X212 X213 X214 X215 X216 X219 X220 X222 X223 X224 X225 X226 X227 X228 X230 X231 X232 X233 X235 X236 X237 X238 X239 X113 X116 X117 X112 X266 X267 X108 SECTION 2 - ELECTRICAL REFERENCE 2-208 1250AJP 3128411 This Page Left Blank Intentionally SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-209 2.1 CONNECTOR INDEX Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures X001 Ground J1, White/Natural - 35 Position AMP351P (Black) -- 2-12. (6E) 2-8. X002 Ground J2, Gray - 35 Position AMP354P (Gray) -- 2-12. (6G) 2-8. X003 Not Used -- -- -- -- X004 Ground J4, Blue - 35 Position AMP355P (Blue) -- 2-12. (7G) 2-8. X005 Not Used -- -- -- -- X006 Not Used -- -- -- -- X007 Ground J7, Black - 35 Position AMP351P (Black) -- 2-12. (7D) 2-8. X008 Ground J8 - 4 Position MMF04P -- 2-12. (7E) 2-8. X009 MTB Ground Bus - 12 Position DT12BP DT12PBR 2-12. (6B) 2-8. X010 MTB Power Bus - 6 Position DT06AP DT06EP032R 2-12. (6B) 2-8. X011 Power Down Relay -- -- 2-12. (4H) 2-8. X012 Ignition On Relay -- -- 2-12. (4H) 2-8. X013 Ground Analyzer - 4 Position AMP04R AMP04P 2-12. (2D) -- X014 CAN 3way - to Ground Module, Green DT03P032GP (Green) -- 2-12. (7B) 2-8. X015 RS232 passthru DT08AP DT08AR 2-12. (3E) -- X016 Ground Panel Relay -- -- 2-12. (3F) 2-8. X017 Tower Boom Transport Switch passthru AMP06P AMP06R 2-11. (1B) -- X018 Ground Swing Switch E06P -- 2-12. (7F) 2-8. X019 Ground Tower Lift Switch E06P -- 2-12. (7F) 2-8. X020 Ground Main Lift Switch E06P -- 2-12. (7G) 2-8. X021 Ground Main Tele Switch E06P -- 2-12. (7G) 2-8. X022 Ground Jib Lift Switch E06P -- 2-12. (7G) 2-8. X023 Ground Jib Swing Switch E06P -- 2-12. (7F) 2-8. X024 Ground Rotate Switch E06P -- 2-12. (7G) 2-8. X025 Ground Level Switch E06P -- 2-12. (7G) 2-8. X026 Ground Start Switch E06P -- 2-12. (7G) 2-8. X027 Officeholder with Cover -- -- 2-12. (3H) -- X028 Ground Hourmeter -- -- 2-12. (7F) 2-8. X029 Ground EMS Switch -- -- 2-12. (3H) 2-8. X030 Ground Key Switch -- -- 2-12. (4H) 2-8. X031 500 Capacity Light PACKARD2LR -- 2-12. (7E) -- X032 Axle Lock Light PACKARD2LR -- 2-12. (7E) -- X033 Glow Plugs Light PACKARD2LR -- 2-12. (7F) -- X034 High Engine Temperature Light PACKARD2LR -- 2-12. (7F) -- X035 Oil Pressure Light PACKARD2LR -- 2-12. (7F) -- X036 Battery Voltage Light PACKARD2LR -- 2-12. (7F) -- X037 1000 Capacity Light PACKARD2LR -- 2-12. (7E) -- X038 Platform Overload (Euro) Light PACKARD2LR -- 2-12. (7E) -- X039 Envelope Light PACKARD2LR -- 2-12. (7E) -- X040 Test Light PACKARD2LR -- 2-12. (7F) -- X041 Not Used -- -- -- -- X042 MTB pass thru - 21 Position DHD21R DHD21P 2-11. (1D) 2-8. X043 MTB pass thru - 19 Position DHD19R DHD21P 2-11. (1G) 2-8. 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. SECTION 2 - ELECTRICAL REFERENCE 2-210 1250AJP 3128411 X047 Main Boom Transport Switch Passthru - 3 Position DT03R DT03P 2-11. (4D) 2-5. X048 Main Rotary Angle Sensor Right - 5 Position PHEONIX5P -- 2-11. (5F) 2-5. X049 Main Rotary Angle Sensor Left - 5 Position PHEONIX5P -- 2-11. (5E) 2-5. X050 Boom Sen sor Pa ss thr u - 19 Position DHD19R DHD19P 2-10. (2F) 2-5. X051 Main Boom Angle Switch DTM04P -- 2-11. (4C) 2-5. X052 Dual Capacity Switch #1 -- -- 2-11. (5D) 2-5. X053 Dual Capacity Switch #2 -- -- 2-11. (5D) 2-5. X054 Main Boom Transport Switch #1 -- -- 2-11. (5D) 2-5. X055 Main Boom Transport Switch #2 -- -- 2-11. (5D) 2-5. X056 Tower Boom Transport Switch -- -- 2-11. (2B) 2-5. X057 Strobe Light AMP02R -- 2-11. (1G) 2-7. X058 BLAM passthru - 12 Position DT12AR DT12AP 2-12. (7A) 2-7. X059 RS232 Backup passthru DT03R -- 2-12. (2D) 2-7. X060 Load Pin Pass Thru - 8 Position (Gray) DT08AR DT08AP 2-13. (1C) 2-5. X061 Not Used -- -- -- -- X062 Load Pin panel - 6 Position ANL06P -- 2-13. (1C) 2-5. X063 Alarm Connector AMP02P -- 2-12. (5G) 2-7. X064 Fuel Level Sensor - 2 Position PACKARD2P -- 2-12. (5F) -- X065 Main Lift PVG - 4 Position (Black) AMPPVG4P (Black) -- 2-13. (2C) 2-7. X066 Tower Lift PVG - 4 Position (Black) AMPPVG4P (Black) -- 2-13. (3C) 2-7. X067 Tower Tele PVG - 4 Position (Black) AMPPVG4P (Black) -- 2-13. (3C) 2-7. X068 PVG Enable Solenoid DIN43650P -- 2-12. (6F) 2-7. X069 Swing Right Solenoid DIN43650P -- 2-12. (5E) 2-7. X070 Swing Left Solenoid DIN43650P -- 2-12. (5E) 2-7. X071 Main Tele Extend Solenoid DIN43650P -- 2-12. (5F) 2-7. X072 Main Tele Proportional Solenoid DIN43650P -- 2-12. (5F) 2-7. X073 Main Tele Retract Solenoid DIN43650P -- 2-12. (5F) 2-7. X074 Main Dump Solenoid DIN43650P -- 2-12. (5F) 2-7. X075 Tower Lift Pilot Solenoid DIN43650P -- 2-12. (5F) 2-7. X076 Tower Tele Pilot Solenoid DIN43650P -- 2-12. (6F) 2-7. X077 Main Lift Pilot Solenoid DIN43650P -- 2-12. (6F) 2-7. X078 Hyd Oil Temp Switch - 2 Position DT02P -- 2-12. (6C) 2-7. X079 Pressure Switch DIN43650P -- 2-12. (6C) 2-7. X080 Tower Lift Enable Solenoid DIN43650P -- 2-12. (5F) 2-7. X081 Tower Tele Enable Solenoid DIN43650P -- 2-12. (6C) 2-7. X082 Main Lift Enable Solenoid DIN43650P -- 2-12. (5F) 2-7. X083 Swivel - 12 Position (Black) DT12BP -- 2-13. (7D) 2-7. X084 Deutz EMR2 Chassis CAN - 3 Position DT03R DT03P 2-12. (1F) 2-7. X085 Not Used -- -- -- -- X086 BLAM J1 - 12 Position (Gray) DT12AP -- 2-13. (5F) 2-7. X087 BLAM J2 - 12 Position (Black) DT12BP -- 2-13. (5E) 2-7. X088 BLAM J3 - 12 Position DT12CP -- 2-13. (6G) 2-7. X089 BLAM J4 - 8 Position DT08AP -- 2-13. (5D) 2-7. X090 BLAM J5 - 12 Position (Green) DT12DP -- 2-13. (5G) 2-7. 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. Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-211 X094 Tower Boom Length Sensor 2 (Bottom) - 3 Position DT03P DT03R 2-13. (7F) 2-5. X095 Tower Angle Sensor1 Passthru - 4 Position (Gray) DT04R DT04P 2-13. (4E) 2-7. X096 Tower Angle Sensor2 Passthru - 4 Position (Gray) DT04P DT04R 2-13. (4E) 2-7. X097 12 Pos Batt Busbar DT12BP DT12PBR 2-13. (4E) 2-7. X098 12 Pos Ground Busbar DT12BP DT12PBR 2-13. (4C) 2-7. X099 Tower Boom Angle Sensor #1 (Right) DTM03P DTM03R 2-13. (3E) 2-5. X100 Tower Boom Angle Sensor #2 (Left) DTM03P DTM03R 2-13. (3E) 2-5. X101 Lights Relay -- -- 2-12. (6G) -- X102 Headlight -- -- -- 2-7. X103 Headlight -- -- -- 2-6. X104 Taillight -- -- -- 2-5. X105 Taillight -- -- -- 2-5. X106 BLAM Pump Passthru DT06R -- 2-13. (4G) -- X107 Horn -- -- 2-12. (6G) 2-7. X108 Aux Power Relay -- -- 2-12. (1E) -- X109 Power Relay Fuse -- -- 2-10. (3G) -- X110 Aux Pump -- -- 2-12. (1D) 2-7. X111 Glow Plugs Relay -- -- 2-12. (2G) -- X112 Start Relay -- -- 2-12. (2G) -- X113 Starter -- -- 2-12. (2H) 2-6. X114 Not Used -- -- -- -- X115 Not Used -- -- -- -- X116 Battery Positive -- -- 2-12. (1B) 2-7. X117 Battery Negative -- -- 2-12. (1B) 2-7. X118 Right Side Drive Reverse Solenoid DIN43650P -- 2-13. (3F) 2-6. X119 Left Side Drive Reverse Solenoid DIN43650P -- 2-13. (3F) 2-6. X120 Right Side Drive Forward Solenoid DIN43650P -- 2-13. (3F) 2-6. X121 Left Side Drive Forward Solenoid DIN43650P -- 2-13. (3F) 2-6. X122 Engine Speed Sensor - 2 Position AMPJT826008P -- 2-12. (3G) -- X123 Engine Oil Pressure Switch -- -- -- -- X124 Engine Coolant Temp Switch -- -- 2-12. (3H) -- X125 Engine Alternator -- -- 2-12. (1G) -- X126 Engine Throttle Actuator DIN43650P -- 2-12. (3F) -- X127 Generator Relay -- -- 2-12. (3C) -- X128 Generator Connector -- -- -- -- X129 Generator Control Box -- -- -- -- X130 Generator Extension -- -- -- -- X131 Generator Extension -- -- -- -- X132 Generator Outlet -- -- -- -- X133 Generator -- -- -- -- X134 Worklight passthru - 3 Position PACKARD3P PACKARD3R -- -- X135 Platform Dump Solenoid DIN43650P -- 2-10. (4F) 2-4. X136 Platform Level Up Solenoid DIN43650PD -- 2-10. (4F) 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. Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures SECTION 2 - ELECTRICAL REFERENCE 2-212 1250AJP 3128411 X141 Platform Jib Swing Left DIN43650P -- 2-10. (4F) 2-4. X142 Platform Jib Up DIN43650P -- 2-10. (4F) 2-4. X143 Platform Jib Down DIN43650P -- 2-10. (4F) 2-4. X144 Jib Stow Pass Thru - 2 Position DT02R -- 2-10. (5H) -- X145 Jib Limit Switch Pass Thru - 2 Position DT02R -- 2-10. (5H) -- X146 Jib Stow Switch -- -- 2-10. (4H) 2-5. X147 Jib Position Switch -- -- 2-10. (4H) 2-5. X148 Platform Level Sensor (Left) DTM03R DTM03P 2-10. (5G) 2-5. X149 Not Used -- -- -- -- X150 Platform Level Sensor (Right) DTM03R DTM03P 2-10. (5G) 2-5. X151 Not Used -- -- -- -- X152 Footswitch -- -- 2-10. (3E) 2-4. X153 Platform Worklight -- -- 2-10. (3H) 2-4. X154 Platform Worklight -- -- 2-10. (3G) 2-4. X155 Generator Switch -- -- 2-10. (5E) 2-4. X156 Floodlights passthru - 3 Position PACKARD3P PACKARD3R -- -- X157 Platform Floodlights component -- -- -- -- X158 Floodlight passthru - 2 Position AMP02P AMP02R -- -- X159 Floodlight passthru - 2 Position AMP02P AMP02R -- -- X160 Platform Control Box Passthru - 19 Position DHD19R DHD19P 2-10. (3H) -- X161 Platform Valve passthru - Deutsch 21 Pin DHD1821R DHD1821P 2-10. (5F) -- X162 Platform Level Passthru #1 -- -- 2-10. (5G) -- X163 Platform Level Passthru #2 -- -- 2-10. (5G) -- X164 Platform passthru - Amp 15 Position AMP15R AMP15P 2-10. (5D) -- X165 Platform J1 Connector - 35 Position (Natural) AMP352P (Neutral) -- 2-10. (6F) -- X166 Platform J2 Connector - 35 Position (Blue) AMP355P (Blue) -- 2-10. (6D) -- X167 Platform J5 Connector, Male - 8 Position AMP08NP -- 2-10. (6C) -- X168 Platform J6 Connector, Female - 8 Position AMP08BP -- 2-10. (6B) -- X169 Platform J7 Connector - 35 Position (Black) AMP351P (Black) -- 2-10. (6F) -- X170 Platform J8 Connector, Male - 2 Position MMF02P -- 2-10. (6D) -- X171 Platform Diagnostics Connector AMP04R -- 2-10. (8B) -- X172 Platform Alarm MMF02P -- 2-10. (5E) -- X173 Platform Analyzer Pass Thru AMP15R AMP15P 2-10. (7B) -- X174 Drive Orientation Override Switch - 6 Position E06P -- 2-10. (8B) 2-4. X175 Platform Capacity Select Switch - 6 Position E06P -- 2-10. (7F) 2-4. X176 Controller Harness/Circuit Board Assembly (Drive and Steer) -- -- 2-10. (5B) 2-4. X177 Platform Engine Start/ Aux Power Switch - 6 Position E06P -- 2-10. (7E) 2-4. X178 Platform Main Boom Telescope Switch - 6 Position E06P -- 2-10. (7G) 2-4. X179 Platform EMS Switch -- -- 2-10. (3F) 2-4. X180 Platform Jib Lift Switch - 6 Position E06P -- 2-10. (7G) 2-4. X181 Platform Lights Switch -- -- 2-10. (7E) 2-4. X182 Platform LED J4 - 6 Position AMP06P -- 2-10. (7C) 2-4. X183 Platform LED J3 - 6 Position AMP06P -- 2-10. (7C) 2-4. 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. Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-213 X188 Platform Rotate Switch - 6 Position E06P -- 2-10. (7G) 2-4. X189 Platform Jib Stow Override -- -- 2-10. (7A) 2-4. X190 Platform LED J1 - 6 Position AMP06P -- 2-10. (8D) 2-4. X191 Platform LED J2 - 6 Position AMP06P -- 2-10. (8D) 2-4. X192 Speed Control Harness -- -- 2-10. (7G) 2-4. X193 Platform Horn Switch -- -- 2-10. (7E) 2-4. X194 Platform Axle Extent/Retract Switch - 6 Position E06P -- 2-10. (7F) 2-4. X195 Platform Level Override Switch - 6 Position E06P -- 2-10. (7G) 2-4. X196 Platform Steer Select Switch - 6 Position E06P -- 2-10. (7F) 2-4. X197 Controller Harness Assembly (Lift and Swing) -- -- 2-10. (5C) 2-4. X198 Platform Drive Speed / Torque Select Switch - 6 Position E06P -- 2-10. (7E) 2-4. X199 Hyd Speed Pot passthru - 6 Position AMP06P -- 2-10. (7G) -- X200 Front Right Steer Angle Sensor - 3 Position DT03P DT03R 2-14. (2D) 2-9. X201 Front Right Steer Passthru Connector, Gray - 4 Position DT04P DT04R 2-14. (2D) -- X202 Front Left Steer Passthru Connector, Gray - 4 Position DT04P DT04R 2-14. (2D) -- X203 Front Left Steer Angle Sensor - 3 Position DT03P DT03R 2-14. (2D) 2-9. X204 Front Right Axle Limit Switch -- -- 2-14. (6G) 2-9. X205 Front Left Axle Limit Switch -- -- 2-14. (7G) 2-9. X206 Front Axles Extend Solenoid DIN43650P -- 2-14. (8G) 2-9. X207 Left Front Steer Right Solenoid DIN43650P -- 2-14. (7G) 2-9. X208 Right Front Steer Right Solenoid DIN43650P -- 2-14. (7D) 2-9. X209 Front Axles Retract Solenoid DIN43650P -- 2-14. (7E) 2-9. X210 Left Front Steer Left Solenoid DIN43650P -- 2-14. (7E) 2-9. X211 Right Front Steer Left Solenoid DIN43650P -- 2-14. (7D) 2-9. X212 Axle Lockout Solenoid DIN43650P -- 2-14. (4G) 2-9. X213 Axle Lockout Pressure Switch DIN43650P -- 2-14. (2G) 2-9. X214 2spd Solenoid DIN43650P -- 2-14. (4F) 2-9. X215 Brake Release Solenoid DIN43650P -- 2-14. (4F) 2-9. X216 Swivel Chassis Connector - 12 Position DT12BR DT12BP 2-14. (5G) 2-9. X217 Not Used -- -- -- -- X218 Not Used -- -- -- -- X219 Right Rear Steer Left Solenoid DIN43650P -- 2-14. (7C) 2-9. X220 Left Rear Steer Left Solenoid DIN43650P -- 2-14. (7C) 2-9. X221 Rear Axles Retract Solenoid DIN43650P -- 2-14. (7E) 2-9. X222 Right Rear Steer Right Solenoid DIN43650P -- 2-14. (7C) 2-9. X223 Left Rear Steer Right Solenoid DIN43650P -- 2-14. (7C) 2-9. X224 Rear Axles Extend Solenoid DIN43650P -- 2-14. (7E) 2-9. X225 Left Rear Axle Limit Switch -- -- 2-14. (7G) 2-9. X226 Right Rear Axle Limit Switch -- -- 2-14. (6G) 2-9. X227 Ground Bus - 6 Position DT06AP -- 2-14. (2F) -- X228 Deleted in Newer revisions - 2 Position DT02P -- -- -- X229 Chassis Module J1 Connector, Gray - 12 Position DT12AP -- 2-14. (5B) 2-9. X230 Chassis Module J2 Connector, Black - 12 Position DT12BP -- 2-14. (8G) 2-9. 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 -- -- -- -- Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures SECTION 2 - ELECTRICAL REFERENCE 2-214 1250AJP 3128411 X235 Chassis Module Diagnostics Connector AMP04R -- 2-14. (7A) 2-9. X236 Rear Right Steer Passthru Connector, Gray - 4 Position DT04P DT04R 2-14. (2C) -- X237 Rear Left Steer Passthru Connector, Gray - 4 Position DT04P -- 2-14. (2C) -- X238 Rear Left Steer Angle Sensor - 3 Position DT03P DT03R 2-14. (2C) 2-9. X239 Rear Right Steer Angle Sensor - 3 Position DT03P DT03R 2-14. (2C) 2-9. X240 EMR2 ECU Equipment Connector AMP25RP -- 2-12. (3G) 2-6. X241 EMR2 ECU Engine Connector AMP25LP -- 2-12. (3G) 2-6. X242 EMR2 Engine Diagnostics Connector ITTC12P -- 2-12. (1F) -- X243 EMR2 Capped 12 position Plug DEUTZ12ENGR -- -- -- X244 EMR2 16 position sensor passthru DEUTZ16P DEUTZ16R -- -- X245 EMR2 12 position passthru DEUTZ12R DEUTZ12P -- -- X246 Skypower Relay -- -- 2-12. (3B) -- X247 Skypower Relay -- -- 2-12. (3B) -- X248 Skypower Control Box -- -- 2-12. (3C) -- X249 Skypower Control Box -- -- -- -- X250 Skypower Generator -- -- -- 2-6. X251 Skypower Generator -- -- -- 2-6. X252 Skypower Distribution Box -- -- -- -- X253 Skypower Outlet -- -- -- -- X254 Skypower Outlet -- -- -- -- X255 Skypower Outlet -- -- -- -- X256 EMR2 charge air pressure - 4 position DEUTZE -- 2-12. (3G) -- X257 EMR2 engine oil pressure -- -- 2-12. (3G) -- X258 EMR2 air filter pressure switch DEUTZG -- -- -- X259 Main Lift PVG unused (Gray) AMPPVG4GP (Gray) -- -- 2-7. X260 Tower Lift PVG unused (Gray) AMPPVG4GP (Gray) -- -- 2-7. X261 Tower Tele PVG unused (Gray) AMPPVG4GP (Gray) -- -- 2-7. X262 Load Pin CAN Pass thru - 3 position DT03P DT03R -- 2-7. X263 Chassis Power - 2 position DT02P DT02R 2-12. (4C) 2-7. X264 Generator Platform Box Pass Thru -- -- -- -- X265 Generator Platform Box Pass Thru -- -- -- -- X266 Chassis Power Relay BOSCH05P -- 2-12. (3C) -- X267 Chassis Power Fuse -- -- 2-12. (2C) -- 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. Table 2-7. Connector Index ID Description End 1 ID End 2 ID Schematic Figures SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-215 2.2 BLAM MODULE CONNECTOR PINOUTS Table 2-8. X086 (J1) BLAM Module Pinout Pin Function Type Range (V) 1 Not Used Input -- 2 Not Used Input -- 3 Not Used Input -- 4 Ground Ground 0VDC 5 V Bat Battery Vbatt 6 CAN HI Input/Output Comm 7 CAN LO Input/Output Comm 8 CAN Shield Ground 0VDC 9 CAN Termination Connection Input/Output Comm 10 CAN Termination Connection Input/Output Comm 11 V Bat Battery Vbatt 12 Ground Ground 0VDC Table 2-9. X087 (J2) BLAM Module Pinout Pin Function Type Range (V) 1 Not Used Input -- 2 Not Used Input -- 3 Ground Ground 0VDC 4 Not Used Input -- 5 Basket Rotate Right Input Vbatt 6 Basket Rotate Left Input Vbatt 7 Spare Input Input -- 8 Tower Boom Angle 1 Input/Output Comm 9 Tower Boom Angle 2 Input/Output Comm 10 Spare Analog Input Input -- 11 Right Drive Pump Forward Output PWM 12 Right Drive Pump Reverse Output PWM Table 2-10. X088 (J3) BLAM Module Pinout Pin Function Type Range (V) 1 Reference Voltage Other Voltage 5VDC 2 Reference Voltage From J3-1 Analog Input 5VDC 3 Ground Ground 0VDC 4 Reference Voltage Other Voltage 5VDC 5 Tower Boom Cylinder Angle Analog Input 5VDC 6 Ground Ground 0VDC 7 Reference Voltage Other Voltage 5VDC 8 Tower Boom Length Sensor 1 Analog Input 5VDC 9 Ground Ground 0VDC 10 Reference Voltage Other Voltage 5VDC 11 Tower Boom Length Sensor 2 Analog Input 5VDC 12 Ground Ground 0VDC SECTION 2 - ELECTRICAL REFERENCE 2-216 1250AJP 3128411 Table 2-11. X089 (J4) BLAM Module Pinout Pin Function Type Range (V) 1 V Bat Battery Vbatt 2 Ground Ground 0VDC 3 CAN HI Input/Output Comm 4 CAN LO Input/Output Comm 5 CAN Shield Ground 0VDC 6 Bootstrap Pin -- -- 7Not Used -- -- 8Not Used -- -- Table 2-12. X090 (J5) BLAM Module Pinout Pin Function Type Range (V) 1 Left Drive Pump Forward Output PWM 2 Left Drive Pump Reverse Output PWM 3 Oscillating Axles Output PWM 4 Tower Boom Transport Angle Output PWM 5 Spare Output Output PWM 6 Spare Output Output PWM 7 Spare Output Output PWM 8 Spare Output Output PWM 9 Analyzer Power Other Voltage Vbatt 10 RS232 Receive Input/Output Comm 11 RS232 Transmit Input/Output Comm 12 Ground Ground 0VDC SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-217 2.3 CHASSIS MODULE CONNECTOR PINOUTS Table 2-13. X229 (J1) Chassis Module Pinout Pin Function Type Range (V) 1Not Used -- -- 2Not Used -- -- 3Not Used -- -- 4 Main Ground Ground 0VDC 5 Main Ignition Vbatt Vbatt 6 CAN HI Input/Output Comm 7 CAN LOW Input/Output Comm 8 CAN Shield Input/Output 0VDC 9 CAN Terminator (Connected to J1-10) Input/Output Comm 10 CAN Terminator (Connected to J1-9) Input/Output Comm 11 Ignition Vbatt Vbatt 12 Not used -- -- Table 2-14. X230 (J2) Chassis Module Pinout Pin Function Type Range (V) 1 Not Used -- -- 2 Not Used -- -- 3 Ground Ground 0VDC 4 Front Axle Extend Limit Switches Input Vbatt 5 Rear Axle Extend Limit Switches Input Vbatt 6 Drive Orientation Switch Input Vbatt 7 Axle Lockout Pressure Switch Input Vbatt 8 Not Used -- -- 9 Not Used -- -- 10 Not Used -- -- 11 Axle Extend Output Vbatt 12 Axle Retract Output Vbatt Table 2-15. X231 (J3) Chassis Module Pinout Pin Function Type Range (V) 1 Reference Voltage Other Voltage 5VDC 2 Front Right Steer Angle Sensor Analog Input 0 - 5VDC 3 Ground Ground 0VDC 4 Reference Voltage Other Voltage 5VDC 5 Front Left Steer Angle Sensor Analog Input 0 - 5VDC 6 Ground Ground 0VDC 7 Reference Voltage Other Voltage 5VDC 8 Rear Right Steer Angle Sensor Analog Input 0 - 5VDC 9 Ground Ground 0VDC 10 Reference Voltage Other Voltage 5VDC 11 Rear Left Steer Angle Sensor Analog Input 0 - 5VDC 12 Ground Ground 0VDC SECTION 2 - ELECTRICAL REFERENCE 2-218 1250AJP 3128411 Table 2-16. X232 (J4) Chassis Module Pinout Pin Function Type Range (V) 1 Axle Lockout Pressure Switch Power Vbatt Vbatt 2 Axle Lockout Solenoid Ground 0VDC 3Not Used -- -- 4Not Used -- -- 5Not Used -- -- 6Not Used -- -- 7Not Used -- -- 8Not Used -- -- Table 2-17. X233 (J5) Chassis Module Pinout Pin Function Type Range (V) 1 Right Front Steer Right Solenoid Output Vbatt 2 Right Front Steer Left Solenoid Outupt Vbatt 3 Left Front Steer Right Solenoid Output Vbatt 4 Left Front Steer Left Solenoid Output Vbatt 5 Right Rear Steer Right Solenoid Output Vbatt 6 Right Rear Steer Left Solenoid Output Vbatt 7 Left Rear Steer Right Solenoid Output Vbatt 8 Left Rear Steer Left Solenoid Output Vbatt 9 Analyzer Power Vbatt Vbatt 10 Analyzer RS-232 Receive Input Comm 11 Analyzer RS-232 Transmit Output Comm 12 Analyzer Ground Ground 0VDC SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-219 2.4 GROUND MODULE CONNECTOR PINOUTS Table 2-18. X001 (J1) Ground Module Pinout Pin Function Type Range (V) 1 Throttle Actuator (Diesel Only) Output PWM 2 Not Used Output -- 3 Tower Boom Lift Power Output Vbatt 4 Ground Ground 0VDC 5 Ground Ground 0VDC 6 Tower Telescope Enable Output Vbatt 7 Not Used Output -- 8 Ground Ground 0VDC 9 Ground Ground 0VDC 10 Ignition On Relay Output Vbatt 11 Start Solenoid (Diesel Only) Output Vbatt 12 Glow Plug (Diesel Only Option) Output Vbatt 13 Auxiliary Power Output Vbatt 14 Coolant Temp (Diesel Only) Input Vbatt 15 Oil Pressure (Diesel Only) Input Vbatt 16 Flywheel Speed Pickup (Diesel Only) Input Freq 17 Ground Ground 0VDC 18 Spare Ground Ground 0VDC 19 Spare Ground Ground 0VDC 20 Two Speed Output Vbatt 21 Main Lift Pilot Pressure Switch Input Vbatt 22 Generator/Welder (Option) Output Vbatt 23 Parking Brake Output Vbatt 24 Constant Battery Battery Vbatt 25 RS-485 Hi Input/Output Comm 26 RS-485 Lo Input/Output Comm 27 Ground Ground 0VDC 28 Analyzer Power Other Voltage 9.5VDC 29 Analyzer RS-232 Rx Input Comm 30 Analyzer RS-232 Tx Output Comm 31 Analyzer Ground Ground 0VDC 32 Alternator Excitation Output -- 33 Ground Shield Ground 0VDC 34 Spare Input -- 35 Hydraulic Oil Temperature Switch Input Vbatt Table 2-19. X002 (J2) Ground Module Pinout Pin Function Type Range (V) 1 Main Lift Pilot Output Vbatt 2Horn Output Vbatt 3 Platform Control Valve Output Vbatt 4 Main Telescope In Output Vbatt 5 Basket Level Up Override Output Vbatt 6 Ground Ground 0VDC 7 Basket Level Down Override Output Vbatt 8 Tower Telescope Power Output PWM SECTION 2 - ELECTRICAL REFERENCE 2-220 1250AJP 3128411 9 Main Telescope Flow Control Output PWM 10 Main Boom Angle Sensor #1 Power Output Vbatt 11 Main Lift Boom Power Output PWM 12 Tower Boom Lift Pilot Output Vbatt 13 Main Dump Output Vbatt 14 Ground Ground 0VDC 15 RS232 Backup Comm. Enable Output Vbatt 16 Main Telescope Out Output Vbatt 17 Ground Ground Vbatt 18 Spare Pin Ground -- 19 Spare Output -- 20 Spare Output -- 21 Main Boom Angle Sensor #2 Power Output PWM 22 spare Output -- 23 Main Boom Lift Enable Output Vbatt 24 Spare Input -- 25 Fuel Sensor Input Vbatt 26 Head/Tail Light Output Vbatt 27 Alarm Output Vbatt 28 Spare Pin Ground -- 29 Ground Ground 0VDC 30 Ground Ground 0VDC 31 PVG Enable Output Vbatt 32 Tower Boom Telescope Pilot Output Vbatt 33 Tower Boom Lift Enable Output Vbatt 34 Swing Left Output PWM 35 Swing Right Output PWM Table 2-20. X004 (J4) Ground Module Pinout Pin Function Type Range (V) 1 Axles Set Lamp Output Vbatt 2 500# Capacity Lamp Output Vbatt 3 Boom Control System Lamp Output Vbatt 4 Start Switch Input Vbatt 5 Basket Level Down Input Vbatt 6 Dual Capacity Switch #2 Input Input Vbatt 7 Upper Telescope In Input Vbatt 8 Jib Down Input Vbatt 9 Jib Left Input Vbatt 10 Tower Up Input Vbatt 11 Main Boom Transport Angle Open Input Vbatt 12 Hour Meter Output Vbatt 13 BCS Calibrated Lamp Output Vbatt 14 Overload Lamp Output Vbatt 15 Spare Output Vbatt 16 Auxiliary Power Input Vbatt 17 Basket Level Up Input Vbatt Table 2-19. X002 (J2) Ground Module Pinout Pin Function Type Range (V) SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-221 18 Dual Capacity Switch #1 Input Input Vbatt 19 Jib Up Input Vbatt 20 Jib Right Input Vbatt 21 Tower Down Input Vbatt 22 Main Boom Transport Angle Closed Input Vbatt 23 Main Boom Lift Up Input Vbatt 24 V Bat Battery Vbatt 25 V Bat Battery Vbatt 26 No Charge Lamp Output Vbatt 27 1000# Capacity Lamp Output Vbatt 28 Engine High Temperature Lamp Output Vbatt 29 Engine Low Oil Pressure Lamp Output Vbatt 30 Upper Telescope Out Input Vbatt 31 Ground Ground 0VDC 32 Spare Pin Ground 0VDC 33 Main Boom Lift Down Input Vbatt 34 Swing Left Input Vbatt 35 Swing Right Input Vbatt Table 2-21. X007 (J7) Ground Module Pinout Pin Function Type Range (V) 1 Platform EMS Input Vbatt 2 Platform Mode Input Vbatt 3 Ground Mode Input Vbatt 4 Spare Input -- 5 Reference Voltage Other Voltage 7VDC 6 CAN Termination Ground Comm 7 Spare Input -- 8 Spare Analog Input 2 Input -- 9 Ground Ground 0VDC 10 Ground Ground 0VDC 11 Tower Boom Transport Length Closed Input Vbatt 12 Main Boom Transport Length #1 Closed Input Vbatt 13 CAN Hi Input/Output Comm 14 Ground Mode Out to Platform Input Vbatt 15 Footswitch Engage Input Vbatt 16 Reference Voltage Other Voltage 7VDC 17 CAN Termination Ground Comm 18 CAN Shield Ground 0VDC 19 Spare Pin Ground -- 20 Spare Analog Input 1 Input -- 21 Main Boom Transport Length #2 Open Input Vbatt 22 Tower Boom Transport Angle Input Vbatt 23 Ground Control Enable Input Vbatt 24 CAN Lo Input/Output Comm 25 Ground Ground 0VDC 26 Reference Voltage Other Voltage 7VDC Table 2-20. X004 (J4) Ground Module Pinout Pin Function Type Range (V) SECTION 2 - ELECTRICAL REFERENCE 2-222 1250AJP 3128411 27 Reference Voltage Other Voltage 7VDC 28 Ground Ground 0VDC 29 V Bat Battery Vbatt 30 V Bat Battery Vbatt 31 V Bat Battery Vbatt 32 V Bat Battery Vbatt 33 V Bat Battery Vbatt 34 V Bat Battery Vbatt 35 Tower Boom Transport Length Open Input Vbatt Table 2-22. X008 (J8) Ground Module Pinout Pin Function Type Range (V) 1 Ground from Battery Ground 0VDC 2 Ground EMS Output Vbatt 3 Ground to Platform Ground 0VDC 4 Ground EMS Out to Platform Output Vbatt Table 2-21. X007 (J7) Ground Module Pinout Pin Function Type Range (V) SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-223 2.5 PLATFORM MODULE CONNECTOR PINOUTS Table 2-23. X165 (J1) Platform Module Pinout Pin Function Type Range (V) 1 Tower Lift Up Input Vbatt 2 Tower Lift Down Input Vbatt 3Not Used -- -- 4Not Used -- -- 5 Main Telescope In Input Vbatt 6 Main Telescope Out Input Vbatt 7 Basket Rotate Right Input Vbatt 8 Basket Rotate Left Input Vbatt 9 Basket Level Up Input Vbatt 10 Basket Level Down Input Vbatt 11 Jib Up Input Vbatt 12 Jib Down Input Vbatt 13 Pump Potentiometer Return Ground 0VDC 14 Start Switch Input Vbatt 15 Auxiliary Switch Input Vbatt 16 Crab Steer Select Input Vbatt 17 Coordinated Steer Select Input Vbatt 18 Switch Input Battery Vbatt Vbatt 19 Inline Limit Switch Input Vbatt 20 LSS Platform Overload Input Vbatt 21 500/1000 # Capacity Select Input Vbatt 22 Not Used -- -- 23 Axle Extend Input Vbatt 24 Axle Retract Input Vbatt 25 Serial Tilt Sensor Input 1 Input/Output Comm 26 Serial Tilt Sensor input 2 Input/Output Comm 27 Two Speed Input Vbatt 28 Engine Speed Input Vbatt 29 Soft Touch Override Switch Input Vbatt 30 Head/Tail Light Switch Input Vbatt 31 Horn Input Vbatt 32 Creep Switch Input Vbatt 33 Not Used -- -- 34 Pump Potentiometer Ref. Voltage Other Voltage 7VDC 35 Pump Potentiometer Input 0 - 7 VDC Table 2-24. X166 (J2) Platform Module Pinout Pin Function Type Range (V) 1 Jib Right Input Vbatt 2 Jib Left Input Vbatt 3 Switch Input Battery Vbatt Vbatt 4 Drive Orientation Override Switch Input Vbatt 5 Basket Stow Switch Input Vbatt 6 Tilt Lamp Output Vbatt 7 Enable Lamp Output Vbatt 8 System Distress/Fault Lamp Output Vbatt SECTION 2 - ELECTRICAL REFERENCE 2-224 1250AJP 3128411 9 Creep Lamp Output Vbatt 10 Not Used -- -- 11 Overload Lamp Output Vbatt 12 500# Capacity Lamp Output Vbatt 13 1000# Capacity Lamp Output Vbatt 14 Axle Set Lamp Output Vbatt 15 Generator On Lamp Output Vbatt 16 Soft Touch Lamp Output Vbatt 17 Glow Plug Lamp Output Vbatt 18 Lamp Return Ground 0VDC 19 Boom Control System Warning Lamp Output Vbatt 20 Auto Leveling System Lamp Output Vbatt 21 Not Used -- -- 22 Fuel 1/4 Full Lamp Output Vbatt 23 Fuel 3/4 Full Lamp Output Vbatt 24 Fuel 1/2 Full Lamp Output Vbatt 25 Fuel Lamp Return Output Vbatt 26 Analyzer PWR Vbatt Vbatt 27 Analyzer Ground Ground 0VDC 28 Analyzer RS232 Receive Input/Output Comm 29 Analyzer RS232 Transmit Input/Output Comm 30 Drive Orientation Lamp Output Vbatt 31 Not Used -- -- 32 Battery Vbatt Vbatt 33 Battery Vbatt Vbatt 34 Switch Input Battery Vbatt Vbatt 35 Fuel Full Lamp Output Vbatt Table 2-25. X167 (J5) Platform Module Pinout Pin Function Type Range (V) 1 Swing & Lift Joystick Supply Vref 7VDC 2 Lift Center Tap Input 0 - 7VDC 3 Lift Signal Input 0 - 7VDC 4 Swing Signal Input 0 - 7VDC 5 Swing Center Tap Input 0 - 7VDC 6 Not Used -- -- 7 Ground Ground 0VDC 8 Not Used -- -- Table 2-24. X166 (J2) Platform Module Pinout Pin Function Type Range (V) SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-225 Table 2-26. X168 (J6) Platform Module Pinout Pin Function Type Range (V) 1 Steer & Drive Joystick Supply Vref 7VDC 2 Drive Center Tap Input 0 - 7VDC 3 Drive Signal Input 0 - 7VDC 4Not Used -- -- 5 Steer Left Input 0 - 7VDC 6 Steer Right Input 0 - 7VDC 7 Ground Ground 0VDC 8Not Used -- -- Table 2-27. X169 (J7) Platform Module Pinout Pin Function Type Range (V) 1 GND Mode Switch Input Vbatt 2 Platform EMS Switch Input Vbatt 3 Platform EMS to GND Module Input Vbatt 4Not Used -- -- 5 Rotate Left Output PWM 6 Rotate Right Output PWM 7Not Used -- -- 8 Footswitch Disengage Input Vbatt 9 Generator On Input Vbatt 10 Not used -- -- 11 Not Used -- -- 12 Not Used -- -- 13 Not Used -- -- 14 Not Used -- -- 15 Basket Level Up Output PWM 16 Basket Level Down Output PWM 17 Jib Block Limit Switch Input Vbatt 18 Soft Touch Limit Switch Input Vbatt 19 Platform Alarm Output Vbatt 20 Platform Alarm Return Ground 0VDC 21 Primary Tilt Sensor Ground Ground 0VDC 22 Not used -- -- 23 Not used -- -- 24 Not used -- -- 25 Jib Up Output PWM 26 Jib Down Output PWM 27 Jib Right Output PWM 28 Jib Left Output PWM 29 Digital Output Return Ground 0VDC 30 CAN LO Input/Output Comm 31 CAN HI Input/Output Comm 32 CAN Shield Ground 0VDC 33 Secondary Tilt Sensor Ground Ground 0VDC 34 Not Used -- -- 35 Not Used -- -- SECTION 2 - ELECTRICAL REFERENCE 2-226 1250AJP 3128411 Table 2-28. X170 (J8) Platform Module Pinout Pin Function Type Range (V) 1 Ground from Ground Module Ground 0VDC 2 Ground EMS Ground 0VDC SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-227 2.6 CONNECTOR LOADING DIAGRAMS Table 2-29. Connector Loading Diagrams ID Description Diagram AMP02P Amp 2 position plug AMP02R Amp 2 position recepta- cle AMPJT82600 8P Amp 2 position plug AMP04P Amp 4 position plug AMP04R Amp 4 position recepta- cle AMP06P Amp 6 position plug AMP06R Amp 6 position recepta- cle 1 2 2 1 1 2 4 3 2 1 4 3 1 321 6 54 321 6 54 SECTION 2 - ELECTRICAL REFERENCE 2-228 1250AJP 3128411 AMP08BP Amp 8 position black plug AMP08NP Amp 8 position natural plug AMP15P Amp 15 position plug AMP15R Amp 15 position recep- tacle AMP25LP Amp Rectangular 25 position plug with key for left AMP25RP Amp Rectangular 25 position plug with key for right AMPPVG4P (Black) Amp PVG Valve 4 posi- tion plug AMPPVG4GP (Gray) Table 2-29. Connector Loading Diagrams ID Description Diagram 1 3 6 8 1 2 3 4 6 7 9 10 12 13 15 14 1 2 3 4 6 7 9 10 12 13 1 5 14 12 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 13 25 12 14 3 15 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 13 25 1 2 3 4 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-229 AMP14P Ampseal 14 position AMP351P (Black) Ampseal 35 position AMP352P (Neutral) AMP354P (Gray) AMP355P (Blue) AN350P Anderson Power Con- nector ANL06P Amphenol 6 Position Sealed Plug BOSCH05P Bosch Relay Sealed Plug Table 2-29. Connector Loading Diagrams ID Description Diagram 1 5 14 10 AMP S oc k e t R e ar Ins e rt 1 12 35 24 AMP S oc k e t R e ar Ins e rt SECTION 2 - ELECTRICAL REFERENCE 2-230 1250AJP 3128411 DEUTZ12ENG R Deutz Supplied 12 posi- tion receptacle DEUTZ12P Deutz Supplied 12 posi- tion plug DEUTZ12R Deutz Supplied 12 posi- tion receptacle DEUTZ16P Deutz Supplied 16 posi- tion plug DEUTZ16R Deutz Supplied 16 posi- tion receptacle Table 2-29. Connector Loading Diagrams ID Description Diagram 1 9 4 1 2 10 11 23 12 4 9 1 23 10 11 1 2 4 9 1 23 1 0 11 1 9 4 12 14 15 23 13 5 8 16 1 9 4 12 14 1 5 23 1 3 5 8 16 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-231 DEUTZE Deutz Supplied 4 posi- tion charge air pressure sensor Plug DEUTZG Deutz Supplied 2 posi- tion air filter pressure switch Receptacle DIN43650P Din 43650 4 position plug DHD14P Deutsch 14 position HD series alum. Plug DHD14R Deutsch 14 position HD series alum. Receptacle Table 2-29. Connector Loading Diagrams ID Description Diagram 1 3 2 4 R e ar Vi e w R e ar Vi e w SECTION 2 - ELECTRICAL REFERENCE 2-232 1250AJP 3128411 DHD19P 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 Table 2-29. Connector Loading Diagrams ID Description Diagram SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-233 DHD21R Deutsch 21 position HD series alum. Receptacle DHTP31R (receptacle) Deutsch HDP 31 posi- tion DHTP31P (plug) DT02P Deutsch 2 position DT series plug DT02R Deutsch 2 position DT series receptacle DT03P Deutsch 3 position DT series plug DT03R Deutsch 3 position DT series