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Troubleshooting 3121203 09-07-05 Global English

1. Blind area 3 97 in2 At 500 psi At 1000 psi At 1500 psi At 2500 psi Annular area 3 19 in2 34 5 bar 69 bar 103 bar 174 bar Area Ratio 1 24 1 Amperage 65 110 140 200 Motor speed 4200 3800 3600 3150 Flow gpm 315 2 85 2 7 2 56 h Flow 1 141794 10 78 10 21 8 94 1 Pressure Setting Procedure P N 4150554 NOTE Relief Valve Settings 1350 Lift up retrocts Main Relief 2700 psi 186 bar 1 the slave cylinder Outrigger Retract 2500 psi 172 4 bor Telescope Out 2400 psi 165 5 bar 5 Telescope In 2200 psi 152 bar Platform Level up 2000 psi 138 bar Platform Level Down 1200 psi 12 a End Swing Left and Right 600 psi 41 bar bag Relief Valve Settings T500J Main Relief 2950 psi 203 5 bar Outrigger Retroct 2500 psi 172 4 bar 94 Telescope Out 2400 psi 165 5 bar Telescope In 2850 psi 196 5 bar Platform Level up 2800 psi 193 bar Platform Level Down 1200 psi SG bar geet noun Jib Swing Left and Right 600 psi 41 bor 7400 EE Bore 2 Rod 1 25 Stroke 19 938 Blind 3 14 in2 Annular 1 92 in2 Area Ratio 1 63 1 ru Bs d Pr Vene route Swing Drive i 1 Motor 5 471 5 88 5 cc 2000 pat 1350 63 1 Geor Ratio 4 138 bor i T500 76 1 Gear Ratio 1 1 j 1 a 1 1 B
2. Figure 7 3 Electrical Schematic T350 T500J 8 7 6 5 4 3 2 1 GROUND CONTROL BOX 1 BLACK i FRONTLEFTOR OIA 12 VDC OUTPUT WHEN H REAR LEFT LU JON GROUND CONTROLS rl 24 SYSTEM DISTRESS gt e YEURED 2462 PONTACHTOR mo SS SANS em ans YO NK san ar SPARE BLACK B peanalchTon ORNREDA 14 NK ORNRED 49 11 ORNIRED 581 TURNTABLE POSi f 3 Wi ewe I DA wr inan pM GND ALARM STD i 5 ORNRED 59 1 TURNTABLE 052 Yo 7 T 968 i a ORNRED 561 HAND BRAKE 1 s ae RI BRNWHT 41 14 OK BAN WHT 41 ORNREDST HAND BRAKE 2 SELECT 2 vin PORTING AE WOT US BLACK IN BLACK 2 3 4 5 6 10 d mmm nei a ene p M ORN72 X068 RIGHT DRIVE FORWARD TES aiia PINK 254 x PINK253 Y up onNe2 RIGHT DRIVE REVERSE THE BROWN 1921 PINK 26341 PINK 253 Dont DOWN DRNE ORN S54 ORNE UMP BROWN 142 BROWN 1424 BLUE 27 34 BLUE 27 JIB i MODULE BLACK PINK 25 2 PINK 25 24 BROWN 13 3 BROWN 133 A g BROWN 14 3 1 BROWN 143 i G 1 1 4 5 BUE NL THE FOLLOWING J2 P
3. PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 PLATFORM EMS Power Input 12VDC 2 PLATFORM MODE Power Input 12VDC 3 GROUND MODE Power Input 12VDC 4 NOTUSED Analog Input 5 NOTUSED Power Output 6 CAN TERMINATION Serial 0 Serial 7 PLATFORM POSITION 1 Analog Input Vbatt 8 PLATFORM POSITION 2 Analog Input Vbatt 9 GROUND Power Output OVDC 10 GROUND Power Output OVDC 11 FRONT LEFT O R SET LIMIT SW Digital Input Vbatt 12 REAR RIGHT O R SET LIMIT SW Digital Input Vbatt 13 CAN HI Serial 0 Serial 14 NOTUSED Power Output 15 NOTUSED Digital Input 16 NOTUSED Power Output 17 CAN TERMINATION Serial 0 Serial 18 CAN SHIELD Power Output Serial 19 GROUND Power Output OVDC 20 NOTUSED Analog Input 21 NOTUSED Digital Input 22 NOTUSED Digital Input 23 FRONT RIGHT O R SET LIMIT SW Digital Input Vbatt 24 CAN LO Serial 1 0 Serial 25 GROUND Power Output OVDC 26 NOTUSED Power Output 27 NOTUSED Power Output 28 GROUND Power Output OVDC 29 IGNITION Power Output Vbatt 30 NOTUSED Power Output 31 NOTUSED Power Output 32 NOTUSED Power Output 33 NOTUSED Power Output 34 NOTUSED Power Output 35 REAR LEFT O R SET LIMIT SW Digital Input Vbatt Table 7 7 X008 J8 Ground Module Pinout PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 GROUND FROM B Power Input O
4. 2 109 Fele Out Preverited e Tilted 1 2 2222222222 M 2 109 3 Battery Voltage Too High System Shutdown sess tnetnetn etn en retten tenente erinnere nennen nennen nennen 2 41 Battery Voltage Too Low System Shutdown sees 2 41 No Charge System Q tp t ur irent rente ced er EE OR XR er UR e Area Ee vea eg es eed enden essen Ee a epe ee 2 95 4 Functions At Cutback Power Module Current Limit entente nennen nen mener entren ene trien 2 78 Power Module Too Hot Please Wait crisissen 288 ke eu 2 99 5 Battery Voltage Too High System Shutdown sse enne nennen tentent eren eren 2 41 Battery Voltage Too Low System Shutdown sese 2 42 Engine Not Ruining ene le eere epi E rede eere Cere ede erbe ed ea ete ie UD 2 60 A 8 T350 T500J 3121203 INTRODUCTION 9 AJACCessory Fault moro t p te e iicet 2 41 CANBUS Failure Accessory Module Communications Lost eese eee ener treten tenter tenent 2 42 Drive Module 3 3 8 del dedi pete bebe id edet dott e the CANBUS Failure Platform Module eee
5. 2 81 3 3 Jib Down Solenoid Short Ground 2 81 3 3 Jib Up Solenoid Open Circuit Ree New bad ete ide c ERROR Bert er e eade jeder 2 82 3 3 Jib Up Solen id Short To Battery i e nere er RR eO an OP Co BEES UR an nn PEOR 2 82 3 3 Jib Up Solenoid Short To Ground 2 83 3 3 Level Down Solenoid Open Circuit 2 87 3 3 Level Down Solenoid Short To Battery 2 87 3 3 Level Down Solenoid Short To Ground 2 88 3 3 Level Up Solenoid Open Circuit 2 88 3 3 Level Up Solenoid Short To Battery 3 3 Level Up Solenoid Short To Ground 2 89 3 3 Lift Down Solenoid Open Circuit essent 2 90 3 3 Lift Down Solenoid Short To Battery 2 2 Xe 2 91 3 3 Lift Down Solenoid Sliort To uii ee nee eid ee ere et RR pe ce onte erede ede 2 91 3 3 PAfe Up solenoid Opern Circuit eds eh he ante ta 2 94 3 3 Lift Up Solenoid Short To Battery serieen etinio aein Dea DE e EE E i Ea E E E E a ET 2 94 3 3 Lift Up Solenoid Short To Ground usa meets deinen up ed e op HR eb bee 2 95 3 3 Optional Ground Alarm Short To Battery 2 96 3 3 Optional Ground Alarm Short To Ground esse
6. 7 186 7 15 HD HDP Contact 14 4 7 186 7 16 HD HDP Locking Contacts Into Position 7 187 7 17 HD HDP Contact Removal 2 7 187 7 18 HD HDP Unlocking Contacts 7 187 7 19 Electrical Schematic Trailer 1 7 188 8 1 Hydraulic TeSt PONS ce Cx a e eo Nac P eR RR Re EUR Se Rhea XE 8 192 8 2 Hydraulic Schematic Electric Powered Machines Sheet 1 2 8 193 3121203 T350 T500J 27 TABLE OF CONTENTS Continued 8 3 8 5 8 6 8 8 8 9 9 2 9 3 9 5 9 6 10 1 10 2 10 3 10 4 TABLE NO 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 11 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 9 11 10 11 11 11 12 28 Hydraulic Schematic Electric Powered Machines Sheet 2 2 8 194 Hydraulic Schematic Engine Powered Machines Sheet 1 2 8 195 Hydraulic Schematic Engine Powered Machines Sheet 2 2 8 196 Hydraulic Schematic Engine Powered Drive Option Sheet 1 2 8 197 Hydraulic Schematic Engine Powered Drive Option Sheet 2
7. entrent 3 3 Swing Right Solenoid Open Circuit 3 3 Swing Right Solenoid Short To Battery 3 3 Swing Right Solenoid Short To Ground 3 3 Telescope In Solenoid Open Circuit 3 3 Telescope In Solenoid Short To Battery 3 3 Telescope In Solenoid Short To Ground 3 3 Telescope Out Solenoid Open Circuit esses ennt entente nennen nre eterne nennen terere tnnt 3 3 Telescope Out Solenoid Short To Battery 3 3 Telescope Out Solenoid Short To Ground 3 3 Throttle Hold Solenoid Open Circuit 3 3 Throttle Hold Solenoid Short To Battery eene entente nter entente nennen nennen 3 3 Throttle Hold Solenoid Short To Ground 2 114 3 3 Throttle Pull Relay Open CitCuit s Ier e e OH P ER E E HE Ere PAL eR ERE E ERR CREER S 2 115 3 3 Throttle Pull Relay Short To Battery 2 115 3 3 Throttle Pull Relay Short To Ground esent Ud hase 2 116 4 4 2 Functions At Cutback Power Module Current Limit 4 2 Power Module Too Hot Please Wait ss 4 3 No Charge OuP t 4 4 Battery Voltage Too High System Shutdown sss rre erret nennen entere enne 4 4 Battery Voltage Too Low System Shutdown sess enne e
8. 2 90 Lift Down Solenoid Short To 2 91 Lift Down Solenoid Short To 2 91 Lift Up amp Tele Out Prevented Tilted amp Above 2 91 Lift Up amp Tele Out Prevented Tilted Unset amp Above 2 92 Lift Up amp Tele Out Prevented Unset amp Above 2 92 Lift Up Prevented Check 0 2 92 Lift Up Prevented Lift Down Then Set 00 2 93 Lift Up Prevented 2 22 2 2 2 2 2 2 22 4 4 2 93 Lift Up Solenoid Open 2 4 2 94 Lift Up Solenoid Short To 2 94 Lift Up Solenoid Short To Ground ec een 2 95 Model Changed Hydraulics Suspended Cycle EMS 2 95 No Charge System 2 95 Open Circuit Pump Motor Wiring 2 96 Optional Ground Alarm Short To 2 96 Optional Gr
9. 1 2 47 Choke Hold Solenoid Short To 2 47 Choke Hold Solenoid Short To 1 2 48 Choke Pull Relay Open 2 48 Choke Pull Relay Short To 2 49 Choke Pull Relay Short To 2 49 Drive amp O R Prevented Operate From Platform 2 50 Drive amp O R Prevented Place Boom On 2 51 Drive amp O R Prevented Set Hand 2 51 Drive Enable Solenoid Short To 2 2 51 Drive Enable Solenoid Short To Ground Or Open 2 52 Drive Left Forward Solenoid Open Circuit 2 52 Drive Left Forward Solenoid Short To Battery 2 53 Drive Left Forward Solenoid Short To 2 53 Drive Left Reverse Solenoid Open Circuit 1 2 54 Drive Left Reverse Solenoid Short To Battery 2 54 Drive Left Reverse Solenoid Short
10. 2 112 Telescope Solenoid Short To Battery 2 112 Telescope Solenoid Short To Ground 2 113 Throttle Hold Solenoid Open Circuit 3 22 ee RER ER CE CS ec 2 113 Throttle Hold Solenoid Short To Battery sariri rorirori i nennen ente E E netten tette 0 2 114 Throttle Hold Solenoid Short To Ground sss eene rettet nennen nenne innere ennt 2 114 Throttle Pull Relay Open Circuit 2 115 Throttle Pull Relay Short To Battery sese eene enne nenne trennt tnt tenti net rettet nenne innere irent nentes enses 2 115 Throttle Pull Relay Short To Ground eter tene reete eis ede eedem P ie der de der ds 2 116 A 10 T350 T500J 3121203 INTRODUCTION A 7 SERVICE FAULT CODE CROSS REFERENCES CODE MESSAGE PAGE NO 0 0 Chassis Tilt Sensor Out Of Range 0 Engine Not Running 2 2 2 2 e 0 Joystick Moved But Trigger Switchi te ee c endo oa ir 2 85 0 Running At Creep Material Hook Mode smiir trennen rennen nennen tnn 2 104 0 Running At Creep Til
11. 5 150 RETRACT VALVE SHORT TO 5 150 RETRACT VALVE SHORT TO 5 150 REEO RVALVE ves hte a ie Bake tr ob b ak lh de e 5 151 R L OUTRIGGER LAMP ON 5 151 R L OUTRIGGER VALVE OPEN 5 151 R L OUTRIGGER VALVE SHORT TO 5 151 R L OUTRIGGER VALVE SHORT 5 151 ROTARY TO JIB TELE 4 gt tacks hee piece pied dod 5 151 ROTARY 5 151 ROTARY TO LIFT SWING rum 2 end ee enh eri DEP GG 5 151 cece ante eta cd 5 152 OUTRIGGER LAMP 5 152 OUTRIGGER VALVE OPEN CIRCUIT 5 152 T350 T500J 25 TABLE OF CONTENTS Continued 5 167 R R OUTRIGGER VALVE SHORT TO 5 152 5 168 R R OUTRIGGER VALVE SHORT TO 5 152 5 169 RUNNING oiee e cep
12. 7 171 X004 J4 Ground Module 1 7 172 X007 J7 Ground Module 7 173 X008 J8 Ground Module 7 173 X060 J1 Platform Module 1 4 1 7 174 X074 J1 Drive Module 1 4 4 7 175 X075 J2 Drive Module 4 7 175 Connector Loading 7 176 Dimensional Data 42 erronee ER SA E REG UR RI e 11 219 ree APA Ec e b ecu 11 219 Electric Power Unit Specifications 11 219 Light Bulb Information ss 3s ere reos ed Aout din dye epe open te V gone d 11 220 Tite Specifications ea aep mes Rost Sh BN dox ege tiene Einen tec 11 220 Engine Specifications an ar arten Ian ewe I DD ea bee 11 221 Engine Battery 4 11 221 Battery Specifications 11 221 Component Weights 3 50 11 222 Component Weights
13. O R Step Pretest Instructions Test Result Corrective Action 2 96 1 Wasthetriggerclosed before Yes Goto step 2 96 2 moving the joystick No Cycle power and again 2 96 2 Was the joystick moved out Yes Go to step 2 96 3 ofthe center position No Possible Cause 4 1 22 2 96 3 Place key switch in platform Measured voltage atX061 6 Yes Goto step 2 96 4 position and pull the emer Vbatt No Goto step 2 96 7 gency stop switches Engage and hold the trigger 2 96 4 Place key switchintheplat With the rotary select switch Yes Goto step 2 96 5 form position and pull the inthe LIFT SW position and No Possible Cause 4 1 18 broken wire emergency stop switches trigger engaged does the Orn Red 49 28 Usingthe analyzer navigate to Diagnostic Message read DIAGNOSTICS gt PLAT LIFT SWING SEL FORM 2 96 5 Place key switch inthe plat With the rotary select switch Yes Go to step 2 96 6 form position and pull the inthe JIB TELE position and No Possible Cause 4 1 18 broken wire emergency stop switches trigger engaged does the Orn Red 49 29 Using the analyzer navigate to Diagnostic Message read DIAGNOSTICS gt PLAT JIB TELE SELECT FORM 2 96 6 Place key switch in the plat With the rotary select switch Yes Possible Cause 4 1 11 form position and pull the inthe LEVEL position and No Possible Cause 4 1 18 broken wire emergency stop switches trigger engaged does the Orn Re
14. RELAY X015 LEVEL LIMIT SWITCH X041 X018 GL JD TELESCOPE LIMIT SWITCH X020 O R JACK O R LIMIT JACK SWITCH VALVE co xoa2 ar X044 6 9 O R JACK LIMIT SWITCH 3121203 VALVE MOTION ALARM X017 X008 J8 X001 Eu 9 X007 X002 J7 J2 X003 X004 93 04 O R O R JACK JACK LIMIT VALVE SWITCH e X047 Pp N Xo X049 045 9 O R O R JACK JACK LIMIT VALVE SWITCH X077 X087 VALVE MOTOR TANK See valve MOTOR SIDE X096 layout ELECTRIC POWERED MACHINE SHOWN RECTIFIER H ra X095 E E 29 VALVE MOTOR TANK MAGNETIC TANK SIDE PICKUP X011 X022 X089 BATTERY STARTER ENGINE POWERED ENGINE POWERED X093 ENGINE CHOKE PULL RELAY Figure 7 4 Electrical Diagram T350 T500J THROTTLE COIL X091 ENGINE THROTTLE RELAY OIL LEVEL SWI
15. 5 137 CHOKE SWITCH GL Ree Ed segete med eis 5 137 GU CHORE stt dne t be CERE m RR cid ep eps 5 137 CL GHOKE SWITCH See tes ea ee ee go 5 137 BL BRIVE SWITCH 5 0 tud a ie ug eds 5 137 CLE JIB DOWN Masur Eod ec bate bai iw hale totem eaten 5 137 GEJIBUR Aem 5 137 SE un dtu eS oet ate e es 5 137 GL LEVEL roo de Ree eco gie Ber tes RO te de 5 138 CE EIRTEDOWN dde ete uti ee m pet eet PY MAE As REE LUE 5 138 CE BIET UP ar A HR RT E eee 5 138 GE O R SER xiu Ooi oed ad accettati ate dob sioe oa udi 5 138 CE O R dosi e bod deed dg Ia ord eh nett a det Eee 5 138 GL START 22 echo nn PEE qs inm Ove S adds 5 138 CE START SWITCH 25 rA A M erbe d te vi P ene s 5 138 GL SWING EBEET zou aa a rare teehee aed det x 5 138 CE SWING RIGHT 4 s 40 822 p Em t ER E FE E pape thee A Rape e 5 138 GE TELE IN n tr enr IR 5 138 T350 T500J 23 TABLE OF CONTENTS Continued 5 51 CE TELE OUT etre e ettet Nis Deed a t Te nete FN 5 139 5 52 CLOSE TRIGGER 8 2 0200 MR aly Jang
16. amp 1509001 REGISTERED COMPANY AGEMENT Troubleshooting Manual Models T350 T500J 3121203 September 7 2005 MG REVISION LOG September 7 2005 Original Issue Of Manual 3121203 T350 T500J REVISION LOG 4 T350 T500J 3121203 INTRODUCTION SECTION A INTRODUCTION A 1 HOW TO USE THIS MANUAL Troubleshooting system problems can be difficult System wiring and hydraulic diagrams are provided in this book to help isolate problems Follow the flow chart of Figure A 1 Each troubleshooting step setup is specified in the step instructions and applies only to that step Any special wiring should be removed after completing the step When a function will not operate with the same speed or power as a machine in good working condition refer to the Trouble shooting By Function 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 Using Analyzer Run Platform and Is Distress Ground System amp Blinking Tests Plug in Analyzer read Help Message NES CENE Troubleshoot by Help Message in Section 2 Ground verything Possible Causes No Component Checks Troubleshoot by function in Section 1 Identify Fault Repair Machine
17. 2 109 2 151 Tele Out Prevented 1 2 109 2 152 Telescope In Solenoid Open 1 2 110 2 153 Telescope In Solenoid Short To 2 110 2 154 Telescope In Solenoid Short To Ground 2 111 2 155 Telescope Out Solenoid Open Circuit 2 2 2 112 2 156 Telescope Out Solenoid Short To Battery 2 112 2 157 Telescope Out Solenoid Short To 1 2 113 2 158 Throttle Hold Solenoid Open 4 2 113 2 159 Throttle Hold Solenoid Short To 2 114 2 160 Throttle Hold Solenoid Short To Ground 2 114 2 161 Throttle Pull Relay Open Circuit 2 eh 2 115 2 162 Throttle Pull Relay Short To Battery 2 115 2 163 Throttle Pull Relay Short To 1 2 116 2 164 Trigger Closed Too Long While In 1 2 116 SECTION 3 COMPONENT CHECKS 3 1 DC Powered Machine Hyd
18. 9L OL d I3H q35901 0081 1 0SEL 0 10 HHEIATIN TICON 69Jn614 996 00000 4009 6 6 JIH qwaung 1 4 A 1 dni3s Tun U31N3 SNOILVHSITVO 3NIHOVIA 3 SS3OOV SOLLSONOVIG d 13H 3121203 350 T500J 9 207 SECTION 9 JLG ANALYZER sonsouBeiq Heys sezAjeuy g 6 NO 440 Ssaursia SAS m NO 1430 i uodn eq jou suaaJos eulos i 1 Jey ejou eseejqd 25 1 2 ejgissod sepnjoui 1no ej FLON Trulia EI NO vmm 440 Liva SAS 1 NO HO Liva I NO OSTON a NO 40 aes sseoov 104 ONIHO Hd i SVE NO 1 Vo 340 135 uo WA TH 1 Ho ONIMS I 350 NWNI m ET zi HXCIVINSH NBdO 135 m I 1440 We WAK 1 SR N340 I WA Hx 1 70 40 NANI nS 1 1 I MS DOHO 001 0 ASH IHOM NG 1
19. Step Pretest Instructions Test Result Corrective Action 3 13 1 Pullthe ground and platform Voltage between X060 1 and Yes Possible Causes 4 1 11 emergency stop switches and X060 2 Vbatt No Goto step 3 13 2 place key switch in the plat ds form position 3 13 2 Pullthe ground and platform Voltage between X059 D and Yes Repair Platform wiring between X059 emergency stop switches and X059 H Vbatt and X060 place key switch in the plat No Goto step 3 13 3 form position nd 3 13 3 Pullthe ground and platform Voltage between X008 4 and Yes Goto step 3 13 5 emergency stop switches and X008 3 Vbatt No Goto step 3 13 4 place key switch in the plat form position 3 13 4 Pullthe ground and platform Voltage on X008 2 Vbatt Yes Possible Causes 4 1 10 emergency stop switches and No lanition Relay Power place key switch in the plat JUDI Rela SONG form position 3 13 5 Pullthe ground and platform Voltage between X019 4 and Yes Goto step 3 13 6 emergency stop switches and NOI ES No Repair power Yel Red 2 11 or Black sce key WIDTH piat wire between X019 and X008 form position 3 13 6 Pullthe ground and platform Voltage between X055 4 and Yes Goto step 3 13 7 emergency stop switches and 055 8 Vbatt No Repair power wires between X055 place key switch in the plat andX019 form position 3 13 7 Pullthe ground and platform Voltage between X057 D and Yes Repair Blue
20. 2 48 T350 T500J 3121203 2 18 CHOKE PULL RELAY SHORT TO BATTERY Distress Lamp 9 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES ADE Code 3 3 Ground module feedback shows that the Engine Choke Pull digital output may be shorted to battery or other function ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Pull Step Pretest Instructions Test Result Corrective Action 2 18 1 Runsystemtest Do other functions fail sys Yes Possible Cause 4 1 15 4 1 1 other tem test wise goto step 2 18 2 No Goto step 2 18 2 2 18 2 Disconnectrelay atX093 Rerun System Test Analyzer Message CHOKE PULL Replace solenoid isolate wires RELAY OPEN CIRCUIT Analyzer Message CHOKE PULL Goto step 2 18 3 RELAY SHORT TO BATTERY 2 18 3 Remove wire WHT YEL 48 4 Rerun System Test Analyzer Message CHOKE PULL Wire WHT YEL 48 4 shorted to bat from X003 4 RELAY OPEN CIRCUIT Repair or replace Analyzer Message CHOKE PULL Possible Cause 4 1 10 RELAY SHORT TO BATTERY 2 19 CHOKE PULL RELAY SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Choke Pull digital output may be shorted to ground or the relay may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Pull Step Pretest Instructions Test Resu
21. RIGHT SIDE MARKER E BREAKAWAY SWITCH LIGHT BATTERY CHARGER EB ELECTRIC BRAKES ELECTRIC BRAKES WHEN EQUIPPED ANSI EXPORT SPECS BREAKAWAY SWITCH ELECTRIC BRAKES ELECTRIC BRAKES C OR WITH HYDRAULIC BRAKES Ref 1870172 Rev C 7 164 SECTION 7 ELECTRICAL REFERENCE X068 Right Fwd 9 80 Tan 070 Right Rev 9 80 X069 Left Rev 9 80 3121203 067 Left Fwd 9 80 o Flow Divider Drive Enable Valve Proximity Sensor Propulsion Module Drive Engagement Release Valve 2ooudo 0 X071 Drive Enable 7 20 Ref 0274754 X072 3 BrakeRelease Cylinder Drive Engage Cylinder Friction Drive Wheel Drive Directional Valve Drive Motor Figure 7 5 Drive and Set T350 T500J 7 165 7 1 SECTION 7 ELECTRICAL REFERENCE Table 7 1 Connector Index 522 Location in Schematic ID Description End 1 ID End 2 ID Figure 7 3 Drawings X001 Ground Module J1 AS352P Neutral 2D Figure 7 1 X002 Ground Module J2 AS354P Gray 26 Figure 7 2 X003 Ground Module J3 14 Figure 7 2
22. ag EINER Doo de uU Re IRR Gad ur DEOR 3 127 Transport Limit Switch 2 122 EIU RR reu pex p ere dee beats 3 128 POSSIBLE CAUSES Possible Causes obese ebur e E rime a 4 129 SYSTEM TEST MESSAGES BATTERY 1 4 LAMP ON 25 ds ctt e ahd E den EN CHR Ra aca RU un te ans 5 133 BATTERY 1 2 EAMP ON 2 2 Eee See Ar ris 5 133 BATTERY S A LAMP ON cot ppt ER ORT E ED td e UE 5 133 BATTERY LAMP QN 2 7 2 oam d REO ee E 5 133 BATTERY VOLTAGE TOO HIQGEL 2 i EAR RE E TR SR 5 133 BATTERY VOLTAGE 11 7 1 5 133 CHECK CHOKE SWITGEI iate a te REALE LM MSRP 5 133 CHECK GROUND PLATFORM 5 133 CHECK DOWN 1 1 2 2 2 5 134 CHECK JIB UP SWITOL 223222 Ere RN DUIS s 5 134 CHECK LEVEL DOWN 5 134 CHECK LEVEL SWITCH 2302 ertet Rp dtm Me pe fe ee doses 5 134 CHECK LIFT DOWN 40 1 5 134 CHECK LIFT UP SWITCH oi renan tinet eh ei etos e eo E CR Re e RT py 5 134 CHECK OUTRIGGER SET 5 1
23. co dus iN 5 148 OP CHOKE SWITGH ivoire Ense 5 148 OP DRIVE SWITGE cP Mahe d te or ote emeret set 5 148 OP JIB DOWN esd res Sealab ee Rue dead roe eas 5 148 OP IBN Peace ise eth 5 148 OP EEVEL DOWN tet bur icu IDE 5 149 OP LEVELUP rone au ux 5 149 EFT DOWN TL 5 149 2 2 IIT RE 5 149 SET e odo Mr erate ta e ee t 5 149 OP O R STOW mran a eti Eri e ente ee ed reddit athe Saepe e dad ee tede 5 149 OP START er 5 149 OR ST RESWITCH rte Peel Re E eh ptt ct tbe velt ee Dep coke ae 5 149 OP SWING EEET tee ere ette Ete E bes a e Neige ee se 5 149 OP SWING 5 149 ee ne wen T Bee 5 150 OP TEEE OULT 2 25 822 er e oe hades Soe eee ad ee ere 5 150 OPEN TRIGGER Aera eerte tea ada coe dietus he oth nee inr En elt Deka rk 5 150 OPT GROUND ALARM 5 150 PLATFORM ALARM ON 5 150 RETRACT VALVE hieu oe ei en noite i 5 150 RETRACT VALVE OPEN CIRCUIT
24. These values not available at time of printing 8 191 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES MAIN VALVE BLOCK DRIVE DIRECTIONAL VALVE DRIVE ENABLE Figure 8 1 Hydraulic Test Ports 8 192 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES Outrigger Cylinders 1350 2 75 Rod 1 5 Stroke 21 7 Blind area 5 93 2 Telescope Cylinder T350 Bore 2 Rod 1 25 Stroke 110 1500 Bore 2 Rod 1 5 Stroke 149 81 Annulor area 4 18 in2 Area Ratio 1 42 1 1500 Bag Pr Bore 3 75 Rod 1 75 Ies es zm uu 2k Stroke 21 375 Blind 11 04 in2 Annulor 8 64 in2 1 Lern Area Ratio 1 27 1 l vi vl es 2 Oo tot Oo tod 1 1 e 1 v2 2 why Poem Lift Cylind i inder 250 1 v1 ook 1350 1 og Bore 3 Ro
25. 160 PSI 160 PSI T IV i 11 11 BAR e 1 T 62 22 2 2 Drive Directional Valve Rotary Fere ae pee ow Divider 1 9 3 1 T Y Differential reliefs M i set ot 750 PSI 52 BAR e Figure 8 6 Hydraulic Schematic Engine Powered Drive Option Sheet 1 of 2 8 197 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES Monual releose valve with detent CLOSED WHEN DRIVING OPEN WHEN TOWING K gt Cage Wheel Cylinder A VN V To the main control valve port 400 51 10 Micron 27 5 BAR i y AT 8 BAR n Byposs 1 e 1 RE e e 44 gt B 5500 PSI T 2 294 i 3000 X 207 BAR amp e 1 D T L L Drive Enable Valve Gear Pump 0 24 in3 3600 rpm 3 75 gpm 14 Ipm 2792642 Figure 8 7 Hydraulic Schematic Engine Powered Drive Option Sheet 2 of 2 3121203 350 T500J 8 198 Left Wheel Motor SECTION 8 HYDRAULIC REFERENCES Right and left wheel designations are determined by the operator Right Wheel Motor A B standing in the platform A B Brake Cylinder ACA V
26. 4 LHS esti SSAYd dI3H DIN3W T3A31 NS NNAW 13 31 805 51531 dNLYVLs SHOLVOIGNI 35012 N3dO 3121203 350 T500J 9 213 SECTION 10 MULTIMETER BASICS SECTION 10 MULTIMETER BASICS 10 1 INTRODUCTION figured for several different circuit measurements Instruc tions for your VOM may vary Please consult the meter A wide variety of multimeters or Volt Ohm Meters VOM operator s manual for more information can be used for troubleshooting your equipment This section shows diagrams of a common digital VOM con e If meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Figure 10 1 Voltage Measurement DC 3121203 350 T500J 10 214 SECTION 10 MULTIMETER BASICS First test meter and leads by touching leads together Resis tance should read a short circuit very low resistance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing e If meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads Figure 10 2 Resistance Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing continuity Disconnect component from
27. 2 41 2 3 Battery Voltage Too High System 2 41 24 Battery Voltage Too Low System Shutdown 2 41 2 5 Battery Voltage Too Low System Shutdown 2 42 2 6 CANBUS Failure Accessory Module Communications 2 42 3121203 T350 T500J 19 TABLE OF CONTENTS Continued 20 2 7 2 8 2 9 2 10 2 11 2 12 2 13 2 14 2 15 2 16 2 17 2 18 2 19 2 20 2 21 2 22 2 23 2 24 2 25 2 26 2 27 2 28 2 29 2 30 2 31 2 32 2 33 2 34 2 35 2 36 2 37 2 38 2 39 2 40 2 41 2 42 2 43 2 44 2 45 2 46 2 47 2 48 2 49 2 50 2 51 2 52 2 53 2 54 2 55 2 56 2 57 2 58 2 59 2 60 2 61 2 62 2 63 2 64 CANBUS Failure Drive 2 43 CANBUS Failure Platform Module 2 44 CANBUS Failure Power 0 2 2 45 Chassis Tilt Sensor Gain Not Calibrated 2 45 Chassis Tilt Sensor Gain Out 2 45 Chassis Tilt Sensor Not 2 46 Chassis Tilt Sensor Out Of Range 2 46 Choke Hold Solenoid Open Circuit
28. Repair or replace CIRCUIT Analyzer Message DRVENABLE Possible Cause 4 1 10 VALVE SHORT TO BATTERY 3121203 T350 T500J 2 51 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 24 DRIVE ENABLE SOLENOID SHORT TO GROUND OR OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Enable Valve PWM output may be disconnected shorted to ground or the sole noid may be defective DRIVE OPTION MACHINES ONLY Step Pretest Instructions Test Result Corrective Action 2 24 1 DisconnectsolenoidatX071 Isthe solenoid resistance Yes Goto step 2 24 2 and measure resistance 7 2 Ohms No Repair Replace solenoid 2 24 2 Remove wire Orn 55 1 from IsX074 11 socshortedor Yes Open Possible Causes Open in Orn 55 1 or X074 11 open to X074 2 s0c Black or Red Blk boom wire Repair or replace Yes Shortto Ground Possible Causes Wire Orn 55 1 shorted to ground Repair or replace No Possible Cause 4 1 1 4 1 10 2 25 DRIVE LEFT FORWARD SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Left Forward Valve PWM output may be disconnected or the solenoid may be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Forward Step Pretest Instructions Test Result Corrective Action 2 25 1 Runsystem test Do other functions fail sys Yes Possible Cause Black