receptacle DT03P032GP (Green) Deutsch 3 position DT series plug with over- mold adaptor DT03P032BP (Blue) Table 2-29. Connector Loading Diagrams ID Description Diagram 28 29 30 31 20 21 22 23 25 24 26 27 18 19 8 9 10 11 12 13 14 15 16 17 7 2 1 6 5 4 3 S oc k e t R e ar Ins e rt 1 2 2 1 B C A B C A B C A B A C SECTION 2 - ELECTRICAL REFERENCE 2-234 1250AJP 3128411 DT04P Deutsch 4 position DT series plug DT04R Deutsch 4 position DT series receptacle DT06AP Deutsch 6 position DT series plug DT06EP032R Deutsch 6 position bus receptacle DT06R Deutsch 6 position DT series receptacle DT08AP Deutsch 8 position DT series plug with A keys DT08AR Deutsch 8 position DT series receptacle with A keys Table 2-29. Connector Loading Diagrams ID Description Diagram SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-235 DT12AP Deutsch 12 position DT series plug with A keys DT12AR Deutsch 12 position DT series receptacle with A keys DT12BP Deutsch 12 position DT series plug with B keys DT12BR Deutsch 12 position DT series receptacle with B keys DT12CP Deutsch 12 position DT series plug with C keys DT12DP Deutsch 12 position DT series plug with D keys Table 2-29. Connector Loading Diagrams ID Description Diagram 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 SECTION 2 - ELECTRICAL REFERENCE 2-236 1250AJP 3128411 DT12PBR Deutsch 12 position bus receptacle DTM03P Deutsch 3 position DTM series mini plug DTM03R Deutsch 3 position DTM series mini receptacle DTM04P Deutsch 4 position DTM series mini plug DTM04R Deutsch 4 position DTM series mini receptacle DTM12AP Deutsch 12 position DT series mini plug with A key DTM12BP Deutsch 12 position DT series mini plug with B key DTP02P Deutsch 2 position DTP series plug Table 2-29. Connector Loading Diagrams ID Description Diagram 1 2 3 4 5 67 8 9 10 11 12 123 12 3 4 3 1 2 1 2 4 3 7 89 10 11 12 6 5 4 3 2 1 7 89 10 11 12 6 5 4 3 2 1 1 2 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-237 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 Table 2-29. Connector Loading Diagrams ID Description Diagram 2 1 1 2 3 4 5 6 1 2 1 2 3 4 Rear View SECTION 2 - ELECTRICAL REFERENCE 2-238 1250AJP 3128411 MMF10P 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- cle PACKARD2P Packard 2 position plug Table 2-29. Connector Loading Diagrams ID Description Diagram 1 2 3 4 5 10 9 8 7 6 12 11 109 87 12 3 4 56 1 13 4 16 5 17 6 18 7 19 8 20 9 21 10 22 11 23 12 24 2 14 3 15 A B SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-239 2.7 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. 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: PACKARD3P Packard 3 position receptacle PACKARD3R Packard 3 position receptacle SUM02N Sumitomo 2 position natural SUM06N Sumitomo 6 position natural Table 2-29. Connector Loading Diagrams ID Description Diagram C B A 1 2 1 2 3 4 5 6 SECTION 2 - ELECTRICAL REFERENCE 2-240 1250AJP 3128411 Figure 2-17. Connector Assembly Figure 1 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 2-19. Connector Assembly Figure 2). 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 SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-241 Figure 2-19. 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 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). SECTION 2 - ELECTRICAL REFERENCE 2-242 1250AJP 3128411 Figure 2-21. 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. Figure 2-22. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. Wedge Lock The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-243 Service - Voltage Reading CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies the effectiveness of the connector seals and could result in system failure. Figure 2-23. Connector Installation SECTION 2 - ELECTRICAL REFERENCE 2-244 1250AJP 3128411 2.8 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 2-24. 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 wedge- lock will snap into place. Rectangular wedges are not oriented. Thy may go in either way. NOTE: The receptacle is shown - use the same procedure for plug. DT/DTP Series Disassembly Figure 2-25. 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 2-26. HD/HDP Contact Installation 1. Grasp contact about 25mm behind the contact crimp barrel. 2. Hold connector with rear grommet facing you. SECTION 2 - ELECTRICAL REFERENCE 3128411 1250AJP 2-245 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 2-27. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 2-28. 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 2-29. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. SECTION 2 - ELECTRICAL REFERENCE 2-246 1250AJP 3128411 This Page Left Blank Intentionally SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-247 SECTION 3. HYDRAULIC REFERENCE Figure 3-1. Main Valve Layout MAIN VALVE M2 M13 M1 M14 ADJUSTMENT SCREW MAIN LIFT RETRACT SHOCK VALVE TOWER LIFT EXTEND SHOCK VALVE MAIN TELE EXTEND SHOCK VALVE LS PORT MAIN LIFT EXTEND SHOCK VALVE TOWER LIFT RETRACT SHOCK VALVE MAIN TELE RETRACT SHOCK VALVE MP1 SECTION 3 - HYDRAULIC REFERENCE 3-248 1250AJP 3128411 Figure 3-2. Pumps Layout LEFT SIDE DRIVE PUMP FUNCTION PUMP RIGHT SIDE DRIVE PUMP LOW PRESS RELIEF ADJ. HIGH PRESS RELIEF ADJ. PUMPS V IEW ROTATED SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-249 Platform Valve Layout Figure 3-3. Platform Valve Layout PLATFORM LEVEL DOWN RELIEF ADJUST JIB UP/DOWN RELIEF ADJUST JIB UP/DOWN SHUTTLE VALVE JIB UP/DOWN 2.0 GPM PLATFORM LEVEL DOWN RELIEF ADJUST 2.0 GPM 0.3 GPM 0.2 GPM 75 PSI CHECK VALVE BASKET SUPPORT 10 MICRON FILTER MP M1 M2 M3 P L1 L 2 R1 R2 S1 S2 J1 J2 T SECTION 3 - HYDRAULIC REFERENCE 3-250 1250AJP 3128411 Pump Circuit Schematic Figure 3-4. Hydraulic Schematic - Pump Circuit - Sheet 1 of 2 a b Ps Ma THROTTLE POSITION G (Fa) (Fe) B SWIVEL PORT #5 SWIVEL PORT #6 1.2mm " OIL COOLER .37in 3 5000 PSI 5000 PSI 1.7in 3 1200SJP, 1350SJP, 1250AJP T2T1R Mb X1 X2 S A #1 - T T - #1 #2 - P P - #2 #5 - B1B1 - #5 #4 - B2 B2 - #4 #3 - A2 A2 - #3 #6 - A1 A1 - #6 #7 - CD CD - #7 SHT. #2 SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-251 Figure 3-5. Hydraulic Schematic - Pump Circuit - Sheet 2 of 2 27 9 2 5 27 G L1 BOOM CTL “P1” Ps a b Ma G (Fa) (Fe) B Mb B L S SWIVEL PORT #4 SWIVEL PORT #3 RESERVOIR SWIVEL PORT #7 SWIVEL PORT #1 SET AT 300 PSI SET AT 3400 PSI 2.74in 3 .37in 3 550 PSI 5000 PSI 5000 PSI 1.7in 3 RT2T1 X1 X2 SA BOOM CTL “LS” BOOM CTL “T3” SECTION 3 - HYDRAULIC REFERENCE 3-252 1250AJP 3128411 Platform Control Schematic Figure 3-6. Hydraulic Schematic - Platform Control - Sheet 1 of 2 1 3 2 1 2 1 2 1 2 1 2 1 2 1 2 BOOM CTL “T2” LEVEL CYLINDER 1200SJP-1350SJP A nnulus: 16.49 sq. in. Cyl. Area Ratio: 1.19:1 PLATFORM ROTATOR Displacement: 14 c.i.r. 10 MICRON ABS B10 >= 1000 IN OUT 1500 PSI 2500 PSI 75 PSI 2000 PSI 3000 PSI (1250AJP) (1200SJP-1350SJP) (1250AJP) (1200SJP-1350SJP) LEVEL CYLINDER 1250AJP Annulus: 14.73 sq. in. Cyl. Area Ratio: 1.33:1 .047 S1S2 24 13 31 24 S2 M1 L1 L2 M2 R1 R2 T P 2.0 GPM 0.2 GPM C2 V2 V1 C1 MP S1 L1 L2 BOOM CTL “P3” 100 PSI BYPASS SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-253 Figure 3-7. Hydraulic Schematic - Platform Control - Sheet 2 of 2 1 2 2 1 2 1 1 2 3 JIB SWING ROTATOR Displacement: 74.2 cu. in. for 244 degrees Displacement: 54.7 cu. in. for 180 degrees JIB CYLINDER Annulus: 5.3 sq. in. Cyl. Area Ratio: 1.33:1 .047 2750 PSI 1200SJP,1350SJP,1250AJP 3 S1 2 1 S2 4 3 S1 2 1 S2 4 S1 S2 M3 J1 J2 0.3 GPM 2.0 GPM C2 V2 V1 C1 2792527 G SECTION 3 - HYDRAULIC REFERENCE 3-254 1250AJP 3128411 Axle Steer Control Schematic Figure 3-8. Hydraulic Schematic - Axle Steer Control - Sheet 1 of 2 2 b PT a A B 1 2 1 1 2 b 1 2 A3 A1 A2 A4 S1 S2 b 1 2 1 a 2 P T S3 S4 REAR AXLE LEFT SIDE LEFT SIDE REAR STEER RIGHT SIDE RIGHT SIDE SWIVEL PORT #1 V2 V1 V1 V2 LEFT RIGHT RIGHT LEFT STEERING CYLINDERS ANNULUS: 10.16 SQ. IN. CYL. AREA RATIO: 1.23:1 AXLE EXTENSION CYLINDERS ANNULUS: 6.48 SQ. IN. C YL. AREA RATI O : 1.4 8 :1 MS1 MS2 MS3 MS4 2500 PSI 2500 PSI MA3 MA4 2600 PSI 2000 PSI 2600 PSI 2000 PSI 1200SJP,1350SJP, 1250AJP SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-255 Figure 3-9. Hydraulic Schematic - Axle Steer Control - Sheet 2 of 2 2 1 2 1 2 1 2 11 2 1 2 a PT b AB A3 A1 A2 S2S1 S3 S4 T P FRONT AXLE LEFT SIDE RIGHT SIDE LEFT SIDE FRONT STEER RIGHT SIDE SWIVEL PORT #2 A4 V2 V1 V1 V2 LEFTRIGHTRIGHT LEFT MA3 MA4 MS1 MS2 MS3 MS4 2000 PSI 2600 PSI 2000 PSI 2600 PSI 2500 PSI 2500 PSI 2792527 G SECTION 3 - HYDRAULIC REFERENCE 3-256 1250AJP 3128411 Traction Control Schematic Figure 3-10. Hydraulic Schematic - Traction Control - Sheet 1 of 2 SWIVEL PORT #6 SWIVEL PORT #5 SWIVEL PORT #4 B2 B1 A1 A2 B5 A5 BR TS B3 A3 1 2 3 2 3 1 1 3 2 1 3 2 2 1 3 1 2 1 2 1 2 1 2 3 24 3 4 2 1.2mm 1.2mm 2.74 CU. IN. MAX 1.0 CU. IN. MIN 2.74 CU. IN. MAX 1.0 CU. IN. MIN .025 ORF. RIGHT B G B LEFT MLOP LOP MBR PRESSURE SWITCH 200 PSI FIXED SET POINT AXLE LOCK OUT TWO SPEED SHIFT BRAKE RELEASE G 1200SJP , 1350SJP , 1250AJP SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-257 Figure 3-11. Hydraulic Schematic - Traction Control - Sheet 2 of 2 SWIVEL PORT #1 SWIVEL PORT #3 SWIVEL PORT #7 D A6 B6 MP B4 A4 1 2 SET AT 500 PSI 2 4 3 2.74 CU. IN. MAX 1.0 CU. IN. MIN 2.74 CU. IN. MAX 1.0 CU. IN. MIN RIGHT G B B LEFT PROVISION FOR ORIFICE G A XLE LOCK OUT CYLINDERS ANNULUS: 16.49 SQ. IN. CYL AREA RATIO: 6.25:1 OSC. AXLE L.O. CYL. OSC. AXLE L.O. CYL. 2792527 G SECTION 3 - HYDRAULIC REFERENCE 3-258 1250AJP 3128411 Boom Control Schematic Figure 3-12. Hydraulic Schematic - Boom Control - Sheet 1 of 2 SWING M To w e r Li f tMain Lift LS 3800 PT To w e r Tel e B A B A B A 1250AJP (P) SWING PVG ENABLE (W) SECTION 3 - HYDRAULIC REFERENCE 3128411 1250AJP 3-259 Figure 3-13. Hydraulic Schematic - Boom Control - Sheet 2 of 2 TOWER LIFT TOWER TELE MAIN LIFT 2792527 G MAIN SWIVEL TELE E PSI. SW A UX. PUMP (R) MAIN DUMP (Q) MAIN TELE PROP. MAIN TELE OUT (L) (M) MAIN TELE IN (I) (J) (K) 1 2 12 CXBA XAN (4 PSI) CXDA XFN (100 PSI) V C 10 MICRON ABS B10 >= 200 43 PSI BYPASS OUT IN PLATFORM CTL “T” PLATFORM CTL “P” SECTION 3 - HYDRAULIC REFERENCE 3-260 1250AJP 3128411 This Page Left Blank Intentionally SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-261 SECTION 4. JLG ANALYZER 4.1 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 1. Connect the cable supplied with the analyzer, to the controller module located in the platform box or at the controller module in the ground control box and connect the remaining end of the cable to the ana- lyzer. NOTE: The cable has a four pin connector at each end of the cable; the cable cannot be connected back- wards. 2. Power up the Control System by turning the key to the platform or ground position and pulling both emergency stop buttons on. Figure 4-1. Ground Analyzer Connection Point Figure 4-2. Platform Analyzer Connection Point 4.2 USING THE ANALYZER With the machine power on and the analyzer connected properly, the analyzer will display the following: 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. SECTION 4 - JLG ANALYZER 4-262 1250AJP 3128411 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. Use the right and left arrow keys to scroll through the fault logs. To return to the beginning, press ESC. two times. POWER CYCLE (0/0) indicates a power up. When a top level menu is selected, a new set of menu items may be offered: for example: DRIVE BOOM SYSTEM DATALOG VERSIONS Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases, such as DRIVE, the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC. key. SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-263 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. SECTION 4 - JLG ANALYZER 4-264 1250AJP 3128411 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. MENU: FROM: PERSONALITIES ACCESS LEVEL 1 MENU: PERSONALITIES PERSONALITIES: DRIVE PERSONALITIES: STEER PERSONALITIES: MAIN LIFT PERSONALITIES: SWING PERSONALITIES: TOWER LIFT PERSONALITIES: MAIN TELESCOPE PERSONALITIES: PLATFORM LEVEL PERSONALITIES: TOWER TELESCOPE PERSONALITIES: PLATFORM ROTATE PERSONALITIES: JIB LIFT PERSONALITIES: GROUND MODE PERSONALITIES: GEN SET/WELDER DRIVE: ACCEL X.XS DRIVE: DECEL X.XS DRIVE: TO: MIN FORWARD X% MACHINE SETUP DRIVE: MAX FORWARD X% DRIVE: MIN REVERSE X% DRIVE: MAX REVERSE X% DRIVE: ELEV. MAX X% DRIVE: CREEP MAX X% STEER: MAX SPEED X% MAIN LIFT: ACCEL X.XS MAIN LIFT: DECEL X.XS MAIN LIFT: MIN UP X% MAIN LIFT: MAX UP X% MAIN LIFT: CREEP UP X% MAIN LIFT: MIN DOWN X% MAIN LIFT: MAX DOWN X% MAIN LIFT: CREEP DOWN X% SWING: ACCEL X.XS SWING: DECEL X.XS SWING: MIN LEFT X% SWING: MAX LEFT X% SWING: CREEP LEFT X% SWING: MIN RIGHT X% SWING: MAX RIGHT X% SWING: CREEP RIGHT X% TOWER LIFT: ACCEL X.XS TOWER LIFT: DECEL MEDIUM TOWER LIFT: MIN UP X% TOWER LIFT: MAX UP X% TOWER LIFT: MIN DOWN X% TOWER LIFT: MAX DOWN X% MAIN TELESCOPE: ACCEL X.XS MAIN TELESCOPE: DECEL X.XS MAIN TELESCOPE: MIN IN X% MAIN TELESCOPE: MAX IN X% MAIN TELESCOPE: MIN OUT X% MAIN TELESCOPE: MAX OUT X% TOWER TELESCOPE: ACCEL X.XS TOWER TELESCOPE: DECEL X.XS TOWER TELESCOPE: MIN IN X% TOWER TELESCOPE: MAX IN X% TOWER TELESCOPE: MIN OUT X% TOWER TELESCOPE: MAX OUT X% PLATFORM LEVEL: ACCEL X.XS PLATFORM LEVEL: DECEL X.XS PLATFORM LEVEL: MIN UP X% PLATFORM LEVEL: MAX UP X% PLATFORM LEVEL: MIN DOWN X% PLATFORM LEVEL: MAX DOWN X% PLATFORM ROTATE: ACCEL X.XS PLATFORM ROTATE: DECEL X.XS PLATFORM ROTATE: MIN LEFT X% PLATFORM ROTATE: MAX LEFT X% PLATFORM ROTATE: MIN RIGHT X% PLATFORM ROTATE: MAX RIGHT X% JIB LIFT: ACCEL X.XS JIB LIFT: DECEL X.XS JIB LIFT: MIN UP X% JIB LIFT: MAX UP X% JIB LIFT: MIN DOWN X% JIB LIFT: MAX DOWN X% GROUND MODE: MAIN UP: XXX% GROUND MODE: MAIN DOWN: XXX% GROUND MODE: SWING: XXX% GROUND MODE: PLT LEVEL: XXX% GROUND MODE: PLT ROTATE: XXX% GROUND MODE: MAIN TELE: XXX% GROUND MODE: TOWER TELE: XXX% GROUND MODE: TOWER UP: XXX% GROUND MODE: TOWER DOWN: XXX% GROUND MODE: JIB (U/D): XXX% GEN SET/WELDER: ENGINE 1800 RPM PERSONALITIES: JIB SWING JIB LIFT: ACCEL X.XS JIB LIFT: DECEL X.XS JIB LIFT: MIN LEFT X% JIB LIFT: MAX LEFT X% JIB LIFT: MIN RIGHT X% JIB LIFT: MAX RIGHT X% GROUND MODE: JIB (L/R): XXX% SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-265 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. FROM: TO: PERSONALITIES CALIBRATIONS TILT: 1=5 DEG TILT: 2=4 DEG TILT: 3=3 DEG TILT: 4=4 DEG PLUS CUT TILT: 5=3 DEG PLUS CUT MENU: MACHINE SETUP MODEL NUMBER: 1200S ENGINE: DEUTZ F4 TIER1 GLOW PLUG: NO GLOW PLUGS ENGINE SHUTDOWN: STARTER LOCKOUT: ENABLED DISABLED CHASSIS TILT: 5 DEGREES SOFT TOUCH: NO GEN SET/WELDER: NO H & T LIGHTS: NO LOAD SYSTEM: NO FUNCTION CUTOUT: NO GROUND ALARM: NO OSCILLATING AXLE: YES MODEL NUMBER: 1250A MODEL NUMBER: 1350S ENGINE: DEUTZ F4 TIER2 GLOW PLUG: AIR INTAKE ENGINE SHUTDOWN: STARTER LOCKOUT: DISABLED ENABLED CHASSIS TILT: 4 DEGREES CHASSIS TILT: 3 DEGREES CHASSIS TILT: 4 DEGREES + CUT CHASSIS TILT: 3 DEGREES + CUT SOFT TOUCH: YES GEN SET/WELDER: BELT DRIVE GEN SET/WELDER: HYDRAULIC DRIVE H & T LIGHTS: YES LOAD SYSTEM: WARN ONLY LOAD SYSTEM: CUTOUT PLATFORM LOAD SYSTEM: CUTOUT ALL LOAD SYSTEM: SPECIAL 1 FUNCTION CUTOUT: BOOM CUTOUT FUNCTION CUTOUT: DRIVE CUTOUT FUNCTION CUTOUT: DRIVE CUT E&T GROUND ALARM: DRIVE GROUND ALARM: DESCENT GROUND ALARM: MOTION OSCILLATING AXLE: NO GLOW PLUG: IN-CYLINDER* ENVELOPE HEIGHT: 1350S: 135' MAX ENVELOPE HEIGHT: 1350S: 125' MAX ENVELOPE HEIGHT: 1350S: 120' MAX ENVELOPE HEIGHT: 1350S: 110' MAX ENVELOPE HEIGHT: 1200S: 120' MAX ENVELOPE HEIGHT: 1200S: 110' MAX ENVELOPE HEIGHT: 1250A: 125' MAX ENVELOPE HEIGHT: 1250A: 100' MAX ENVELOPE HEIGHT: 1250A: 80' MAX MARKET: ANSI USA MARKET: ANSI EXPORT MARKET: CSA MARKET: CE MARKET: AUSTRALIA MARKET: JAPAN ENGINE: DEUTZ ECM GEN SET CUTOUT: MOTION ENABLED GEN SET CUTOUT: MOTION CUTOUT TEMP DISPLAY: CELSIUS TEMP DISPLAY: FAHRENHEIT SECTION 4 - JLG ANALYZER 4-266 1250AJP 3128411 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. FROM: MACHINE SETUP MENU: CALIBRATIONS CALIBRATIONS: STEER CALIBRATIONS: DRIVE CALIBRATE STEER? CALIBRATE DRIVE? CALIBRATIONS: LEVEL UP CRKPT CALIBRATIONS: LEVEL DOWN CRKPT CALIBRATE LEVEL UP CRACKPOINT? CALIBRATE LEVEL DOWN CRACKPOINT? CALIBRATIONS: MAIN LIFT CRKPT CALIBRATIONS: MAIN TELE CRKPT CALIBRATE MAIN LIFT CRACKPOINT? CALIBRATE MAIN TELE CRACKPOINT? CALIBRATIONS: TILT SENSOR