29. 2792642 F Figure 8 9 Hydraulic Schematic Electric Powered Drive Option Sheet 2 of 2 3121203 350 T500J 8 200 SECTION 8 HYDRAULIC REFERENCES 8 201 T350 T500J 3121203 SECTION 9 JLG ANALYZER SECTION 9 JLG ANALYZER 9 1 INTRODUCTION The Control System may be accessed utilizing a custom designed hand held analyzer Analyzer Kit JLG part no The JLG Control System controller has a built in LED to 2901443 which will display two lines of information at a indicate any faults The system stores recent faults which time by scrolling through the program may be accessed for troubleshooting MENU Analyzer Display gt HELP PRESS ENTER Enter Key Escape Key Toreuname or 4 access previous Left amp Right Arrow Keys Keys lt Used to move between Top Level Sub Level and item Figure 9 1 Hand Held Analyzer 3121203 350 T500J 9 202 SECTION 9 JLG ANALYZER 9 2 TO CONNECT THE JLG CONTROL SYSTEM ANALYZER 1 Connect the cable supplied with the analyzer to the controller module in the ground control box and connect the remaining end of the cable to the 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 ground position and pulling the emergency stop button on 9 3 USING THE ANALYZER With the machine power on and the analyzer connected
30. nennen ersten nennen 2 56 Drive Right Forward Solenoid Short To Ground sse nennen nennen 2 57 Drive Right Reverse Solenoid Open Circuit ero E e MER Ha rire 2 57 Drive Right Reverse Solenoid Short To Battery esses eene 2 58 Drive Right Reverse Solenoid Short To Ground Dump Solenoid Open Circuit Dump Solenoid Short To Battery i Dump Solenoid Short To Ground E rettet tet reines esee EEPROM Failure Check All Settings u ae an rrr RR RR Li erede ERE ERES Extend O R Solenoid Open Circuit 5 5 ettet tre SERERE CE er Extend O R Solernoid Short To Battery 2 1 rtr erstere Bienen ahnen Extend O R Solenoid Short To Ground Front Left O R Solenoid Open Circuit 23 2 nenne eb me dee DH caia greens Front Left O R Solenoid Short To Battery Front Left O R Solenoid Short To Ground Front Right O R Solenoid Open Circuit da Front Right O R Solenoid Short To Battery iege tree ode eee deer He o o e Front Right O R Solenoid Short To Ground Function Problem Jib Up And Down Both Selected entreteni
31. 2 160 THROTTLE HOLD SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Throttle Hold digital output may be shorted to ground or solenoid may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Throttle Hold Step Pretest Instructions Test Result Corrective Action 2 160 1 Disconnect solenoid 1 097 Rerun System Test Analyzer Message THROTTLE Repair Replace solenoid and isolate wires HOLD SOLENOID OPEN CIR CUIT Analyzer Message THROTTLE Goto step 2 160 2 HOLD SOLENOID SHORT TO GROUND 2 160 2 Remove wire WHT YEL 48 3 Rerun System Test Analyzer Message THROTTLE Wire WHT YEL 48 3 shorted to from X003 11 HOLD SOLENOID OPEN CIR ground Repair or replace CUIT Analyzer Message THROTTLE Possible Cause 4 1 10 HOLD SOLENOID SHORT TO GROUND 2 114 T350 T500J 3121203 2 161 THROTTLE PULL RELAY OPEN CIRCUIT Distress Lamp 9 may be defective ENGINE POWERED MACHINES ONLY ADE Code 3 3 Ground module feedback shows that the Engine Throttle Pull digital output may be disconnected from the relay or the relay Functions Disabled Engine Powered Machines Only Engine Throttle Pull SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 162 THROTTLE PULL RELAY SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Step Pretest Instructions Test Result Corr
32. Ue E ev EDDIE 16 SECTION TROUBLESHOOTING SAFETY PRECAUTIONS B 1 General Em B 17 B 2 Hydraulic System B 17 Troubleshooting 12 22 17 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 1 All Functions 2 1 29 1 2 Pump Motor Will Not Operate DC Powered Models 1 29 1 3 All Functions Inoperative Engine Starts And Runs Engine Models 1 30 1 4 All Functions Inoperative Pump Motor Runs Dc Powered 1 30 1 5 Battery Charger Not Functioning 1 31 1 6 Engine Will Not Crank Engine 1 32 1 7 Engine Cranks But Will Not Start Engine 1 33 1 8 Engine High Idle Inoperative Engine 0 6 1 33 1 9 Engine Low Idle Inoperative Engine Models 1 33 1 10 Ground Controls 1 34 1 11 Platform Controls 1 34 1 12 Ground Leveling Not
33. 2 2 102 2 136 Retract O R Solenoid Short To 1 2 103 2 137 Retract O R Solenoid Short To Ground 1 2 103 2 138 Running At Creep Material Hook 2 104 2 139 Running At Creep Tilted amp Above 2 104 2 140 Running At Creep Unset amp Above Elevation 2 104 2 141 Start Solenoid Open Circuit 2 105 2 142 Start Solenoid Short To Battery 0 2 105 2 143 Start Solenoid Short To 4 0 2 106 2 144 Swing Left Solenoid Open 4 7 22 4 2 106 2 145 Swing Left Solenoid Short To 2 107 2 146 Swing Left Solenoid Short To Ground 2 7 2 4 2 107 2 147 Swing Right Solenoid Open Circuit 2 108 2 148 Swing Right Solenoid Short To Battery 2 108 2 149 Swing Right Solenoid Short To Ground 0 0c eect eee 2 109 2 150 Tele Out Prevented Set 0
34. 9 9 Power Module Failure Check Power Circuits Or Mosfet Short Circuit 9 9 Power Module Failure Internal Error 3121203 T350 T500J A 13 INTRODUCTION 9 9 Power Module Failure Personality Range Error A 8 POWER MODULE FLASH CODES DE FAULT DESCRIPTION TROUBLESHOOTING REFERENCE Steady No Fault Off Internal Failure Controller Damaged 2 125 Power Module Failure Check Power Circuits Or Mosfet Short Circuit 1 Personality Out Of Range Or CRC Fault 2 127 Power Module Failure Personality Range Error 2 Input Active On Power Up Or Undefined Input 2 126 Power Module Failure Internal Error 3 Short Circuit Detected In Power Block 2 125 Power Module Failure Check Power Circuits Or Mosfet Short Circuit 4 Line Contactor Not Responding To Command 5 Field Loss Detected 6 Reserved 7 Battery Voltage High or Low 2 3 Battery Voltage Too High System Shutdown 2 4 Battery Voltage Too Low System Shutdown 8 Controller Hot 2 79 Functions At Cutback Power Module Current Limit 2 128 Power Module Too Hot Please Wait 9 Reserved 10 Communication Loss 2 9 CANBUS Failure Power Module 11 System Condition Out Of Range 2 126 Power Module Failure Internal Error A 9 GROUND REFERENCE On engine powered machines battery negative X100 should be used as the ground reference for voltage measurements unless stated otherwise On electric powered mac
35. 1 1 1 v2 v2 Wie L 1 Lift Cylinder 2 V1 V1 2 1350 Pec les 1390 3 Td oa Rod 1 75 Stroke 54 75 L Blind area 7 068 112 1 Annular grea 4 66 in2 BE ia Area Ratio 1 51 1 V2 oe V2 1500 ev n Bore 3 75 2 Stroke 38 Blind oreo 11 04 2 Hitch En Annular area 7 9 in2 Right side Jacks Left side Area Ratio 1 4 1 when towing when towing the vehicle the vehicle 1 1 Go var V21 79 Junction Mani fold fa 7 8 9 1 11 15 hd 12 o 14 X 3 64 X 1 2 354 5 6 orifice 0 072 Of V1 1 1 t e RA ae M 453 n zu LA L8 1 1 i T nS E Lift Up Retract X B2 tend 1 5 T YT e Outrigger e lt 1 87 psi zoe 6 bar 1 1 1 142 psi s 10 bar T H Hre ts 0 011 t x Geor 0 E Menus ti 0 24 3 4 escent IH rn K m nat 1 1 gt 1 NE I 1 D 15 bor T 1 1 1 1 T21 1 1 1 L Figure 8 4 Hydraulic Schematic Engine Powered Machines Sheet 1 of 2 8 195 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES Slave and Master Cylinders T3550 Bore 2 Rod 1 Stroke 7 375 Blind area 3 14 in2 Annular 2 35 in2 Area Ratio 1 33 1
36. 2 8 198 Hydraulic Schematic Electric Powered Drive Option Sheet 1 of 2 8 199 Hydraulic Schematic Electric Powered Drive Option Sheet 2 of 2 8 200 Hand Held Analyzer emet ag Ge PG el on 9 202 An lyzer Elow Chatt 4 2 nee EE ES PG RN ERR es 9 207 Analyzer Flow Chart Diagnostics 9 208 Analyzer Flow Chart 9 209 System Test Flow Chart Platform 9 211 System Test Flow Chart Ground Station Tests 9 213 Voltage Measurement 4 10 214 Resistance 1 1424 4 10 215 Continuity 14 2 1 10 215 Current Measurement 2 10 216 LIST OF TABLES TITLE PAGE NO Gonnector sce QU e en eh en 7 166 X001 J1 Ground Module 41 7 169 X002 J2 Ground Module 2 2 7 170 X003 J3 Ground Module
37. 2 96 Optiorial Ground Alarm Short To Battery 1 2220 epe pete bitte bete de 2 96 Optional Ground Alarm Short To Ground 2 3 e pete epe dote 2 96 Platform Position Detection Faulty esistente ether nre eren e nn E tette 2 97 Power Module Failure Check Power Circuits Or Mosfet Short Circuit entente ettet nennen nnne 2 98 Power Module Failure Internal Error 1 2 EE EEr EEEa EES ENEKE tenen 2 98 Power Module Failure Personality Range Error sse eret entente 2 99 Rear Left O R Solenoid Open Circuit E EEA E nnne 2 99 Rear Left O R Solenoid Short To Battery EA EOT O A 2 100 Rear Left O R Solenoid Short Ground 2 100 Rear Right O R Solenoid Open Circuit nennen nnns 2 101 Rear Right O R Solenoid Short To Battery 2 101 Rear Right O R Solenoid Short To Ground 2 102 RetractO R Solenoid Open Circuit ran RE I erdt io E d 2 102 Retract O R Soleno1d Short To Baltery Bra antenne rede ie m ded de ede 2 103 Retract O R Solenoid Short To Ground
38. 9 47 CL START SWITCH ENGINE POWERED MACHINES ONLY System test prompt to close the platform Start switch Push the Start button at the platform panel to test the Start switch input and continue the test 9 48 CL SWING LEFT System test prompt to close the Swing Left switch Push the Swing switch at the ground panel to the Left position to test the switch input and continue the test 9 49 CL SWING RIGHT System test prompt to close the Swing Right switch Push the Swing switch at the ground panel to the Right position to test the switch input and continue the test 9 50 CL TELE IN System test prompt to close the Telescope In switch Push the Telescope switch at the ground panel to the In position to test the switch input and continue the test 5 138 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 9 51 CL TELE OUT System test prompt to close the Telescope Out switch Push the Telescope switch at the ground panel to the Out position to test the switch input and continue the test 5 52 CLOSE TRIGGER System test prompt to close the platform joystick Trigger switch Push the Trigger switch at the platform panel to test the switch input and continue the test 5 53 DRIVE SWITCH CL DRIVE OPTION MACHINES ONLY System test response indicating that the platform drive switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 54 DRV ENABLE DRIVE OPT
39. Distress Lamp 9 ADE Code 2 2 The joystick X axis side to side when facing the console wiper signal input is outside the acceptable voltage range The wiper wire being off the wiper wire shorted to B or the wiper wire shorted to B ground could cause this difficulty Functions Disabled at Platform Only Swing Left Swing Right Telescope In Telescope Out Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 94 1 Does the joystick returnto Yes Goto step 2 94 2 the centered position when No Possible Cause 4 1 22 moved der 2 94 2 Hold the joystick atthe left Is the X Joystk Voltage Yes Goto step 2 94 3 extent Using the analyzer between 0 75 and 2 25 No Goto step 2 94 4 navigate to DIAGNOSTICS gt Volts PLATFORM gt X JOYSTK 2 94 3 Hold the joystick atthe right Is the X Joystk Voltage Yes Possible Cause 4 1 26 4 1 23 extent Using the analyzer between 2 75 and 4 25 No Goto step 2 94 4 navigate to DIAGNOSTICS gt Volts PLATFORM gt X JOYSTK 2 94 4 Place key switchin platform Measured voltage between Yes Go to step 2 94 6 position and pull the emer X061 1 and X061 2 5V No Goto step 2 94 5 gency stop switches 2 94 5 Disconnect X061 Placekey Measured voltage between Yes Possible Cause Short or Open in Yel switch in platform position X060 5 and X6
40. See 3 14 Power Module Power switch inthe ground position emergency stop switch is pulled 2 9 2 Make surethat machine is Measured RESISTANCE Yes Goto step 2 9 5 powered off and power mod between X010 10 Red wire No Goto step 2 9 3 ule is properly connected and X010 11 Black 600 inu 2 9 3 Disconnect X010 Measured RESISTANCE Yes Goto Step 2 9 4 between X010 10 pin and No X010 11 pin 1200 Possible Causes 4 1 12 2 9 4 DisconnectX054 Measured RESISTANCE Yes Goto Step 2 9 7 between X054 1 Repair platform CAN termination 054 3 50 12007 resistor atX057 2 9 5 Testforcontinuity between Yes Goto step 2 9 6 010 10 X007 13 Repair red wire between 010 10 X007 13 2 9 6 continuity between Yes Possible Causes 4 1 12 4 1 10 X010 11 and X007 24 4 1 13 No Repair black wire between X010 11 and X007 24 2 9 7 Disconnect Ground Module at Measured ground module Yes Possible Causes 4 1 12 4 1 10 X007 CAN resistance between 4 1 13 X007 13 soc and x No Repair CAN wiring between X010 and 2 10 CHASSIS TILT SENSOR GAIN NOT CALIBRATED Distress Lamp 9 ADE Code 9 9 Indicates that the chassis tilt sensor calibration information has become corrupted Vehicle will indicate that it is tilted at all times This calibration data is programmed at the factory Functions Disabled Same as Tilted Possible Causes 4 1 10 2 11 CHASSIS TILT
41. Problem Solved Figure A 1 Troubleshooting Flow Chart 3121203 T350 T500J A 5 INTRODUCTION A 2 VISUAL INSPECTION Perform a thorough visual and hands on inspection before starting any troubleshooting procedure You can quickly find the cause of many problems just by looking Has the vehicle been serviced recently Check that everything has been reconnected properly Inspect Hoses for Correct routing Pinches and kinks Splits cuts or breaks Inspect Wiring for Contact with sharp edges Contact with hot surfaces Pinched burned or chafed insulation Proper routing and connections Check Sensors and Actuators for Damage Check Electrical Connectors for Corrosion on pins Bent or damaged pins Contacts not properly seated in housing Bad wire crimps to terminals A 3 CONNECTOR REFERENCES Electrical connectors are given a three digit identifier number preceded with X See 7 1 Connector Index for a list X404 21 refers to terminal 21 pin and socket of connector X404 X404 21 soc refers to the socket side of terminal 21 connector 404 X404 21 pin refers to the pin side of terminal 21 connector 404 A 4 READING FAULT CODES Current and logged system fault codes can be read from the analyzer Refer to 9 3 Using the Analyzer User flash codes can be read from flashes of the ground or platform control panel system distress lamp Refer to A 5 User Fault Codes ADE service flash codes ca
42. 4 1 10 gency stop switch No Possible Causes 4 1 10 2 68 T350 T500J 3121203 2 61 FUNCTION PROBLEM UP AND DOWN BOTH SELECTED Distress Lamp 9 T500J MODELS ONLY SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES ADE Code 2 3 The digital inputs from both jib up and jib down ground panel switches are active Functions Disabled at Ground Only Jib Up Jib Down Step Pretest Instructions Test Result Corrective Action 2 61 1 DisconnectX032 Pullthe Is fault Function Problem Yes Goto step 2 61 2 ground emergency stop Jib Up And Down Both No Possible Causes 4 1 18 switch and place key switch in Selected still present the ground position 2 61 2 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Blue 27 2 enable switch X014 25 pin and X014 1 pin wire No Goto step 2 61 3 2 61 3 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Blue 28 2 enable switch X014 24 pin and X014 1 pin wire No Goto step 2 61 4 2 61 4 Remove X004 19 soc from Isfault Function Problem Yes Possible Causes 4 1 10 X004 Jib Up And Down Both No Possible Causes Shortin Blue 27 2 1 Selected still present wire or Blue 28 2 1 wire 2 62 FUNCTION PROBLEM JIB UP PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground jib up switch was closed when the machine was powered The switch could be accidentally held mechanically Stuck or elec
43. 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cP at 18 C 2700 at 40 C 55 cSt at 100 C 9 3 cSt Viscosity Index 152 T350 T500J 3121203 PROPOSITION 65 WARNING e Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia PO 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 Steven son 80 Suite 71 13092 310 Campinas SP JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Europe B V Jupiterstraat 234 JLG Industries Pty
44. DIAGNOSTICS Yes Goto step 1 12 3 gt GROUND gt Outrigger Possible Causes 4 1 20 4 1 19 4 1 18 switch indicators agree with 0 4 1 36 R positions u 1 12 3 Are some outriggers operating Yes Possible Causes 4 1 62 4 1 10 properly No Possible Causes 4 1 63 4 1 62 4 1 10 1 34 T350 T500J 3121203 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 13 LIFT DOWN FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 13 1 Basic check of likely causes Possible Causes 4 1 33 4 1 37 4 1 49 1 13 2 Does Manual Descentlower Yes Possible Causes 4 1 38 4 1 59 4 1 48 the boom 4 1 10 No Possible Causes 4 1 41 4 1 47 4 1 10 1 14 LIFT UP FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 14 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 14 2 Engage enable and lift up DC Is pump motor running Yes Goto step 1 14 3 switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 14 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 14 3 Install a 0 to 5000 PSI 345 bar pressure gauge atthe manifold G port Engage the enable and Lift up switch Checkthe pressure Above Min Lift Up Pressure psi bar Below Min Lift Up Pressure psi bar Goto step 1 14 5 Goto step 1 14 4 1 14 4 Plumb a 0 to 5000 PSI 345 bar pressur
45. LIFTDOWN Digital Output PWM 23 ENGINE START Digital Output 12VDC 24 ENGINE POWER MODE FUTURE Digital Input 25 NOTUSED Analog Input 26 OVERLOAD INDICATOR Digital Output 27 SYSTEMDISTRESS INDICATOR Digital Output Vbatt 28 GROUND Power Output OVDC 29 GROUND Power Output OVDC 30 GROUND Power Output OVDC 31 Depopulated 32 HOUR METER Digital Output 12VDC 33 NOTUSED Digital Output 34 SWING LEFT Digital Output 12VDC 35 SWING RIGHT Digital Output 12VDC 3121203 T350 T500J 7 170 SECTION 7 ELECTRICAL REFERENCE Table 7 4 X003 J3 Ground Module Pinout PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 Depopulated 2 FRONT LEFT O R Digital Output 12VDC 3 GROUND Power Output OVDC 4 CHOKE PULL RELAY Digital Output 12VDC 5 Depopulated 6 FRONT RIGHT O R Digital Output 12VDC 7 CHOKEHOLD SOLENOID Digital Output 12VDC 8 REAR LEFT O R Digital Output 12VDC 9 THROTTLE PULL RELAY Digital Output 12VDC 10 REAR RIGHT O R Digital Output 12VDC 11 THROTTLE HOLD SOLENOID Digital Output 12VDC 12 GROUND Power Output OVDC 13 EXTEND O R Digital Output 12VDC 14 RETRACT O R Digital Output 12VDC 7 171 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Table 7 5 X004 J4 Ground Module Pinout PIN T SERIES FUNCTION TYPE 1 0
46. Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 42 1 DisconnectsolenoidatX087 Rerun System Test Analyzer Message DUMP VALVE Repair Replace solenoid andisolate wires OPEN CIRCUIT Analyzer Message DUMP VALVE Goto step 2 42 2 SHORT TO GROUND 2 42 2 Remove wire Red Wht50 1 1 Rerun System Test Analyzer Message DUMP VALVE Wire Red Wht 50 1 1 or Red Wht 50 1 from X002 9 OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message DUMP VALVE Possible Cause 4 1 10 SHORT TO GROUND 2 43 EEPROM FAILURE CHECK ALL SETTINGS Distress Lamp 9 ADE Code 9 9 The control system detected an internal memory failure Personalities and Machine Setup settings may be reset to default values Functions Disabled Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Possible Causes 4 1 16 4 1 10 2 44 ENGINE NOT RUNNING Distress Lamp 5 ADE Code None The control system does not detect that the engine is running Engine RPM is Zero AND Machine Setup s POWER is set to 1 ENGINE If the engine will not start see 1 6 Engi
47. Ltd Unit 1 24 Industrial Com plex Herman Street Meadowdale Germiston South Africa Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude IhIpohl Bei Bremen 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 Phone 27 11 453 1334 Fax 27 11 453 1342 Plataformas Elevadoras JLG Iberica S L Trapadella 2 PI Castellbisbal Sur Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Italia Via Po 22 20010 Pregnana Milanese JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 84 93 77 11762 JLG Industries Sweden Enkopingsvagen 150 Box 704
48. No Goto step 2 150 2 2 150 2 Are any outriggers unset Yes Level the machine before trying again No 3 11 Outrigger Switches All Set 2 151 TELE OUT PREVENTED TILTED Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the telescope out position the platform is stowed but the vehicle is tilted Functions Disabled Telescope Out Step Pretest Instructions Test Result Corrective Action 2 151 1 Is the machine tilted more Yes Level the machine and try again than 2 degrees No Goto step 2 113 2 2 151 2 Analyzer DIAGNOSTICS gt Yes 3 16 Tilt Sensor er Possible Causes 4 1 10 nated 3121203 T350 T500J 2 109 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 152 TELESCOPE IN SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Telescope In digital output may be disconnected or the solenoid may be defective The start solenoid fuse should be checked Functions Disabled Telescope In Step Pretest Instructions Test Result Corrective Action 2 152 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 152 2 No Goto step 2 152 2 2 152 2 Disconnect solenoid Short Rerun System Test Analyzer Message TELESCOPE Replace solenoid and or connector X083 1 soc to X083 2 soc IN VALVE SHORT TO GROUND Anal
49. RANGE V 1 Depopulated Digital Output 2 Depopulated Digital Output 3 Depopulated Digital Output 4 ENGINE START Digital Input Vbatt 5 LEVEL DOWN Digital Input Vbatt 6 NOTUSED Digital Input 7 TELESCOPE IN Digital Input Vbatt 8 JIB DOWN Digital Input Vbatt 9 O R STOW Digital Input Vbatt 10 NOT USED Digital Input 11 TRANSPORT LIMIT Digital Input Vbatt 12 Depopulated Digital Output 13 REAR LEFT O R INDICATOR Digital Output Vbatt 14 REAR RIGHT O R INDICATOR Digital Output Vbatt 15 Depopulated Digital Output 16 ENGINE CHOKE GLOW PLUG Digital Input Vbatt 17 LEVEL UP Digital Input Vbatt 18 NOT USED Digital Input 19 JIBUP Digital Input Vbatt 20 O RSET Digital Input Vbatt 21 TELESCOPE IN LIMIT SWITCH Digital Input Vbatt 22 NOT USED Digital Input 23 LIFT UP Digital Input Vbatt 24 IGNITION Power Output OVDC 25 IGNITION Power Output OVDC 26 FRONT RIGHT O R INDICATOR Digital Output Vbatt 27 Depopulated Digital Output 28 Depopulated Digital Output 29 FRONT LEFT O R INDICATOR Digital Output Vbatt 30 TELESCOPE OUT Digital Input Vbatt 31 GROUND Power Output OVDC 32 GROUND Power Output OVDC 33 LIFT DOWN Digital Input Vbatt 34 SWING LEFT Digital Input Vbatt 35 SWING RIGHT Digital Input Vbatt 3121203 T350 T500J 7 172 SECTION 7 ELECTRICAL REFERENCE Table 7 6 X007 J7 Ground Module Pinout
50. RED 311 RED RED a T gt Buck lt iue d BLACK u 3 succ BLACK GREEN 730 GREEN ANALYZER BS 2 i E Ss Y YELRED 2 18 ALTE HELD 4 p SHIELD SHIELD DAE 2 su 2 9 sn WHITE VN ANALZER TRANSMIT Ww EC e ORNRED 422 TIL E ORANGE 5 K ORANGE Y 5 7 E BLACKSHELD lt 28 BLACKISHIELD ANALYZER GROUND 7 YELLOW F YELLOW Is vanmar IGN RELAY 86 BITTENI i ORNRED 4921 EMS lt BROW 6 BROWN 1 BROWNS 7 9 BROWN SPARE IGN RELAY 86 THE FOLLOWING POSON ARE ROT BLACK 12 i ORNRED 4927 IGN RELAY 86 14 15 17 18 19 20 BLACK 12 u 1 6 lt 3 muB 9 y ORNRED 499 DAREN ANMA ORNED 4928 ORNBLK K E ORNBLK lt ORNBLK 910 gt ORNRED 49 10 23 25 26 27 32 39 34 35 BATTERY 2 o E lt g lt 4 BLUE 284 1 RED 12 2 gt Am 83 d lt BRNBLK lt BRNIBLK lt BRNIBLK BRNBLK S BRNBLK gt 2 5 BLACK RED 12 UN lt PUMP i Tal i WHTIVEL 48 1 m lt TO SYSTEM gt NOT AVAILABLE 8 24V SYSTEM B E d ON JIB MODEL GFEB D RED WIRING INFO FOR SEVCON FOR CONNECTOR WIRING
51. Resistance gt 1kOhms between 2 and B Ensure that there is an open circuit between the M2 and B Terminals Inter nally there are MOSFET transistors between these terminals that should be high impedance when the module is un powered Place the Black meter lead on B and the Red meter lead on M2 Note that a measurement of increasing resistance capacitor charge is normal but a persistently low impedance is not 7 Resistance 120 Ohms between Pins 10 amp 11 Ensure that the resistor that terminates the CAN bus is within tolerance between pins 10 and 11 on the 12 position Mini Fit Jr Connector B Place the Red meter lead on pin 10 and the Black meter lead on pin 11 The resistance should measure between 110 130 Ohms 3121203 350 T500J 3 119 3 Pump Motor Electrical Evaluation Several basic electrical tests can be performed on the Pump Motor Failure of one of these evaluations is significant and may indicate that the device is physically damaged 1 Make all measurements with a voltmeter set to resistance scale Ohms Disconnect the Main Battery Disconnect and all pump motor cables during this analysis 2 Resistance 5 Ohms between Motor Terminals The internal windings are very low impedance and should appear to be a short circuit for an ordinary voltmeter other tests can determine if the windings are truly shorted High resistance can signal worn brushes a faulty commut
52. The boom must be completely telescoped in closing the telescope limit switch before the outriggers can be stowed Functions Disabled Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 122 1 Is the boom fully retracted Yes See 3 15 Telescope Limit Switch No Retractthe boom 2 123 OUTRIGGERS PREVENTED ELEVATED Distress Lamp 2 ADE Code 2 5 The ground module senses the ground panel outrigger switch is in the set or stow position but the boom transport limit switch is open The boom must be completely lowered into transport position closing the transport limit switch before the outriggers can be moved Functions Disabled Set Extend O R Step Pretest Instructions Test Result Corrective Action 2 123 1 Is the boom fully lowered Yes 3 17 Transport Limit Switch No Lower the boom 2 124 PLATFORM POSITION DETECTION FAULTY Distress Lamp 9 ADE Code 2 1 The platform console may optionally be plugged into the chassis for use with the material hook The proper voltages are not being measured at the Platform Position Analog Inputs X007 7 and X007 8 to determine whether the Platform Console is plugged in at the Platform or Chassis Connectors X007 7 should be B and X007 8 should be GND when the Platform Con sole is plugged into the Platform Connector X007 7 should be GND and X007 8 should be B when the Platform Console is plugged into the Chassis Con
53. X004 Ground Module J4 AS355P Blue 36 Figure 7 2 X007 Ground Module J7 AS351P Black 3D Figure 7 2 X008 Ground Module J8 MO4P 3E Figure 7 2 X009 IGN Relay No Drawing 5F Figure 7 2 X010 Power Module Sevcon P MMF12P 26 Figure 7 2 X011 Main Harness power No Drawing 10 Figure 7 2 X012 Drive Module DTO6R X013 Ground Module Supply DTPO2P DTPO2R 5H Figure 7 1 X014 Ground Control Panel DHTP31P plug DHTP31R recepta 4H Figure 7 1 cle X015 Transport Limit Pass through DTO2R DTO2P 4F Figure 7 1 X016 Lift Down Pass through DTO2R DTO2P 1G Figure 7 1 X017 Strobe Alarm Pass through DTO4R DTO4P 2F Figure 7 1 X018 Tele Limit Pass through DT02P DT02R 4F Figure 7 1 019 Boom Cable DT12AP DT12AR 4E Figure 7 1 X020 Outrigger Switches Pass through DT12AR DT12AP 2C Figure 7 1 X021 Valves Pass through DT12AR DT12AP 2B Figure 7 1 X022 Engine Pass through DTO8AR DTO8AP 4B Figure 7 1 X023 Ground Outriggers Sw 06 4 Figure 7 4 X024 Ground Swing Sw 06 46 Figure 7 4 X025 Ground Enable Sw No Drawing 4 Figure 7 4 X026 Ground Key Sw No Drawing 5G Figure 7 4 X027 Ground Hour Meter No Drawing Figure 7 4 X028 Ground Alarm No Drawing Figure 7 4 X029 Analyzer Port AMPO4P 1 Figure 7 4 X030 Ground LED Board MMFO8P 4 Figure 7 4 X031 Ground LiftSw E06P 4G Figure 7 4 X032 Ground Sw E06P 4G
54. i I MS LVIS WAR NMOa 001 0 GM AUD 1 00 9 03000 ES0 NadO 2USADCA 1354074 ne i 9 001 0196001 1 XISAOPA WA an Lan 1 1 100901000 E uSJOnX 1 I 6001 0196001 ALSAOPX I I Nado ur INNI 1 55070 T Er NadO MS LAT Nado dn i i WK ae Bro dnd N340 8 I I 1 1 mum NO HO 001 0 asso 8Ir ENIMS LAN NO SET WMd N3dO LVIS BAJT H3994 1 I I I S3AWA WHOA Sa SOLLSONSVIG 9 208 350 T500J 3121203 senjeuosJag 1Jez euy 7 6 uodn Buipuedep jou sueeJos jeu esbeoj d lt Jez A pue 4 550 sepnjoui umoys Inofe FLLON 3121203 SECTION 9 JLG ANALYZER 00 056 XVW 001 0 A34 H 001 0 001 0 XVW A38 1 A08 2 092 9608 9608 0 96001 0 NIN 0 d3349 A34 1 i AOS L 00 L 001 1 001 001 s XVW 1431 MOLS L XYN NG LXVIN NG L LNO 2 022 96001 95001 96001 001 NIN 1431 L MOLS I Na L NIN LNO i A00 v 0S E 96001 960
55. repair open between X013 1 Vbatt Repair open in Red 1 1 3121203 T350 T500J 3 123 3 3 10 JOYSTICK DIAGNOSTICS Step Pretest Instructions Test Result Corrective Action 3 10 1 Usingthe analyzer navigateto Is the X Joystk Voltage Yes Goto step 3 10 2 DIAGNOSTICS gt PLAT between 2 25 and 2 75 N 10 FORM gt X JOYSTK 0 Goto step 3 10 3 3 10 2 Using the analyzer navigate to Is the Y Joystk Voltage Yes Possible Causes 4 1 23 4 1 22 DIAGNOSTICS gt PLAT between 2 25 and 2 75 N to step 3 10 FORM gt Y JOYSTK 3 10 3 Pullthe ground emergency Using a multimeter is the Yes Goto step 3 10 4 Stop switch and place key voltage between X061 4 and No Goto step 3 1 switch in platform position X062 2 between 2 25V and Keep the joystick centered 2 75V 3 10 4 Pullthe ground emergency Using a multimeter is the Yes Possible Causes Intermittent Voltage stop switch and place key voltage between X061 3 and fluctuation 4 1 22 switch in platform position X062 2 between 2 25V and Goto step 3 10 5 Keep the joystick centered 2 75V peus 3 10 5 Voltage between X061 1 and Yes Possible Causes 4 1 22 X061 2 5V 0 5 No Goto step 3 10 6 3 10 6 Voltage between X060 5 and Yes Repair broken wire Yel Red 2 18 or X060 7 5V 4 0 5 black between Platform module and joystick No
56. 1 10 2 50 FRONT LEFT SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Front Left Outrigger Valve digital output may be shorted to ground or the solenoid may be defective Functions Disabled Front Left O R Step Pretest Instructions Test Result Corrective Action 2 50 1 Disconnect solenoid atX046 Rerun System Test Analyzer Message F L OUTRIG Repair Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message F L OUTRIG Goto step 2 50 2 GER VALVE SHORT TO GROUND 2 50 2 Remove wire Orn Red 49 5 Rerun System Test Analyzer Message F L OUTRIG Wire Orn Red 49 5 or White wire to from X003 2 GER VALVE OPEN CIRCUIT X046 shorted to ground Repair or replace Analyzer Message F L OUTRIG Possible Cause 4 1 10 GER VALVE SHORT TO GROUND 3121203 T350 T500J 2 63 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 51 FRONT RIGHT 0 R SOLENOID OPEN CIRCUIT Distress Lamp 9 relay may be defective ADE Code 3 3 Ground module feedback shows that the Front Right Outrigger digital output may be disconnected from the relay or the Functions Disabled Front Right O R Step Pretest Instructions Test Result Corrective Action 2 51 1 Runsystem test Do other functions fail sys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise Goto step 2 51 2 No Goto step 2 51 2 2 51 2 Di
57. 143 5 86 F L OUTRIGGER VALVE SHORT TO 5 143 5 87 E RO RIVALWE Stat ara exc dre n PR en tenter me nn cett e e og 5 143 5 88 F R OUTRIGGER LAMP ON 5 143 5 89 F R OUTRIGGER VALVE OPEN 4 5 144 5 90 F R OUTRIGGER VALVE SHORT TO 5 144 5 91 F R OUTRIGGER VALVE SHORT TO 5 144 5 92 GROUND ALARM ON 3 8 048 ee Pont Oba ac 5 144 5 93 TILT ANGLE oe xa RR PE ER dame ic eec dede 5 144 5 94 JIB DNVABVE wei MEE Rex rerba 5 144 5 95 JIB DOWN CLT eget ec e o ee eta Cle dee te dade LR ns De ee e 5 144 5 96 JIB DOWN VALVE OPEN 1 5 144 5 97 JIB DOWN VALVE SHORT 5 145 5 98 JIB DOWN VALVE SHORT TO 5 145 5 99 JIB URIGE Ha ur ne Tees ee er 5 145 5 100 JIB UP VALVE rn nre ia m Rei certi ERROR gea ace act ee 5 145 5 101 JIB UP VALVE 5 145 5 102 JIB UP VALVE SHORT TO BATTE
58. 15 ORNRED 49 29 BOO NN SEE Ce LOCATION i CONTROL CABLE CABLE m 2s POWER MODULE IN 1600371 ORNRED 4025 HOOK GND SHIELD CAN BUS CABLE CONTROL REMOTE YELRED243 GN RELAY87 i 4 24VSYSTEM D THE FOLLOWING J7 POSITIONS ARE NOT USED JIB DOWN PWM 4 5 9 10 14 15 16 20 21 22 TT ENGINE MAG SPEED PICK UP BLACK 12 gt i FRONTILEFT OUTRIGGER SET LIMITSWITCH BLACK lt CORN RED 49 1 5514012580 WHTYELAET SEE ENGINE AREA B4 RU i FRONTRIGHT OUTRIGGER SETLIMITSWITCH mt BLACK ORNRED 492 REARILEFT OUTRIGGER SET LIMIT SWITCH 2 ORNRED 493 es YEURED 2 18 REAR RIGHT OUTRIGGER SET LIMIT SWITCH 7 BLACK ORNIRED 49 4 d i WHITE lt lt YEURED 24 mi ABOUT HALL EFFECT PLATFORM JOYSTICK 5 POWER MODULE CONNECTOR NO OIL a X00743 CAN HI RED DETAIL AND LOCATION PRESSURE USE JUMPER FROM 17 ON 00724 CAN LO BLACK ELECTRIC ONLY ENGINE POWERED MACHINES ONLY i 090 ENGINE STOP RELAY YELRED 24 IGN RELAY 87 ORNRED 495 WHITE 206 FRONTAEFT OUTRIGGER ORN RED 49 7 gt WHITE X048 REAR LEFT OUTRIGGER 1 CHOKE PULL LIS qe WITYEL 484 THE FOLLOWING J3 POSITIONS ORNRED 496 WHITE JT FRONTRIGHT OUTRIGGER Em X091 ENGINE THROTTLE PULL RELAY THROTTLE HOLD EL WHTIVEL 4 3 ARE NOT USED 1 5 ONET 5S3 gt 29 2088 exten OF mi THROTTLE PULL TITE WHTIVEL 482 owes FT 2 X003 0 BLACK z CHOKE
59. 22 Depopulated Digital Output 23 Depopulated 24 CONSTANT BATTERY Power Input 12VDC 25 Depopulated 26 Depopulated 27 GROUND Power Output OVDC 28 ANALYZER POWER Power Output 9 5VDC 29 RS 232 RECEIVE Serial Input Digital Comm 30 RS 232 TRANSMIT Serial Output Digital Comm 31 ANALYZER RETURN Power Output OVDC 32 Depopulated Power Output 33 GROUND Power Output OVDC 34 NOTUSED Digital Input 35 ELECTRIC POWER MODE FUTURE Digital Input 7 169 T350 T500J 3121203 Table 7 3 X002 42 Ground Module Pinout SECTION 7 ELECTRICAL REFERENCE PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 Depopulated 2 Depopulated 3 NOTUSED Digital Output 4 TELESCOPE IN Digital Output 12VDC 5 LEVELUP Digital Output 12VDC 6 GROUND Power Output OVDC 7 LEVEL DOWN Digital Output 12VDC 8 OPTIONAL GROUND ALARM Digital Output PWM 9 DUMP VALVE Digital Output PWM 10 ROTATE LEFT FUTURE Digital Output 11 LIFTUP Digital Output 12VDC 12 JIBUP Digital Output 12VDC 13 Depopulated 14 GROUND Power Output OVDC 15 NOTUSED Digital Output 16 TELESCOPE OUT Digital Output 12VDC 17 GROUND Power Output OVDC 18 GROUND Power Output OVDC 19 GROUND ALARM Digital Output PWM 20 JIBDOWN Digital Output PWM 21 ROTATE RIGHT FUTURE Digital Output 22
60. 3 broken jumper to 002 14 VALVE SHORT TO GROUND Repair or replace Analyzer Message LIFT UP Possible Cause 4 1 10 VALVE OPEN CIRCUIT 2 115 LIFT UP SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Lift Up digital output may be shorted to battery or other function Functions Disabled Lift Up Step Pretest Instructions Test Result Corrective Action 2 115 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise goto step 2 115 2 No Goto step 2 115 2 2 115 2 Disconnect solenoid at X084 Rerun System Test Analyzer Message LIFT UP Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message LIFT UP Goto step 2 115 3 VALVE SHORT TO BATTERY 2 115 3 Remove wire 3 3 1 from Rerun System Test Analyzer Message LIFT UP Wire Tan 3 3 1 or Tan 3 3 shorted to X002 11 VALVE OPEN CIRCUIT battery Repair or replace Analyzer Message LIFT UP Repair Replace wire Tan 3 3 1 VALVE SHORT TO BATTERY 2 94 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 116 LIFT UP SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Lift Up digital output may be shorted to ground or the solenoid may be defective Functions Disabled Lift Up Step Pretest Instructions Test Result Corrective
61. 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 97 JIB DOWN VALVE SHORT TO BATTERY The system test detected a short to battery in the Jib Down valve circuit See 2 89 Jib Down Solenoid Short To Battery 5 98 DOWN VALVE SHORT TO GROUND The system test detected a short to ground in the Jib Down valve circuit See 2 90 Jib Down Solenoid Short To Ground 5 99 JIB UP CL System test response indicating that the ground Jib Up switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 100 JIB UP VALVE System test prompt indicating that it is currently testing this circuit 5 101 UP VALVE OPEN CIRCUIT The system test detected an open in the Jib Up valve circuit See 2 91 Jib Up Solenoid Open Circuit 5 102 UP VALVE SHORT TO BATTERY The system test detected a short to battery in the Jib Up valve circuit See 2 92 Jib Up Solenoid Short To Battery 5 103 UP VALVE SHORT TO GROUND The system test detected a short to ground in the Jib Up valve circuit See 2 93 Jib Up Solenoid Short To Ground 5 104 JOYSTICK FORWARD TO System test prompt to move the platform joystick forward to the extent for the system to check the voltage Move the joystick all the way forward to continue the system test Otherwise see possible cause 4 1 22 5 105 JOYSTICK LEFT TO MAX System test prompt to move the platform joystick left to the extent for
62. 345 bar Engage the enable and Tele Above Min Tele Out Pressure psi Goto step 1 15 5 pressure gauge atthe manifold scope Out switch Checkthe G port pressure Below Min Tele Out Pressure psi Goto step 1 15 4 bar 1 15 4 Plumb a 0 to 5000 PSI 345 Engage the enable and Tele Above Min Tele Out Pressure psi Possible Causes 4 1 38 4 1 45 bar pressure gauge into the scope Out switch Check pres bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port sure at manifold P port Below Min Tele Out Pressure psi Possible Causes 4 1 10 4 1 46 bar 4 1 47 4 1 74 4 1 45 4 1 39 1 15 5 Plumb a 010 5000 PSI 345 Check pressure atthe tele Above Min Tele Out Pressure psi Possible Causes 4 1 49 4 1 48 4 1 41 Possible Causes 4 1 42 4 1 50 1 16 TELESCOPE IN FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 16 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 16 2 Engage enable andtelescope DC Is pump motor running Yes Goto step 1 16 3 in switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 16 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 16 3 Install a 0 to 5000 PSI 345 bar pressure gauge atthe Engage the enable and Tele scopein switch Checkthe Above Min Tele In Pressure psi bar Goto step 1 16 5 manifold port pressure Bel
63. 4 1 10 4 1 47 bar pressure gaugeintothe switch does pressure rise No Possible Causes 4 1 37 4 1 45 4 1 74 manifold P port above 100PSI minimum func 41754139 tion pressure Kati 1 2 PUMP MOTOR WILL NOT OPERATE DC POWERED MODELS Step Pretest Instructions Test Result Corrective Action 1 2 1 Voltage between and B Yes Goto step 1 2 2 X102 and X101 Vbatt No See 3 2 DC Powered Machine Power 1 2 2 Engage enable and lift up Voltage between M1andM2 Yes Goto step 1 2 3 Switch X103 and X104 Vbatt No Possible Causes 4 1 12 1 2 3 Engage enable and lift up Voltage between X115 and Yes Possible Causes 4 1 69 Switch X114 Vbatt No Goto step 1 2 4 1 2 4 Engage enable and lift up Voltage between X115 and Yes Goto step 1 2 5 Switch X101 Vbatt No Possible Causes 4 1 70 4 1 72 4 1 12 1 2 5 Engage enable and lift up Voltage between X114 and Yes Possible Causes 4 1 12 switch X102 Vbatt No Possible Causes 4 1 71 4 1 72 4 1 12 3121203 T350 T500J 1 29 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 3 ALL FUNCTIONS INOPERATIVE ENGINE STARTS AND RUNS ENGINE MODELS Step Pretest Instructions Test Result Corrective Action 1 3 1 Basic check of likely causes Possible Causes 4 1 68 1 3 2 Try both ground and platform One set of controls functions See 1 10 Ground Controls Inoperative or controls 1 11 Platform Controls Inoperative Both sets of c
64. 5000 11 222 Hydraulic Oil 2 nnt eiie oed eod ae 11 222 Mobilfluld 424 SPECS x RUM E etr HR BR Ded e ER lbs s don 11 223 T350 T500J 3121203 SECTION 1 TROUBLESHOOTING BY FUNCTION SECTION 1 TROUBLESHOOTING BY FUNCTION 1 1 ALL FUNCTIONS INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 1 1 Basic check of likely causes Possible Causes 4 1 66 4 1 67 4 1 68 14 2 Do panel indicatorlights blink Yes Goto step 1 1 3 at power on No Ground controller not powered Perform component check 3 2 DC Powered Machine Poweror3 7 Engine Powered Machine Power 1 1 3 Try both ground and platform One set of controls functions See 1 10 Ground Controls Inoperative or controls 1 11 Platform Controls Inoperative Both sets of controlinoperable Goto step 1 1 4 1 1 4 Is the hydraulic pump motor Yes Goto step 1 1 5 running while activating afunc Perform component check 3 1 DC tion Powered Machine Hydraulic Pump or 3 6 Engine Powered Machine Hydrau lic Pump 1 1 5 Connecta 0 5000 PSI pres While holding enable and liftup Yes Possible Causes 4 1 37 4 1 47 sure gauge atthe manifold G switch does pressure rise No Goto step 1 1 6 port above 100PSI minimum func tion pressure 1 1 6 Plumba0to 5000 PSI 345 While holding enable andliftup Yes Possible Causes 4 1 40
65. 6 1 Does the engine turn the Yes Possible Causes 4 1 37 4 1 43 pump 4 1 46 4 1 39 No Possible Causes 4 1 73 3 7 ENGINE POWERED MACHINE POWER Step Pretest Instructions Test Result Corrective Action 3 7 1 Disconnect battery and check lessthan 12V Charge or replace batteries for 12V across terminals 12V or greater Goto step 3 7 2 3 7 2 Disconnect X008 Measure voltage between Vbatt Goto step 3 7 3 X099 and X008 1 soc ov Possible Causes 4 1 5 4 1 1 3 7 3 Pullthe ground emergency Check Voltage on X008 2 OV Goto step 3 7 4 stop switch and place key Vbatt Battery Power OK switch in ground position 3 7 4 Pullthe ground emergency Check Voltage on X009 87 OV See 3 9 Ignition Relay Power stop switch and place key Vbatt Repair open in YEL RED 2 8 switch in ground position 3 8 GROUND MODULE POWER Step Pretest Instructions Test Result Corrective Action 3 8 1 Pullthe ground emergency Voltage between X008 2 and Yes Ground Module Power OK Possible stop switch and place key X008 1 Vbatt Causes 4 1 10 Switch in ground position No Goto step 3 8 2 3 8 2 Testfor continuity between Yes 3 2 DC Powered Machine X008 1 and B X101 for Poweror3 7 Engine Powered electric X100 for engine Machine Power No Repair black ground wire between 008 1 and B 3 122 T350 T500J 3121203 3 9 IGNITION RELAY POWER SECTION 3 COMPONENT CHECKS Step Pretest Instructions Test Resul
66. 64 3 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Pink 26 2 enable switch X014 26 pin and X014 1 pin wire No Goto step 2 64 4 2 64 4 RemoveX004 17 socfrom Is fault Function Problem Yes Possible Causes 4 1 10 004 Level Up DownBoth Possible Causes Short in Pink 25 2 1 Selected still present wire or Pink 26 2 1 wire 2 70 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 65 FUNCTION PROBLEM LEVEL UP PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground level up switch was closed when the machine was powered The switch could be accidentally held mechani cally stuck or electrically shorted Functions Disabled at Ground Only Level Up Step Pretest Instructions Test Result Corrective Action 2 65 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 65 2 2 65 2 DisconnectX034 Placekey Is fault Function Problem Yes Goto step 2 65 3 switch in ground position and Level Up Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 65 3 Remove X014 27 pin from Is fault Function Problem Yes Goto step 2 65 4 X014 Place key switch in Level Up Permanently No Possible Causes Shortin Pink 25 2 ground position and pullthe Selected still present wire emergency stop switch 2 65 4 Place key switch in ground Measured voltag
67. 8 eg s norusen RN V TURN SIGNAL MODULE RED j i jj LOGIC CIRCUIT FOR LEFT P CENTER BRAKE LIGHT SIDE MARKER LEFT C TAL AMBER Lu RED ANSI amp ANSI EXPORT SPECS WITH ELECTRIC BRAKES RED 5 TURN 10V SIGNAL RED zr RIGHT mM mE SIDE MARKER 4 a 20 UGHT RED z6 E 5 BE 5 a TUA WHITE GD lt 00 WHITE WHITE WHITE RED BROWN BROWN BROWN m YELLOW YELLOW YELLOW YELLOW 5 GREEN RT RT GREEN GREEN GREEN CENTER 1 BRAKE LIGHT Su EM um TE i BLACK 275 NOT USED gs V TURN BRAKE BLUBLK SIGNAL MODULE RED ME LOGIC CIRCUIT FOR IT 5 x CENTER BRAKE LIGHT SIDE MARKER LEFT TAL AMBER BRAKE LIGHT RED 3121203 Figure 7 19 Electrical Schematic Trailer T350 T500J 7 188 SECTION 7 ELECTRICAL REFERENCE 7 189 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES SECTION 8 HYDRAULIC REFERENCES 3121203 350 T500J 8 190 SECTION 8 HYDRAULIC REFERENCES 8 1 SOLENOIDS Connector Function Nominal Resistance Ohms X077 Swing Left 8 0 X078 Swing Right 8 0 X079 Jib Up T500J 8 0 X056 Jib Down T500J 9 8 X080 Level Up 8 0 X081 Level Down 8 0 X082 Telescope Out 8 0 X083 Telescope In 8 0 X084 Lift Up 8 0 X039 LiftDown 9 8 X085 Outrigger Stow 8 0 X086 Outri
68. Causes 4 1 40 4 1 10 4 1 47 bar pressure gaugeintothe switch does pressure rise No Possible Causes 4 1 37 4 1 45 4 1 39 manifold P port above 100PSI minimum func ged venta tion pressure 1 30 T350 T500J 3121203 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 5 BATTERY CHARGER NOT FUNCTIONING PROPERLY Delta Q Charger Normal Operation Description Stage Description Startup The charger will automatically turn on and go through a short self test with the LED indicator alternating red green fortwo sec onds If the charger is connected to a battery pack atrickle current will be applied until a minimum voltage is reached If the charger is used in an off board application and the charger is waiting to be plugged into a battery pack the charging algorithm number will be displayed for 11 seconds before ultimately displaying an under voltage fault fault disappears when plugged into battery pack Typically lasts from 5 seconds to 2 minutes Bulk Typically 8096 of the total recharge is restored during the bulk phase where a constant 25 Amp output is being delivered This time varies depending upon the depth of discharge Absorption Outputreduced to prevent sulfation build up Time depends upon the initial level of battery charge and varies from 1hour mini mum to 5 1 2 hours At completion of this phase 90 charge has been obtained Finish Delivers for at least 1 hour to finish charge There wil
69. Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 54 1 Does the joystickreturnto Yes Goto step 2 54 2 the centered position when No Possible Cause 4 1 22 moved 2 54 2 Performacheck ofthe Joy Fault still present after power Goto step 2 54 3 stick see 3 10 Joystick cycle Diagnostics 2 54 3 Performthe voltmeter joystick Using a multimeter is the Yes Go to step 2 54 4 testof 3 10 Joystick Diag voltage between X061 4 and uo Possible Causes 4 1 22 4 1 11 nostics while powering the X062 2 between 2 25V and machine 2 75V 2 54 4 Performthe voltmeter joystick Using a multimeter is the Yes Possible Causes 4 1 11 testof 3 10 Joystick Diag voltage between X061 3 and wo Possible Causes 4 1 22 4 1 11 nostics while powering the X062 2 between 2 25V and machine 2 75V 3121203 T350 T500J 2 65 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 55 FUNCTION LOCKED OUT TRIGGER PERMANENTLY CLOSED Distress Lamp 1 ADE Code 2 2 The platform trigger was closed when the platform was powered The switch could be accidentally held mechanically stuck or electrically shorted Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right
70. Engage enable and lift up Voltage between X115 and Yes Possible Causes 4 1 69 switch X114 Vbatt No Goto step 314 3 1 4 Engage enable and lift up Voltage between X115 and Yes Goto step 3 1 5 Switch X101 Vbatt No Possible Causes 4 1 70 4 1 72 4 1 12 3 1 5 Engage enable and lift up Voltage between X114 and Yes Possible Causes 4 1 12 Switch X102 Vbatt No Possible Causes 4 1 71 4 1 72 4 1 12 3 2 DC POWERED MACHINE POWER Step Pretest Instructions Test Result Corrective Action 3 2 1 Disconnect batteries and less than 6V Charge or replace batteries check for 6V across each bat 6V or greater Goto step 3 2 2 tery 3 2 2 DisconnectX105 Checkfor 24V across 105 0V Repair open in battery cables orter minals 24V Goto step 3 2 3 3 2 3 Measure Voltage across Power 0V Repair open in battery cables orter Module X102 and X101 minals B 24V Goto step 3 2 4 3 2 4 Pullthe ground emergency Check Voltage on X008 2 OV Goto step 3 2 5 stop switch and place key Vbatt Battery Power OK Switch in ground position 3 2 5 Pullthe ground emergency Check Voltage on X009 87 0 See 3 9 Ignition Relay Power Stop switch and place key Vbatt Repair open in YEL RED 2 8 Switch in ground position 3 3 DC POWERED MACHINE POWER MODULE Theory of Operation The Power Module is essentially a low side switch for the pump motor The positive terminal of the pump is tied to Battery Positive after the Line Contactor The
71. FUNCTION PROBLEM TELESCOPE IN PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground telescope in switch was closed when the machine was powered The switch could be accidentally held mechanically stuck or electrically shorted Functions Disabled at Ground Only Telescope In Step Pretest Instructions Test Result Corrective Action 2 71 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 77 2 2 77 2 DisconnectX033 Placekey Isfault FunctionProblem Yes Goto step 2 77 3 switch in ground position and Telescope In Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 71 3 Remove X014 20 pin from Is fault Function Problem Yes Goto step 2 77 4 X014 Place key switch in Telescope In Permanently No Possible Causes Shortin Brown 13 2 ground position and pullthe Selected still present wire emergency stop switch 2 71 4 Place key switch in ground Measured voltage at X004 7 Yes Possible Causes Short in Brown 13 position and pull the emer Vbatt 2 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 3121203 T350 T500J 2 77 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 78 FUNCTION PROBLEM TELESCOPE OUT PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground telescope out switch was closed when the machine was powered The switch could be accidentally held mechanicall
72. Figure 7 4 X033 Ground Tele Sw 06 4G Figure 7 4 X034 Ground Level Sw 06 4G Figure 7 4 X035 Ground Choke Sw No Drawing 4H Figure 7 4 X036 Ground Start Sw No Drawing 4 Figure 7 4 X037 EMG Stop No Drawing 5G Figure 7 4 X038 Strobe Light DTO2R DTO2P 1E X039 Lift Down Valve Solenoid DTO2P 16 Figure 7 1 X040 Transport Limit Sw No Drawing 4F Figure 7 1 041 Tele Limit Sw No Drawing 4 Figure 7 1 X042 F L Outrigger Limit Sw No Drawing 40 Figure 7 1 043 F R Outrigger Limit Sw No Drawing 4D Figure 7 1 X044 R L Outrigger Limit Sw No Drawing 4D Figure 7 1 X045 R R Outrigger Limit Sw No Drawing 4D Figure 7 1 X046 F L Outrigger Valve Solenoid DTO2P 1C Figure 7 1 3121203 T350 T500J 7 166 SECTION 7 ELECTRICAL REFERENCE Table 7 1 Connector Index m Location in Schematic 2 Description End 1 ID End 2 ID Figure 7 3 Drawings X047 F R Outrigger Valve Solenoid DTO2P 1 Figure 7 1 X048 R L Outrigger Valve Solenoid DTO2P 16 Figure 7 1 X049 R R Outrigger Valve Solenoid DTO2P 1B Figure 7 1 X050 Motion Alarm DTO3P 1F X051 LiftHook Harness to X019 DT12AR 4 Figure 7 4 X052 Lift Hook Harness to X054 DT12AP Figure 7 4 053 LiftHook Harness to Console X058 DHD14
73. Ibs 200 kg 440 bs 200 kg Maximum Work Load Capacity w o Rotator 500105 230 kg 500105 230 kg Maximum Work Load Capacity w Rotator amp Panel Tray 320 Ibs 145 kg 320 Ibs 145 kg Maximum Work Load Capacity w o Rotator amp w Panel Tray 350165 158 kg 350105 158 kg Material Hook Capacity Optional 500105 230 kg 500105 230 kg Accessory Tray Capacity 2501 5 114 kg 250 bs 114 kg Panel Tray Capacity w Rotator 70 Ibs 32 kg 7013 32 kg Panel Tray Capacity w o Rotator 100 Ibs 45 kg 100 Ibs 45 kg Swing 410 non continuous 410 non continuous Max Vertical Platform Height Unrestricted 35 ft 10 6 50ft 15 2m Vertical Reach unrestricted 35 ft 10 4m 5011 15 2m Horizontal Reach from centerline ofmachine from outrigger pad edge 20ft 6 1 m 14 ft 4 27 m 31 ft 9 45 m 25 ft 7 62 m Up and Over Clearance 15ft 4 57 m 18ft 5 49 m Maximum Outrigger Load 1950 Ibs 884 5 kg 2660 1206 5 kg Maximum Ground Bearing Pressure 22 5 psi 1 58 kg cm 30 7 psi 2 15 kg cm Maximum Travel Gradeability 2096 2096 Maximum Sideslope 11 11 Max Hydraulic System Pressure 2700 psi 186 Bar 2950 psi 203 Bar Maximum Operating Wind Speed 28 mph 12 5 m s 28 mph 12 5 m s Maximum Horizontal Manual Force 90 Ib force 400 90 Ib force 400 Electrical System Voltage Elect