CALIBRATIONS: BOOM SENSORS POSITION 1: CHECK SYSTEM? POSITION 1: CHECK SYSTEM? CALIBRATIONS: CALIBRATIONS: DEUTZ SETUP: NONE AVAILABLE CALIBRATIONS: BOOM VALVES CALIBRATE BOOM VALVES? DEUTZ SETUP: DEUTZ SETUP: DEUTZ SETUP: DEUTZ SETUP: SETUP 1 SETUP 2 SETUP 3 SETUP 4 SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-267 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. TO: SHEET 2 FROM: TO: HELP:PRESS ENTER SYSTEM TEST MENU: DIAGNOSTICS DIAGNOSTICS: DRIVE DIAGNOSTICS: BOOM FUNCTIONS DIAGNOSTICS: ENGINE DIAGNOSTICS: SYSTEM JOYSTICK LIFT: MAIN UP XXX% JOYSTICK SWING: LEFT XXX% PLATFORM LEVEL: UP XXX% PLATFORM ROTATE: LEFT XXX% MAIN TELESCOPE: IN XXX% TOWER TELESCOPE: IN XXX% TOWER LIFT: UP XXX% JIB LIFT: UP XXX% FUNCTION SPEED: PUMP POT XXX% CREEP SWITCH: CLOSED CREEP MODE: OFF GROUND MODULE BATTERY: XX.XV PLATFORM MODULE BATTERY: XX.XV AMBIENT TEMPERATURE:XXXC PLATFORM SELECT KEYSWITCH:CLOSED GROUND SELECT KEYSWITCH: OPEN STATION CONTROL: GROUND CREEP SWITCH: CLOSED CREEP MODE: OFF JOYSTICK DRIVE: FORWARD XXX% JOYSTICK STEER: LEFT XXX% STEER TYPE: NORMAL BRAKES STATUS: LOCKED CREEP SWITCH: CLOSED CREEP MODE: OFF 2-SPEED SWITCH: CLOSED 2-SPEED VALVE OUTPUT: OFF HIGH ENGINE SWITCH: OPEN START SEQUENCE: NOT ACTIVE BATTERY VOLTAGE: XX.XV COOLANT TEMPERATURE:XXXC ENGINE OIL PRESSURE:XXXXPSI AMBIENT TEMPERATURE:XXXC FUEL LEVEL SENSOR: OK STARTER CRANK TIME: XX S ENGINE SPEED ACTUAL: XXXX RPM L FRONT WHEEL ANGLE: XX.X R FRONT WHEEL ANGLE: XX.X L REAR WHEEL ANGLE: XX.X R REAR WHEEL ANGLE: XX.X DRV. ORIENTATION SWITCH: CLOSED DRV. ORIENTATION OVERRIDE: OPEN JIB SWING: LEFT XXX% PLATFORM CONTROL VALVE: OFF CHASSIS TILT: XX.X DEGREES CHASSIS TILT X-AXIS: X.X CHASSIS TILT Y-AXIS: X.X AUXILIARY POWER SWITCH: OPEN HORN SWITCH: OPEN SOFT TOUCH LIMIT SWITCH: OPEN SOFT TOUCH OVERRIDE: OPEN GENSET/WELDER SWITCH: OPEN LIGHTS SWITCH: OPEN PLATFORM TILT1 ANGLE: XX.X DEG PLATFORM TILT2 ANGLE: XX.X DEG OSCILATING AXLE PRES. SW.: OPEN HYDRAULIC OIL TEMP. SW.: OPEN HYDRAULIC OIL: WARM UP NOT DONE MAIN LIFT PILOT PRES. SW.: OPEN CABLE BREAK SWITCH: CLOSED DRIVE OUTPUT: FORWARD XXX% STEER OUTPUT: LEFT XXX% DRIVE MODE: MID ENGINE LIFT OUTPUT: MAIN UP XXX% SWING OUTPUT: LEFT XXX% ENGINE SPEED TARGET: XXXX RPM TRANSPORT MODE: OUT OF TRANSPORT PLATFORM TILT1 RAW: XXXX PLATFORM TILT2 RAW: XXXX FOOTSWITCH INPUT GROUND: OPEN FOOTSWITCH INPUT PLATFORM: CLOSED SECTION 4 - JLG ANALYZER 4-268 1250AJP 3128411 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. FROM: TO: SHEET 1 SHEET 3 BCS STATUS: NORMAL JIB STOWED LIMIT SWITCH: CLOSED JIB STOWED LIMIT OVERRIDE: OPEN AXLE INPUT SW.: EXTEND CLOSED DIAGNOSTICS: BCS MAIN BOOM ANGLE ZONE: 4 MAIN BOOM LENGTH ZONE: A DIAGNOSTICS: LOAD PIN DIAGNOSTICS: ENVELOPE DIAGNOSTICS: BOOM SENSORS LOAD PIN MOMENT VALUE: XXXX LOAD PIN RATIO VALUE: XX.XXX LOAD PIN ANGLE VALUE: XXX.X LOAD PIN VECTOR FORCE: XXXXXX LOAD PIN MOMENT RAW: XXXXX LOAD PIN RATIO RAW: XX.XXX LOAD PIN ANGLE RAW: XXX.X LOAD PIN V-FORCE RAW: XXXXXXXX LOAD PIN ANGLE CAL POINT: XXX.X LOAD PIN V-FORCE CAL: XXXXX LOAD PIN MOMENT CAL POINT: XXXXX LOAD PIN ERROR FLAGS: 0X0000 LOAD PIN X-AXIS VALUE: XXX LOAD PIN Y-AXIS VALUE: XXX LOAD PIN X-AXIS RAW VALUE: XXX LOAD PIN Y-AXIS RAW VALUE: XXX TOWER LENGTH 1 SENSOR: X.X" TOWER LENGTH 2 SENSOR: X.X" TOWER ANGLE 1 SENSOR: XX.X TOWER ANGLE 2 SENSOR: XX.X TOWER CYLINDER ANGLE: XX.X MAIN ANGLE 1 TO TOWER: XX.X MAIN ANGLE 2 TO TOWER: XX.X TOWER LENGTH 2 A/D: XXXXX TOWER ANGLE 2 A/D: XX.X TOWER CYLINDER ANGLE A/D: XXXXX MAIN LIFT 1 ANGLE A/D: XXXXX MAIN LIFT 2 ANGLE A/D: XXXXX MAIN LIFT 1 RAW ANGLE: XXX.X MAIN LIFT 2 RAW ANGLE: XXX.X TOWER RETRACTED LENGTH 1: XXXXXX TOWER RETRACTED LENGTH 2: XXXXXX TOWER EXTENDED LENGTH 1: XXXXXX TOWER EXTENDED LENGTH 2: XXXXXX TOWER TRIP POINT LENGTH: XXXX.X" TOWER ANGLE 1 LOW CAL: XXX.X TOWER ANGLE 2 LOW CAL: XXX.X TOWER ANGLE 1 HIGH CAL: XXX.X TOWER ANGLE 2 HIGH CAL: XXX.X TOWER CYLINDER LOW CAL: XXXXXX TOWER CYLINDER HIGH CAL: XXXXXX MAIN ANGLE 1 LOW CAL: XXXXXX MAIN ANGLE 2 LOW CAL: XXXXXX MAIN ANGLE 1 HIGH CAL: XXXXXX MAIN ANGLE 2 HIGH CAL: XXXXXX MAIN TRIP POINT ANGLE: XXX.X MAIN ANGLE L TO GRAVITY: XXX.X MAIN ANGLE H TO GRAVITY: XXX.X TOWER LENGTH 1 A/D: XXXXX TOWER ANGLE 1 A/D: XX.X MAIN BOOM LENGTH: XXX.X" MAIN BOOM ANGLE1: XX.X DEG MAIN BOOM ANGLE2: XX.X DEG MAIN BOOM A/D LENGTH: XXXXX MAIN BOOM A/D BOOM CONTROL: ANGLE1: XXX.X AUTOMATIC MAIN BOOM A/D ANGLE2: XXX.X MODE SW: OPEN PLATFORM STOWED: NO MAIN ENVELOPE STATUS: NOMINAL TOWER ENVELOPE STATUS: NOMINAL DIAGNOSTICS: TRANSPORT DATA TOWER LIFT STATUS: STOWED TOWER TELESCOPE STATUS:RETRACTED MAIN LIFT STATUS: ELEVATED MAIN TELESCOPE STATUS:RETRACTED AXLE STATUS: EXTENDED MAIN BOOM LENGTH SWITCH NC: OPEN MAIN BOOM LENGTH SWITCH NO:CLOSED MAIN BOOM LENGTH ZONE: A/D DUAL CAPACITY SWITCH NC: OPEN DUAL CAPACITY SWITCH NO:CLOSED DUAL CAPACITY LENGTH ZONE: A/B TOWER TELESCOPE SWITCH NC: OPEN TOWER TELESCOPE SWITCH NO:CLOSED TOWER TELESCOPE STATUS:RETRACTED TOWER LIFT ANGLE SWITCH: OPEN MAIN LIFT ANGLE SWITCH NC: OPEN MAIN LIFT ANGLE SWITCH NO:CLOSED MAIN LIFT ANGLE STATUS:TRANSPORT TRANSPORT MODE: OUT OF TRANSPORT DIAGNOSTICS: BOOM SWITCHES MAIN ENVELOPE LOW: NOMINAL ELEC. RETRIEVAL: NOT ACTIVE HYD. RETRIEVAL: NOT ACTIVE SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-269 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. FROM: SHEET 2 DIAGNOSTICS: LOAD DIAGNOSTICS: CAN STATISTICS DIAGNOSTICS: DATALOG DIAGNOSTICS: VERSIONS DIAGNOSTICS: CALIBRATION DATA PLATFORM LOAD STATE: OK CAN STATISTICS RX/SEC: X CAN STATISTICS TX/SEC: X CAN STATISTICS BUS OFF X CAN STATISTICS PASSIVE XXXXX DATALOG: ON XXH XXM DATALOG: ENGINE XH XM DATALOG: DRIVE XH XM DATALOG: LIFT XH XM DATALOG: SWING XH XM DATALOG: TELE XH XM DATALOG: MAX TEMP XXC DATALOG: MIN TEMP XXC DATALOG: MAX VOLTS XX.XV DATALOG: RENTAL XH XM DATALOG: ERASE RENTAL? GROUND MODULE SOFTWARE: P7.X GROUND MODULE HARDWARE: REV 4 GROUND MODULE S/N: XXXXXX PLATFORM MODULE SOFTWARE: P7.X PLATFORM MODULE HARDWARE: REV 2 PLATFORM MODULE S/N: XXXXXX DIAGNOSTICS: MOMENT CAN STATISTICS MSG ERROR: XXXX PLATFORM UP CAL: X PLATFORM DOWN CAL: X LEFT FORWARD DRIVE CAL: XXXX RIGHT FORWARD DRIVE CAL: XXXX LEFT REVERSE DRIVE CAL: XXXX RIGHT REVERSE DRIVE CAL: XXXX L FRONT STEER CAL: XXXXX R FRONT STEER CAL: XXXXX L REAR STEER CAL: XXXXX R REAR STEER CAL: XXXXX MAIN LIFT UP CAL: XXXXX MAIN LIFT DOWN CAL: XXXX MAIN TELESCOPE IN CAL: XXXXX MAIN TELESCOPE OUT CAL: XXXXX MAIN ANGLE 1 LO CAL: X MAIN ANGLE 1 HI CAL: X MAIN ANGLE 2 LO CAL: X MAIN ANGLE 2 HI CAL: X LENGTH RETRACTED CAL: XXXXX LENGTH EXTENDED CAL: XXXXX YELLOW WITNESS MARK CAL: X LENGTH SWITCH CAL: XXXXX CHASSIS MODULE SOFTWARE: P7.X B.L.A. MODULE SOFTWARE: P7.X ACTUAL MOMENT XXXXXXXX LB*IN OVER MOMENT XXXXXXXX LB*IN UNDER MOMENT XXXXXXXX LB*IN UNDER MOMENT CAL POINT: X YELLOW WITNESS CAL: XXXXXXXX GREEN WITNESS CAL: XXXXXXXX LOAD PIN RATIO VALUE: XX.XXX LOAD PIN ERROR FLAGS: 0X0000 SKY WELDER INSTALLED: NO SKY CUTTER INSTALLED: NO SKY GLAZIER INSTALLED: NO SKY BRIGHT INSTALLED: NO PIPE RACKS INSTALLED: NO CAMERA MOUNT INSTALLED: NO CYLINDER PIN SOFTWARE: RX.XX CYLINDER PIN S/N: XXXXXX MAIN ANGLE 1 S/N: XXXXXX MAIN ANGLE 1 REV X.X VERSIONS: ANALYZER V6.3 MAIN ANGLE 2 S/N: XXXXXX MAIN ANGLE 2 REV X.X DUAL CAPACITY SWITCH NC: OPEN DUAL CAPACITY SWITCH NO:CLOSED DUAL CAPACITY LENGTH ZONE: A/B PLATFORM CAPACITY:1000 LB JIB IN-LINE SWITCH: OPEN GROUND MODULE CNST DATA: P7.X SECTION 4 - JLG ANALYZER 4-270 1250AJP 3128411 4.3 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER When the analyzer is first connected, you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting can- not be accidentally altered. To change the access level, the correct password must be entered. To enter the pass- word, scroll to the ACCESS LEVEL menu. For example: MENU: ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu. Using the UP or DOWN arrow keys, enter the first digit 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 pass- word. 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. Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- word was entered correctly: MENU: ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings. SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-271 4.4 ADJUSTING PARAMETERS USING THE HAND HELD ANALYZER Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example: PERSONALITIES: DRIVE ACCEL 1.0s There will be a minimum and maximum for the value to ensure efficient operation. The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular per- sonality. 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. 4.5 MACHINE SETUP When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2 = LIFT DOWN The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when lifting down. There are certain settings allowed to install optional features or select the machine model. When selection the machine model to match the size of the machine, the personality settings will all default to the factory recommended setting. NOTE: Refer to Table 4-2. Machine Personality Settings and Speeds on Pg. 277 in this Service Manual for the recommended factory settings. NOTE: Password 33271 will give you access to level 1, which will permit you to change all machine person- ality settings. There is a setting that JLG strongly recommends that you do not change. This setting is so noted below: ELEVATION CUTBACK CHANGING THIS SETTING MAY ADVERSELY AFFECT THE PER- FORMANCE OF YOUR MACHINE. SECTION 4 - JLG ANALYZER 4-272 1250AJP 3128411 Table 4-1. Machine Configuration Programming Information Configuration Digit Number Description Default Number NOTE: The machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default MODEL NUMBER: 1 1 1200S 1 2 1250A 3 1350S ENVELOPE HEIGHT: 2 1 1350S: 135' MAX 5 2 1350S: 125' MAX 3 1350S: 120' MAX 4 1350S: 110' MAX 5 1200S: 120' MAX 6 1200S: 110' MAX 7 1250A: 125' MAX 8 1250A: 100' MAX 9 1250A: 80' MAX NOTE: The default settings (bold) will vary depending on the model selection with selection # 5 being the initial default setting. MARKET: 3 0ANSI USA 0 1 ANSI EXPORT 2CSA 3CE 4 AUSTRALIA 5JAPAN ENGINE: 4 1 DEUTZ F4 TIER1: Deutz BF4M1011 Diesel (Tier 1) 3 2 DEUTZ F4 TIER2: Deutz BF4M2011 Diesel (Tier 2) 3 DEUTZ ECM: Engine Control Module SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-273 GLOW PLUG: 5 0 NO GLOW PLUGS: No glow plugs installed. 2 1 AIR INTAKE: Glow plugs installed in the air intake on the manifold. 2 IN-CYLINDER: Glow plugs installed in each cylinder. STARTER LOCKOUT: 6 0 DISABLED: Automatic pre-glow time determined by ambient air temperature; engine start can be attempted at any time during pre-glow. 0 1 ENABLED: Automatic pre-glow time determined by ambient air temperature; engine start is NOT permitted until pre-glow is finished. ENGINE SHUTDOWN: 7 0 DISABLED: No engine shutdown. 1 1 ENABLED: Shutdown engine when coolant temperature is greater than 110 deg. C or the oil pressure is less than 8 PSI. TILT: 8 1 5 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 5 degrees and above elevation; also reduces drive speed to creep. 1 2 4 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above elevation; also reduces drive speed to creep. 3 3 DEGREES: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees and above elevation; also reduces drive speed to creep. 4 4 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 4 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up. 5 3 DEGREES + CUT: Reduces the maximum speed of all boom functions to creep when tilted more than 3 degrees and above elevation; also disallows tower lift up, tower telescope out, drive, main telescope out and main lift up. NOTE: Any of the selections above will light the tilt lamp when a tilted condition occurs and will sound the platform alarm when the machine is also above elevation. SOFT TOUCH: 9 0 NO: No soft touch system installed. 0 1 YES: Soft touch system installed. Table 4-1. Machine Configuration Programming Information Configuration Digit Number Description Default Number SECTION 4 - JLG ANALYZER 4-274 1250AJP 3128411 GEN SET/WELDER: 10 0NO: No generator installed. 1 1 BELT DRIVE: Belt driven setup. 2 HYDRAULIC DRIVE: Hydraulic driven setup. GEN SET CUTOUT: 11* 0 MOTION ENABLED: Motion enabled when generator is ON. 0 1 MOTION CUTOUT: Motion cutout in platform mode only. * Only visible if Gen Set / Welder Menu selection is not 0. H & T LIGHTS: 12 0 NO: No head and tail lights installed. 0 1 YES: Head and tail lights installed. LOAD SYSTEM: 13* 0 NO: No load sensor installed. 0 1 WARN ONLY: Functions in creep, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF). 2 CUTOUT PLATFORM: All functions cutout, overload lamp lit, platform alarm beeps (5 sec ON, 2 sec OFF). 3 CUTOUT ALL: All functions cutout, flash overload light (500mS on, 500mS off), plat- form alarm beeps (5 sec ON, 2 sec OFF). 4 SPECIAL 1: Functions in creep, overload lamp lit, disables main telescope out & main lift up, platform alarm beeps (5 sec ON, 2 sec OFF). * Only visible under certain market selections. * Certain market selections will limit load system options or alter default setting. Table 4-1. Machine Configuration Programming Information Configuration Digit Number Description Default Number SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-275 FUNCTION CUTOUT: 14* 0NO: No drive cutout. 0 1 BOOM CUTOUT: Boom function cutout while driving above elevation. 2 DRIVE CUTOUT: Drive cutout above elevation. 3 DRIVE CUT E&T: Drive cutout above elevation and tilted. * Only visible under certain market selections. * Certain market selections will limit function cutout options or alter default setting. GROUND ALARM: 15* 0 NO: No ground alarm installed. 0 1 DRIVE: Travel alarm sounds when the drive function is active (Option). 2 DESCENT: Descent alarm sounds when lift down is active (Option). 3 MOTION: Motion alarm sounds when any function is active (Option). * Certain market selections will alter default setting. OSCILLATING AXLE: 16 0 NO: No oscillating axle system installed. 1 1 YES: Oscillating axle system installed. TEMPERATURE: 17* 0 CELSIUS: Celsius unit selection. 1 1 FAHRENHEIT: Fahrenheit unit selection. * Certain market selections will alter default setting. 4150364-15 Table 4-1. Machine Configuration Programming Information Configuration Digit Number Description Default Number SECTION 4 - JLG ANALYZER 4-276 1250AJP 3128411 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 MODEL NUMBER ENVELOPE HEIGHT MARKET ENGINE GLOW PLUGS ENGINE SHUTDOWN TILT SOFT TOUCH GEN SET / WELDER GEN SET CUTOUT HEAD & TAIL LIGHTS ANSI USA 2 7 0 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1 ANSI EXPORT 2 7 1 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1 CSA 2 7 2 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1 CE 2 7 3 3 0 1 2 0 112 3 4 5 0 1 0 1 2 0 1 0 1 AUSTRALIA 2 7 4 3 0 1 2 0 112 3 4 5 0 1 0 1 2 0 1 0 1 JAPAN 2 7 5 3 0 1 2 0 1 1 2 3 4 5 0 1 0 1 2 0 1 0 1 1250AJP LOAD SYSTEM FUNCTION CUTOUT GROUND ALARM OSCILLATING AXLE TEMPERATURE ANSI USA 0 X X X X 0 X X X 0 1 2 3 0 1 0 1 ANSI EXPORT 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1 CSA 0 X X X X 0 1 2 3 0 1 2 3 0 1 0 1 CE 0 X 2 3 X 0 1 X X 0 1 2 3 0 1 0 1 AUSTRALIA 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1 JAPAN 0 1 2 3 4 0 1 2 3 0 1 2 3 0 1 0 1 SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-277 Table 4-2. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds DRIVE: ACCEL X.Xs Displays/adjusts drive acceleration 0.1 to 5.0 sec 2.0 DECEL X.Xs Displays/adjusts drive deceleration 0.1 to 3.0 sec 1.3 MIN forward XX% Displays/adjusts minimum forward drive speed 0 to 35% 1 MAX forward XXX% Displays/adjusts maximum forward drive speed 0 to 100% 100 36-38 (see orientation) MIN reverse XX% Displays/adjusts minimum reverse drive speed 0 to 35% 1 MAX reverse XXX% Displays/adjusts maximum reverse drive speed 0 to 100% 100 36-38 (see orientation) ELEV. MAX XX% Displays/adjusts maximum drive speed NOTE: used when elevation cutout switches are limiting maximum speed 0 to 50% 25 93-104 (see orientation) CREEP MAX XX% Displays/adjusts maximum drive speed NOTE: used when creep switch on pump pot is active 0 to 50% 35 79-87 (see orientation) STEER: max SPEED XXX% Displays/adjusts maximum steer speed. 