74. Message TELESCOPE Goto step 2 155 3 OUT VALVE OPEN CIRCUIT 2 155 3 Replace X002 16 with a Rerun System Test Analyzer Message TELESCOPE Wire Brown 14 3 1 or Brown 14 3 jumperto X002 14 OUT VALVE SHORT TO GROUND broken Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 OUT VALVE OPEN CIRCUIT 2 156 TELESCOPE OUT SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Telescope Out digital output may be shorted to battery or other function Functions Disabled Telescope Out Step Pretest Instructions Test Result Corrective Action 2 156 1 Run systemtest Do other functions fail sys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise go to step 2 156 2 No Goto step 2 156 2 2 156 2 Disconnect solenoid atX082 Rerun System Test Analyzer Message TELESCOPE Replace solenoid OUT VALVE OPEN CIRCUIT Analyzer Message TELESCOPE Goto step 2 156 3 OUT VALVE SHORT TO BAT 2 156 3 Remove wire Brown 14 3 1 Rerun System Test Analyzer Message TELESCOPE Wire Brown 14 3 1 or Brown 14 3 from X002 16 OUT VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 OUT VALVE SHORT TO BAT TERY 2 112 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 157 TELESCOPE OUT SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Telescope Out
75. O R Set Extend O R Stow Retract O R Usingthe analyzer navigate to DIAGNOSTICS gt PLAT FORM does the analyzer show is selected Diagnostic Message LIFT SWING SEL Diagnostic Message JIB TELE SELECT Step Pretest Instructions Test Result Corrective Action 2 55 1 Is the trigger mechanically Yes Repair or replace the joystick trigger stuck No Goto step 2 55 2 2 55 2 Disconnect X061 Make sure Testforcontinuitybetween Yes Possible Causes 4 1 22 trigger is not engaged X061 5 pin and X061 6 pin No Goto step 2 55 3 2 55 3 Disconnect X061 Pullthe ground emergency Fault Message JOYSTICK Possible Causes 4 1 22 stop switch and placekey FAULTY Y AXIS WIPER OUT OF switch in platform position RANGE Fault Message FUNCTION Goto step 2 55 4 LOCKED OUT TRIGGER PER MANENTLY CLOSED 2 55 4 Place key switch in the plat Does the displayed function Yes Repairthe Yel Red 2 17 wire between form position and pull the selected change as you X060 6 and X063 orthe rotary select emergency stop switches change the rotatory select switch Using the analyzer navigateto switch No Goto step 2 DIAGNOSTICS gt PLAT FORM 2 55 5 Place key switchintheplat With the rotary selector Diagnostic Message LEVEL Possible Causes Shortin wire Orn form position and pull the switch in the platform level SELECT Red 49 27 4 1 11 emergency stop switches ing position which fu
76. Operating 8 191 9 JLG ANALYZER Introduction oto as Hs eI CASU ETE UL 9 202 To Connect the JLG Control System 9 203 Using the Analyzer eode emet eee oe Eua rb Pea e p Dd ge db RS 9 203 Changing the Access Level of the Hand Held 9 204 Adjusting Parameters Using the Hand Held Analyzer 9 205 Machine 5 5 mee eR ee ee dase da e Rea tete ier en 9 206 Systemi Test cas oa adeunt e Coe tie a d celo 9 210 User Fault Codes u ae ar adr PG e Ma ee bua eie pe AA 9 212 SECTION 10 MULTIMETER BASICS 10 1 Introduction eh bim eere Eee bra bu 10 214 SECTION 11 SPECIFICATIONS 11 1 Introduction uem de adi Rex ees pied tere eddie Aaa tied uie 11 218 11 2 Operating specifications 11 218 LIST OF FIGURES FIGURE NO TITLE PAGE NO A 1 Troubleshooting Flow A 5 2 Ground Module Fault LED A 6 A 3 Power Module Fault LED ion enui i a Ed RM ier d eod qned deer e ded A 7 A 4 Basic Electronic Module Connections A 15 2 1 Pl
77. Possible Causes 4 1 11 3 11 OUTRIGGER SWITCHES ALL SET Step Pretest Instructions Test Result Corrective Action 3 11 1 Analyzer DIAGNOSTICS gt OFF Goto step 3 11 2 3 11 2 Disconnect X020 Testforcontinuity between Yes Possible Causes Broken Orn Red 49 X020 1 and X020 2 1 or Yel Red 2 6 Wire 4 1 10 No Possible Causes 4 1 19 4 1 20 4 1 18 broken white or black wire between X020 and X042 3 11 3 Analyzer DIAGNOSTICS OFF Goto step 3 11 4 GROUND gt F R O R SET ON Goto step 3 11 5 3 11 4 DisconnectX020 Testforcontinuity between Yes Possible Causes Broken Orn Red 49 X020 1 and X020 3 2 or Yel Red 2 6 Wire 4 1 10 No Possible Causes 4 1 19 4 1 20 4 1 18 broken white or black wire between X020 and X043 3 11 5 Analyzer DIAGNOSTICS OFF Goto step 3 11 6 GROUND gt R L O R SET ON Goto step 3 11 7 3 11 6 Disconnect X020 Testfor continuity between Yes Possible Causes Broken Orn Red 49 X020 1 and X020 4 3 or Yel Red 2 6 Wire 4 1 10 No Possible Causes 4 1 19 4 1 20 4 1 18 broken white or black wire between X020 and X044 3 124 T350 T500J 3121203 SECTION 3 COMPONENT CHECKS Step Pretest Instructions Test Result Corrective Action 3 11 7 Analyzer DIAGNOSTICS OFF Goto step 3 11 8 GROUND gt R RO RSET gy Possible Causes 4 1 23 4 1 10 3 11 8 Disconnect X020 Testfor continuity between Yes Possible Causes Broken Orn Red 49 X020 1 an
78. Possible Causes Short in Orn Wht 55 position and pull the emer X004 20 Vbatt 2 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 3121203 T350 T500J 2 73 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 71 FUNCTION PROBLEM OUTRIGGER STOW PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground Outrigger Stow switch was closed when the machine was powered The switch could be accidentally held mechanically stuck or electrically shorted Functions Disabled at Ground Only Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 71 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 71 2 2 71 2 DisconnectX023 Placekey Is fault Function Problem Yes Goto step 2 71 3 switch in ground position and pull the emergency stop Switch Remove X014 6 pin from X014 Place key switch in ground position and pull the emergency stop switch Outrigger Stow Permanently no Possible Causes 4 1 18 Selected still present 2 71 3 Is fault Function Problem Goto step 2 71 4 Outrigger Stow Permanently No Possible Causes Short in Orn Wht 55 Selected still present duis 2 71 4 Place key switch in ground Measured voltage atX004 9 Yes Possible Causes Short in Orn Wht 55 position and pull the emer Vbatt 1 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 72 FUNCTION PROBLEM RO
79. Rear Insert Blue DHD14P Deutsch 14 position HD series alum Plug 3121203 350 T500J 7 176 SECTION 7 ELECTRICAL REFERENCE Table 7 11 Connector Loading Diagrams ID Description Diagram DHD14R Deutsch 14 position HD series alum Receptacle DHTP31R Deutsch HDP 31 posi receptacle tion DHTP31P plug DTO2P Deutsch 2 position DT series plug pex za 2 p Li B DTO2R Deutsch 2 position DT series receptacle Deutsch 3 position DT series plug DTO4P Deutsch 4 position DT series plug DTO4R Deutsch 4 position DT seriesreceptacle 7 177 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Table 7 11 Connector Loading Diagrams ID Description Diagram DTOGAP Deutsch 6 position DT series plug DTO6R Deutsch 6 position DT seriesreceptacle DTO8AP Deutsch 8 position DT series plug DTO8AR Deutsch 8 position DT series receptacle DT12AP Deutsch 12 position DT series plug DT12AR Deutsch 12 position DT series receptacle 6 4 2 3121203 350 T500J 7 178 SECTION 7 ELECTRICAL REFERENCE Table 7 11 Connector Loading Diagrams ID Description Diagram DTMO4P Deutsch 4 position DTM series mini plug DTMO4R Deutsch 4 position DTM series mini receptacle DTM12AP Deutsch 12 position DT series mini plug with A 7 9 10 11 12 key 00009
80. SECTION 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 WARNING 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 WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER TROUBLESHOOTING SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR B 2 HYDRAULIC SYSTEM SAFETY It should be noted that the
81. SHORT TO BAT TERY 2 29 3 Remove wire Orn 8 4 from Rerun System Test Analyzer Message DRV LEFT Wire Orn 8 4 shorted to battery Repair X074 8 REV VALVE OPEN CIRCUIT orreplace Analyzer Message DRV LEFT Possible Cause 4 1 10 REV VALVE SHORT TO BAT TERY 2 54 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 30 DRIVE LEFT REVERSE SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the drive left reverse digital output may be shorted to ground or the relay may be defec tive DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Reverse Step Pretest Instructions Test Result Corrective Action 2 30 1 Disconnect solenoid at X069 Rerun System Test Analyzer Message DRV LEFT Repair Replace solenoid and isolate wires REV VALVE OPEN CIRCUIT Analyzer Message DRV LEFT Goto step 2 30 2 REV VALVE SHORT TO GROUND 2 30 2 Remove wire Orn 8 4 from Rerun System Test Analyzer Message DRV LEFT Wire Orn 8 4 shorted to ground Repair X074 8 REV VALVE OPEN CIRCUIT or replace Analyzer Message DRV LEFT Possible Cause 4 1 10 REV VALVE SHORT TO GROUND 2 31 DRIVE PREVENTED LIFT DOWN Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive or Outriggers but the Boom was not detected to be stowed by the Transport limit switch at 040 When th
82. See 2 124 Platform Position Detec switches and place key switch tion Faulty in the platform position No Possible Cause Orn Blk boom wire open or swapped with Blu BIk wire See 2 124 Platform Position Detec tion Faulty 2 50 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 21 DRIVE amp 0 R PREVENTED PLACE BOOM ON REST Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive or Outriggers but the Boom was not detected by the Turntable posi tion sensor at X073 or an error was detected with the sensor When the boom is against the rest TURNTABLE1 input X074 3 and 2 input X074 4 OV This could be caused by the boom not being properly stowed on the rest an obstruction over the switch the switch adjusted too far from the boom should be within 0 188 of the boom or a faulty transport limit switch or turntable position switch If an error has been detected the switch must be reset before drive will function DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive See 3 5 Drive Sensor Reset 2 22 DRIVE amp 0 PREVENTED SET HAND BRAKE Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive or Outriggers but the Hand Brake was not detected by the hand brake position sensor at X072 as set applied or an error was detected with the sensor If the hand brake appears to be in the proper position exami
83. Step Pretest Instructions Test Result Corrective Action 2 118 1 Does the electric start work Yes Possible Cause 4 1 4 4 1 3 4 1 29 4 1 30 No Possible Cause 4 1 28 3121203 T350 T500J 2 95 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 119 OPEN CIRCUIT PUMP MOTOR WIRING Distress Lamp 9 ADE Code 7 7 The Power Module detected an error in the Pump Motor Wiring Check power wiring and re cycle power to clear difficulty Alternately there may be an issue open field armature or brush with the Motor Functions Disabled Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Drive Step Pretest Instructions Tet Reut Corrective Action 2 119 1 While operating Lift Up isthe Yes See Open Circuit Pump Motor in 3 3 Voltage between X115 and DC Powered Machine Power Module X114 No 3 3 DC Powered Machine Power Module 2 120 OPTIONAL GROUND ALARM SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the optional ground alarm PWM output may be shorted to battery or another function All Functions Operable Step Pretest Instructions Test Result Corrective Action 2 120 1 Disconnectalarm atX050 and Is the fault removed Yes Possi
84. To 2 55 Drive Prevented Lift 2 2 55 Drive Prevented Stow 006 2 55 Drive Prevented 2 55 Drive Right Forward Solenoid Open 1 2 56 Drive Right Forward Solenoid Short To 2 56 Drive Right Forward Solenoid Short To 2 57 Drive Right Reverse Solenoid Open 1 2 2 57 Drive Right Reverse Solenoid Short To Battery 2 58 Drive Right Reverse Solenoid Short To 2 58 Dump Solenoid Open Circuit 2 59 Dump Solenoid Short To Battery 2 59 Dump Solenoid Short To 2 60 EEPROM Failure Check All 0 2 60 Engine Not Running i 2 44 pompes ek hg LY Ge doe Sect ae 2 60 Extend O R Solenoid Open
85. White 21 3 1 or White 21 3 from X002 34 VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message SWING LEFT Possible Cause 4 1 10 VALVE SHORT TO BATTERY 2 146 SWING LEFT SOLENOID SHORT TO GROUND Distress Lamp 9 tive Functions Disabled Swing Left ADE Code 3 3 Ground module feedback shows that the Swing Left digital output may be shorted to ground or the solenoid may be defec Step Pretest Instructions Test Result Corrective Action 2 146 1 Disconnect solenoid atX077 Rerun System Test Analyzer Message SWING LEFT Repair Replace solenoid VALVE OPEN CIRCUIT Analyzer Message SWING LEFT Goto step 2 146 2 VALVE SHORT TO GROUND 2 146 2 Remove wire White 21 3 1 Rerun System Test Analyzer Message SWING LEFT Wire White 21 3 1 or White 21 3 from X002 34 VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message SWING LEFT Possible Cause 4 1 10 VALVE SHORT TO GROUND 3121203 T350 T500J 2 107 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 147 SWING RIGHT SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Swing Right digital output may be disconnected or the solenoid may be defective The start solenoid fuse should be checked Functions Disabled Swing Right Step Pretest Instructions Test Result Corrective Action 2 147 1 Runsystem test Do other fu
86. before the con trol system will accept their values and allow drive and set functions Turntable Position Sensor If an error is detected with the switch or the transport switch does not agree with the turntable position switch then TURN TBL SW ERR is displayed in the diagnostics When the boom is set on the boom rest the transport switch should already be closed Transport Turntable1 should change from Off to On and Turntable2 should change from On to Off Turntable1 3 120 T350 T500J 3121203 and Turntable2 should always be in opposite states To reset the switch lift boom till transport switch opens then lower onto rest SECTION 3 COMPONENT CHECKS again Step Pretest Instructions Test Result Corrective Action 3 5 1 Place boom onrest TURNTBL SW ERR dis Yes Goto step 3 5 2 Check Analyzer gt Diag played No Switch is already reset nostics gt Drive 3 5 2 Check Analyzer gt Diag TURNTABLE1 dis Yes Goto step 3 5 3 nostics gt Drive played No Goto step 3 5 5 3 5 3 Check Analyzer gt Diag TURNTABLE2 OFF dis Yes Goto step 3 5 4 nostics gt Drive played No Possible Causes Orn Red 59 1 wire shorted 4 1 18 3 5 4 Check Analyzer gt Diag TRANS LMT SW dis Yes Liftboom till transport switch nostics gt System played opens then lower onto rest again to resetthe switch No Possible Causes Badtransport switch see 3 17 Transport Limit Switch 3 5
87. digital inputs from both lift up and lift down ground panel switches are active Distress Lamp 9 Functions Disabled at Ground Only Lift Up Lift Down Selected still present Step Pretest Instructions Test Result Corrective Action 2 67 1 DisconnectX031 Pullthe Is fault Function Problem Yes Go to step 2 67 2 ground emergency stop LiftUp And Down Both No Possible Causes 4 1 18 switch and place key switch in Selected still present LN the ground position 2 67 2 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Tan 3 2 wire enable switch X014 23 pin and X014 1 pin No Goto step 2 67 3 2 67 3 Disconnect X014 Hold the Measure continuity between Yes Possible Causes Shortin Tan 4 2 wire enable switch X014 22 pin and X014 1 pin No Goto step 2 67 4 2 67 4 Remove X004 23 soc from Is fault Function Problem Yes Possible Causes 4 1 10 004 Lift Up And Down Both No Possible Causes Shortin Tan 3 2 1 wire or Tan 4 2 1 wire 2 68 FUNCTION PROBLEM LIFT UP PERMANENTLY SELECTED ADE Code 2 3 The ground lift up switch was closed when the machine was powered The switch could be accidentally held mechanically Distress Lamp 1 stuck or electrically shorted Functions Disabled at Ground Only Lift Up Step Pretest Instructions Test Result Corrective Action 2 68 1 Is the switch mechanically Yes Repair or replace t
88. digital output may be shorted to ground or solenoid may be defective Functions Disabled Telescope Out Step Pretest Instructions Test Result Corrective Action 2 157 1 Disconnect solenoid atX082 Rerun System Test Analyzer Message TELESCOPE Repair Replace solenoid OUT VALVE OPEN CIRCUIT Analyzer Message TELESCOPE Goto step 2 157 2 OUT VALVE SHORT TO GROUND 2 157 2 Remove wire Brown 14 3 1 Rerun System Test Analyzer Message TELESCOPE Wire Brown 14 3 1 or Brown 14 3 from X002 16 OUT VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 OUT VALVE SHORT TO GROUND 2 158 THROTTLE HOLD SOLENOID OPEN CIRCUIT Distress Lamp 9 noid may be defective ENGINE POWERED MACHINES ONLY ADE Code 3 3 Ground module feedback shows that the Engine Throttle Hold digital output may be disconnected from solenoid or the sole Functions Disabled Engine Powered Machines Only Engine Throttle Hold Step Pretest Instructions Test Result Corrective Action 2 158 1 Run system test Do other functions fail sys Yes Check 4 1 15 4 1 1 otherwise go to tem test step 2 158 2 No Goto step 2 158 2 2 158 2 Disconnect solenoid at X097 Rerun System Test Analyzer Message THROTTLE Replace solenoid and or connector On harness end short X097 HOLD SOLENOID SHORT TO WHT YEL 48 3to X097 GROUND BLACK wire Analyzer Mes
89. eie eet ee thanh abbate stiano tata tia tinta nati ti tinte or en ran CANBUS Failure Power Module Chassis Tilt Sensor Gain Not Calibrated Chassis Tilt Sensor Gain Out Of Range a Chassis Tilt Sensor Not Calibrated 0 1 222225222 222 aan HER ae ote eoe eed pera Choke Hold Solenoid Open Circuit Choke Hold Solenoid Short To Battery sse Choke Hold Solenoid Short To Ground Choke Pull Relay Open Circuit Choke Pull Relay Short To Battery Choke Pull Relay Short To Ground Drive Enable Solenoid Short To Battery Drive Enable Solenoid Short To Ground Or Open Circuit bs Drive Left Forward Solenoid Open Circuit 2 52 Drive Left Forward Solenoid Short To Battery 2 53 Drive Left Forward Solenoid Short To Ground 2 53 Drive Left Reverse Solenoid Open Circuit Drive Left Reverse Solenoid Short To Battery Drive Left Reverse Solenoid Short To Ground Drive Right Forward Solenoid Open Circuit ie Drive Right Forward Solenoid Short To Battery
90. esses eene 2 103 Start Solenoid Open Circuit nah ann dei des de ede aede E ra dava dicas 2 105 Start Solenoid Short To Battery eei dei des 2 105 Start Solenoid Short Fo Ground siso ainra 2a RER eden es 2 106 Swing Left Solenoid Open Circuit nennen enne entente nennen enses esent 2 106 Swing Left Solenoid Short To Battery eene enne enne senses tet tet tette nnne inneren 2 107 Swing Left Solenoid Short To Ground esses tst nennt tette nenne tenete enne 2 107 Swing Right Solenoid Open Circuit sss enses ntn nennt netten tette tenente enne 2 108 Swing Right Solenoid Short To Battery 2 108 Swing Right Solenoid Short To Ground Reese en BREI 2 109 Telescope In Solenoid Open CIrCUIU usa eo e eb eb lob e nebat bee habi deb 2 110 Telescope In Solenoid Short To Battery e EE aea a a xi epe aede aee 2 110 Telescope In Solenoid Short To Ground ener 2 111 Telescope Solenoid Open Circuit
91. ground wire temtest broken 4 1 1 otherwise Goto step 2 25 2 No Goto step 2 25 2 2 25 2 ShortX067 1 soc to Rerun System Test Analyzer Message DRV LEFT Replace solenoid and or connector X067 2 soc FWD VALVE SHORT TO GROUND Analyzer Message DRV LEFT Goto step 2 25 3 FWD VALVE OPEN CIRCUIT 2 25 3 Replace X074 7 with a jumper Rerun System Test Analyzer Message DRV LEFT Wire Orn 7 4 broken Repair or replace to X074 2 FWD VALVE SHORT TO GROUND Analyzer Message DRV LEFT Possible Cause 4 1 10 FWD VALVE OPEN CIRCUIT 2 52 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 26 DRIVE LEFT FORWARD SOLENOID SHORT TO BATTERY Distress Lamp 9 be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Forward ADE Code 3 3 Drive module feedback shows that the Drive Left Forward Valve PWM output may be shorted to battery or the solenoid may Step Pretest Instructions Test Result Corrective Action 2 26 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 26 2 No Goto step 2 26 2 2 26 2 Disconnect solenoid atX074 Rerun System Test Analyzer Message DRV LEFT Replace solenoid and isolate wires FWD VALVE OPEN CIRCUIT Analyzer Message DRV LEFT Goto step 2 26 3 FWD VALVE SHORT TO BAT TERY 2 26 3 Remove wire Orn 7 4 from
92. pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engaging 2 Pierce one of the unused wire seals to allow the trapped air inside the housing to escape 3 Install a hole plug into this and or any unused wire seal that has silicone dielectric compound escaping from it 7 181 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Assembly Check to be sure the wedge lock is in the open or as shipped position See Figure 7 6 Proceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Figure 7 6 Connector Assembly Figure 1 1 insert a contact push it straight into the appropriate circuit cavity as far as it will go See Figure 7 8 2 Pull back on the contact wire with a force of 1 or 2 Ibs to be sure the retention fingers are holding the contact See Fig ure 7 8 PLUG AND HEADER AS
93. rpm Fuel Consumption 0 51 Ib hph 313 g kWh 230 g PSh Fuel Type Unleaded gasoline with a pump octane rating of 86 or higher Spark Plug BPR6ES DENSO W20EPR U Spark Plug Gap 0 028 0 031 in 0 70 0 80 mm Table 11 7 Engine Battery Specifications BCI Group Size Cranking Performance 550 amps 32 F 0 C 450 amps 0 F 18 C Reserve Capacity 80 minutes 32 F 0 C Batteries Electric Machines Table 11 8 Battery Specifications AT 40 F 40 C Open Circuit Volt age Voltage 6 Volt Amp Hour Rating 20 hour rate 220 Reserve Capacity 75 Amps 110 Minutes Greater or Equal to 6 Volts Life Cycle Rating 600 Cycles Internal Resistance more than 2 5 mOhms 70 F 21 C 4 0 m Ohms 0 F 18 C Battery Weight minimum allowable 61 Ibs 27 7 kg 11 221 T350 T500J 3121203 SECTION 11 SPECIFICATIONS Component Weights Table 11 9 Component Weights T350 Component Pounds Kg Kilograms Frame bare 592 269 Turntable bare 127 58 Booms amp Cylinders Assy 1130 513 Main Boom 626 284 Engine Assy Incl Tray 116 53 Engine bare 57 26 Master Cylinder 18 8 Axle 140 64 Platform w Rotator 143 65 Platform w o Rotator 73 33 Table 11 10 Component Weights T500J Component Poun
94. stowed key switch off and key removed park brake applied BATTERY SHOULD ALWAYS BE DISCONNECTEDDUR ING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS 3121203 T350 T500J B 17 18 350 T500J 3121203 5 SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION A 1 How Use This Manual iae gs e Rey eR DRE E ERR ger A 5 A 2 Visual Inspection xu a weds uA Seda wee ux MR ERN DOT S ve o A 6 A 3 Connector References A 6 4 Reading Fault Codes se calles ins b eet PAE Qe AE eer ee a oboe KR A 6 A 5 User Fault Codes ADIRI Ae E pud eben EIU Eee evi A 7 A 6 User Fault Code Cross A 8 A 7 Service Fault Code Cross References A 11 A 8 Power Module Flash Codes A 14 A 9 Ground Reference tod wt ge ode kp Eu beg Uu eh rs ie og Hen A 14 A 10 Control Module A 15 A 11 D we ccu A 16 A 12 Critical Vehicle Interlock A 16 A 13 Outriggers t aa
95. the Pump Motor Negative Terminal and Ground Reference is 24V If not examine the issues within Open Circuit Pump Motor This voltage should ramp to approximately OV when Lift Up is operated from Ground Mode If not examine the cable between the terminal and the Power Module compartment M2 Terminal Inspect crimps for corrosion and ensure that bolted connections are tight Ensure that the cable is not crushed 3 118 T350 T500J 3121203 SECTION 3 COMPONENT CHECKS Open Circuit Pump Motor This issue will prevent the Pump Motor from operating Under DIAGNOSTICS gt PUMP the JLG Analyzer will show PUMP PWM 100 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode Pull the Main Battery Disconnect to completely de energize the Control System Next detach the cable from Pump Motor Positive Terminal Using a voltmeter set for resistance measurement Ohms ensure that the resistance between the Pump Motor Positive and Negative Terminals is less than 2 Ohms If not examine the pump motor for worn brushes or broken ter minals After examination re connect the Pump Motor Positive Terminal and the Main Battery Disconnect Short Circuit between Pump Motor Positive and Negative Terminals This issue will prevent the Pump Motor from operating Under DIAGNOSTICS gt PUMP the JLG Analyzer will show an erratic reading for PUMP PWM 6 and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode Pull the Main Battery Disconnect
96. the system to check the voltage Move the joystick all the way left to continue the system test Otherwise see possible cause 4 1 22 5 106 JOYSTICK REVERSE TO System test prompt to move the platform joystick reverse to the extent for the system to check the voltage Move the joystick all the way rearward to continue the system test Otherwise see possible cause 4 1 22 3121203 T350 T500J 5 145 SECTION 5 SYSTEM TEST MESSAGES 9 107 JOYSTICK RIGHT TO MAX System test prompt to move the platform joystick right to the extent for the system to check the voltage Move the joystick all the way right to continue the system test Otherwise see possible cause 4 1 22 5 108 LEVEL DN VALVE System test prompt indicating that it is currently testing this circuit 5 109 LEVEL DOWN CL System test response indicating that the ground level down switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 110 LEVEL DOWN VALVE OPEN CIRCUIT The system test detected an open in the Level Down valve circuit See 2 98 Level Down Solenoid Open Circuit 9 111 LEVEL DOWN VALVE SHORT TO BATTERY The system test detected a short to battery in the Level Down valve circuit See 2 99 Level Down Solenoid Short To Battery 9 112 LEVEL DOWN VALVE SHORT TO GROUND The system test detected a short to ground in the Level Down valve circuit See 2 100 Level Down Solenoid Sh
97. to completely de energize the Control System Next detach both Pump Motor Terminals and insulate them independently Re connect the Main Battery Disconnect and re try Lift Up If the same symptoms persist erratic PUMP PWM PUMP CUR around 150A examine the cabling between the Pump Motor and Power Module com partment for a short circuit If the symptoms change suspect a short circuited or mechanically frozen pump motor A clamp on ammeter set for 200A DC can be placed on either Pump Motor Cable for verification During Lift Up the amme ter will read approximately 150A Power Module Electrical Evaluation Several basic electrical tests can be performed on the Power Module Failure of one of these evaluations is significant and may indicate that the device is physically damaged If a Power Module is suspected to be faulty thoroughly examine the rest of the system for possible damage Make all measurements with a voltmeter set to resistance scale Ohms Disconnect the Main Battery Disconnect and all cables from the Power Module during this analysis Wait 60 seconds after power is disconnected to allow internal charge to dissipate risk of hazard improper readings otherwise 1 Resistance gt 100kOhms all Terminals to Housing Ensure that there is an open circuit between all terminals of the Power Module and the module s aluminum housing The device is fully potted and all electronics are insulted from the housing Place the Black meter lea
98. 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 T350 T500J 9 204 SECTION 9 JLG ANALYZER Once the correct password is displayed press ENTER 9 5 ADJUSTING PARAMETERS USING THE The access level should display the following if the pass word was entered correctly HAND HELD ANALYZER 2 N Once you have gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to MG adjust its value for example E LEVEL 1 4 JG E ENTER PERSONALITIES S LIFT RCCEL 1 05 SC ENTER V c E MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings PERSONALITIES LIFT ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular 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 9 205 T350 T500J 3121203 9 6 MACHINE SETUP When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value f
99. to ground in the Telescope Out valve circuit See 2 157 Telescope Out Solenoid Short To Ground 3121203 T350 T500J 5 155 SECTION 5 SYSTEM TEST MESSAGES 5 197 TESTS COMPLETE System test message indicating that the testing is completed 5 198 THROTTLE HOLD ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 199 THROTTLE HOLD SOLENOID OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open in the Throttle Hold circuit See 2 158 Throttle Hold Solenoid Open Circuit 5 200 THROTTLE HOLD SOLENOID SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the Engine Throttle Hold circuit See 2 159 Throttle Hold Solenoid Short To Battery 5 201 THROTTLE HOLD SOLENOID SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the Engine Throttle Hold valve circuit See 2 160 Throttle Hold Solenoid Short To Ground 5 202 THROTTLE PULL ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 203 THROTTLE PULL RELAY OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open in the Throttle Pull circuit See 2 161 Throttle Pull Relay Open Circuit 5 204 THROTTLE PULL RELAY SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the Engine Throttle Pull circuit See 2 162 Throttle Pull Re
100. to test the switch input and continue the test 5 146 SWING RIGHT System test prompt to open the ground panel Swing Right switch Release the switch at the ground panel to test the switch input and continue the test 3121203 T350 T500J 5 149 SECTION 5 SYSTEM TEST MESSAGES 5 147 OP TELE IN System test prompt to open the ground panel Telescope In switch Release the switch at the ground panel to test the switch input and continue the test 9 148 TELE OUT System test prompt to open the ground panel Telescope Out switch Release the switch at the ground panel to test the switch input and continue the test 5 149 OPEN TRIGGER System test prompt to open the platform trigger switch Release the switch at the platform panel to test the switch input and continue the test 9 150 OPT GROUND ALARM ON Ground system test is sounding the optional ground motion alarm Step Pretest Instructions Test Result Corrective Action 5 150 1 Doesthe alarm sound prop Yes Press ENTER onthe analyzerto con erly tinue the system test No Possible Causes Broken Yel Red 2 13 or Yel Red 2 14 or black wire Bad ground alarm 4 1 10 5 151 PLATFORM ALARM ON System test prompt to check that the platform alarm is sounding If alarm is sounding properly press ENTER on the analyzer to continue the system test Otherwise see possible cause 4 1 11 5 152 RETRACT VALVE System test prompt indicating that i
101. wire emergency stop switch 2 75 4 Place key switch in ground Measured voltage at Yes Possible Causes Short in White 22 2 position and pull the emer X004 35 Vbatt 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 76 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 76 FUNCTION PROBLEM TELESCOPE IN AND OUT BOTH SELECTED Distress Lamp 9 ADE Code 2 3 The digital inputs from both telescope in and telescope out ground panel switches are active Functions Disabled at Ground Only Telescope In Telescope Out Selected still present Step Pretest Instructions Test Result Corrective Action 2 76 1 Disconnect X033 Pull the Is fault Function Problem Yes Goto step 2 76 2 ground emergency stop Telescope In And Out Both No Possible Causes 4 1 18 switch and place key switch in Selected still present the ground position 2 76 2 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Brown 13 2 enable switch X014 20 pin and X014 1 pin wire No Goto step 2 76 3 2 76 3 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Brown 14 2 enable switch X014 21 pin and X014 1 pin wire No Goto step 2 76 4 2 76 4 Remove X004 7 soc from Is fault Function Problem Yes Possible Causes 4 1 10 X004 Telescope In And OutBoth Possible Causes Shortin Brown 13 2 1 wire or Brown 14 2 1 wire 2 71
102. with the rest of the system The control sys tem may resume operation once the difficulty has been corrected ELECTRIC POWERED MACHINES ONLY Functions Disabled Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Possible Causes 4 1 13 4 1 12 2 83 GROUND ALARM SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the ground alarm PWM output may be shorted to battery or another function All Functions Operable Step Pretest Instructions Test Result Corrective Action 2 83 1 Disconnect alarm atX028 and Is the fault removed Yes Possible Causes 4 1 25 isolate wires No Goto step 2 83 2 2 83 2 Remove X014 17 fromX014 Is the fault removed Yes Wire Orn Red 49 11 or black ground wire shorted to battery Repair or replace No Goto step 2 83 3 2 83 3 Remove X002 19 from X002 Is the fault removed Yes Wire Orn Red 49 11 1 shorted to bat Repair or replace No Possible Causes 4 1 10 2 84 GROUND ALARM SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that ground alarm PWM output may be shorted to ground or the solenoid may be defective Functions Operable Step Pretest Instructions Test Result Corrective Action 2 84 1 Disconnectalarm atX028 and Is the fault removed Yes Possi
103. 0 6 54 3 2 1 DTM12BP Deutsch 12 position DT series mini plug with B 7 10 11 12 OT X X YF 6 5 4 3 DTPO2P Deutsch 2 position DTP series plug DTPO2R Deutsch 2 position DTP seriesreceptacle 06 Eaton Toggle Switch L IS 159 14 2 HO S 3 6 SE 7 179 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Table 7 11 Connector Loading Diagrams ID Description Diagram M04P Molex 4 position MMFO8P Molex Mini Fit 8 position plug MMF10P Molex Mini Fit 10 posi tion plug MMF12P Molex Mini Fit 12 posi tion plug 7 81 9 10 7117 f 12 12 3 4 5 6 MMF16P Molex Mini Fit 16 posi tion plug 3121203 350 T500J 7 180 SECTION 7 ELECTRICAL REFERENCE Table 7 11 Connector Loading Diagrams ID Description Diagram PWPO3P Packard 3 position receptacle Bn NO 3 SUMO2N Sumitomo 2 position natural SUMO6N Sumitomo 6 position natural 7 6 WORKING WITH 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
104. 0 7 5V Red 2 18 or Black joystick ground and the emergency stop 4 1 22 Switches No Possible Cause 4 1 11 2 94 6 Place key switch in platform Measured voltage between Yes Possible Cause Short or Open in Orn position and pull the emer X060 6 and X060 7 between Red 49 22 gency stop switches 0 75 and 2 25 Volts No Possible Cause 4 1 22 3121203 T350 T500J 2 83 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 95 JOYSTICK FAULTY Y AXIS WIPER OUT OF RANGE Distress Lamp 9 ADE Code 2 2 The joystick Y axis fore and aft when facing the console wiper signal input is outside the acceptable voltage range The wiper wire being off the wiper wire shorted to B or the wiper wire shorted to B ground could cause this difficulty Functions Disabled at Platform Only Lift Up Lift Down Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 95 1 Does the joystickreturnto Yes Go to step 2 95 2 the centered position when No Possible Cause 4 1 22 moved c 2 95 2 Holdthe joystick atthe for Isthe Y Joystk Voltage Yes Goto step 2 95 3 ward extent Using the ana between 0 75 and 2 25 No Goto step 2 95 4 lyzer navigate to Volts DIAGNOSTICS gt PLAT FORM gt Y JOYSTK 2 95 3 Holdthe joystick atthe rear Is the Y Joystk Voltage Yes Possib
105. 01 96001 96001 96001 LI3S L LXVI 2 NI LXVIN 1331 9334 i I I I I 082 092 96001 96001 96001 96001 96001 96001 001 1 NIW LAS NIN dn L NIN NI 7L NIN 1431 L 2 dn 0334 i I 1 i AOS 1 00 50 50 m 60 Sot 501 Le AM4 10 ro r0 303a r0 303a V0 Le i I 2 022 8 01 50 9 so s so s so s so s 50 NIW 48 F0 1399V v0 I 7399Y F0 1399V F0 714904 F01300V 01400 i 1 A I i A I XOLLSAOP SY399IH LNO T em l 340959181 ONIMS ian S3lLlIVNOSH3d 350 T500J 9 209 SECTION 9 JLG ANALYZER 9 7 SYSTEM TEST 4 The analyzer screen should read The Control System Incorporates a built in system test to We lt check the system components and functions To use this MG function use the following procedures Platform Test HELP PRESS ENTER 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 Sy d 4 4 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 NUS 6 Follow the flow Figure 9 5 System Test Fl
106. 04 3 Have outriggers come Yes Retractthe boom before lowering unset No Goto step 2 104 4 2 104 4 ANALYZER gt DIAGNOS Yes See 3 16 Tilt Sensor bs ee No See 3 11 Outrigger Switches All Set LED illuminated 2 105 LIFT DOWN SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Lift Down PWM output may be disconnected or the solenoid may be defective Functions Disabled Lift Down Step Pretest Instructions Test Result Corrective Action 2 105 1 Short X039 1 soc to Is the fault removed Yes Repair Replace solenoid 039 2 50 Goto step 2 105 2 2 105 2 ShortX016 1 pinto Is the fault removed Yes Tan 4 3 or black wire broken between X016 2 pin X016 and X039 Repair or replace No Goto step 2 105 3 2 105 3 Short X002 22 pin to B Is the fault removed Yes Tan 4 3 1 or black wire broken between X002 and X016 Repair or replace No Possible Causes 4 1 10 2 90 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 106 LIFT DOWN SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Lift Down PWM output may be shorted to battery or other function Functions Disabled Lift Down Step Pretest Instructions Test Result Corrective Action 2 106 1 Disconnect solenoid atX039 Rerun System Test Analyzer Message LIFT DOWN Repair Replace solenoid and isolate wires VALVE
107. 07 24 4 1 13 Repairblack wire between X060 4 and X007 24 2 8 7 Disconnect Power Module at Measured power module Yes Goto step 2 8 8 X010 CAN resistance between No Possible Causes 4 1 12 X010 10 pin and X010 11 pin 1200 2 8 8 Disconnect Ground Module at Measured ground module Yes Possible Causes 4 1 11 X007 CAN resistance between No Repair CAN wiring between X010 and X007 13 soc and X054 007 24 50 600 2 8 9 Disconnect Ground Module at Measured ground module Yes Possible Causes 4 1 14 4 1 11 X007 CAN resistance between No Goto step 2 8 10 X007 13 pin and 2d X007 24 pin 2 1200 2 8 10 Disconnect X007 Test harness for continuity Yes Possible Causes 4 1 10 between X007 6 s0cand Repair or replace black jumper wire 007 17 50 between X007 6 soc and X007 17 soc 2 44 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 9 CANBUS FAILURE POWER MODULE Distress Lamp 9 ADE Code 6 6 System cannot communicate with the electric power control module ELECTRIC POWERED MACHINES ONLY Functions Disabled Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 9 1 Pullthe ground emergency Does the power module LED Yes Goto step 2 9 2 stop switch and place key light solidly when the ground
108. 1 Level Down Solenoid DTO2P 10 Figure 7 2 X082 Tele Out Solenoid DTO2P 16 Figure 7 2 X083 Tele In Solenoid DTO2P 10 Figure 7 2 084 LiftUp Solenoid DTO2P 16 Figure 7 2 085 O RStow Solenoid DTO2P 1 Figure 7 2 X086 O R Set Solenoid DTO2P 1 Figure 7 2 X087 Dump Valve Solenoid DTO2P 16 Figure 7 2 X088 Starter Sol Fuse No Drawing 7 Figure 7 1 X089 Starter Sol No Drawing 6B Figure 7 1 X090 Engine Stop Relay No Drawing 6C Figure 7 1 X091 Throttle Pull Relay No Drawing 6B Figure 7 1 X092 Engine Oil Level Switch No Drawing 7C Figure 7 1 7 167 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Table 7 1 Connector Index ID Description End 1 ID End 2 ID Baise Drawings X093 Engine Choke Pull Relay No Drawing 6B Figure 7 1 X095 Engine Mag Pickup SUMO2N Figure 7 1 X096 Engine Rectifier SUMO6N 6 Figure 7 1 X097 Engine Throttle Solenoid PWPOSP Figure 7 1 098 Engine Choke Solenoid No Drawing 7B Figure 7 1 X099 Engine Powered Battery Pos No Drawing X100 Engine Powered Battery Neg No Drawing 6A 101 Power Module Sevcon B No Drawing 1C Figure 7 2 X102 Power Module Sevcon B No Drawing 1C Figure 7 2 X103 Power Module Sevcon M1 No Drawing 1C Figure 7 2 X104 Power Module Sevcon M2 No Drawing 1C Figure 7
109. 1 12 2 129 REAR LEFT O R SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Rear Left Outrigger digital output may be disconnected or the solenoid may be defective Functions Disabled Rear Left O R Step Pretest Instructions Test Result Corrective Action 2 129 1 Run system test Do other functions failsys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 129 2 No Goto step 2 129 2 2 129 2 Disconnect solenoid atX048 Rerun System Test Analyzer Message R L OUTRIG Replace solenoid and or connector Short X048 1 soc to GER VALVE SHORT TO GROUND 048 2 50 Analyzer Message R L OUTRIG Goto step 2 129 3 GER VALVE OPEN CIRCUIT 2 129 3 Replace X003 8 with a jumper Rerun System Test Analyzer Message R L OUTRIG Wire Orn Red 49 7 or White wire to X003 3 GER VALVE SHORT TO GROUND between X020 and X048 broken Repair or replace Analyzer Message R L OUTRIG Possible Cause 4 1 10 GER VALVE OPEN CIRCUIT 3121203 T350 T500J 2 99 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 130 REAR LEFT 0 R SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Rear Left Outrigger digital output may be shorted to battery or other function Functions Disabled Rear Left O R Step Pretest Instructions Test Result Corrective Action 2 130 1 Run system te
110. 2 X105 Power Module Cable In line AN350P 1C X106 6V Batt 1 Pos No Drawing 1C X107 6V Batt 1 Neg No Drawing 1 X108 6V Batt 2 Pos No Drawing 1 X109 6V Batt 2 Neg No Drawing 1 X110 6V Batt 3 Pos No Drawing 1 X111 3 Neg No Drawing 1 X112 6VBatt 4 Pos No Drawing 1 X113 6V Batt 4 Neg No Drawing 1 X114 Electric Pump Neg No Drawing 1 Figure 7 2 X115 Electric Pump Pos No Drawing 1C Figure 7 2 X116 Battery Charger AC Cord No Drawing 1 3121203 T350 T500J 7 168 SECTION 7 ELECTRICAL REFERENCE 7 2 GROUND MODULE CONNECTOR PINOUTS Table 7 2 X001 J1 Ground Module Pinout PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 Depopulated 2 Depopulated 3 Depopulated 4 GROUND Power Output OVDC 5 GROUND Power Output OVDC 6 Depopulated 7 Depopulated 8 GROUND Power Output OVDC 9 GROUND Power Input 0 0 10 Depopulated 11 Depopulated 12 Depopulated 13 Depopulated 14 NOTUSED Analog Input 15 NOTUSED Analog Input 16 ENGINE MAGNETO SPEED PICKUP Digital Input AC Cou pled Freq 17 GROUND Power Output OVDC 18 GROUND Power Output OVDC 19 GROUND Power Output OVDC 20 Depopulated 21 NOTUSED Digital Input
111. 2 61 Extend O R Solenoid Short To 10 2 61 Extend O R Solenoid Short To Ground 2 62 Front Left O R Solenoid Open 1 2 62 Front Left O R Solenoid Short To 2 63 Front Left O R Solenoid Short To Ground 1 2 63 Front Right O R Solenoid Open Circuit 2 64 Front Right O R Solenoid Short To Battery 2 64 Front Right O R Solenoid Short To 2 65 Function Locked Out Joystick Not Centered At Startup 2 65 Function Locked Out Trigger Permanently 2 66 Function Problem Engine Choke Permanently 2 66 Function Problem Engine Choke Permanently Selected 2 67 Function Problem Engine Start Permanently Selected 2 67 Function Problem Engine Start Permanently Selected 2 68 Function Problem Jib Down Permanently Selected 2 68 Function Problem Jib Up And Down Both Selected 2 69 Func
112. 2 Does engine start with manual Yes Possible Causes Check start motor recoil wiring 4 1 4 4 1 79 No Goto step 1 7 3 1 7 3 Turn key switch to ground 15 090 87 black wire Yes Goto step 1 7 4 position and pull the emer shorted to ground No Possible Causes 4 1 92 4 1 93 gency stop es qM 1 7 4 Turn key switch to ground Is the Voltage between Yes Possible Causes 4 1 81 position and pull the emer X090 86 and X090 85 No Goto step 1 7 5 gency stop Vbatt 5 1 7 5 Turn key switch to ground Isthe Voltage onX022 2 Yes Possible Causes Broken Yel Red 2 3 position and pull the emer Vbatt between X022 2 and X090 86 Broken gency stop black ground wire on X090 85 No Possible Causes Broken Yel Red 2 3 wire between X022 2 and X009 87 See 3 9 Ignition Relay Power 1 8 ENGINE HIGH IDLE INOPERATIVE ENGINE MODELS The throttle solenoid engages the engine throttle to high speed To actuate the throttle solenoid the Ground Module Engine Throttle Hold output is turned on continuously while the Ground Module Engine Throttle Pull output is momentarily turned on energizing the Engine Throttle Pull Relay to provide higher current to the throttle solenoid while pulling The Engine Throttle Hold output remains on during a function and an additional 1 second afterwards as well as 5 seconds after engine startup Step Pretest Instructions Test Result Corrective Action 1 8 1 Turn key switch to ground Does vo
113. 200 Module To Keyswitch Ground Position Vbatt At X057 CAN LO 4 To EMS Vbatt 2 Ignition Power from Ignition Relay 87 Vbatt Ground from B Ground for Platform Module Ignition Power for Platform Module Vbatt Drive Module Analyzer Power Analyzer RS232 Receive Machines with Drive Option Only Analyzer RS232 Transmit Analyzer Analyzer Ground 9 X074 Constant Battery Vbatt 10 XO 7 5 1 2 Ignition Power from Ignition Relay 87 Vbatt Ground from Ignition Relay 85 Figure A 4 Basic Electronic Module Connections 3121203 T350 T500J A 15 INTRODUCTION A 11 TILT X and Y axis tilt are combined through a calculation to form the tilt value used by the control system The machine is consid ered Tilted whenever this calculated tilt value is above 2 degrees from calibrated level zero tilt An outrigger is considered set when the pivot pin slides up and closes the outrigger limit switch The ground control panel outrigger LEDs blink whenever they are set but the machine is tilted Once the outriggers are set and the machine is not tilted the outrigger LEDs remain on steady The platform outrigger LED blinks till all four outriggers are set then lights steady The platform tilt LED lights whenever the machine is tilted Orientation The Ground Module shall be mounted such that the Tilt Sensor s X Axis responds t
114. 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 40 DUMP SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Dump Valve PWM output may be disconnected or the solenoid may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 40 1 Runsystemtest Do other functions fail sys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise Goto step 2 40 2 No Goto step 2 40 2 2 40 2 Disconnect solenoid atX087 Rerun System Test Analyzer Message DUMP VALVE Replace solenoid and or connector ShortX087 1 soc to SHORT TO GROUND 087 2 50 Analyzer Message DUMP VALVE Goto step 2 40 3 OPEN CIRCUIT 2 40 3 Replace X002 9 with a jumper Rerun System Test Analyzer Message DUMP VALVE Wire Red Wht 50 1 1 or Red Wht 50 to X002 14 SHORT TO GROUND 1 broken Repair or replace Analyzer Message DUMP VALVE Possible Cause 4 1 10 OPEN CIRCUIT 2 41 DUMP SOLENOID SHORT TO BATTERY Distress Lamp 9 tive ADE Code 3 3 Ground module feedback shows that the Dump Valve PWM output may be shorted to battery or the solenoid may be de
115. 34 CHECK OUTRIGGER STOW 5 134 CHECK POWER amp CAN WIRING TO PLATFORM 5 135 CHECK POWER amp CAN WIRING TO POWER MODULE 5 135 CHECK START SWITCH e ERE dE me eg Ea Re Eee s 5 135 CHECK SWING LEFT 5 135 CHECK SWING RIGHT 71 222 2 2 2 5 135 CHECK TELESCOPE IN 5 135 CHECK TELESCOPE OUT 5 135 CHECKING INPUTS 5 32 8 ou poeta oct exem he e Ier Ote uei aed 5 136 ERE De HR N Ve bep PEE Iu BAN EFE ea ES 5 136 ates RE it neh e ted e s 5 136 CHOKE HOLD SOLENOID 2 5 136 CHOKE HOLD SOLENOID SHORT TO BATTERY 5 136 CHOKE HOLD SOLENOID SHORT TO 5 136 GHOKE PULL ee ee pce oe oc en FARE TAREA se 5 136 CHOKE PULL RELAY OPEN CIRCUIT 5 136 CHOKE PULL RELAY SHORT TO BATTERY 5 137 CHOKE PULL RELAY SHORT TO GROUND
116. 4 1 81 Gas Only Engine stop relay may be defective Repair or replace 4 1 82 Gas Only Engine speed feedback incorrect Repair Wht Yel 48 7 between X001 16 and X095 or contact factory 4 1 83 Gas Only Engine may be out of fuel Refuel 4 1 84 Gas Only Fuel may be old or bad Drain fuel tank and carburetor Refuel with fresh gasoline 4 1 85 Gas Only Fuel valve may be turned off Move engine fuel lever to ON 4 1 86 Gas Only Engine choke may be open Engage the choke unless engine is warm 4 1 87 Gas Only Engine oil level may be low Check Add oil 4 1 88 Gas Only Spark plug may be faulty Gap or replace spark plug 4 1 89 Gas Only Fuel filter may be clogged Clean or replace 4 1 90 Gas Only Air filter may be clogged Clean or replace 4 1 91 Gas Only Fuel system may be clogged Repair or replace 4 1 92 Gas Only Carburetor may be flooded Dry and reinstall spark plug Start engine with throttle in fast position 4 1 93 Gas Only Engine idle setting may be too low Increase idle speed to specified value 3121203 350 T500J 4 131 SECTION 4 POSSIBLE CAUSES 4 132 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES SECTION 5 SYSTEM TEST MESSAGES This section Lists all of the possible message responses from the system test mode 9 1 BATTERY 1 4 LAMP ON Platform system test is illuminating the platform battery indicator ELECTRIC POWERED MACHINES ONLY Step Pretest Instructions Test Result Corrective Action 5 1 1 Does batte
117. 4 1 pin 2 wire No Goto step 2 69 3 2 69 3 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Orn Wht 55 enable switch X014 6 pin and X014 1 pin 1 wire No Goto step 2 69 4 2 69 4 Remove X004 20 soc from Isfault Function Problem Yes Possible Causes 4 1 10 004 Outrigger Set And SON Both No Possible Causes Shortin Orn Wht55 Selected still present 2 1 wire or Orn Wht 55 1 1 wire 2 70 FUNCTION PROBLEM OUTRIGGER SET PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground O R Set switch was closed when the machine was powered The switch could be accidentally held mechani cally stuck or electrically shorted Functions Disabled at Ground Only Set Extend O R Step Pretest Instructions Test Result Corrective Action 2 70 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 70 2 2 70 2 DisconnectX023 Place key Is fault Function Problem Yes Goto step 2 70 3 switch in ground position and Outrigger Set Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 70 3 Remove X014 5 pin from Is fault Function Problem Yes Goto step 2 70 4 X014 Place key switch in Outrigger Set Permanently No Possible Causes Short in Orn Wht 55 ground position and pullthe Selected still present 2 wire emergency stop switch 2 70 4 Place key switch in ground Measured voltage at Yes
118. 5 bar pressure gauge atthe left switch Checkthe pres psi bar manifold G port Sure Below Min Swing LeftPressure Goto step 1 17 4 psi bar 1 17 4 Plumb a 0 to 5000 PSI 345 Engage the enable and swing Above Min Swing Left Pressure Possible Causes 4 1 38 4 1 45 bar pressure gaugeintothe leftswitch Checkpressureat psi bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port manifold P port Below Min Swing LeftPressure Possible Causes 4 1 10 4 1 46 psi bar 4 1 47 4 1 74 4 1 45 4 1 39 1 17 5 Plumb 010 5000 PSI 345 Check pressure atthe swing Above Min Swing Left Pressure Possible Causes 4 1 49 4 1 48 bar pressure gaugeintothe motor while activating swing psi bar 4 1 41 hose from the swing motor left at ground controls Below Min Swing LeftPressure Possible Causes 4 1 42 4 1 53 psi bar 1 18 SWING RIGHT FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 18 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 18 2 Engage enable and swingright DC Is pump motor running Yes Goto step 1 18 3 switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 18 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 18 3 Install a0 to 5000 PSI 345 Engage the enable and swing Above Min Swing RightPressure Goto step 1 18 5 b
119. 5 Is boom on rest Yes Possible Causes Switch obstructed 4 1 20 Orn Red 58 1 wire broken 4 1 18 No Place boom on rest and try again Hand Brake Position Sensor If an error is detected with the switch HAND BRK SW ERR is displayed in the diagnostics As the hand brake is applied Brake1 should change from Off to On and Brake2 should change from On to Off Brake1 and Brake2 should always be in opposite states To reset the switch cycle the hand brake Step Pretest Instructions Test Result Corrective Action 3 5 6 Apply hand brake Check HAND BRK SW ERR dis Yes Goto step 3 5 7 Analyzer gt Diagnostics played No Switch is already reset gt Drive 3 5 7 Check Analyzer gt Diag BRAKE1 ON displayed Yes Goto step 3 5 8 nostics gt Drive No Goto step 3 5 9 3 5 8 Check Analyzer gt Diag BRAKE2 OFF displayed Yes Cycle hand brake to resetthe switch nostics gt Drive No Possible Causes Orn Red 57 1 wire broken 4 1 18 3 5 9 Is hand brake applied Yes Possible Causes Switch obstructed Orn Red 56 1 wire bro ken brake cable broken 4 1 20 4 1 18 No Place boom on rest and try again 3121203 T350 T500J 3 121 3 3 6 ENGINE POWERED MACHINE HYDRAULIC PUMP Step Pretest Instructions Test Result Corrective Action 3