0 to 100% 100 MAIN LIFT: ACCEl X.Xs Displays/adjusts main lift acceleration 0.1 to 5.0 sec 1.0 DECEl X.Xs Displays/adjusts main lift deceleration 0.1 to 3.0 sec 1.0 MIN Up XX% Displays/adjusts minimum main lift up speed 0 to 60% 1 MAX UP XX% Displays/adjusts maximum main lift up speed 0 to 60% 60 57-69 (see orientation) CREEP UP XX% Displays/adjusts maximum main lift up speed NOTE: used when creep switch on pump pot is active 0 to 65% 35 MIN DOWN XX% Displays/adjusts minimum main lift down speed 0 to 60% 1 MAX DOWN XXX% Displays/adjusts maximum main lift down speed 0 to 60% 60 59-70 (see orientation) CREEP DOWN XX% Displays/adjusts maximum main lift down speed NOTE: used when creep switch on pump pot is active 0 to 75% 35 SECTION 4 - JLG ANALYZER 4-278 1250AJP 3128411 SWING: ACCEL X.Xs Displays/adjusts swing acceleration 0.1 to 5.0 sec 2.0 DECEL X.Xs Displays/adjusts swing deceleration 0.1 to 3.0 sec 1.5 MIN LEFT XX% Displays/adjusts minimum swing left speed 0 to 50% 20 MAX LEFT XXX% Displays/adjusts maximum swing left speed 0 to 65% 73 102-146 (see orientation) CREEP LEFT XX% Displays/adjusts maximum swing left speed NOTE: used when creep switch on pump pot is active 0 to 65% 45 MIN RIGHT XX% Displays/adjusts minimum swing right speed 0 to 50% 20 MAX RIGHT XXX% Displays/adjusts maximum swing right speed 0 to 65% 65 102-146 (see orientation) CREEP RIGHT XX% Displays/adjusts maximum swing right speed NOTE: used when creep switch on pump pot is active 0 to 65% 45 TOWER LIFT: ACCEl X.Xs Displays/adjusts tower lift acceleration 1.0 to 1.0 sec 1.0 DECElSLOW-FAST Displays/adjusts tower lift deceleration Slow, Medium, Fast 0.5 MIN Up XX% Displays/adjusts minimum tower lift up speed 1 to 1% 1 MAX UP XX% Displays/adjusts maximum tower lift up speed 60 to 60% 60 90-107 (see orientation) MIN DOWN XX% Displays/adjusts minimum tower lift down speed 1 to 1% 1 MAX DOWN XXX% Displays/adjusts maximum tower lift down speed 60 to 60% 60 94-107 (see orientation) MAIN TELESCOPE: ACCEL X.Xs Displays/adjusts main telescope acceler- ation 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts main telescope deceler- ation 0.1 to 3.0 sec 0.5 MIN IN XX% Displays/adjusts minimum main tele- scope in speed. Same as Creep speed 0 to 65% 40 MAX IN XXX% Displays/adjusts maximum main tele- scope in speed 0 to 100% 85 35-54 (see orientation) MIN OUT XX% Displays/adjusts minimum main tele- scope out speed. Same as Creep speed 0 to 65% 40 MAX OUT XXX% Displays/adjusts maximum main tele- scope out speed 0 to 100% 85 29-49 (see orientation) Table 4-2. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-279 TOWER TELESCOPE: ACCEL X.Xs Displays/adjusts tower telescope acceler- ation 1.0 to 1.0 sec 1.0 DECEL X.Xs Displays/adjusts tower telescope deceler- ation 0.5 to 0.5 sec 0.5 MIN IN XX% Displays/adjusts minimum tower tele- scope in speed. Same as Creep speed 1 to 1% 1 MAX IN XXX% Displays/adjusts maximum tower tele- scope in speed 60 to 60% 60 MIN OUT XX% Displays/adjusts minimum tower tele- scope out speed. Same as Creep speed 1 to 1% 1 MAX OUT XXX% Displays/adjusts maximum tower tele- scope out speed 60 to 60% 60 BASKET LEVEL: ACCEL X.Xs Displays/adjusts basket level acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts basket level deceleration 0.1 to 3.0 sec 0.5 MIN UP XX% Displays/adjusts minimum basket level up speed. Same as Creep speed 0 to 65% 40 MAX UP XXX% Displays/adjusts maximum basket level up speed 0 to 100% 70 MIN DOWN XX% Displays/adjusts minimum basket level down speed. Same as Creep speed 0 to 65% 40 MAX DOWN XXX% Displays/adjusts maximum basket level down speed 0 to 100% 70 BASKET ROTATE: ACCEL X.Xs Displays/adjusts basket rotate accelera- tion 0.1 to 5.0 sec 1.0 DECEL X.Xs Displays/adjusts basket rotate decelera- tion 0.1 to 3.0 sec 0.5 MIN LEFT XX% Displays/adjusts minimum basket rotate left speed. Same as Creep speed 0 to 100% 60 MAX LEFT XXX% Displays/adjusts maximum basket rotate left speed 0 to 100% 60 24-30 (180°) MIN RIGHT XX% Displays/adjusts minimum basket rotate right speed. Same as Creep speed 0 to 100% 60 MAX RIGHT XXX% Displays/adjusts maximum basket rotate right speed 0 to 100% 60 24-30 (180°) JIB LIFT: Table 4-2. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds SECTION 4 - JLG ANALYZER 4-280 1250AJP 3128411 ACCEL X.Xs Displays/adjusts jib lift acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts jib lift deceleration 0.1 to 3.0 sec 1.0 MIN UP XX% Displays/adjusts minimum jib up speed. Same as Creep speed 0 to 65% 40 MAX UP XXX% Displays/adjusts maximum jib up speed 0 to 100% 65 30-36 MIN DOWN XX% Displays/adjusts minimum jib down speed. Same as Creep speed 0 to 65% 40 MAX DOWN XXX% Displays/adjusts maximum jib down speed 0 to 100% 60 30-36 JIB SWING: ACCEL X.Xs Displays/adjusts jib swing acceleration 0.1 to 5.0 sec 1.5 DECEL X.Xs Displays/adjusts jib swing deceleration 0.1 to 3.0 sec 0.5 MIN LEFT XX% Displays/adjusts minimum jib left speed. Same as Creep speed 0 to 65% 40 MAX LEFT XXX% Displays/adjusts maximum jib left speed 0 to 100% 70 42-47 (125°) MIN RIGHT XX% Displays/adjusts minimum jib right speed. Same as Creep speed 0 to 65% 40 MAX RIGHT XXX% Displays/adjusts maximum jib right speed 0 to 100% 70 42-47 (125°) GROUND MODE: m. LIFT UP XXX% Displays/adjusts fixed main lift up speed 0 to 100% 60 m. lift DN XXX% Displays/adjusts main lift down speed 0 to 100% 60 SWING XXX% Displays/adjusts fixed swing speed 0 to 65% 45 BASKET LVL XXX% Displays/adjusts fixed basket level speed 0 to 100% 75 BASKET ROT XXX% Displays/adjusts fixed basket rotate speed 0 to 100% 75 MAIN TELE XXX% Displays/adjusts fixed main telescope speed 0 to 100% 65 TOWER TELE XXX% Displays/adjusts fixed tower telescope speed Not displayed if TOWER TELE=NO 40 to 40% 40 T. LIFT UP XXX% Displays/adjusts fixed tower lift up speed Not displayed if TOWER LIFT=NO 40 to 40% 40 T. LIFT DN XXX% Displays/adjusts fixed tower lift down speed Not displayed if TOWER LIFT=NO 40 to 40% 40 JIB (U/D) XXX% Displays/adjusts jib lift speed Not displayed if JIB = 0 0 to 100% 60 JIB (L/R) XXX% Displays/adjusts jib swing speed Displayed if JIB = 2 0 to 100% 70 GEN SET/WELDER: Engine XXXX RPM Control generator/welder RPM. Not dis- played if GEN SET/WELDER = 0 1200-2800 1800 Table 4-2. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-281 NOTE: Personality settings can be adjusted anywhere within the adjustment range in order to achieve optimum machine per- formance. Stop watch should start when the function is activated.Not with the controller or switch. Unless noted, function speeds should be measured from platform. Platform speed knob must be at full speed (fully clockwise). All test should be done with the oil temp above 100° F (38° C). 4150517-3 Table 4-2. Machine Personality Settings and Speeds Submenu (Displayed on Analyzer 1st Line) Parameter (Displayed on Analyzer 2nd Line) Description Range DEFAULT VALUES TIME RANGE (SEC) (SEE 4.6 Machine Orientation When Setting Speeds SECTION 4 - JLG ANALYZER 4-282 1250AJP 3128411 4.6 MACHINE ORIENTATION WHEN SETTING SPEEDS MAIN BOOM LIFT UP: From platform control, lowest ele- vation up to maximum elevation, main boom retracted, tower boom on boom rest. MAIN BOOM LIFT DOWN: From platform control, maxi- mum elevation down to minimum elevation, main boom retracted, tower boom on boom rest. TOWER BOOM LIFT UP: From platform control, lowest elevation up to maximum elevation, main boom retracted and horizontal. TOWER BOOM LIFT DOWN: From platform control, max- imum elevation down to minimum elevation, main boom retracted and horizontal. SWING RIGHT (Max): 360 Degrees, from platform con- trol, main boom retracted, tower boom on boom rest. SWING LEFT (Max): 360 Degrees, from platform control, main boom retracted, tower boom on boom rest. MAIN BOOM TELESCOPE OUT: from platform control, main boom horizontal, tower boom on boom rest, 500 lb. capacity selected, jib swing centered. MAIN BOOM TELESCOPE IN: from platform control, boom horizontal, tower boom on boom rest, 500 lb. capacity selected, jib swing centered. DRIVE FORWARD (Max): high speed - low torque set- ting, drive 200 ft. front wheels to front wheels. Timed after machine has obtained maximum speed. DRIVE REVERSE (Max): high speed - low torque setting, drive 200 ft. front wheels to front wheels. Timed after machine has obtained maximum speed. DRIVE FORWARD (Creep Max): high torque - low speed setting, platform speed knob at full creep DRIVE REVERSE (Creep Max): high torque - low speed setting, platform speed knob at full creep DRIVE FORWARD (Elevated Max - Boom Beyond Transport): high speed - low torque setting, platform speed knob out of creep, Lift boom above transport, drive forward 50 ft. DRIVE REVERSE (Elevated Max - Boom Beyond Trans- port): high speed - low torque setting, platform speed knob out of creep, Lift boom above transport, drive back- ward 50 ft. Test Notes 1. Personality settings can be adjusted anywhere within the adjustment range in order to achieve opti- mum machine performance 2. Stop watch should start when the function is acti- vated.Not with the controller or switch. 3. Unless noted, function speeds should be measured from platform. 4. Platform speed knob must be at full speed (fully clockwise). 5. All test should be done with the oil temp above 100° F (38° C). 4.7 SYSTEM TEST The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Test from the Platform 1. Position the Platform/Ground select switch to the Platform position. SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-283 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. 4. The analyzer screen should read: 5. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate. 6. Follow the flow path in Figure 4-10. System Test Flow Chart - Platform Tests on Pg. 284 and go through the component tests. Hit the ESC key dur- ing 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). SECTION 4 - JLG ANALYZER 4-284 1250AJP 3128411 Figure 4-10. System Test Flow Chart - Platform Tests SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-285 Test from the Ground Station 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: 5. Use the arrow button to reach SYSTEM TEST. Hit Enter. The analyzer will prompt you asking if you want to activate the system test; hit Enter again to activate. 6. Follow the flow path in Figure 4-11. System Test Flow Chart - Ground Station Tests on Pg. 286 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). SECTION 4 - JLG ANALYZER 4-286 1250AJP 3128411 Figure 4-11. System Test Flow Chart - Ground Station Tests SECTION 4 - JLG ANALYZER 3128411 1250AJP 4-287 Table 4-3. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer Description RUNNING Initial display when system test is run; certain “critical” checks are made. Prob- lems that can be reported include below messages. ONLY 1 ANALYZER! Do not connect two Analyzers while running the system test. BATTERY TOO LOW The system test cannot run with battery voltage below minimum (9 V). BATTERY TOO HIGH The system test cannot run with battery voltage above maximum. (16 V). CHECK CAN WIRING The system test cannot run in platform mode unless data is being received from the platform and ground modules. The system test cannot run in ground mode unless data is being received from the platform module. CHECK SPEED There is an open- or short- circuit in the speed encoder wiring. Check speed encoder. BAD GROUND MODULE An internal problem was detected in the ground module. HIGH TILT ANGLE The vehicle is very tilted (19.3°), or the tilt sensor has been damaged. Check tilt sensor. HOT ENGINE The engine temperature exceeds 100×C. This is only a warning. BAD I/O PORTS The controller detected a problem with its internal circuits at switch on. If other problems are also detected, the controller may need replacing. SUSPECT EEPROM The controller detected a problem with its EEPROM stored personality settings at switch on. Check and, if necessary correct, all personality settings. OPEN FSW In platform mode, the footswitch must be open at the start of the test. CLOSE FSW In platform mode, the footswitch must be closed when this message is dis- played; the footswitch MUST BE KEPT CLOSED during the valve & contactor tests. BAD FSW The two footswitch signals are not changing together, probably because one is open-circuit. One footswitch signal (“FSW1”) is routed to the power module, the other (“FSW2”) is routed to the platform module. Check footswitch and wir- ing. TESTING VALVES Indicates that the valve test is beginning. Each valve is alternately energized and de-energized; checks are made for open- and short- circuit valve coils. NOTE: In platform mode, the footswitch must be closed. NOTE: Tower lift valves are not tested if TOWER LIFT=NO. Tower telescope valves are not tested if TOWER TELE=NO. Jib valves are not tested if JIB = NO. Extendable axle valves are not tested if EXT AXLES=NO. Four wheel steer valves are not tested if 4WS=NO. NOTE: Left/right jib valves are not tested unless JIB = SIDESWING. Problems that can be reported include below messages. CANT TEST VALVES There is a wiring problem, which prevents the valve test from functioning cor- rectly. Check valve wiring. Check ground alarm & hour meter wiring. XXXXXXX S/C The named valve is drawing too much current so is presumed to be short-cir- cuited. Check valve wiring. XXXXXXX O/C The named valve is drawing too little current so is presumed to be open-circuit. Check valve wiring. SECTION 4 - JLG ANALYZER 4-288 1250AJP 3128411 CHECKING INPUTS Indicates that the inputs test is beginning. Every input is checked to ensure that it is in its “normal” position; function switches should be open, cutout switches should be closed, joysticks should be in neutral. In platform mode any non-neutral platform switch or joystick is reported; any active cutouts are reported. In ground mode any non-neutral ground switches is reported; any active cut- outs are reported. NOTE: Switches, which are not in use (due to the settings of machine digits), are not checked. NOTE: The pump pot is checked only for a wire-off condition; it can be at any demand from creep to maximum. Problems that can be reported include below messages. CHECK XXXXXXX The named switch is not in its “normal” position. Check switch & wiring. CHECK XXXXXXX JOY The named joystick appears to be faulty. Check joystick. TESTING LAMPS Indicates that the lamps test is beginning. Each lamp is energized in turn; a prompt asks for confirmation that the lamp is lit. ENTER must be pressed or clicked to continue the test. NOTE: Lamps, which are not in use (due to the settings of machine digits), are not checked. NOTE: Platform Lamps are only tested in platform mode. NOTE: The GM overload lamp and 500# capacity lamp are not tested. NOTE: Head and tail lamps are tested in both platform and ground mode if enabled by a machine digit. TESTING ALARMS Indicates that the alarms test is beginning. Each alarm is energized in turn; a prompt asks for confirmation that the alarm is sounding. ENTER must be pressed or clicked to continue the test. NOTE: The platform alarm and the horn are only tested in platform mode. NOTE: The ground alarm is not tested if GROUND ALARM = NO. TEST ALL INPUTS? Prompts whether to check every operator input. If ESC is pressed or clicked, the system test ends. If ENTER is pressed or clicked, each operator input is prompted for in turn. In platform mode every platform switch and joystick is tested. In ground mode every ground switch is tested. NOTE: Tower lift switches are not tested if TOWER LIFT=NO. Tower telescope switches are not tested if TOWER TELE=NO. Jib switches are not tested if JIB = NO. Extendable axle switches are not tested if EXT AXLES=NO. Four wheel steer switches are not tested if 4WS=NO. NOTE: Left/right jib switches are not tested unless JIB = SIDESWING. Prompts displayed during the operator input test below messages. CLOSE XXXXXXX The named switch should be closed. OPEN XXXXXXX The named switch should be opened. XXXXXXX XXXXXXX TO MAX The named joystick should be pushed to its full extent in the named direction. XXXXXXX XXXXXXX TO MIN The named joystick should be returned to neutral from the named direction. PUMP POT TO MAX The pump pot should be turned to maximum. PUMP POT TO MIN The pump pot should be turned to minimum. MULTIPLE CLOSURE More than one operator input is closed; if only one has been operated, there could be a short between two inputs. TESTS COMPLETE Indicates that the system test is complete. Any problems reported should have been noted and should now be rectified. Press ESC/CANCEL to return to the RUN SYSTEM TEST Analyzer menu. Table 4-3. System Test Messages Message Displayed on Analyzer Message Displayed on Analyzer Description SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-289 SECTION 5. CALIBRATIONS 5.1 CALIBRATION INSTRUCTIONS This machine incorporates a variety of sensors and a high degree of function interaction. For safety and proper machine functionality, the calibration procedures must be repeated for any control module replacement, system cal- ibration related fault, or removal or replacement of any sensors, valves, coils, motors, or pumps. The chart below lists the calibrations required and potential reasons for re- calibration. All calibration procedures are menu driven through the use of the standard JLG analyzer. With the exception of steering calibration, no external tools are required to com- plete the calibration procedures. The user is prompted to exercise the machine in a specific order to use the machines physical properties to consistently establish sensor response and the interaction of valves, pumps, and motors. Steering calibration also uses the analyzer and is performed on one side of the machine at a time requiring the use of a string or other means to determine when the tires are in line with each other. With the excep- tion of the load control calibration, all calibrations are accessed by connecting the analyzer into the control sys- tem inside the main terminal box or on the bottom of the platform control box. Calibration of the platform load sens- ing system is accessed by connecting the analyzer directly into the LSS module. Table 5-1. Calibrations Listed by Symptom Symptom Calibration Boom control system inaccuracy Boom Sensors Drive lugs engine Drive Drive pulls to one side Drive Load control inaccuracy Platform Load Sensing Platform leveling erratic Platform Level Crack Point Speed control for slow speed is poor Drive Tilt indication inaccuracy Chassis Tilt Wheel misaligned persistently Steering Table 5-2. Calibrations Listed by Service Action Service Action Calibration BLAM removal Boom Sensors BLAM replacement Boom Sensors Drive Chassis Module replacement Steering Drive pump/coil replacement Drive LSS module replacement Platform Load Sensing Ground Module removal Boom Sensors Chassis Tilt Ground Module replacement Boom Sensors Chassis Tilt Drive Platform Level Crack Point Steering Load cell removal or replacement Platform Load Sensing Load pin removal or replacement Boom Sensors Main boom angle sensor removal or replacement Boom Sensors Main lift valve/control module replacement Boom Valve Main terminal box removal or replacement Chassis Tilt Platform level valve/coil replacement Platform Level Crack Point Platform module replacement Platform Level Crack Point Steer Angle Sensor replacement Steering Tower boom angle sensor removal or replacement Boom Sensors Tower boom length sensor removal or replacement Boom Sensors Tower lift cylinder angle sensor removal or replacement Boom Sensors Tower lift valve/control module replace- ment Boom Valve Tower telescope valve/control module replacement Boom Valve Table 5-2. Calibrations Listed by Service Action Service Action Calibration SECTION 5 - CALIBRATIONS 5-290 1250AJP 3128411 5.2 CALIBRATING STEER When calibrating steering, each individual wheel must be calibrated in order to make the tire and wheel parallel with the frame. Two methods to help ensure proper calibration are the use of a carpenter’s square to square the spindle to the axle or aligning the two wheels on one side using a stretched string. 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. 3. Pull out the Emergency Stop switch and Start the engine. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-291 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. 8. Use the arrow keys to reach Steer. The screen will read: 9. Hit Enter. The screen will read: SECTION 5 - CALIBRATIONS 5-292 1250AJP 3128411 10. Hit Enter. The screen will read: 11. Hit Enter again. The screen will read: 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. 13. Hit Enter. The screen will read: 14. Repeat steps 10 thru 12 for left rear steer. 15. Left Rear Steer Calibration will be followed by Right Forward Steer Calibration which will be followed by Right Rear Steer Calibration. 16. After completing all the Steer Calibrations, hit ESC twice to go back to CALIBRATIONS. 5.3 CALIBRATING DRIVE 1. Position the Platform/Ground select switch to the Platform position. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-293 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. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the right Arrow key to reach CALIBRATIONS. Hit Enter. SECTION 5 - CALIBRATIONS 5-294 1250AJP 3128411 8. Use the arrow keys to reach DRIVE. 9. Hit Enter. The screen will read: 10. Hit Enter again. The screen will read: 11. Hit Enter again. The screen will read: 12. Activate the Drive Joystick forward full stroke until the machine just begins to move, then leave off the joystick immediately. The display will read CRK PT = and show the numeric crack point value. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-295 13. Hit Enter. The number displayed will be the value that the crack point is set to. The screen will show: 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. 17. After completing all the Drive Calibrations, hit ESC twice to go back to CALIBRATIONS. SECTION 5 - CALIBRATIONS 5-296 1250AJP 3128411 5.4 CALIBRATING BOOM VALVES 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. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit 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: SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-297 9. Hit Enter. The screen will read: 10. Hit Enter. The screen will read: 11. If the main lift wiring and hosing is properly installed and not damaged, hit enter. The screen will read: 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 SECTION 5 - CALIBRATIONS 5-298 1250AJP 3128411 read: 14. The control system will next calibrate the LIFT, TWR 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. 15. After completing Boom Valve Calibration, hit ESC twice to go back to CALIBRATIONS. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-299 5.5 ELECTRONIC PLATFORM LEVELING Platform Leveling Fault Warning If a fault occurs in the platform leveling system the follow- ing will occur: 1. Automatic platform leveling will stop (except when there is a fault in only one sensor automatic leveling will remain active as the control system will use the other sensor to control leveling) 2. The level fault lamp will flash 3. The audible alarm will sound 4. All functions will default to creep speed if the plat- form is out of the transport position. To reset the fault the emergency stop switch should be recycled. IMPORTANT IF THE FAULT PERSISTS BRING THE PLATFORM TO THE GROUND POSITION, SWITCH THE MACHINE OFF AND CONTACT A QUALIFIED SERVICE REPRESENTATIVE TO INVESTIGATE THE FAULT. Fault Response ERROR RESPONSE If basket level varies from the current setpoint by ± 5.5° for more than 1.5 seconds when the platform is not in the transport position, the following events will occur: 1. The platform dump valve will be disabled (level, rotate and jib functions disabled). 2. The level system fault lamp will flash (to indicate that the leveling function has been lost). 3. The platform alarm will sound. 4. A system fault will be logged. 5. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the plat- form is in the transport position see below). When the unit is in the transport position and driving and the current setpoint varies by ± 5.5° for more than 8 sec- onds the events 1,2,3 & 4 above will occur. (note function speeds will operate normally). Cycling the EMS will clear the fault and allow the operator to operate the machine as a new level setpoint is taken. VALVE DRIVER ERRORS There are three possible level valve driver errors, short to battery, short to ground, and open circuit. 1. In the case of a short to ground or an open circuit, the platform valve cannot be turned on and the fol- lowing will occur: a. All interactions with platform leveling shall cease b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost). c. The platform alarm will sound. d. A system fault will be logged. e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport position). 2. In the case of a short to battery on one of the plat- form leveling valves, the valve cannot be turned off and the following will occur: a. The platform dump valve will be turned off to prevent unintended tilting of the platform. b. All interactions with platform leveling shall cease. c. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost). d. The platform alarm will sound. e. A system fault will be logged. f. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport position) 3. In the case of a short to battery on the platform dump valve, the valve cannot be turned off. The con- trollability of the platform leveling function will be impaired and the following will occur: a. All interactions with platform leveling shall cease. b. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost). c. The platform alarm will sound. d. A system fault will be logged. e. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the platform is in the transport position). Lift, swing, drive and telescope will continue to operate In each of the cases above it shall be necessary to re- cycle the EMS to clear the fault. Operable functions shall be in the creep mode except while below elevation. TILT SENSOR ERRORS If the secondary tilt sensor is faulty, the control system will continue to utilize information from the primary sensor. SECTION 5 - CALIBRATIONS 5-300 1250AJP 3128411 If the primary sensor is faulty, the control system will switch to the backup sensor for control. In both cases above the following will occur: 1. The Electronic Leveling System Fault Lamp will flash (to indicate that there is a leveling fault). 2. The platform alarm will sound. 3. A system fault will be logged. 4. All function speeds (lift, swing, telescope, jib and drive) will be placed in creep mode (except when the platform is in the transport position). 5. Automatic leveling remains active. Lift, swing, drive and telescope will continue to operate. In each of the cases above it will be necessary to re-cycle the EMS to clear the fault. Operable functions shall be in the creep mode except while below elevation. When both sensors appear to be working but have mea- surements that disagree by ±5.5° The following will occur: 1. All interactions with platform leveling shall cease. 2. The Electronic Leveling System Fault Lamp shall flash (to indicate that the leveling function has been lost). 3. The platform alarm will sound. 4. A system fault will be logged. 5. All function speeds (lift, swing, telescope and drive) will be placed in creep mode (except when the plat- form is in the transport position) At this point, the operator must use the level up and down toggle switch to manually level during descent. It shall be necessary to re-cycle the EMS to clear the fault. CAN Errors The Ground Module has two direct outputs dedicated to overriding the Platform Module’s control of the leveling valves. The Ground Module “Platform Level Up/Down” outputs are used to control the platform level up and down valves. When in ground mode, if the Ground Module reads a plat- form leveling switch command, the switch command is communicated over CAN to the Platform Module where it is handled normally. If Ground Module determines that CAN communication is inoperable, it turns on the platform control valve and the appropriate platform leveling override outputs while the switch is engaged. If the Platform Module is still running when CAN is down nothing will operate when in platform mode. When the operator switches to ground mode, the platform will not control any of its valve outputs and a CAN error message is signaled. Additional Platform and Jib Valves The high side drivers for the platform left and right and the jib up and down valves are be located in the Platform Module and are proportional. Flow through the valves is individually controllable. The individually controlled duty cycle will be the same as would otherwise have been commanded to the flow control valve. Only one platform or jib function is allowed at one time to limit the amount of current draw, minimizing the voltage drop on the supply to the Platform Module. The function is enabled first shall remain active until it is released. Any other function commanded while another function is active is ignored. Platform Leveling Calibration Procedure STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode. 5. Go to the “Personalities” menu and adjust the fol- lowing personalities. Refer to the Personality Ranges/Defaults table in Section 6 - JLG Control System for proper setting values. Basket Level Up Min Basket Level Up Max Basket Level Down Max Jib Up Min Jib Down Min 6. Recycle EMS. STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS 1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer. 3. Manually level the platform with the switch on the MTB. 4. Go to the “Access Level 2” screen. 5. Enter “33271” to get into Access Level 1 mode. 6. Go to the “Calibrations” menu and hit ENTER. 7. Use RIGHT ARROW go to “Plat. Leveling” screen. 8. Hit ENTER. “Calibrate?” prompt should appear. 9. Hit ENTER again to calibrate level sensors. 10. When calibration has been successful “Cal. Com- plete” should appear. 11. Cycle power to the machine. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-301 STEP 3: BLEEDING THE PLATFORM VALVES 1. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode. 5. Go to the “Personalities” menu. 6. Using the left arrow button, go to the “Ground Mode” menu. 7. Hit ENTER. 8. Using the UP/DOWN arrows, adjust the following personalities to 100%. Basket Rotate Basket Level Jib U/D (if configured) Start up the machine and exercise each above plat- form function (from the ground) eight (8) to ten (10) times for 5 seconds in each direction. 9. Return the personality settings back to the values 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. Put machine into “Ground Mode”. 2. Start machine and plug in Analyzer. 3. Go to the “Access Level 2” screen. 4. Enter “33271” to get into Access Level 1 mode. 5. Go to the “Calibrations” menu and hit ENTER. 6. Go to the “Basket U Crkpt” Screen. Hit ENTER. 7. “Calibrate?” prompt should appear. Hit ENTER again. 8. You will hear engine go to 1800 rpm. 9. Using UP ARROW, increase the value until you see the basket up movement. 10. Hit ENTER again. “Cal. Complete” message should appear 11. Engine should again return to idle. 12. Hit ESC should return to “Basket U Crkpt” screen. 13. Hit RIGHT ARROWto get to the “Basket D Crkpt” screen. Hit ENTER. 14. “Calibrate?” prompt should appear. Hit ENTER again. 15. You will hear engine go to 1800 rpm. Using DOWN ARROW, decrease the value until you see the basket down movement. Hit ENTER again. “Cal. Complete” message should appear Engine should again return to idle. Hit ESC to exit. Cycle power to the machine. SECTION 5 - CALIBRATIONS 5-302 1250AJP 3128411 5.6 CALIBRATING PLATFORM LEVEL STEP 1: SETTING THE PLATFORM VALVE MINIMUMS 1. Position the Platform/Ground select switch to the Ground position. 2. Plug the analyzer into the connector inside the Ground control box. 3. Pull out the Emergency Stop switch and start the engine. 4. The analyzer screen should read: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Use the arrow button to reach PERSONALITIES adjust the following personalities. Refer to the Per- sonality 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. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-303 STEP 2: CALIBRATING THE PLATFORM LEVEL SENSORS 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. Manually level the platform with the switch on the Main Terminal Box. 5. The analyzer screen should read: 6. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 7. Enter the Access Code, 33271. 8. Use the arrow button to reach CALIBRATIONS menu and hit ENTER. 9. Use right arrow go to PLAT. LEVELING screen. SECTION 5 - CALIBRATIONS 5-304 1250AJP 3128411 10. Hit ENTER. The screen should read: 11. Hit ENTER again to calibrate level sensors. 12. When calibration has been successful CAL. COM- PLETE should appear. 13. Cycle power to the machine. STEP 3: BLEEDING THE PLATFORM VALVES 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: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Go to the PERSONALITIES menu. 8. Using the left arrow button, go to the GROUND MODE menu. 9. Hit ENTER. 10. Using the UP/DOWN arrows, adjust the following personalities to 100%. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-305 Basket Rotate Basket Level Jib U/D (if configured) Start up the machine and exercise each above plat- form function (from the ground) eight (8) to ten (10) times for 5 seconds in each direction. 11. Return the personality settings back to the values 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. 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: 5. Use the arrow button to reach ACCESS LEVEL 2. Hit Enter. 6. Enter the Access Code, 33271. 7. Go to the CALIBRATIONS menu and hit ENTER. 8. Go to the BASKET U CRKPT Screen. Hit ENTER. 9. CALIBRATE? prompt should appear. Hit ENTER again. 10. You will hear engine go to 1800 rpm. 11. Using UP ARROW, increase the value until you see the basket up movement. 12. Hit ENTER again. CAL. COMPLETE message should appear 13. Engine should again return to idle. 14. Hit ESC should return to BASKET U CRKPT screen. 15. Hit RIGHT ARROW to get to the “BASKET D CRKPT” screen. Hit ENTER. 16. CALIBRATE? prompt should appear. Hit ENTER again. 17. You will hear engine go to 1800 rpm. Using DOWN ARROW, decrease the value until you see the basket down movement. SECTION 5 - CALIBRATIONS 5-306 1250AJP 3128411 Hit ENTER again. CAL. COMPLETE message should appear Engine should again return to idle. Hit ESC to exit. Cycle power to the machine. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-307 5.7 CALIBRATING TILT SENSOR IMPORTANT A NEW TILT MODULE WILL ACT AS IF IT IS TILTED ALL OF THE TIME UNTIL THE FOLLOWING PROCEDURE IS PERFORMED. DO NOT CALIBRATE THE LEVEL SENSOR EXCEPT ON A LEVEL SURFACE. 1. Use the following procedure to calibrate the tilt sen- sor. Before the tilt sensor can be calibrated, the following conditions must be met: a. Steering previously calibrated. b. Axles extended. c. Wheels straight. d. Turntable centered. e. Boom fully retracted. f. Boom angle is less than 45°. g. Machine on firm, level ground. 2. Position the Platform/Ground select switch to the Ground position. 3. Plug the analyzer into the connector inside the Ground control box. 4. Pull out the Emergency Stop switch and start the engine. 5. The analyzer screen should read: 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. SECTION 5 - CALIBRATIONS 5-308 1250AJP 3128411 9. Use the arrow keys to reach the TILT SENSOR. The screen should read: 10. Press ENTER. 11. When prompted, swing turntable 180° to opposite end of chassis. 12. Press ENTER. The screen should read: 13. Upon completing swing calibration, swing turntable 180° back to the stowed position. 14. Hit ESC twice to go back to CALIBRATIONS. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-309 5.8 BOOM SENSOR CALIBRATION Step 1 - Position 1 (Initial Position – Booms Stowed With Jib Lifted To Max Angle) With both tower and main booms stowed, lift the jib up to maximum angle as shown below. The control system will prompt and check for initial condi- tions. The analyzer will read: To begin calibration of the boom sensors, the following conditions must first be met: • Steering and tilt previously calibrated • Axles extended • Wheels straight • Platform unloaded and booms clean •Jib raised • Jib swing centered • Platform level and centered • Turntable centered in the normal driving direction • Tower boom retracted and lowered • Main boom retracted and lowered • Level ground (must be under 1.5°). Visible through DIAGNOSTICS ? SYSTEM ? CHASSIS TILT: XX.X DEGREES. • Ground mode selected After these conditions are met, follow all sub-sections below in sequence to properly calibrate all boom sensors. 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. Visible through DIAGNOSTICS ? CAN STATIS- TICS ? BUS OFF (or MSG ERR) • MN LFT VLV FAULT - there is a fault being reported on the main lift valve • TW LFT VLV FAULT - there is a fault being reported on the tower lift valve • TW TEL VLV FAULT - there is a fault being reported on the tower tele valve • LOAD PIN FAULT - communications to load pin lost • MAIN ANGL1 FAULT - main angle #1 (right side) is not communicating on the CAN bus. This could be a power issue or communications (CAN) issue. • MAIN ANGL2 FAULT - main angle #2 (left side) is not communicating on the CAN bus. This could be a power issue or communications (CAN) issue. • TWR ANGL1 FAULT - invalid data received from the right (#1) tower angle sensor • TWR ANGL2 FAULT - invalid data received from the left (#2) tower angle sensor • CYL ANGL FAULT - invalid raw data received from the tower lift cylinder angle. • TWR LEN1 FAULT - raw top (#1) length sensor A/D counts are unknown by the ground module. This value is sent out from the BLAM module. • TWR LEN2 FAULT - raw bottom (#2) length sensor A/D counts are unknown by the ground module. This value is sent out from the BLAM module. • EXTEND AXLES - one or more axle switches not closed. Visible through DIAGNOSTICS ? TRANSPORT DATA ? AXLE STATUS: XXX (EXTENDED or RETRACTED) • CENTER WHEELS - one or more wheels steered beyond 10° of straight. Visible through DIAGNOSTICS ? DRIVE ? L FRONT WHEEL ANGLE: XX.X (similar for other wheels) • TWR IN - tower boom transport length switch must be indicating retracted. Visible through DIAGNOSTICS ? SECTION 5 - CALIBRATIONS 5-310 1250AJP 3128411 TRANSPORT DATA ? TOWER TELESCOPE STATUS: XXX (RETRACTED or EXTENDED). For the tower boom to be retracted the twr transport switch closed must be closed (DIAGNOSTICS ? BOOM SWITCHES ? TOWER TELESCOPE SWITCH NC: XX (CLOSED or OPEN)) and the twr transport switch open must be opened (DIAG- NOSTICS ? BOOM SWITCHES ? TOWER TELESCOPE SWITCH NC: XX (CLOSED or OPEN)). Raw top (#1) length sensor A/D counts must be less than 1388 counts. Visible through ACCESS LEVEL 1 ? DIAGNOS- TICS ? BOOM SENSORS ? TOWER LENGTH 1 A/D: XXXXX. Raw bottom (#2) length sensor A/D counts must be less than 1698 counts. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER LENGTH 2 A/D: XXXXX. • MAIN DOWN - main boom transport angle switches must be indicating below elevation. Visible through DIAGNOSTICS ? TRANSPORT DATA ? TRANSPORT MODE: XXX (OUT OF TRANSPORT or TRANSPORT). For the main boom to be below elevation the main transport angle switch closed must be closed (DIAG- NOSTICS ? BOOM SWITCHES ? MAIN LIFT ANGLE SWITCH NC: XXX (CLOSED or OPEN)) and the main transport angle switch open must be opened (DIAG- NOSTICS ? BOOM SWITCHES ? MAIN LIFT ANGLE SWITCH NO: XXX (CLOSED or OPEN)). • TOWER DOWN - raw tower lift cylinder angle A/D counts higher than 11385. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER CYLINDER ANGLE A/D: XXXXX. • RETRACT MAIN - control system must recognize the main boom to be in length zone A. Visible through DIAGNOSTICS ? BCS ? MAIN BOOM LENGTH ZONE: X (A, B, C, or D). For the main boom to be considered in length zone A the main transport length normally open switch must be open (DIAGNOSTICS ? BOOM SWITCHES ? MAIN BOOM LENGTH SWITCH NO: XX (CLOSED or OPEN)) and the main transport length nor- mally closed switch must be closed (DIAGNOSTICS ? BOOM SWITCHES ? MAIN BOOM LENGTH SWITCH NC: XX (CLOSED or OPEN)). Also, the normally closed Dual capacity switch must be closed (DIAGNOSTICS ? BOOM SWITCHES ? DUAL CAPACITY SWITCH NC (CLOSED or OPEN)) and the normally open Dual capacity switch must be opened (DIAGNOSTICS ? BOOM SWITCHES ? DUAL CAPACITY SWITCH NO (CLOSED or OPEN)). • ALIGN TURNTABLE - drive orientation switch must be in the closed state. Visible through DIAGNOSTICS ? DRIVE ? DRV. ORIENTATION SWITCH: XX (CLOSED or OPEN) • CENTER JIB SWING - jib centered switch must be in the closed state. 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. • CAL STEERING - control system requires a valid steer- ing calibration prior to boom sensors calibration •CAL TILT SENSOR - control system requires a valid chassis tilt calibration prior to boom sensors calibration • SELECT GRND MODE - must calibrate in ground mode • REMOVE DONGLE - the system detects that a Dongle is attached. The dongle must be removed prior to boom sensors calibration Potential Calibration Failure Messages: • MAIN ANGL1 FAULT - main angle sensor #1 (right) raw value is not between 5° and 25°. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? MAIN LIFT 1 RAW ANGLE: XXX.X. • MAIN ANGL2 FAULT - main angle sensor #2 (left) raw value is not between 155° and 175°. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? MAIN LIFT 2 RAW ANGLE: XXX.X. • TWR LEN1 FAULT - Raw top (#1) length sensor A/D counts must be between 1388 counts and 410 counts. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER LENGTH 1 A/D: XXXXX. • TWR LEN2 FAULT - Raw bottom (#2) length sensor A/D counts must be between 1698 counts and 720 counts. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER LENGTH 2 A/D: XXXXX. • CYL ANGL FAULT - the tower cylinder angle A/D counts must be between 4721 counts and 11385 counts. Visi- ble through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER CYLINDER ANGLE A/D: XXXXX. Step 2 - Position 2 The analyzer will read: SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-311 Lift Main Boom To Stop - Control System Will Stop At Main Boom Angle Limit Switch Trip Point - Approx 15° Above To we r Potential Calibration Failure Messages: • TWR NOT IN - control system detected movement of tower telescope during main lift movement (length sen- sor 1 read more than 80 counts of movement during main lift) • TWR NOT DWN - control system detected movement of tower lift during main lift movement (tower cylinder angle sensor read more than 80 counts of movement during main lift) • MAIN ANGL FAULT - control system did not detect change in state of main boom transport angle switch before raw main boom angle sensors reached 30° rela- tive to tower. • MAIN UP TO STOP - the transport angle switch has not changed states. Visible through DIAGNOSTICS ? BOOM SWITCHES ? MAIN LIFT ANGLE SWITCH NC: XX (CLOSED or OPEN) and DIAGNOSTICS ? BOOM SWITCHES ? MAIN LIFT ANGLE SWITCH NO: XX (CLOSED or OPEN). Step 3 - Position 3 The analyzer will read: Swing turntable 180° - Technician must center turntable over opposite end of chassis Potential Calibration Failure Messages: • DRIVE ORNT SW - control system must detect change in state of the drive orientation switch. Visible through DIAGNOSTICS ? DRIVE ? DRV. ORIENTATION SWITCH: XX (CLOSED or OPEN) • TWR ANGL1 FAILED - the raw tower boom angle #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 SECTION 5 - CALIBRATIONS 5-312 1250AJP 3128411 ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER ANGLE 2 A/D: XX.X. • TILT CAL FAULT - control system detected ground slope of more than 1.75° using current calibration data regard- less of initial chassis tilt reading Step 4 - Position 4 The analyzer will read: Lift tower to max angle (approx 79°) 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. • TWR ANGL1 FAILED - the raw tower boom angle #1 (right) must be between 36.3° and 56.3°. 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 36.3° and 56.3°. Visible through DIAGNOSTICS ? BOOM SENSORS ? TOWER ANGLE 2 A/D: XX.X. Step 5 - Position 5 The analyzer will read: Telescope tower out to max length SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-313 Potential Calibration Failure Messages: • TWR NOT UP - control system detected movement of tower lift cylinder angle sensor during tower telescope movement (tower cylinder angle sensor read more than 665 counts during tower telescope). Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER CYLINDER ANGLE A/D: XXXXX. • TWR LEN FAULT - control system did not detect change in state of tower transport length switch within 1 to 7 inches (2.5 to 17.8 cm) of movement using raw length sensor data. • TWR LEN1 FAULT - raw top (#1) length sensor A/D counts not between 28267 and 29245. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? TOWER LENGTH 1 A/D: XXXXX. • TWR LEN2 FAULT - raw bottom (#2) length sensor A/D counts not between 28577 and 29555. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? 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) Step 6 - Position 6 The analyzer will read: Lift main boom to max angle SECTION 5 - CALIBRATIONS 5-314 1250AJP 3128411 Potential Calibration Failure Messages: • TWR NOT OUT - control system detected movement of tower length sensor during main lift movement (more than 80 counts) • MAIN ANGL1 FAULT - right side (#1) sensor not reading raw values between 155° and 175°. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? MAIN LIFT 1 RAW ANGLE: XXX.X. • MAIN ANGL2 FAULT - left side (#2) sensor not reading raw values between 5° and 25°. Visible through ACCESS LEVEL 1 ? DIAGNOSTICS ? BOOM SENSORS ? MAIN LIFT 2 RAW ANGLE: XXX.X. • MAIN A SW FAULT - control system did not detect change in state of main boom transport angle switch within main boom angle sensor readings of 12.8° and 18.8°. Visible through DIAGNOSTICS ? BOOM SEN- SORS ? MAIN ANGLE 1 TO TWR XX.X. Step 7 - Position 7 The analyzer will read: Telescope tower in to min length Potential Calibration Failure Messages: SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-315 • MAIN NOT UP - control system detected movement of main boom angle sensor during tower telescope move- ment (more than 80 counts) • TWR IN TO MIN - tower length sensor not reading between 304.9" and 305.9" (774.4 and 776.9 cm) when ENTER is pressed. Visible through DIAGNOSTICS ? BOOM SENSORS ? TOWER LENGTH 1 SENSOR: X.X". Control system will allow additional attempts to retract tower. Step 8 - Position 8 The analyzer will read: Lift tower down to stop – control system will stop at cylin- der angle reading of 74.6° (approx 70° tower angle) Potential Calibration Failure Messages: • TOWER TOO LOW - control system detected tower angle less than 66° (visible through DIAGNOSTICS ? BOOM SENSORS ? MAIN ANGLE L TO GRAVITY: XXX.X) without stopping between tower lift cylinder angle readings of 74.1° to 75.1° (visible through DIAG- NOSTICS ? BOOM SENSORS ? TOWER CYLINDER ANGLE: XX.X). • TWR UP TO STOP - tower lift cylinder angle sensor not reading between 74.1° and 75.1° when ENTER is pressed. Control system will allow additional attempts to correct tower angle. • TOWER DOWN TO STOP - tower lift cylinder angle sen- sor not reading between 74.1° and 75.1° when ENTER is pressed. 