120. 50 T500J 2 81 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 91 JIB UP SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Jib Up digital output may be disconnected or the solenoid may be defective T500J MODELS ONLY Functions Disabled Jib Up jumperto X002 14 Step Pretest Instructions Test Result Corrective Action 2 91 1 Run system test Do other functions fail sys Yes Possible Causes Black ground wire tem test from X002 14 broken 4 1 1 other wise Goto step 2 91 2 No Goto step 2 91 3 2 91 2 Disconnectsolenoid Short RerunSystem Test Analyzer Message JIB UP VALVE Replace solenoid and or connector X079 1 soc to X079 2 soc SHORT TO GROUND Analyzer Message JIB UP VALVE Goto step 2 91 3 OPEN CIRCUIT 2 91 3 Replace X002 12 witha Rerun System Test Analyzer Message JIB UP VALVE Wire Blue 27 3 1 or Blue 27 3 broken SHORT TO GROUND Analyzer Message JIB UP VALVE OPEN CIRCUIT Repair or replace Possible Cause 4 1 10 2 92 JIB UP SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Jib Up digital output may be shorted to battery or other function T500J MODELS ONLY Functions Disabled Jib Up Step Pretest Instructions Test Result Corrective Action 2 92 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wi
121. 7 shorted to battery Repair or replace Analyzer Message F R OUTRIG Possible Cause 4 1 10 GER VALVE SHORT TO BAT TERY 2 64 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 53 FRONT RIGHT 0 R SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Front Right Outrigger Valve digital output may be shorted to ground or the sole noid may be defective Functions Disabled Front Right O R Analyzer Message OUTRIG GER VALVE SHORT TO GROUND Step Pretest Instructions Test Result Corrective Action 2 53 1 Disconnect solenoid atX047 Rerun System Test Analyzer Message F R OUTRIG Repair Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message F R OUTRIG Goto step 2 53 2 GER VALVE SHORT TO GROUND 2 53 2 Remove wire Orn Red 49 6 Rerun System Test Analyzer Message F R OUTRIG Wire Orn Red 49 6 or White wire to from X003 6 GER VALVE OPEN CIRCUIT X047 shorted to ground Repair or replace Possible Cause 4 1 10 2 54 FUNCTION LOCKED OUT JOYSTICK NOT CENTERED AT STARTUP Distress Lamp 1 ADE Code 2 2 The joystick signal was not at the proper voltage level for neutral determined from personalities when the platform was powered Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level
122. A 1 tO bod 6 8 zu vn Left Right in en Si tel Gl Pal 5 say EI A A UU 871 Ta J T Hut T500J Platform Jib 33 e eu 0 081 771 M 1 1 Orifice fe 1 1 T C X Py i X HI m t Ext 22 X R trest T 32 i etrac xten ee Extend i xten 1 1 1 1 1 Extend Retract e X 1 1 e e Q Telescope Platform Swing 1 Level Figure 8 3 Hydraulic Schematic Electric Powered Machines Sheet 2 of 2 3121203 350 T500J 2792642 8 194 SECTION 8 HYDRAULIC REFERENCES Outrigger Cylinders Telescope Cylinder 1350 1350 1500 Bore 2 75 Bore 2 Bore 2 Rod 1 5 Rod 1 25 Rod 1 5 Stroke 21 7 Stroke 110 Stroke 149 81 Blind oreo 5 93 in2 Annular area 4 18 in2 Area Ratio 1 42 1 T500 Bore 3 75 Rod 1 75 a 1 m Stroke 21 375 Blind oreo 11 04 in2 LI ee Annular area 8 64 in2 2 au 2 Area Rotio 1 27 1 1 1 5271 1 1 1
123. Action 2 116 1 Disconnect solenoid atX084 Rerun System Test Analyzer Message LIFT UP Repair Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message LIFT UP Goto step 2 116 2 VALVE SHORT TO GROUND 2 116 2 Remove wire Tan 3 3 1 from Rerun System Test Analyzer Message LIFT UP Wire Tan 3 3 1 or Tan 3 3 shorted to 002 11 VALVE OPEN CIRCUIT ground Repair or replace Analyzer Message LIFT UP Possible Cause 4 1 10 VALVE SHORT TO GROUND 2 117 MODEL CHANGED HYDRAULICS SUSPENDED CYCLE EMS Distress Lamp 2 ADE Code 2 5 The user changed the Model Selection using the JLG Analyzer All functions are being prevented until the EMS is cycled Functions Disabled Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R 2 118 NO CHARGE SYSTEM OUTPUT Distress Lamp 3 ADE Code 4 3 The engine has been running for at least 15 seconds and the battery voltage is still below 11 5V except when operating Out riggers ENGINE POWERED MACHINES ONLY Functions Disabled Electric Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R
124. Both Selected 2 3 Function Problem Level Up Permanently Selected eene enne eene 2 3 Function Problem Lift Down Permanently Selected sessi en eterne nennen eren 2 3 Function Problem Lift Up And Down Both Selected 2 2 2 1101000000000000000000000000 2 3 Function Problem Lift Up Permanently Selected sisse seen eterne tenente 2 3 Function Problem Outrigger Set And Stow Both Selected 2 73 2 3 Function Problem Outrigger Set Permanently Selected 2 73 2 3 Function Problem Outrigger Stow Permanently Selected 2 74 2 3 Function Problem Swing Left And Right Both Selected esses eren nennen emen 2 75 2 3 Function Problem Swing Left Permanently Selected esses enne entren enne 2 76 2 3 Function Problem Swing Right Permanently Selected 222 4 0 1 0000000000000000000000000 0 2 76 2 3 Function Problem Telescope In And Out Both Selected sse enne 2 77 2 3 Function Problem Telescope In Permanently Selected 2 77 2 3 Function Problem Telescope Permanently Selected 2 78 2 5 Drive amp O R Prevented Operate From Platform 2 5 Drive amp O R Prevented Place Boom On Rest 2 5 Drive amp O R Prevented Set Hand Brake i 2 5 D
125. Code 3 3 Ground module feedback shows that the Engine Choke Hold digital output may be shorted to battery or other function ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Hold 2 47 Step Pretest Instructions Test Result Corrective Action 2 15 1 Run system test Do other functions fail sys Yes Possible Cause 4 1 15 4 1 1 other tem test wise goto step 2 15 2 No Goto step 2 15 2 2 15 2 Disconnect solenoid atX098 Rerun System Test Analyzer Message CHOKE Replace solenoid andisolate wires HOLD SOLENOID OPEN CIR CUIT Analyzer Message CHOKE Goto step 2 15 3 HOLD SOLENOID SHORT TO BATTERY 2 15 3 Remove wire WHT YEL 48 5 Rerun System Test Analyzer Message CHOKE Wire WHT YEL 48 5 shorted to bat from X003 7 HOLD SOLENOID OPEN CIR tery Repair or replace CUIT Analyzer Message CHOKE Possible Cause 4 1 10 HOLD SOLENOID SHORT TO BATTERY 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 16 CHOKE HOLD SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Choke Hold digital output may be shorted to ground or solenoid may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 16 1 DisconnectsolenoidatX098 Rerun System Test Analyzer Message CHO
126. DC 24VDC Amperage 90 140 230 Speed 4000rpm 3600rpm 2900rpm Pump FlowRate 3 0gpm 2 7gpm 2 2gpm 11 3 10 2 8 3 lpm Ipm Ipm Displace 0 192 cu in ment 3 15 11 219 350 T500J 3121203 Taillight and Marker Light Bulb Information Table 11 4 Light Bulb Information Tires 3121203 SECTION 11 SPECIFICATIONS Bulb JLG Part 4 Stop Turn Taillight 7026341 Side Marker 7026342 Boom Taillight 7016626 Side Marker Light 7027717 Table 11 5 Tire Specifications T350 T500J ANSI CE ANSI CE Size 205 R14 185 R14C 225 75 R15 225 75 R16 Load Rat 1760105 1984lbs 2540lbs 319016 ing 50 psi 65 psi 60 psi 83 psi 798 kg 900 kg 1152kg 1450 kg 345 kPa 450kPa 414kPa 575 kPa Ply Rating 6 C 8 D 6 D 10 E Load Range Weight 36 Ibs 16 36 Ibs 16 46105 21 52 Ibs 24 kg kg kg kg Speed 5 Category Inflation 50 psi 345 kPa 65 psi 60 psi Pressure 448 kPa 414 kPa Wheel Nut 90 120ft 66 ft Ibs 90 120 ft 221 ft Ibs Torque Ibs 122 90 Nm Ibs 122 300 Nm 164 Nm 164 Nm T350 T500J 11 220 SECTION 11 SPECIFICATIONS Table 11 6 Engine Specifications Type 4 stroke overhead valve single cylin der Displacement 16 5 cu in 270 cm Bore x Stroke 3 0x2 3in 77 x58 Max Output 9 bhp 6 6 kW at 3 600 rpm Max Torque 14 1 ft bs 19 1 Nm at2 500
127. DS m 55 ix Motor 5 4 in3 88 5 cc 1350 63 1 Gear Ratio T500 76 1 Gear Ratio B A 8 6 Left Right UMP E Tel e TSB oe 777 7 Ho To 11 i 500 e225 Platform Jib 217 f 1 0 051 123 orifices tes T E 1 Jib Extend 2 Valve I 51 i 52 51 x i 52 1 Retract Extend Swing Swing 1 Right Left X g H 1 51 52 Retract Extend e e i 1 1 e e e Swing 1 eve 2792642 F Figure 8 5 Hydraulic Schematic Engine Powered Machines Sheet 2 of 2 3121203 350 T500J 8 196 SECTION 8 HYDRAULIC REFERENCES Right and left wheel designations Right Wheel Motor are determmined by the operator standing in the plotform Left Wheel Motor Brake Cylinder ACA V V VI everse Forward Reverse Forward M2 B M3 ior c HHES 0 LEY IT LA ds m REVERSE OP COIL BOTTOM COIL rv i i ___ _ _ _ e pu 1 m len 2 57 i me P
128. Distress Lamp 9 may be defective ADE Code 3 3 Ground module feedback shows that the Extend Outrigger Valve digital output may be shorted to ground or the solenoid Functions Disabled Set Extend O R Step Pretest Instructions Test Result Corrective Action 2 47 1 DisconnectsolenoidatX086 Rerun System Test Analyzer Message EXTEND Repair Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message EXTEND Goto step 2 47 2 VALVE SHORT TO GROUND 2 47 2 Remove wire Orn Wht55 3 1 Rerun System Test Analyzer Message EXTEND Orn Wht 55 3 1 or Orn Wht 55 3 from X003 13 VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message EXTEND Possible Cause 4 1 10 VALVE SHORT TO GROUND 2 48 FRONT LEFT 0 R SOLENOID OPEN CIRCUIT Distress Lamp 9 may be defective ADE Code 3 3 Ground module feedback shows that the Front Left Outrigger digital output may be disconnected from the relay or the relay Functions Disabled Front Left O R to X003 3 GER VALVE SHORT TO GROUND Analyzer Message F L OUTRIG GER VALVE OPEN CIRCUIT Step Pretest Instructions Test Result Corrective Action 2 48 1 Run system test Do other functions failsys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise Goto step 2 48 2 No Go to step 2 48 2 2 48 2 Disconnect solenoid at Rerun System Test Analyzer Message F L OUTRIG Replace sole
129. E CLOSED and LIFT SW CLOSED Any other combination PLATFORM Any other combination Go to step 2 72 3 2 72 3 Place key switch inthe plat While holding the enable JIB TELE CLOSED and LEVEL Possible Causes Shortin Orn Red 49 form position and pull the switch check Level Lift SW CLOSED 27 wire 4 1 11 Possible Causes Shortin Orn Red 49 28 wire 4 1 11 Possible Causes 4 1 11 2 74 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES When Rotary Select Switch is centered in the LIFT SWING position the circuit is completed to X060 10 When Rotary Select Switch is turned to the LEVEL position the circuit is completed to X060 9 When Rotary Select Switch is turned to the TELE JIB position the circuit is completed to X060 15 Level Tele Jib X063 1 2 sl 4 5 6 Level Input from Lift Swing Tele Jib X060 9 Orn Trigger Switch X060 10 Orn X060 15 Orn Red 49 27 X061 6 Yel Red 49 28 Red 49 29 Red 2 17 Figure 2 1 Platform Rotary Select Switch 2 73 FUNCTION PROBLEM SWING LEFT AND RIGHT BOTH SELECTED Distress Lamp 9 ADE Code 2 3 The digital inputs from both swing left and swing right ground panel switches are active Functions Disabled at Ground Only Swing Left Swing Right Step Pretest Instructions Test Result Corrective Action 2 73 1 Disconnect X024 Pull the Is fault Functi
130. ERED MODELS ONLY Functions Disabled Engine Powered Machines Only Engine Start Analyzer Message START SOLE NOID OPEN CIRCUIT Step Pretest Instructions Test Result Corrective Action 2 141 1 Isthe start solenoid fuseat Yes Replace the fuse X088 blown No Goto step 2 141 2 2 141 2 Disconnect solenoid at X089 Rerun System Test Analyzer Message START SOLE Replace solenoid and or connector On harness end short X089 to NOID SHORT TO GROUND B Analyzer Message START SOLE Goto step 2 141 3 NOID OPEN CIRCUIT 2 141 3 Replace X002 23 with a Rerun System Test Analyzer Message START SOLE Wire Wht Yel 48 6 or wire between jumperto X002 14 NOID SHORT TO GROUND X022 and X089 broken Repair or replace Possible Cause 4 1 10 2 142 START SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Start digital output may be shorted to battery or other function Functions Disabled Engine Powered Machines Only Engine Start Analyzer Message START SOLENOID SHORT TO BATTERY Step Pretest Instructions Test Result Corrective Action 2 142 1 Disconnect solenoid atX089 Rerun System Test Analyzer Message START Replace solenoid and isolate wires SOLENOID OPEN CIRCUIT Analyzer Message START Goto step 2 142 2 SOLENOID SHORT TO BATTERY 2 142 2 Remove wire Wht Yel 48 6 Rerun System Test Analyzer Message
131. EVEL Replace solenoid and or connector X081 soc1 to X081 2 soc DOWN VALVE SHORT TO GROUND Analyzer Message LEVEL Goto step 2 98 3 DOWN VALVE OPEN CIRCUIT 2 98 3 Replace X002 7 with a jumper Rerun System Test Analyzer Message LEVEL Wire Pink 26 3 1 or Pink 26 3 broken to X002 14 DOWN VALVE SHORT TO Repair or replace GROUND Analyzer Message LEVEL Possible Cause 4 1 10 DOWN VALVE OPEN CIRCUIT 2 99 LEVEL DOWN SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Platform Level Down digital output may be shorted to battery or other function Functions Disabled Level Down Step Pretest Instructions Test Result Corrective Action 2 99 1 Run system test Do other functions fail sys Yes Possible Causes Black ground wire tem test broken 4 1 1 otherwise go to step 2 99 2 No Go to step 2 99 2 2 99 2 Disconnect solenoid atX081 Rerun System Test Analyzer Message LEVEL Replace solenoid and isolate wires DOWN VALVE OPEN CIRCUIT Analyzer Message LEVEL Go to step 2 99 3 DOWN VALVE SHORT TO BAT TERY 2 99 3 Remove wire Pink 26 3 1 Rerun System Test Analyzer Message LEVEL Wire Pink 26 3 1 or Pink 26 3 shorted from X002 7 DOWN VALVE OPEN CIRCUIT to battery Repair or replace Analyzer Message LEVEL Possible Cause 4 1 10 DOWN VALVE SHORT TO BAT TERY 3121203 T350 T500J 2 87 SECTION 2 TROUBLESHOOT
132. Engine Start circuit See 2 142 Start Solenoid Short To Battery 5 174 START SOLENOID SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the Engine Start circuit See 2 143 Start Solenoid Short To Ground 5 175 START SWITCH CL ENGINE POWERED MACHINES ONLY System test response indicating that the platform start switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 176 SWING LEFT CL ENGINE POWERED MACHINES ONLY System test response indicating that the ground swing left switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 177 SWING LEFT VALVE OPEN CIRCUIT The system test detected an open in the Swing Left valve circuit See 2 144 Swing Left Solenoid Open Circuit 9 178 SWING LEFT VALVE SHORT TO BATTERY The system test detected a short to battery in the Swing Left valve circuit See 2 145 Swing Left Solenoid Short To Battery 3121203 T350 T500J 5 153 SECTION 5 SYSTEM TEST MESSAGES 9 179 SWING LEFT VALVE SHORT TO GROUND The system test detected a short to ground in the Swing Left valve circuit See 2 146 Swing Left Solenoid Short To Ground 5 180 SWING LT VALVE System test prompt indicating that it is currently testing this circuit 5 181 SWING RIGHT CL System test response indicating that the ground Swing R
133. Functioning Properly 1 34 1 13 Lift Down Function I II 1 35 1 14 Lift Up Function Inoperative 14 4 Ile 1 35 1 15 Telescope Out Function 1 36 1 16 Telescope In Function Inoperative 1 36 1 17 Swing Left Function 1 37 1 18 Swing Right Function 1 37 1 19 Platform Leveling Up Function 1 38 1 20 Platform Leveling Down Function Inoperative 1 39 1 21 Jib Up Function Inoperative 1 40 1 22 Jib Down Function 1 1 0 1 40 1 23 Outrigger Set Function 1 40 1 24 Outrigger Stow Function Inoperative 0 1 40 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 1 Accessory ienen uo teet Eesti qu WE Eid ue EISE 2 41 2 2 Battery Voltage Too High System
134. HIGHT REV zi cie imbre eS savers ae Pea ee IS 5 141 5 70 DRV RIGHT REV VALVE OPEN 5 141 5 71 DRV RIGHT REV VALVE SHORT TO BATTERY 5 141 5 72 DRV RIGHT REV VALVE SHORT TO 5 141 5 73 DUMP VALVE ente Re d ac eges oce dde 5 141 5 74 DUMP VALVE OPEN CIRCUIT 5 141 5 75 DUMP VALVE SHORT TO BATTERY 4 5 142 5 76 DUMP VALVE SHORT TO GROUND 5 142 5 77 ENABLE EAMP ON ana t odere ye deese A euis iden Bauch adda gag du eel a 5 142 5 78 EXTEND VALVE t rime a cae Pet ets Rede ios aotem esie estet 5 142 5 79 EXTEND VALVE OPEN CIRCUIT 5 142 5 80 EXTEND VALVE SHORT TO 5 142 5 81 EXTEND VALVE SHORT TO 5 142 5 82 F E OJR VALVE aie en Era d me C SL nen E cuta en egit e tdg 5 142 5 83 F L OUTRIGGER LAMP ON oen nd e exa cue esa ne 5 143 5 84 F L OUTRIGGER VALVE OPEN 5 143 5 85 F L OUTRIGGER VALVE SHORT TO 5
135. HOLD SER 485 IRED 494 gt lg REAR RIGHT OUTRIGGER f 3 vy er BLACK ENGNESPEED PICKUP 4602 Black 9 72 gt suc Y093 ENGINE CHOKE PULL RELAY ENGINE START lt lt B CHOKE HOLD X098 CHOKE SOLENOID 2 MACHINE i LOADING VIEW X096 VOLTAGE REGULATOR BATTERY BLACK 12 i c2 CN MTB 31 POS CONNECTOR AT FRAME HARNESS STARTER i MOTOR WHTVEL 48 13 REFERENCE 1870172 C a bii xp AQUAM quM D ALL WIRES ARE 18 GA UNLESS NOTED OTHERWISE 5 2POS CONNECTOR AT FRAME HARNESS Sd NOTE SEE 1870185 FOR ALL TRAILER WIRING i X030 Q amp POS CONNECTOR AT GROUND CONTROL LED BOARD BRAKE OPTIONS COUNTRY SPEC 1870172 15 X022 8 POS CONNECTOR AT FRONT LEFT OUTRIGGER FOR TROUBLE 12V ENGINE BATTERY TOCHARGECOL 020 12 POS CONN OUTRIGGER VALVE LIMIT SWITCH GROUND BOLT ON 1095 i ENGINE HOUSING 7 163 SECTION 7 ELECTRICAL REFERENCE X035 X032 GROUND CONTROL BOX X036 X033 X027 X026 0 009 X039 A LIFT DOWN PROP VALVE 040 TRANSPORT ABOVE
136. IGHT VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message SWING Possible Cause 4 1 10 RIGHT VALVE SHORT TO BAT TERY 2 108 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 149 SWING RIGHT SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Swing Right digital output may be shorted to ground or the solenoid may be defec tive Functions Disabled Swing Right Step Pretest Instructions Test Result Corrective Action 2 149 1 Disconnect solenoid atX078 Rerun System Test Analyzer Message SWING Repair Replace solenoid RIGHT VALVE OPEN CIRCUIT Analyzer Message SWING Goto step 2 149 2 RIGHT VALVE SHORT TO GROUND 2 149 2 Remove wire White 22 3 1 Rerun System Test Analyzer Message SWING Wire White 22 3 1 or White 22 3 from X002 35 RIGHT VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message SWING Possible Cause 4 1 10 RIGHT VALVE SHORT TO GROUND 2 150 TELE OUT PREVENTED SET OUTRIGGERS Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the telescope out position while the Platform is Stowed but the vehicle s Outrig gers are improperly set Telescope Out is prevented until all outriggers are set Functions Disabled Telescope Out Step Pretest Instructions Test Result Corrective Action 2 150 1 Isthe boom elevated Yes 3 17 Transport Limit Switch
137. INES ONLY Functions Disabled Engine Choke Pull Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 57 1 Is the switch mechanically Yes Repair or replace the switch stuck No Go to step 2 57 2 2 57 2 DisconnectX035 Placekey Isfault FunctionProblem Yes Goto step 2 57 3 switch in ground position and Engine Choke Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 57 3 Remove X014 13 pin from Is fault Function Problem Yes Goto step 2 57 4 X014 Place key switch in Engine Choke Permanently No Possible Causes Shortin Wht Yel 48 ground position and pullthe Selected still present 9 wire emergency stop switch 2 57 4 Pullthe emergency stop Measured voltage at Yes Possible Causes Short in Wht Yel 48 switches and place key switch X004 16 Vbatt 9 1 wire 4 1 10 in the ground position No Possible Causes 4 1 10 2 58 FUNCTION PROBLEM ENGINE START PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 2 The platform engine start switch was closed when the platform was powered The switch could be accidentally held mechanically stuck or electrically shorted ENGINE POWERED MACHINES ONLY Functions Disabled at Platform Only Engine Start Engine Throttle Pull Engine Throttle Hold Step Pretest Instructions Test Result Corrective Action 2 58 1 Is the switch mechanically Yes Repair or replace the switch s
138. ING BY FAULT MESSAGES 2 100 LEVEL DOWN SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Platform Level Down digital output may be shorted to ground or the solenoid may be defective Functions Disabled Level Down Step Pretest Instructions Test Result Corrective Action 2 100 1 Disconnect solenoid 1 081 Rerun System Test Analyzer Message LEVEL Repair Replace solenoid andisolate wires DOWN VALVE SHORT TO GROUND Analyzer Message LEVEL Goto step 2 100 2 DOWN VALVE OPEN CIRCUIT 2 100 2 Remove wire Pink 26 3 1 Rerun System Test Analyzer Message LEVEL Wire Pink 26 3 1 or Pink 26 3 shorted from X002 7 DOWN VALVE OPEN CIRCUIT to ground Repair or replace Analyzer Message LEVEL Possible Cause 4 1 10 DOWN VALVE SHORT TO GROUND 2 101 LEVEL UP SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Platform Level Up digital output may be disconnected or the solenoid may be defective Functions Disabled Level Up Step Pretest Instructions Test Result Corrective Action 2 101 1 Run system test Dootherfunctionsfailsys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 101 2 No Goto step 2 101 2 2 101 2 Short X080 1 soc to Rerun System Test Analyzer Message LEVEL UP Replace solenoid and or connector X080 2 soc VALVE SHORT TO GROUND Analyzer Message LEVEL UP G
139. ION MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 55 DRV ENABLE SHORT TO GROUND OR OPEN CIRCUIT DRIVE OPTION MACHINES ONLY The system test detected an open circuit or short to ground in the drive enable valve circuit See 2 24 Drive Enable Solenoid Short To Ground Or Open Circuit 5 56 DRV ENABLE VALVE SHORT TO BATTERY DRIVE OPTION MACHINES ONLY The system test detected a short to battery in the drive enable valve circuit See 2 23 Drive Enable Solenoid Short To Battery 9 57 DRV LEFT FWD DRIVE OPTION MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 58 DRV LEFT FWD VALVE OPEN CIRCUIT DRIVE OPTION MACHINES ONLY The system test detected an open circuit in the drive right reverse valve circuit See 2 25 Drive Left Forward Solenoid Open Circuit 3121203 T350 T500J 5 139 SECTION 5 SYSTEM TEST MESSAGES 5 59 DRV LEFT FWD VALVE SHORT TO BATTERY DRIVE OPTION MACHINES ONLY The system test detected a short to battery in the drive left forward valve circuit See 2 26 Drive Left Forward Solenoid Short To Battery 5 60 DRV LEFT FWD VALVE SHORT TO GROUND DRIVE OPTION MACHINES ONLY The system test detected a short to ground in the drive left forward valve circuit See 2 27 Drive Left Forward Solenoid Short To Ground 9 61 DRV LEFT REV DRIVE OPTION MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 62 DRV LEFT REV VAL
140. KE Repair Replace solenoid andisolate wires HOLD SOLENOID OPEN CIR CUIT Analyzer Message CHOKE Goto step 2 16 2 HOLD SOLENOID SHORT TO GROUND 2 16 2 Remove wire WHT YEL 48 5 Rerun System Test Analyzer Message CHOKE Wire WHT YEL 48 5 shorted to from X003 7 HOLD SOLENOID OPEN CIR ground Repair or replace CUIT Analyzer Message CHOKE Possible Cause 4 1 10 HOLD SOLENOID SHORT TO GROUND 2 17 CHOKE PULL RELAY OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Choke Pull digital output may be disconnected from the relay or the relay may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Pull Step Pretest Instructions Test Result Corrective Action 2 17 1 Runsystem test Do other functions fail sys Yes Check 4 1 15 4 1 1 otherwise go to tem test step 2 17 2 No Goto step 2 17 2 2 17 2 Disconnectrelay atX093 At Rerun System Test Analyzer Message CHOKE PULL Replace solenoid and or connector harness end short X093 86 RELAY SHORT TO GROUND WHT YEL 48 410 093 85 Analyzer Message CHOKE PULL Goto step 2 17 3 BLACK wire RELAY OPEN CIRCUIT 2 17 3 Replace X003 4 with a jumper Rerun System Test Analyzer Message CHOKE PULL Wire WHT YEL 48 4 broken Repair or to X003 3 RELAY SHORT TO GROUND replace Analyzer Message CHOKE PULL Possible Cause 4 1 10 RELAY OPEN CIRCUIT
141. LENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Retract Stow Outriggers digital output may be shorted to battery or other function Functions Disabled Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 136 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 136 2 No Go to step 2 136 2 2 136 2 Disconnect solenoid atX085 Rerun System Test Analyzer Message RETRACT Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message RETRACT Goto step 2 136 3 VALVE SHORT TO BATTERY 2 136 3 Remove wire Orn Wht55 4 1 Rerun System Test Analyzer Message RETRACT Wire Orn Wht 55 4 1 or Orn Wht 55 4 from X003 14 VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message RETRACT Repair Replace wire Orn Wht 55 4 1 VALVE SHORT TO BATTERY 2 137 RETRACT 0 R SOLENOID SHORT TO GROUND Distress Lamp 9 may be defective ADE Code 3 3 Ground module feedback shows that the Retract Stow Outriggers digital output may be shorted to ground or the solenoid Functions Disabled Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 137 1 DisconnectsolenoidatX085 Rerun System Test Analyzer Message RETRACT Repair Replace solenoid andisolate wires VALVE OPEN CIRCUIT Analyzer Message RE
142. LOV j 1531 W31SAS Wall gt J8 O 049 0 O MOHHV 1 H3INd 4 1 H31N3 SS34d 3121203 350 T500J 9 211 SECTION 9 JLG ANALYZER Ground Test 6 Follow the flow path in Figure 9 6 System Test Flow Chart Ground Station Tests and go through the 1 Position the Platform Ground select switch to the component tests Hit the ESC key during any part of Ground position the test to return to the main menu without complet u ing all tests or wait until all tests are complete Dur 2 Plug the analyzer into the connector inside the ing the TEST ALL INPUTS sequence the analyzer Ground control box allows control switches to be operated and shows if they are closed CL or open OP 9 8 USER FAULT CODES A single digit fault code blinks on the Platform and the Ground control panel to signal the operator of a proce dure fault These Codes are as follows 1 gt Procedure i e Did Not Close Trigger Joystick Not Centered etc 2 gt Vehicle Setup i e Outriggers Not Set Machine Not Level 3 gt Battery Charger Engaged 4 gt Excessive Duty Cycle Power Module Thermal Cutout 5 Batteries Discharged Start Engine Turn Off System 3 Pull out the Emergency Stop switch and Start the 6 gt Not Used engine 7 gt Not Used 4 The analyzer screen should re