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. SECTION 5 - CALIBRATIONS 5-316 1250AJP 3128411 Step 9 - Position 9 The analyzer will read: Swing turntable 180° - Technician must center turntable over original end of chassis Potential Calibration Failure Messages: • DRIVE ORNT SW - control system must detect change in state of the drive orientation switch. Visible through DIAGNOSTICS ? DRIVE ? DRV. ORIENTATION SWITCH: XX (CLOSED or OPEN) • 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. SECTION 5 - CALIBRATIONS 3128411 1250AJP 5-317 Step 10 - Position 10 The analyzer will read: Lift main down to stop – control system will stop when main boom is 15° above tower Potential Calibration Failure Messages: • MAIN UP TO STOP – main boom angle sensor not read- ing between 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 pressed. Control system will allow additional attempts to correct main boom angle. Step 11 - Position 11 The analyzer will read: Lift tower down to min angle Potential Calibration Failure Messages: • TWR NOT DOWN - tower cylinder angle sensor reads more than 5.9° when ENTER is pressed. Visible through DIAGNOSTICS ? BOOM SENSORS ? TOWER CYLIN- DER ANGLE: XX.X. Control system will allow additional attempts to correct tower angle. SECTION 5 - CALIBRATIONS 5-318 1250AJP 3128411 This Page Left Blank Intentionally SECTION 6 - MULTIMETER BASICS 3128411 1250AJP 6-319 SECTION 6. MULTIMETER BASICS 6.1 INTRODUCTION A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows dia- grams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary. Please consult the meter operator’s manual for more information. Grounding "Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch it to a good path to the negative side of the voltage source. Backprobing To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type, great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically designed for this technique, especially on sealed connectors. Whenever possible insert probes into the side of the connec- tor such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed con- nector by backprobing both sides of a connector terminal and measuring resistance. Do this after giving each wire a gentle pull to ensure the wires are still attached to the contact and contacts are seated in the connector. Min/Max Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the solenoid and meter, is held down. Polarity Getting a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed. Check what reading is expected, the location of the signal and that the leads are connected to the device under test cor- rectly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other port goes to the positive side of the signal. Scale M = Mega = 1,000,000 * (Displayed Number) k = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 µ = micro = (Displayed Number) / 1,000,000 Example: 1.2 kΩ = 1200 Ω Example: 50 mA = 0.05 A SECTION 6 - MULTIMETER BASICS 6-320 1250AJP 3128411 Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads • First test meter and leads by touching leads together. Resistance should read a short circuit (very low resis- tance) • Circuit power must be turned OFF before 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 SECTION 6 - MULTIMETER BASICS 3128411 1250AJP 6-321 6.2 CONTINUITY MEASUREMENT OVER LONG DISTANCES When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test. • These wires must be able to be isolated from other wires, etc. • Jumper or method to connect contacts on one side of harness. • Meter that can measure resistance or continuity. 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. Current Measurement Continuity Measurement Figure 6-3. Current Measurement (DC) Figure 6-4. Continuity Measurement • Set up the meter for the expected current range • Be sure to connect the meter leads to the correct jacks for the current range you have selected • If meter is not auto ranging, set it to the correct range (See multi meter’s operation manual) • Use firm contact with meter leads • Some meters require a separate button press to enable audible continuity testing • Circuit power must be turned OFF before testing conti- nuity • 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 con- tinuity SECTION 6 - MULTIMETER BASICS 6-322 1250AJP 3128411 Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2, and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach of the jumper. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely iso- lated disconnect battery terminals also, as a precaution. In the example, X160 and X050, which are 83’ apart, will be discon- nected. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not, repair the shorted wires or replace the harness. On one side, jumper from contact of wire #1 and wire #2. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no continuity, repair wires or consult schematic for other wires to use for test. Jumper from wire under test to wire #1. Measure continuity. If there is continuity, the wire under test is good. See Figure 6-6. Example Continuity Test Setup on Pg. 323 for a typical measurement. In the example, the wire under test is good. Resistance of a wire increases as the length increases and as the diameter decreases. One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through . 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 SECTION 6 - MULTIMETER BASICS 3128411 1250AJP 6-323 Figure 6-6. Example Continuity Test Setup SECTION 6 - MULTIMETER BASICS 6-324 1250AJP 3128411 This Page Left Blank Intentionally JLG Worldwide Locations Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 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 Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025 JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711 JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035 JLG Industries (Italia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 9359 5845 JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493 JLG Polska UI. Krolewska 00-060 Warsawa Poland Phone: (48) 91 4320 245 Fax: (48) 91 4358 200 JLG Industries (Europe) Wright Business Centre, 1 Lonmay Road Queenslie,Glasgow Scotland Phone: (44) (0) 141 781 6725 Fax: (44) (0) 141 773 1908 JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342 Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762 JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfalla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534
SECTION 3 — 1CHASSIS & TURNTABLE
3121171
– JLG Lift –
3-139
Diagnostic Trouble Codes
The numeric diagnostic trouble codes assigned to the
faults in this section are cross-referenced to SAE’s «Rec-
ommended Practice for Diagnostic Trouble Code Defini-
tions» (SAE J2012). While these codes are recommended,
the manufacturer may define their own codes by assign-
ing a new number to the flash code in the diagnostic cali-
bration. This will assign both the DTC as displayed in
EDIS as well as the flash code output on the MIL output
pin. EDIS may be used to connect to the DGC ECM via
CAN.
CAN
The DGC supports SAE J1939 CAN based diagnostic
support. This includes:
• DM1: Active Diagnostic Trouble Codes
• DM2: Previously Active Diagnostic Trouble Codes
• DM3: Diagnostic Data Clear/Reset of Previously Active
DTCs
• DM4: Freeze Frame Parameters
• DM5: Diagnostic Readiness (bytes 1, 2, and 3 are sup-
ported)
• DM11: Diagnostic Data Clear/Reset For Active DTCs
• DM12: Emissions-Related Active Diagnostic Trouble
Codes
• DM19: Calibration Information
All diagnostic trouble codes broadcast over CAN will be
SAE J1939 DM1 and DM2 formatted messages. DGC
ECMs are compliant with J1939 OBD-M, supporting the
Diagnostic Messages above as well as user indicators and
CAN data defined in the OBD-M protocol. Faults available
for broadcast and their respective SPN/FMI numbers are
dependent on the application and engine calibration.
There are 4 CAN SPN/FMI lists available in the DGC soft-
ware set, contact EControls Inc. for a list of CAN SPN/
FMIs.
The data capture at the occurrence of a fault, known in the
ECM as fault snapshot (FSS), is available upon DM4
request. The following bytes are supported for DM4 if con-
figured in the ECM software:
• Byte 1: Freeze Frame Length
• Byte 2-6: SPN, FMI, SPN Conversion Method, and
Occurrence
• Byte 7: Manifold Absolute Pressure
• Byte 8-9: Engine Speed
• Byte 10: Engine Load (MAP based estimate)
• Byte 11: Engine Coolant Temperature
• Byte 14: # of starts since fault was last active
• Byte 15: Index into FSS_storage table for Fault Snap
Shot retrieval
Resetting active and previously active DTCs is handled
through DM11 and DM3, respectively DM1 and DM2 lamp
indicators are assigned to each fault based on the fault.s
diagnostic action as defined in the calibration. The lamps
are assigned based on the configuration outlined in Table
3-7.
MIL Output
The MIL output is used to convey fault information to the
equipment operator. The MIL is always on (grounded)
when the system is in a key-on (Vsw), engine-off state.
This provides assurance that the output is functional. If a
DTC is logged as previously-active (historic), the MIL will
send a single flash for the “Blink on-time” every “Blink off-
time.”
Table 3-7. J1939 Diagnostic Lamp Configuration
ECI DIAGNOSTIC ACTION
J1939 LAMP
MIL
MIL
Soft Warning
Amber
Hard Warning, Low Rev Limit,
Shutdown
Red Stop
Power Derate 1 & 2
Protect
Forced Idle
None (use in combination with
other action)
РАЗДЕЛ 3 — ОРГАНЫ УПРАВЛЕНИЯ И ИНДИКАТОРЫ МАШИНЫ
3-16
— Подъемник JLG —
3122801
10. Индикатор неисправности системы
Лампочка показывает, что система управления
компании «JLG» обнаружила неисправность, и в
память системы был введен диагностический код
неисправности. Коды неисправностей и процедуры
их извлечения из памяти системы см. в Руководстве
по техобслуживанию.
При включении машины ключом индикатор
неисправности зажигается на 2-3 секунды для
самотестирования.
11. Индикатор ориентации движения
Если стрела повешена вне задних управляемых шин
или дальше в любом направлении, индикаторная
лампочка ориентации движения загорается, когда
выбирается функция движения. Это сигнал для
оператора убедиться в том, что управление
движением осуществляется в нужном направлении
(то есть контролирует ситуации реверсирования).
12. Индикатор установки осей
Показывает, что оси полностью выдвинуты.
Индикаторная лампочка будет мигать во время
выдвижения или втягивания осей и горит ровным
светом, когда оси полностью выдвинуты. Лампочка
гаснет, когда оси полностью втянуты.
13. Сигнальный индикатор системы управления стрелой
Показывает, что платформа находится вне рабочей
зоны, и что некоторые функции стрелы (то есть
подъем, телескопическое соединение) могут быть
деактивированы. При попытке использовать
деактивированные функции индикаторная лампочка
начинает мигать и раздается звуковой сигнал.
Немедленно верните платформу на землю. Если
индикаторная лампочка продолжает гореть, это
означает, что был обнаружен отказ или повреждение
системы управления стрелой. Если обнаружено
повреждение, то перед использованием машины
система должна быть отремонтирована силами
персонала, уполномоченного компанией «JLG».
Вы здесь
Страница 50 в инструкции по эксплуатации JLG 1250AJP Operator Manual
РАЗДЕЛ 3 ОРГАНЫ УПРАВЛЕНИЯ И ИНДИКАТОРЫ МАШИНЫ 3-16
Подъемник JLG
3122801
10 Индикатор неисправности системы
Лампочка показывает что система управления компании «JLG» обнаружила неисправность и в память системы был введен диагностический код неисправности Коды неисправностей и процедуры их извлечения из памяти системы см в Руководстве по техобслуживанию При включении машины ключом индикатор неисправности зажигается на 2-3 секунды для самотестирования.
11 Индикатор ориентации движения
Если стрела повешена вне задних управляемых шин или дальше в любом направлении индикаторная лампочка ориентации движения загорается когда выбирается функция движения Это сигнал для оператора убедиться в том что управление движением осуществляется в нужном направлении (то есть контролирует ситуации реверсирования) 12 Индикатор установки осей
Показывает что оси полностью выдвинуты
Индикаторная лампочка будет мигать во время выдвижения или втягивания осей и горит ровным светом когда оси полностью выдвинуты Лампочка гаснет когда оси полностью втянуты 13 Сигнальный индикатор системы управления стрелой
Показывает что платформа находится вне рабочей зоны и что некоторые функции стрелы (то есть подъем телескопическое соединение) могут быть деактивированы При попытке использовать деактивированные функции индикаторная лампочка начинает мигать и раздается звуковой сигнал
Немедленно верните платформу на землю Если индикаторная лампочка продолжает гореть это означает что был обнаружен отказ или повреждение системы управления стрелой Если обнаружено повреждение то перед использованием машины система должна быть отремонтирована силами персонала уполномоченного компанией «JLG»
Specifications:1277/1277117-1250ajp.pdf file (04 Feb 2023) |
Accompanying Data:
JLG 1250AJP Boom Lifts, Lifting Systems PDF Troubleshooting Manual (Updated: Saturday 4th of February 2023 06:30:58 PM)
Rating: 4.6 (rated by 7 users)
Compatible devices: 600SJ, 40H, E450A, 4045R, 1200SJP, E450AJ, 740A, 4394RT.
Recommended Documentation:
Text Version of JLG 1250AJP Troubleshooting Manual
(Ocr-Read Summary of Contents, UPD: 04 February 2023)
-
259, SECTION 3 — HYDRAULIC REFERENCE 3128411 1250AJP 3-259 Figure 3-13. Hydraulic Schematic — Boom Control — Sheet 2 of 2 TOWER LIFT TOWER TELE MAIN LIFT 2792527 G MAIN SWIVEL TELE E PSI. SW A UX. PUMP (R) MAIN DUMP (Q) MAIN TELE PROP. MAIN TELE OUT (L) (M) MAIN TELE IN (I) (J) (K) 1 2 12 CXBA XAN (4…
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142, SECTION 1 — FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-142 1250AJP 3128411 1.289 START SOLENOID SHORT TO BATTERY Start solenoid short to battery. The engine start solenoid output [X001.11] is shorted to battery. See 1.377 COMMON STB OR OC PROCEDURE on Pg. 174. 1.290 START SOLENOID…
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27, JLG 1250AJP 3128411 1250AJP 27 TABLE OF CONTENTS (Continued) 1.248 PLATFORM MODULE SOFTWARE UPDATE REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-123 1.249 PLATFORM SENSOR REF VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .…
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316, JLG 1250AJP SECTION 5 — CALIBRATIONS 5-316 1250AJP 3128411 Step 9 — Position 9 The analyzer will read: Swing turntable 180° — Technician must center turntable over original end of chassis Potential Calibration Failure Messages: • DRIVE ORNT SW — control system must detect change in state of the drive ori…
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237, SECTION 2 — ELECTRICAL REFERENCE 3128411 1250AJP 2-237 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 Table 2-29. Connecto…
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320, JLG 1250AJP SECTION 6 — MULTIMETER BASICS 6-320 1250AJP 3128411 Voltage Measurement Resistance Measurement Figure 6-1. Voltage Measurement (DC) Figure 6-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with …
-
218, SECTION 2 — ELECTRICAL REFERENCE 2-218 1250AJP 3128411 Table 2-16. X232 (J4) Chassis Module Pinout Pin Function Type Range (V) 1 Axle Lockout Pressure Switch Power Vbatt Vbatt 2 Axle Lockout Solenoid Ground 0VDC 3Not Used — — 4Not Used — — 5Not Used — — 6Not Used — — 7Not Used — — 8Not Used —…
-
164, JLG 1250AJP SECTION 1 — FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-164 1250AJP 3128411 1.362 TWR CYL ANGLE SENSOR OUT OF RANGE HIGH Tower cylinder angle sensor out of range high. The tower lift cylinder angle sensor [X092] is reading over 23484 A/D counts (4.46 volts). 1.363 TWR CYL ANGLE…
-
299, SECTION 5 — CALIBRATIONS 3128411 1250AJP 5-299 5.5 ELECTRONIC PLATFORM LEVELING Platform Leveling Fault Warning If a fault occurs in the platform leveling system the follow- ing will occur: 1. Automatic platform leveling will stop (except when there is a fault in only one sensor automatic le…
-
160, SECTION 1 — FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-160 1250AJP 3128411 1.354 TRN DUAL CAP SWITCHES BAD Transport or dual capacity switches bad. The main length transport switches are reporting “A/D”, but the dual capacity length switches are reporting a disagreement. See Tabl…
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177, SECTION 2 — ELECTRICAL REFERENCE 3128411 1250AJP 2-177 SECTION 2. ELECTRICAL REFERENCE Limit Switch States Table 2-1. Limit Switch States Connector Switch Normally Open or Closed Reference State X051 Main Boom Transport Angle Prox 1-4 NC, 2-3 NO 2-3 Closed = Transport X052 Dual …
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98, SECTION 1 — FAULT DICTIONARY AND SELECTED TROUBLESHOOTING 1-98 1250AJP 3128411 1.178 LT FNT STEER LT STG Left front steer left short to ground. The control system detected a short to ground on the chassis module left front steer left valve output [X233.4]. 1.179 LT FNT STEER RT STB OR OC Left front steer right…
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