143. Module s prior to V1 10 a Power Wiring Issue 4 1 12 2 98 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 127 POWER MODULE FAILURE PERSONALITY RANGE ERROR Distress Lamp 9 ADE Code 9 9 The Power Module detected an out of range or corrupt personality setting Reset control system Personalities to default set tings to clear difficulty Enter Access Level 1 on the JLG Analyzer re select Model and cycle EMS after 5 seconds May indi cate a Power Module issue if it cannot be reset Reference 3 3 DC Powered Machine Power Module Functions Disabled Electric Powered Machines Only Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Possible Causes Personality setting out of range 4 1 12 2 128 POWER MODULE TOO HOT PLEASE WAIT Distress Lamp 4 ADE Code 4 2 The Power Module has reached thermal cutout Allow to cool by powering down May indicate that the vehicle is operating in extremely high ambient temperatures or a faulty Power Module Reference 3 3 DC Powered Machine Power Module Functions Disabled Electric Powered Machines Only Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Possible Causes High operating temperature 4
144. NCE be Yes Possible Causes 4 1 9 4 1 10 4 1 13 No Goto step 2 7 6 2 7 6 Disconnect X054 Measured RESISTANCE be Yes Electric Machine Go to Step 2 7 9 tween X054 1 soc Engine Machine Goto Step 2 7 10 X054 3 s0c 1200 ae Repair platform CAN termination resistor atX057 2 7 7 Makesurethat machine is Testfor continuity between Yes Goto step 2 7 8 powered off and drive module 075 9 and X007 13 No Repair red wire between X075 9 and is properly connected X007 13 2 7 8 Make sure that machine is Testfor continuity between Yes Possible Causes 4 1 9 4 1 10 powered off and drive module X075 10 and X007 24 4 1 13 is properly connected No Repair black wire between X075 10 and X007 24 2 7 9 Disconnect Power Module at Measured power module Yes Possible Causes 4 1 10 X010 CAN resistance between No Possible Causes 4 1 12 X010 10 pin and E X010 11 pin 2 1200 2 7 10 Disconnect Ground Module at Measured ground module Yes Possible Causes 4 1 10 X007 CAN resistance between No Goto step 2 7 11 007 13 and 007 24 1200 2 7 11 Disconnect X007 Testharnessforcontinuity Yes Possible Causes 4 1 10 between X007 6 socand No Repair or replace black jumper wire between X007 6 soc and X007 17 soc 3121203 T350 T500J 2 43 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 8 CANBUS FAILURE PLATFORM MODULE Distress Lamp 9 ADE Code 6 6
145. OPEN CIRCUIT Analyzer Message LIFTDOWN Goto step 2 106 2 VALVE SHORT TO BATTERY 2 106 2 Remove wire Tan 4 3 1 from Rerun System Test Analyzer Message LIFTDOWN Wire Tan 4 3 1 or Tan 4 3 shortedto X002 22 VALVE OPEN CIRCUIT battery Repair or replace Analyzer Message LIFT DOWN Possible Cause 4 1 10 VALVE SHORT TO BATTERY 2 107 LIFT DOWN SOLENOID SHORT TO GROUND Distress Lamp 9 Functions Disabled Lift Down ADE Code 3 3 Ground module feedback shows that the Lift Down PWM output may be shorted to ground or the solenoid may be defective Step Pretest Instructions Test Result Corrective Action 2 107 1 Disconnect solenoid atX039 Rerun System Test Analyzer Message LIFTDOWN Repair Replace solenoid andisolate wires VALVE OPEN CIRCUIT Analyzer Message LIFTDOWN Goto step 2 107 2 VALVE SHORT TO GROUND 2 107 2 Remove wire 4 3 1 from Rerun System Test Analyzer Message LIFTDOWN Wire 4 3 1 or Tan 4 3 shorted to X002 22 VALVE OPEN CIRCUIT ground Repair or replace Analyzer Message LIFTDOWN Possible Cause 4 1 10 VALVE SHORT TO GROUND 2 108 LIFT UP amp TELE OUT PREVENTED TILTED amp ABOVE ELEVATION Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the lift up or tele out position but RETRIEVAL A is active While RETRIEVAL A is active the boom cannot be lifted up or telescoped out any further to prevent further destab
146. OSITIONS ARE NOT USED WHITE 22 3 WHITE 22 3 T I But 12 10 13 15 17 18 I WHITE 214 7 WHITE 21 3 inna REDET 5044 DO neo Mir so par oue uu em i MN Went O BRA ENGINE OU swing Mehr yN WHITE 2224 E YEURED 246 un WHITE 21 2 iN WHITE 21 244 Lu a 5 BLACK TRANSPORT z BLACK ORNIRED 4952 i 5 LIMIT SWITCH wte nen 226 BUE QE U Mates GROUND E FM gaa a in mii yif RED 226 1 YEURED 215 POWER MODULE SEE POWER MODULE AREA 0 2 i WHITE ANALYZER TRANSMIT Sax mt AO ENGINE START SEE ENGINE AREA BA GREEN ANALYZER RECEIVE EE dg Yu onset HEDA a ig a x YELRED 241 5 ENABLE K 352 i 5 588 ND FROM BATTERY SYSTEM DISTRESS R a MTB EMS input 2 BATTERY 5 OPTIONAL nn IGN RELAY 3 YELRED STROBE LIGHT i PLATFORM BOX CAN BUS CABLE OPTIONAL AD CONNECTOR FRAME m x059 X055 HARNESS IGN RELAY 67 3 1 YELRED 2 12 55 puck REDBLK 4 lt lt GND TO PLATFORM A gt gt IX YELRED 220 BLUE 0 Sanit sue 4 4 Eure eus to wrom v veuneo 2 I i AN ANALYZER POWER d gt RED RED 4 A lt RED A RED RED 11 lt
147. OUTRIGGER VALVE OPEN CIRCUIT The system test detected an open in the F R Outrigger valve circuit See 2 51 Front Right O R Solenoid Open Circuit 9 90 F R OUTRIGGER VALVE SHORT TO BATTERY The system test detected a short to battery in the F R Outrigger valve circuit See 2 52 Front Right O R Solenoid Short To Battery 9 91 F R OUTRIGGER VALVE SHORT TO GROUND The system test detected a short to ground in the F R Outrigger valve circuit See 2 53 Front Right O R Solenoid Short To Ground 5 92 GROUND ALARM ON Ground system test is sounding the ground alarm Step Pretest Instructions Test Result Corrective Action 5 92 1 Does ground alarm sound Yes Press ENTER onthe analyzerto con properly tinuethe system test No Possible Causes Broken Orn Red 49 11 orblack wire Bad ground alarm 4 1 10 5 93 HIGH TILT ANGLE System test prompt that the tilt sensor is reporting an unsafe tilt angle 19 degrees or more See 2 13 Chassis Tilt Sensor Out Of Range 9 94 JIB DN VALVE System test prompt indicating that it is currently testing this circuit 5 95 DOWN CL System test response indicating that the ground Jib Down switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 96 DOWN VALVE OPEN CIRCUIT The system test detected an open in the Jib Down valve circuit See 2 88 Jib Down Solenoid Open Circuit 5 144 T350 T500J
148. Platform Level Up digital output may be shorted to ground or the solenoid may be defective Functions Disabled Level Up Step Pretest Instructions Test Result Corrective Action 2 103 1 Disconnect solenoid atX080 Rerun System Test Analyzer Message LEVEL UP Repair Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message LEVEL UP Go to step 2 103 2 VALVE SHORT TO GROUND 2 103 2 Remove wire Pink 25 3 1 Rerun System Test Analyzer Message LEVEL UP Wire Pink 25 3 1 or Pink 25 3 shorted from X002 5 VALVE OPEN CIRCUIT to ground Repair or replace Analyzer Message LEVEL UP Possible Cause 4 1 10 VALVE SHORT TO GROUND 3121203 T350 T500J 2 89 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 104 LIFT DOWN PREVENTED TELE IN FIRST Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the lift down position but the boom telescope limit switch is open and RETRIEVAL A or RETRIEVAL B are active While RETRIEVAL A or RETRIEVAL B are active the boom must be completely telescoped in closing the telescope limit switch before the boom can be lowered Functions Disabled Lift Down Step Pretest Instructions Test Result Corrective Action 2 104 1 Is the boom fully retracted Yes 3 15 Telescope Limit Switch No Goto step 2 104 2 2 104 2 Isthe machinetilted more Yes Retractthe boom before lowering than 4 5 degrees No Goto step 2 104 3 2 1
149. Possible Causes 4 1 10 9 84 F L OUTRIGGER VALVE OPEN CIRCUIT The system test detected an open in the F L Outrigger valve circuit See 2 48 Front Left O R Solenoid Open Circuit 9 85 F L OUTRIGGER VALVE SHORT TO BATTERY The system test detected a short to battery in the F L Outrigger valve circuit See 2 49 Front Left O R Solenoid Short To Battery 5 86 F L OUTRIGGER VALVE SHORT TO GROUND The system test detected a short to ground in the F L Outrigger valve circuit See 2 50 Front Left O R Solenoid Short To Ground 9 87 F R O R VALVE System test prompt indicating that it is currently testing this circuit 5 88 F R OUTRIGGER LAMP ON System test prompt to check that the ground F R Outrigger lamp is illuminated Step Pretest Instructions Test Result Corrective Action 5 88 1 Does this indicator illuminate Yes Press ENTER onthe analyzerto con properly tinue the system test No Go to step 5 88 2 5 88 2 Do other indicators illuminate Yes Possible Causes Check wiring instead No Goto step 5 88 3 5 88 3 Voltage at X030 6 12VDC Yes Possible Causes 4 1 27 No Go to step 5 88 4 3121203 T350 T500J 5 143 SECTION 5 SYSTEM TEST MESSAGES Step Pretest Instructions Test Result Corrective Action 5 88 4 Voltage atX004 26 Yes Possible Causes Check wires Brn 12VDC Wht 47 22 Brn Wht 47 22 1 and Black No Possible Causes 4 1 10 5 89 F R
150. Pressure Setting outa EE Procedure P N 4150554 Rod 1 Relief Valve Settings 7350 Stroke 9 625 Main Relief 2700 psi 186 bor Blind orea 3 97 in2 Outrigger Retract 2500 psi 172 4 bar Annular area 3 19 in2 Telescope Out 2400 psi 165 5 Bar Platform Level up 2000 psi 138 bor TO Platform Level Down 1200 psi v Bot SE ATM Swing Left and Right 600 psi 41 bar Area Ratio 1 24 1 Telescope In 2200 psi 152 bar T 1 amp T 1 Relief Valve Settings T500J Main Relief 2950 psi 203 5 Outrigger Retract 2500 psi 172 4 bar Telescope Out 2400 psi 165 5 Telescope In 2850 psi 196 5 bar Platform Level up 2800 psi 193 bar Platform Level Down 1200 psi v Ba Lift up retrocts the slove cylinder Swing Left ond Right 600 psi 41 bor Platform Jib Cylinder T500 Bore 2 Rod 1 25 Pu Stroke 19 938 Blind area 3 14 in2 Annular area 1 92 in2 Area Ratio 1 63 1 60 psi 1 Wy Zu INS v2 5555 5 1 1 1 2000 psi 1 9 158 bar 1 1 1 1 1 1 1 1 1 1 Swing Drive
151. R 50 Figure 7 4 X054 Platform Harness to X019 DT12AP 5E Figure 7 1 X055 Platform Boom Connector DT12AR 4 Figure 7 1 X056 Jib Down Valve Solenoid DTO2P 60 Figure 7 1 X057 Platform Harness to console X058 DHD14R 6E Figure 7 1 X058 Platform Console Main DHD14P 6E Figure 7 1 X059 Console Pass through DHD14P 6E Figure 7 4 X060 Platform Module MMF16P 8E Figure 7 4 X061 Joystick MMF10P 70 Figure 7 4 062 EMGStop Drawing Figure 7 4 X063 Rotary Select Sw No Drawing 7D Figure 7 4 X064 Choke Sw No Drawing 80 Figure 7 4 X065 StartSw No Drawing 80 Figure 7 4 066 Alarm Drawing 8E Figure 7 4 X067 Drive Left Forward Solenoid DTO2P Figure 7 5 X068 Drive Right Forward Solenoid DTO2P 76 Figure 7 5 X069 Drive Left Reverse Solenoid DTO2P 7G Figure 7 5 X070 Drive Right Reverse Solenoid DTO2P 7G Figure 7 5 X071 Drive Enable Solenoid DTO2P 76 Figure 7 5 072 Position Switch DTMO4P DTMO4R 7H Figure 7 5 X073 Turntable Position Switch DTMO4P DTMO4R 7H Figure 7 5 X074 Drive Module J1 DTM12BP Figure 7 5 X075 Drive Module J2 DTM12AP 7G Figure 7 5 X076 Drive Module Analyzer Port 4 Figure 7 4 077 Swing LeftSolenoid DTO2P 16 Figure 7 2 X078 Swing Right Solenoid DTO2P 16 Figure 7 2 X079 Jib Up Solenoid DTO2P 16 Figure 7 2 X080 Level Up Solenoid DTO2P 16 Figure 7 2 X08
152. RY 5 145 5 103 JIB UP VALVE SHORT TO 5 145 5 104 JOYSTICK FORWARD TO MAX 5 145 5 105 JOYSTICK LEFT TO MAX we Pe qe pier i I rA ey 5 145 5 106 JOYSTICK REVERSE 4 44 5 145 5 107 JOYSTICK RIGHT TO 5 146 5 108 LEVEL DN VALVE e eed 5 146 24 T350 T500J 3121203 5 5 109 5 110 5 111 5 112 5 113 5 114 5 115 5 116 5 117 5 118 5 119 5 120 5 121 5 122 5 123 5 124 5 125 5 126 5 127 5 128 5 129 5 130 5 131 5 132 5 133 5 134 5 135 5 136 5 137 5 138 5 139 5 140 5 141 5 142 5 143 5 144 5 145 5 146 5 147 5 148 5 149 5 150 5 151 5 152 5 153 5 154 5 155 5 156 5 157 5 158 5 159 5 160 5 161 5 162 5 163 5 164 5 165 5 166 3121203 LEVEL DOWN GL z 28 00 Au AAs eub en ebore epi 5 146 LEVEL DOWN VALVE OPEN 5 146 LEVEL DOWN VALVE SHORT TO 5 146 LEVEL DOWN VALVE SHORT TO 5 146 Nac Rec 5 146 EEVEL UP VALVE orent en
153. Rear Left O R Rear Right O R Set Extend O Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Drive Possible Causes 4 1 2 4 1 3 4 1 4 2 6 CANBUS FAILURE ACCESSORY MODULE COMMUNICATIONS LOST Distress Lamp 9 ADE Code 6 6 System cannot communicate with an installed accessory Step Pretest Instructions Test Result Corrective Action 2 6 1 Is an accessory installed Yes Referto Information Supplied with Accessory No Possible Causes 4 1 2 2 42 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 7 CANBUS FAILURE DRIVE MODULE Distress Lamp 9 ADE Code 6 6 System cannot communicate with the drive module DRIVE OPTION MACHINES ONLY Functions Disabled Machines With Drive Option Only Drive X057 tween X057 A pin and X057 C pin 600 Step Pretest Instructions Test Result Corrective Action 2 7 1 Basic check oflikely causes Possible Causes 4 1 2 Goto step 2 7 2 2 7 2 Pullthe ground emergency Voltage between X074 1 and Yes Goto step 2 7 3 stop switchandplacekey X074 2 Vbatt See 3 4 Drive Module Power Switch in ground position 2 7 3 Make surethat machine is Measured RESISTANCE be Yes Goto step 2 7 7 roo true ca 2 7 4 Disconnectdrive moduleat Measured RESISTANCE be Yes Possible Causes 4 1 9 2 7 5 Disconnectdrive module at Measured RESISTA
154. Rerun System Test Analyzer Message DRV LEFT Wire Orn 7 4 shorted to battery Repair 074 7 FWD VALVE OPEN CIRCUIT or replace Analyzer Message DRV LEFT Possible Cause 4 1 10 FWD VALVE SHORT TO BAT TERY 2 27 DRIVE LEFT FORWARD SOLENOID SHORT TO GROUND Distress Lamp 9 tive ADE Code 3 3 Drive module feedback shows that the drive left forward digital output may be shorted to ground or the relay may be defec DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Forward 2 53 Step Pretest Instructions Test Result Corrective Action 2 27 1 Disconnect solenoid atX074 Rerun System Test Analyzer Message DRV LEFT Repair Replace solenoid and isolate wires FWD VALVE OPEN CIRCUIT Analyzer Message DRV LEFT Goto step 2 27 2 FWD VALVE SHORT TO GROUND 2 27 2 Remove wire Orn 7 4 from Rerun System Test Analyzer Message DRV LEFT Wire Orn 7 4 shorted to ground Repair X074 7 FWD VALVE OPEN CIRCUIT or replace Analyzer Message DRV LEFT Possible Cause 4 1 10 FWD VALVE SHORT TO GROUND 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 28 DRIVE LEFT REVERSE SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Left Reverse Valve PWM output may be disconnected or the solenoid may be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Re
155. Reverse Valve PWM output may be disconnected or the solenoid may be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Right Reverse 2 57 Step Pretest Instructions Test Result Corrective Action 2 37 1 Runsystem test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise Goto step 2 37 2 No Go to step 2 37 2 2 37 2 ShortX070 1 soc to Rerun System Test Analyzer Message DRV RIGHT Replace solenoid and or connector X070 2 soc REV VALVE SHORT TO GROUND Analyzer Message DRVRIGHT Goto step 2 37 3 REV VALVE OPEN CIRCUIT 2 37 3 Replace X074 10 with a Rerun System Test Analyzer Message DRVRIGHT Wire Orn 8 2 broken Repair or replace jumperto X074 2 REV VALVE SHORT TO GROUND Analyzer Message DRVRIGHT Possible Cause 4 1 10 REV VALVE OPEN CIRCUIT 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 38 DRIVE RIGHT REVERSE SOLENOID SHORT TO BATTERY Distress Lamp 9 be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Right Reverse ADE Code 3 3 Drive module feedback shows that the Drive Right Reverse Valve PWM output may be shorted to battery or the solenoid may Step Pretest Instructions Test Result Corrective Action 2 38 1 Runsystem test Do other functions fail sys Yes Possible Cause Black ground wire t
156. Rs ne 5 139 5 53 DRIVE SWITCH CL PERDE Seu Seed DR DE V M e E rt e 5 139 5 54 DRV ENABLE at ea dia ordi e eta d e nee a 5 139 5 55 DRV ENABLE SHORT TO GROUND OR OPEN CIRCUIT 5 139 5 56 DRV ENABLE VALVE SHORT 5 139 5 57 DRV EBERT FWD ere teeth e xe na desea e egre eta DR 5 139 5 58 DRV LEFT FWD VALVE OPEN 4 5 139 5 59 DRV LEFT FWD VALVE SHORT TO 5 140 5 60 DRV LEFT FWD VALVE SHORT TO 5 140 5 61 DRV LEFT REV zu esu eerte e Euge diae Mk aedes ke af den 5 140 5 62 DRV LEFT REV VALVE OPEN CIRCUIT 5 140 5 63 DRV LEFT REV VALVE SHORT TO BATTERY 5 140 5 64 DRV LEFT REV VALVE SHORT TO GROUND 5 140 5 65 DBV RIGHT 22 2 Ner GE DRE RR RE gni 5 140 5 66 DRV RIGHT FWD VALVE OPEN CIRCUIT 5 140 5 67 DRV RIGHT FWD VALVE SHORT 5 141 5 68 DRV RIGHT FWD VALVE SHORT TO 5 141 5 69 DBRV
157. S Ground module feedback shows that the Telescope In digital output may be shorted to ground or the solenoid may be defective Functions Disabled Telescope In Step Pretest Instructions Test Result Corrective Action 2 154 1 Disconnect solenoid atX083 Rerun System Test Analyzer Message TELESCOPE Repair Replace solenoid IN VALVE OPEN CIRCUIT Analyzer Message TELESCOPE Goto step 2 154 2 IN VALVE SHORT TO GROUND 2 154 2 Remove wire Brown 13 3 1 Rerun System Test Analyzer Message TELESCOPE Wire Brown 13 3 1 or Brown 13 3 from X002 4 IN VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 IN VALVE SHORT TO GROUND 3121203 T350 T500J 2 111 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 155 TELESCOPE OUT SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Telescope Out digital output may be disconnected or the solenoid may be defec tive Functions Disabled Telescope Out Step Pretest Instructions Test Result Corrective Action 2 155 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 155 2 No Goto step 2 155 2 2 155 2 Disconnect solenoid Short Rerun System Test Analyzer Message TELESCOPE Replace solenoid and or connector X082 1 soc to X082 2 soc OUT VALVE SHORT TO GROUND Analyzer
158. S LAMP 5 154 5 187 TELE IN GL ocu ertet quete el ee A tun A Dor i E ater ay 5 155 5 188 TELE IN VALVE EE e E RR aeo ER SE E 5 155 5 189 TELE QUT ie iore en Cre EN e sert ee vid dert 5 155 5190 TELE OUT VALVE citer deter mean td ote D at ae REB RT EI d dent 5 155 5 191 TELESCOPE IN VALVE 5 155 5 192 TELESCOPE IN VALVE SHORT 5 155 5 193 TELESCOPE IN VALVE SHORT TO 5 155 5 194 TELESCOPE OUT VALVE OPEN 1 5 155 5 195 TELESCOPE OUT VALVE SHORT 5 155 5 196 TELESCOPE OUT VALVE SHORT TO 5 155 5 97 TESTS COMPLETE eei eredi len deo ern diese des da board alto andes 5 156 5 198 THROTTLE HOLD ste tuere oe usen ep eoe e e iat i ete Lg 5 156 5 199 THROTTLE HOLD SOLENOID OPEN CIRCUIT 5 156 5 200 THROTTLE HOLD SOLENOID SHORT TO BATTERY 5 156 5 201 THROTTLE HOLD SOLENOID SHORT TO GROUND 5 156 5 202 IHROTILEPULL niet TV am dedo eA Qa ula
159. SEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 7 7 AMP Connector 3121203 T350 T500J 7 182 SECTION 7 ELECTRICAL REFERENCE SS SS NN Tsay 71 c PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 7 8 Connector Assembly Figure 2 3 After all required contacts have been inserted the wedge lock must be closed to its locked position Release the lock ing latches by squeezing them inward See Figure 7 9 SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 7 9 Connector Assembly Figure 3 7 183 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE Figure 7 11 Connector Disassembly 4 Slide the wedge lock into the housing until it is flush with the housing See Figure 7 10 WEDGE LOCK FLUSH WITH A SASS SST Figure 7 10 Connector Assembly Figure 4 Disassembly 1 Insert a 4 8 mm 3 16 wide screwdriver blade between the mating seal and one of the red wedge lock tabs 2 Pry open the wedge lock to the open position 3 While rotating the wire back and forth over a half turn 1 4 turn in each direction gently pull the wire until the contact is removed NOTE The wedge lock should never be removed from the housing for insertion or removal of the contacts Wedge Lock The wedge lock has slotted openings in the forward o
160. SENSOR GAIN OUT OF RANGE Distress Lamp 9 ADE Code 9 9 Indicates that the chassis tilt sensor calibration information has become corrupted Vehicle will indicate that it is tilted at all times This calibration data is programmed at the factory Functions Disabled Same as Tilted Possible Causes 4 1 10 3121203 T350 T500J 2 45 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 12 CHASSIS TILT SENSOR NOT CALIBRATED Distress Lamp 9 ADE Code 8 1 The tilt sensor calibration has not been performed for the chassis tilt sensor Tilt reading displayed as 90 and vehicle assumed to be tilted Functions Disabled Same as Tilted Step Pretest Instructions Test Result Corrective Action 2 12 1 Has the tilt sensor calibration Yes Possible Causes 4 1 10 been run No Run the tilt sensor calibration 2 13 CHASSIS TILT SENSOR OUT OF RANGE Distress Lamp None ADE Code None Tilt Sensor read angle greater than 19 for more than 4 seconds after 2 second power up delay Tilt reading displayed as 90 and vehicle assumed to be tilted Functions Disabled Same as Tilted Step Pretest Instructions Test Result Corrective Action 2 13 1 Isthe machine tilted 19 or Yes Level machine before operating more No Goto step 2 13 2 2 13 2 Is the ground module prop Yes Goto step 2 13 3 erly oriented and mounted yo Properly secure the ground module with the machine resting on a level surface Runthe tilt sen
161. START Wire Wht Yel 48 6 or wire between from X002 23 SOLENOID OPEN CIRCUIT X022 and X089 shorted to battery Repair or replace Possible Cause 4 1 10 3121203 T350 T500J 2 105 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 143 START SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Start digital output may be shorted to ground or the solenoid may be defective Functions Disabled Engine Powered Machines Only Engine Start Step Pretest Instructions Test Result Corrective Action 2 143 1 Disconnect solenoid atX089 Rerun System Test Analyzer Message START Repair Replace solenoid and isolate wires SOLENOID OPEN CIRCUIT Analyzer Message START Goto step 2 143 2 SOLENOID SHORT TO GROUND 2 143 2 Remove wire Wht Yel 48 6 Rerun System Test Analyzer Message START Wire Wht Yel 48 6 or wire between from X002 23 SOLENOID OPEN CIRCUIT X022 and X089 shorted to ground Repair or replace Analyzer Message START Possible Cause 4 1 10 SOLENOID SHORT TO GROUND 2 144 SWING LEFT SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Swing Left digital output may be disconnected or the solenoid may be defective The start solenoid fuse should be checked Functions Disabled Swing Left Step Pretest Instructions Test Result Corrective Action 2 144 1 Run system test Do other functio
162. Short To Battery 5 122 LIFT DOWN VALVE SHORT TO GROUND The system test detected a short to ground in the Lift Up valve circuit See 2 107 Lift Down Solenoid Short To Ground 9 123 LIFT UP CL System test response indicating that the ground lift up switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 124 LIFT UP VALVE System test prompt indicating that it is currently testing this circuit 9 125 LIFT UP VALVE OPEN CIRCUIT The system test detected an open in the Lift Up valve circuit See 2 114 Lift Up Solenoid Open Circuit 9 126 LIFT UP VALVE SHORT TO BATTERY The system test detected a short to battery in the Lift Up valve circuit See 2 115 Lift Up Solenoid Short To Battery 3121203 T350 T500J 5 147 SECTION 5 SYSTEM TEST MESSAGES 9 127 LIFT UP VALVE SHORT TO GROUND The system test detected a short to ground in the Lift Up valve circuit See 2 116 Lift Up Solenoid Short To Ground 5 128 MULTIPLE CLOSURE System test response indicating that multiple switches have been closed when a single switch was expected The desired switch may or may not be one of the switches closing Make sure that no other switches are being activated or check the switch wiring 5 129 O R SET CL System test response indicating that the ground Outrigger Set switch has been closed when a different switch was expected Make sure the correct switch is being ac
163. Solenoid Short To Ground E 3 3 Choke Pull Relay Open Circuit ee rendere deem BERG Pe ati DR Reade ini ie andes 3 3 Choke Pull Relay Short To Battery sisse entrent nne nettes 3 3 Choke Pull Relay Short To Ground 3 3 Drive Enable Solernoid Short To Battery pie eee e ee e b ERE eet d em ep le 2 51 3 3 Drive Enable Solenoid Short To Ground Or Open Circuit 2 52 3 3 Drive Left Forward Solenoid Open Circuit sse eene nennen tene 2 52 3 3 Drive Left Forward Solenoid Short To Battery 2 53 3 3 Drive Left Forward Solenoid Short To Ground 2 53 3 3 Drive Left Reverse Solenoid Open Circuit 2 54 3 3 Drive Reverse Solenoid Short To Battery 2 54 3 3 Drive Left Reverse Solenoid Short To Ground 2 55 3 3 Drive Right Forward Solenoid Open Circuit esses eene enne entree nennen 2 56 3 3 Drive Right Forward Solenoid Short To Battery nenne nennen en nennen nenne nennen 2 56 3 3 Drive Right Forward Solenoid Short To Ground 2 57 3 3 Drive Right Reverse Solenoid Open Circuit eene eerie nennen nenne 2 57 3 3 Drive Right Reverse Solenoid Short To Battery esses eene nente enne 2 58 3 3 Drive Right Reverse Solenoid Short To Groun
164. System cannot communicate with the platform module Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 8 1 Pullthe ground emergency on lights blink Yes Goto step 2 8 2 stopswitchandplacekey the platform emergen See 3 13 Platform Module Power switch in the platform position Stop switch is pulled 2 8 2 surethat machine is N ED Yes Goto step 2 8 5 powered off and platform tween Red wire and A Goto step 2 8 3 module is properly connected 4060 4 Black 600 dx 2 8 3 Disconnect X054 Measured RESISTANCE be Yes Electric Machine Go to Step 2 8 7 tween X054 1 soc_ and Engine Machine Go to Step 2 8 9 X054 3 soc 1200 No Goto step 2 8 4 2 8 4 DisconnectX054 andX057 Measured RESISTANCE be Yes Possible Causes 4 1 11 MoT Cin ite ar No Repair platform CAN termination resistor atX057 2 8 5 Testfor continuity between Yes Goto step 2 8 6 X060 3 and X007 13 No Repair red wire between X060 3and X007 13 2 8 6 Testfor continuity between Yes Possible Causes 4 1 11 4 1 10 X060 4 and X0
165. TARY SELECTOR SWITCH Distress Lamp 9 ADE Code 2 2 More than one of the three digital inputs from the platform rotary selector switch are active Only one of the inputs should be active at one time to indicate the selected mode Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R emergency stop switches Turn the selector switch to the center position Lift Swing and JIB Tele switches for Closed status in ANA LYZER gt DIAGNOSTICS gt LIFT SW CLOSED and JIB TELE CLOSED Step Pretest Instructions Test Result Corrective Action 2 72 1 Disconnect X063 Placekey Is fault Function Problem Yes Goto step 2 72 2 switch in the platform position Rotary Selector Switch still No Possible Causes 4 1 18 and pullthe emergency stop present switches 2 72 2 Place key switch inthe plat While holding the enable LIFT SW CLOSED and LEVEL Possible Causes Shortin Orn Red 49 form position and pull the switch check Level Lift SW CLOSED 27 wire 4 1 11 Possible Causes Shortin Orn Red 49 29 wire 4 1 11 emergency stop switches Turn the selector switch to the right position JIB Tele and JIB Tele switches for Closed status in ANA LYZER gt DIAGNOSTICS gt PLATFORM JIB TEL
166. TCH SEVCON MODULE ELECTRIC POWERED X097 092 k LEFT SIDE MARKER LIGHT LEFT SIDE TAILLIGHT 1 9 LIGHT AUSTRALIAN amp CE SPECS RIGHT SIDE TAILLIGHT LEFT LEFT REAR PLATE TAILLIGHT FOGLIGHT LIGHT TAILLIGHT RIGHT TAILLIGHT MARKER LIGHT RIGHT TAILLIGHT LEFT SIDE MARKER LIGHT E23 RIGHT SIDE WITH HYDRAULIC BRAKES en 060 a1 059 PLATFORM CONSOLE Nm 6 X052 LOCATED ON T T AT ALG X061 X019 ox d LIFT HOOK STOW X058 LENA X055 __ X054 0000 DRIVE DIRECTIONAL DRIVE PROXIMITY VALVE OPTIONAL DRIVE ENABLE X074 3 SWITCHES OPTIONAL X068 X067 OPTIONAL Sp G X073 LOCATED AT PLATFORM 4 fis PIVOT X063 X072 X075 42 RT o o MODULE N OPTIONAL VALVE X066 X101 Tm X102 X064 X062 X065 TT BATTERIES 012 070 069 6 5 ELECTRIC POWERED X112 Fi B BATTERY N HARGER 2 ELECTRIC POWERED X021 X116 114
167. TRACT Goto step 2 137 2 VALVE SHORT TO GROUND 2 137 2 Remove wire Orn Wht55 4 1 Rerun System Test Analyzer Message RETRACT Wire Orn Wht 55 4 1 or Orn Wht 55 4 from X003 14 VALVE OPEN CIRCUIT shorted to ground Repair or replace Analyzer Message RETRACT Possible Cause 4 1 10 VALVE SHORT TO GROUND 3121203 T350 T500J 2 103 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 138 RUNNING AT CREEP MATERIAL HOOK MODE Distress Lamp None ADE Code None All function speeds are limited to creep because at the vehicle is being operated in Ground Mode while the Material Hook is in use Functions in Creep Mode Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Step Pretest Instructions Test Result Corrective Action 2 138 1 Isthe platform console Yes Goto step 2 138 2 plugged into the optional No See 2 124 Platform Position Detection material hook harness Faulty 2 138 2 Isthe key switch turned to Yes Turnthe key to platform position for the platform position material hook operation with the plat form console No Possible Causes Faulty keyswitch wir ing See 2 97 Keyswitch Faulty 4 1 10 2 139 RUNNING AT CREEP TILTED amp ABOVE ELEVATION Distress Lamp 2 ADE Code None All function speeds are limited to creep because the vehicle is tilted and the platform is elevated Functions in Creep Mode Lift Up Lift Down Swing Left Swing Right Tele
168. Test Result Corrective Action 1 21 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 21 2 Engage enable and jib up DC Is pump motor running Yes Goto step 1 21 3 switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 21 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 21 3 Install a0 to 5000 PSI 345 Engage the enable andjibup Above Min Jib UpPressurepsi Goto step 1 21 5 bar pressure gauge atthe switch Checkthe pressure bar manifold G port Below Min Jib UpPressurepsi Goto step 1 21 4 bar 1 21 4 Plumb a 0 to 5000 PSI 345 Engage the enable andjibup Above Min Jib UpPressurepsi Possible Causes 4 1 38 4 1 45 bar pressure gauge intothe switch Check pressure at bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port manifold P port Below Min Jib Up Pressure psi Possible Causes 4 1 46 4 1 47 bar 4 1 74 4 1 45 4 1 39 4 1 10 1 21 5 Plumb a0 to 5000 PSI 345 Check pressure atthe jib cylin Above Min Jib Up Pressurepsi Possible Causes 4 1 49 4 1 48 bar pressure gauge into the hose from the jib cylinder cap end der while activating jib up at ground controls bar Below Min Jib Up Pressure psi bar 4 1 41 Possible Causes 4 1 42 4 1 60 1 22 JIB DOWN FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 22 1 Basic check
169. VDC 2 IGN PWR FROM IGN RELAY 87 Power Input Vbatt 3 GROUND FOR PLATFORM MODULE Power Output OVDC 4 IGN PWR FOR PLATFORM MODULE Power Output Vbatt 7 173 T350 T500J 3121203 7 3 PLATFORM MODULE CONNECTOR PINOUT Table 7 8 X060 J1 Platform Module Pinout SECTION 7 ELECTRICAL REFERENCE PIN T SERIES FUNCTION TYPE 1 0 RANGE V 1 IGNITION Power Input Vbatt 2 SYSTEM GROUND Power Input OVDC 3 CANH Serial 0 Serial 4 CANL Serial VO Serial 5 JOYSTICK SUPPLY Power Output 5VDC 6 JOYSTICK X AXIS Analog Input 5VDC 7 JOYSTICK GROUND Power Output OVDC 8 JOYSTICK Y AXIS Analog Input 5VDC 9 ROTARY POSITION 1 Digital Input Vbatt 10 ROTARY POSITION 2 Digital Input Vbatt 11 SWITCH GROUND Power Output OVDC 12 PLATFORM ALARM Analog Output OVDC 13 START SWITCH Digital Input Vbatt 14 CHOKE GLOW SWITCH Digital Input Vbatt 15 ROTARY POSITION 3 Digital Input Vbatt 16 DRIVE amp SET SWITCH Digital Input Vbatt 3121203 T350 T500J 7 174 SECTION 7 ELECTRICAL REFERENCE 7 4 DRIVE MODULE CONNECTOR PINOUT Table 7 9 X074 J1 Drive Module Pinout PIN T SERIES FUNCTION TYPE 1 0 RANGE 1 IGNITION Power Input Vbatt 2 SYSTEM GROUND Power Input 0VDC 3 TURNTABLE POSITION 1 Digital Input Vbatt 4 TURNTABLE POSITION 2 Analog Input Vbatt 5 SPARE INPUT 2 Analo
170. VE OPEN CIRCUIT DRIVE OPTION MACHINES ONLY The system test detected an open circuit in the drive right reverse valve circuit See 2 28 Drive Left Reverse Solenoid Open Circuit 5 63 DRV LEFT REV VALVE SHORT TO BATTERY DRIVE OPTION MACHINES ONLY The system test detected a short to battery in the drive left reverse valve circuit See 2 29 Drive Left Reverse Solenoid Short To Battery 5 64 DRV LEFT REV VALVE SHORT TO GROUND DRIVE OPTION MACHINES ONLY The system test detected a short to ground in the drive left reverse valve circuit See 2 30 Drive Left Reverse Solenoid Short To Ground 5 65 DRV RIGHT FWD DRIVE OPTION MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 66 DRV RIGHT FWD VALVE OPEN CIRCUIT DRIVE OPTION MACHINES ONLY The system test detected an open circuit in the drive right forward valve circuit See 2 34 Drive Right Forward Solenoid Open Circuit 5 140 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 67 DRV RIGHT FWD VALVE SHORT TO BATTERY DRIVE OPTION MACHINES ONLY The system test detected a short to battery in the drive right forward valve circuit See 2 35 Drive Right Forward Solenoid Short To Battery 5 68 DRV RIGHT FWD VALVE SHORT TO GROUND DRIVE OPTION MACHINES ONLY The system test detected a short to ground in the drive right forward valve circuit See 2 36 Drive Right Forward Solenoid Short To Ground 5 69 DRV RIGHT REV DRIVE OPTION MACHINES ONLY System test p
171. VI Reverse Forward E Reverse Forward 2 3 M4 5 I amp pas ath 51 M i v un 1 1 an Figure 8 8 Hydraulic Schematic Electric Powered Drive Option Sheet 1 of 2 1 S if lt WIDER 1 52 1 RM EN MA 1 BOTTOM COIL e TOP COIL T 160 PSI 160 PSI T 1 1 1 1 OHY T 62 P2 Q2 qs 7 Drive Directional Valve Rotary E T wu Divider il Differential reliefs set at 750 PSI 52 BAR des a 9 T350 T500J 3121203 SECTION 8 HYDRAULIC REFERENCES Manual release valve with detent CLOSED WHEN DRIVING OPEN WHEN TOWING 2 1 Cage Wheel Cylinder 4 IA V V bo X 9G C P1 o o 10 Micron 400 PSI Absolute NAT POENIS ar psi 6 gt t Bypass control valve port 1 1 gt 1 54554 3500 PSI a 2 B OH SR 3000 ly Pr 207 BAR 1 1 L D T Drive Enable Valve
172. a eese e Mh etudes LE cbe 5 146 LEVEL UP VALVE OPEN 5 146 LEVEL UP VALVE SHORT TO BATTERY 5 146 LEVEL UP VALVE SHORT TO GROUND 5 147 LIET DN VAEVESs asit rct vide ert taedas Lie ius 5 147 EIET BOWNNIGL 5 147 LIFT DOWN VALVE OPEN 5 147 LIFT DOWN VALVE SHORT TO 5 147 LIFT DOWN VALVE SHORT TO 5 147 EIFLLUPRICE ae apn Sen muri ue Act A ea Rote ook 5 147 EIFT UP VALVE 4 4 322 0 ee nope et Eee dee beber Debet m etes e e in 5 147 LIFT UP VALVE OPEN 5 147 LIFT UP VALVE SHORT TO BATTERY 5 147 LIFT UP VALVE SHORT TO GROUND 5 148 MULETIPLE GLOSUBE eei e ret eere Got fecti ec ez idt An a t ed eee ety 5 148 O R SET GL rettet ttc IN elc edere screen re ve tain ut s 5 148 O PSET EAMP QN duo eta Mate anton ea t de a te hel AOS db RE erbe 5 148 O R STOW ete rhe ere te ete Lap Star ec 5 148 urs ut caes
173. ad 8 gt Not Used E 9 gt Vehicle Requires Service HELP PRESS ENTER S V J 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 3121203 T350 T500J 9 212 SECTION 9 JLG ANALYZER 1591 uomnejs 1591 9 6 u399lH1nO 1 9 340HO 001 ADVLIOA Adallvd 1 HOLVOIGNI SNIMS TINd 340HO LHOIH ana xa OHO WO HH 19 15 MOLS Y O YO 44 13S Y O Y O T4 NMOG 13 31 wavy 13191 140 air anal m HOLVOIGNI Y399IHLNO HH INVA TINTON anna ino OL NYO U3MOd HOLVOIONI NI 5781 GION310S U3O9IHLNO 4 4 mem ONIS 106 re YOLVOIGNI 31LIOUHL 1431 ONIMS HADSIINO T3 NMOG 141 103138 WHOALW1d YOLWOIONI Sout NMOG 147 JaNGOHE SS3HLSIC dn 14n WALSAS GION31OS 3131dWOOo 9 SWHVIV S3HOLIMS 1551 SNIDNA 1931 5 9 SLSAL IMYA DEIN 9013 3NIHOVIN ANNIN T3A31 AGL WSS 401 LX3N 3H1 OL MOHHV LHOIH XOU OU own 1 O49S 0 MOHHV WALI MOHHV LHOIH
174. age above 18 Volts for an engine powered machine ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Drive Possible Causes 4 1 2 4 1 3 4 1 4 2 4 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN Distress Lamp 3 ADE Code 4 4 The system detected a battery voltage below 16 Volts for an electric powered machine ELECTRIC POWERED MACHINES ONLY Functions Disabled Electric Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O Stow Retract O R Drive Possible Causes 4 1 2 4 1 3 4 1 4 3121203 T350 T500J 2 41 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 5 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN Distress Lamp 5 ADE Code 4 4 The system detected a battery voltage below 9 Volts for an engine powered machine ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R
175. ar pressure gauge atthe right switch Checkthe pres psi bar manifold G port Surg Below Min Swing Right Pressure Goto step 1 18 4 psi bar 1 18 4 Plumb 010 5000 PSI 345 Engage the enable and swing Above Min Swing RightPressure Possible Causes 4 1 38 4 1 45 bar pressure gauge intothe right switch Check pressure at psi bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port manifold P port Below Min Swing Right Pressure Possible Causes 4 1 10 4 1 46 psi bar 4 1 47 4 1 74 4 1 45 4 1 39 1 18 5 Plumb a 0 to 5000 PSI 345 Check pressure atthe swing Above Min Swing RightPressure Possible Causes 4 1 49 4 1 48 bar pressure gaugeintothe motor while activating swing psi bar 4 1 41 hose fromthe swing motor right at ground controls Below Min Swing Right Pressure Possible Causes 4 1 42 4 1 52 cylinder psi bar 3121203 T350 T500J 1 37 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 19 PLATFORM LEVELING UP FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 19 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 19 2 Engage enable and LevelUp DC Ispump motor running Yes Goto step 1 19 3 Switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 19 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 19 3 Install a0 to 5000 PSI 345 Engage the enable and Lev
176. at X004 14 Yes Possible Causes Check wires Brn 12VDC Wht 47 23 Brn Wht 47 23 1 and Black No Possible Causes 4 1 10 5 166 R R OUTRIGGER VALVE OPEN CIRCUIT The system test detected an open in the Rear Right Outrigger valve circuit See 2 132 Rear Right O R Solenoid Open Circuit 5 167 R R OUTRIGGER VALVE SHORT TO BATTERY The system test detected a short to battery in the Rear Right Outriggers valve circuit See 2 133 Rear Right O R Solenoid Short To Battery 5 168 R R OUTRIGGER VALVE SHORT TO GROUND The system test detected a short to ground in the Rear Right Outriggers valve circuit See 2 134 Rear Right O R Solenoid Short To Ground 5 169 RUNNING System test prompt indicating that it is currently running tests 5 170 START CL ENGINE POWERED MACHINES ONLY System test response indicating that the ground start switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 152 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 171 START SOLENOID ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 172 START SOLENOID OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open in the Start circuit See 2 141 Start Solenoid Open Circuit 5 173 START SOLENOID SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the
177. atform Rotary Select 2 75 3 1 Power Module Gircuit vi oo na iden IS 3 118 7 1 Frame Connector Layout 7 162 7 2 Ground Control Valve Connections 7 162 7 3 Electrical Schematic son iira s T rus nals tod o tele Vea ate 7 163 7 4 Electrical Diagrar E ea AH RC EUER ee 7 164 7 5 Drive and Set a tio Sra para ec RE Ag dae De rin do den ed 7 165 7 6 Connector Assembly Figure 1 1 47 7 182 7 7 AMP ConneGtor cse et RECEN RE Die 7 182 7 8 Connector Assembly Figure 2 1 7 4 7 183 7 9 Connector Assembly Figure 3 1 7 183 7 10 Connector Assembly Figure 4 7 184 7 11 Connector 2 e aa ERR NE EATUR 7 184 7 12 Connector Installation 155 vetu ve npo edes du ne Ee ERE Gee toe 7 185 7 13 DT DTP Contact Installation 2 7 186 7 14 Contact
178. ator or open windings 3 Resistance 1 MegaOhm between Motor Terminals and Motor Housing The internal windings should be electrically isolated from the motor housing Low resistance may be an indication of a broken motor terminal damaged brush faulty commutator or burned winding 3 4 DRIVE MODULE POWER Step Pretest Instructions Test Result Corrective Action 3 4 1 Voltage between e and Yes Goto step 3 4 2 A958 Br No Goto step 3 4 4 3 4 2 Pullthe ground emergency Voltage between X012 1 and Yes Repair or replace Yel Red 2 16 wire stop switchandplacekey 012 2 Vbatt between X012 1 and X074 1 Switch in ground position No Goto step 3 4 3 3 4 3 Pullthe ground emergency Voltage on X009 87 Vbatt Yes Repair or replace Yel Red 2 16 wire stop switch and place key between X009 87 and X012 1 Switch in ground position No See 3 9 Ignition Relay Power 3 4 4 Voltage between X012 2 and Yes Repair or replace Black wire between X099 Vbatt X074 2 and X012 2 No Goto step 3 4 5 3 4 5 Voltage between 009 85 Yes Repair or replace Black wire between and X099 B Vbatt X012 2 and X009 85 No Goto step 3 4 6 3 4 6 Voltage between X004 32 Yes Repair or replace Black wire between and X099 Vbatt X009 85 and X004 32 No Consult Factory 3 5 DRIVE SENSOR RESET If an error is detected with the turntable position sensor or hand brake position sensor they need to be reset
179. ble Causes 4 1 25 isolate wires No Goto step 2 120 2 2 120 2 Remove X017 4 from X017 Is the fault removed Yes Wire Yel Red 2 13 or black ground wire between X017 and X050 shorted to battery Repair or replace No Goto step 2 120 3 2 120 3 Remove X002 8 from X002 Is the fault removed Yes Wire Yel Red 2 13 between X017 and X002 shorted to battery Repair or replace No Possible Causes 4 1 10 2 121 OPTIONAL GROUND ALARM SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that optional ground alarm PWM output may be shorted to ground or the solenoid may be defective All Functions Operable Step Pretest Instructions Test Result Corrective Action 2 121 1 Disconnect alarm at X050 and Is the fault removed Yes Possible Causes 4 1 25 isolate wires No Goto step 2 121 2 2 121 2 Remove X017 4 from X017 Is the fault removed Yes Wire Yel Red 2 13 or black ground wire shorted to ground Repair or replace No Goto step 2 121 3 2 121 3 Remove X002 8 from X002 Is the fault removed Yes Wire Yel Red 2 13 shorted to ground Repair or replace No Possible Causes 4 1 10 2 96 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 122 OUTRIGGER STOW PREVENTED TELE IN FIRST Distress Lamp 2 ADE Code 2 5 The ground module senses the ground panel outrigger switch is in the stow position but the boom telescope limit switch is open
180. ble Causes 4 1 25 isolate wires No Goto step 2 84 2 2 84 2 Remove X014 17 fromX014 Is the faultremoved Yes Wire Orn Red 49 11 or black ground wire shorted to ground Repair or replace No Goto step 2 84 3 2 84 3 Remove X002 19 from X002 Is the fault removed Yes Wire Orn Red 49 11 1 shortedto ground Repair or replace No Possible Causes 4 1 10 3121203 T350 T500J 2 79 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 85 GROUND MODULE FAILURE REF VOLTAGE OUT OF RANGE Distress Lamp 9 ADE Code 9 9 The Ground Module has detected that the 7V reference voltage source is out of range This be caused by a wiring short to one of the reference voltage pins on the Ground Module or by a faulty Ground Module All Functions Operable Possible Causes 4 1 10 2 86 GROUND MODULE FAILURE VLOW FET FAILURE Distress Lamp 9 ADE Code 9 9 The control system will not function because the Ground Module has experienced a hardware failure that prevents it from reading High Sensing Digital Inputs Functions Disabled Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Possible Causes 4 1 10 2 87 HOURMETER SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground m
181. circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity Figure 10 3 Continuity Measurement 10 215 T350 T500J 3121203 SECTION 10 MULTIMETER BASICS Set the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the cur rent range you have selected e If meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads Figure 10 4 Current Measurement DC 3121203 350 T500J 10 216 SECTION 10 MULTIMETER BASICS 10 217 T350 T500J 3121203 11 1 INTRODUCTION SECTION 11 SPECIFICATIONS SECTION 11 SPECIFICATIONS This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine Other Publications Available T350 amp T500J Operation and Safety Manual 3121197 T350 Service and Maintenance Manual T500J Service and Maintenance Manual T350 amp T500J Illustrated Parts Manual m 3121198 m 3121200 MERDA 3121199 11 2 OPERATING SPECIFICATIONS MODEL T350 T500J Tongue Weight ANSI 252165 114 kg 350 Ibs 154 kg Maximum Allowable Tow Speed Do NOT exceed legal speed limit 65 mph 105 kph 65 mph 105 kph Maximum Work Load Capacity w Rotator 440
182. d sese eee nennen enne entrent treten tenete nennt 2 58 3 3 Dump Solenoid Open Circuit 2 59 3 3 Dump Solenoid Short To Battery 2 59 3 3 Dump Solenoid Short To Ground 2 60 3 3 Extend O R Solenoid Open Circuit 2 61 3 3 Extend O R Solenoid Short To Battery 2 61 3 3 Extend O R Solenoid Short To Ground sess eerte 2 62 3 3 Front Left O R Solenoid Open Circuit rr hits in RER de tede dee c RR RR e eee BAD 2 62 3 3 Front Left O R Solenoid Short To Battery 1 1 011 0 10000000000000 2 63 3 3 Front Left O R Solenoid Short To Ground esee eene entretient rennen entrent tree tentent ente 2 63 3 3 Front Right O R Solenoid Open Circuit 2 64 3 3 Front Right O R Solenoid Short To Battery 2 64 3 3 Front Right O R Solenoid Short To Ground esses 2 65 33 Ground Alarm Short To Battery eg ere De p 2 79 3 3 Ground Alarm Short To Ground 2 79 3 3 Hourmeter Short To Battery 2 80 3 3 Jib Down Solenoid Open Circuit 2 80 3 3 Jib Down Solenoid Short To Battery
183. d 1 75 2 Stroke 34 75 i i Blind area 7 068 in2 EE EN Anneler reo 2106 in2 v2 NE v2 rea Ratio 1 51 T500 Bore 3 75 1 1 Rod 2 m Bi 220 04 112 ind area 5 Hitch End Jj Right side Jacks Left side Area 8569569 4 7 nue when towing when towing the vehicle the vehicle 1 1 1 0209 Bary V2i 1 Junction gt Mani fold X x 7 8 9 10 O 13 X I NN 5 12 t T tu 3 64 11 2 3 4 5 6 orifice 0 072 V1 1 T 2s E TEA E E Ha pp LA e 1 3 5 Outrigger ee LY 1 X ie NH ber 2 1 1 52 Retroct Extend i e gt ee i p ie 142 psi 6 bor ZN 10 bar e e Manual ee Descent Hs 1 ed T2 Suction gt Figure 8 2 Hydraulic Schematic Electric Powered Machines Sheet 1 of 2 8 193 T350 T500J 3121203 Slave and Master Cylinders 7350 Bore 2 Rod 1 Stroke 7 375 Blind area 3 14 in2 Annular area 2 35 SECTION 8 HYDRAULIC REFERENCES 2 Pump Motor Spec s Area Ratio 1 33 1 Power 3 0 kW Voltage 24VDC T500 Pump Displacement 0 1922 in3 3 15 Bore 2 25 All valves coils ore 12VDC Rod 1 Stroke 9 625
184. d 49 27 Usingthe analyzer navigateto Diagnostic Message read DIAGNOSTICS gt PLAT LEVEL SELECT FORM 2 96 7 Place key switch in platform Measured voltage atX061 5 Yes Go to step 2 96 8 position and pullthe emer No Possible Cause Open in wire Yel Red gency stop switches 2 19 2 96 8 061 Engage and Testfor continuity between Yes Possible Cause Open in wire Yel Red hold the trigger X061 5 pin and X061 6 pin 2 17 No Possible Causes 4 1 22 3121203 T350 T500J 2 85 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 97 KEYSWITCH FAULTY Distress Lamp 9 ADE Code 2 1 The Platform and Ground Mode inputs from the keyswitch Platform X007 2 Ground X007 3 are active at the same time The control system will default to Ground Mode Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 97 1 Extract X014 15 Switch Key Is the fault removed Yes Goto step 2 97 2 to Ground Mode and pull the No Goto step 2 97 3 ground emergency stop switch 2 97 2 ExtractX014 15 Switch Key Measured voltage atX026 1 Yes Re
185. d X020 4 4 or Yel Red 2 6 Wire 4 1 10 No Possible Causes 4 1 19 4 1 20 4 1 18 broken white or black wire between X020 and X045 3 12 OUTRIGGER SWITCHES ALL STOWED Step Pretest Instructions Test Result Corrective Action 3 12 1 Analyzer DIAGNOSTICS OFF Goto step 3 12 3 3 12 2 Disconnect X020 2 Voltage on X020 2 soc Yes Possible Causes 4 1 19 4 1 20 Vbatt 4 1 18 shorted black wire between X020 and X042 Possible Causes Orn Red 49 1 shorted 4 1 10 3 12 3 Analyzer DIAGNOSTICS OFF Goto step 3 12 5 GROUND gt F R O R SET ON Goto step 3 12 4 3 12 4 Disconnect X020 3 Voltage on X020 3 soc Yes Possible Causes 4 1 19 4 1 20 Vbatt 4 1 18 shorted black wire between X020 and X043 No Possible Causes Orn Red 49 2 shorted 4 1 10 3 12 5 Analyzer DIAGNOSTICS OFF Goto step 3 12 7 3 12 6 Disconnect X020 4 Voltage on X020 4 soc Yes Possible Causes 4 1 19 4 1 20 Vbatt 4 1 18 shorted black wire between X020 and X044 No Possible Causes Orn Red 49 3 shorted 4 1 10 3 12 7 Analyzer DIAGNOSTICS OFF Possible Causes 4 1 23 4 1 10 GROUND gt R R O R SET ON Goto step 3 12 8 3 12 8 Disconnect X020 5 Voltage on X020 5 soc Yes Possible Causes 4 1 19 4 1 20 Vbatt 4 1 18 shorted black wire between X020 and X045 Possible Causes Orn Red 49 3 shorted 4 1 10 3121203 T350 T500J 3 125 3 3 13 PLATFORM MODULE POWER
186. d on the housing and use the Red meter lead to probe all terminals 2 Resistance 2 Ohms between 1 Ensure that there is a short circuit between the and M1 Terminals Internally there is a low impedance current measurement shunt for the Armature portion of Traction Place the Red meter lead on and the Black meter lead M1 3 Resistance gt 1MegaOhms between F1 and B F2 and B Ensure that there is an open circuit between the two Field Terminals F1 amp F2 and B Internally there are MOSFET transistors between these terminals that should be high impedance when the module is un powered Place the Black meter lead on B and the Red meter lead on F1 F1 4 Resistance gt 1MegaOhms between F1 and B F2 and B Ensure that there is an open circuit between the two Field Terminals F1 amp F2 and Internally there are MOSFET transistors between these terminals that should be high impedance when the module is un powered Place the Black meter lead on and the Red meter lead on F1 F1 5 Resistance gt 100kOhms between P and B Ensure that there is an open circuit between the P and the B Terminals Internally there are MOSFET transistors between these terminals that should be high impedance when the module is un powered Place the Black meter lead on B and the Red meter lead on P Note that a measurement of increasing resistance capacitor charge is normal but a persistently low impedance is not 6
187. defective Repair or replace 4 1 42 Hose may be pinched at turntable Repair or replace 4 1 43 Hydraulic Manifold may be defective Repair or replace 4 1 44 Check Valve may be defective Repair or replace 4 1 45 Main Relief Valve may be defective Repair or replace 4 1 46 Incorrect hose routing to tank Repair hose routing 4 1 47 Torn hose Repair or replace 4 1 48 Holding valve may be defective Repair or replace 4 1 49 Motion may be mechanically limited Remove any obstructions 4 1 50 Telescope Out valve may be defective Repair or replace 4 1 51 Telescope In valve may be defective Repair or replace 4 1 52 Swing Left valve may be defective Repair or replace 4 1 53 Swing Right valve may be defective Repair or replace 4 1 54 Level Up Extend valve may be defective Repair or replace 4 1 55 Level Up Extend Relief may be set incorrectly Check or Set See Service Manual 4 1 56 Level Down Retract valve may be defective Repair or replace 4 1 57 Level Down Retract Relief may be set incorrectly Check or Set See Service Manual 4 1 58 Lift up valve may be defective Repair or replace 4 1 59 Lift Down valve may be defective Repair or replace 4 1 60 Jib up valve may be defective Repair or replace 4 1 61 Jib Down valve may be defective Repair or replace 4 1 62 Outrigger Enable valve on cylinder may be defective Repair or replace 4 1 63 Outrigger Extend Retract valve may be defective Repair or replace 4 1 64 X011 is not connected to the battery Connect X011 red wire t
188. ds Kilograms Frame bare 597 271 Frame CE Aus bare 892 382 Turntable bare 262 119 Booms amp Cylinders Assy 1891 859 Main Boom 957 435 Engine Assy Incl Tray 116 53 Engine bare 57 26 Axle ANSI 221 100 CE 271 123 Platform w Rotator 143 65 Platform w o Rotator 73 33 Lubrication HYDRAULIC OIL Table 11 11 Hydraulic Oil Hydraulic System S A E Viscosity Operating Temperature Range Grade 0 to 180 F 10W 18 to 83 0 to 210 F 10W 20 10W30 18 to 99 C 50 10 210 F 20W 20 10 to 99 C NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscos ity index of 152 3121203 T350 T500J 11 222 SECTION 11 SPECIFICATIONS NOTE When temperatures remain consistently below 20 degrees F 7 degrees C JLG Industries recommends the use of Mobil DTE13 Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommendations 11 223 Table 11 12 Mobilfluid 424 Specs SAE Grade 10W30 Gravity API 29 0 Density Lb Gal 60 7 35 Pour Point Max
189. dule may be defective Contact Factory 4 1 12 Power module may be defective Contact Factory 4 1 13 Improper or incompatible software may be installed Check software versions and replace if necessary 4 1 14 CAN wiring between ground and platform may be Check contacts at X007 X019 X010 X055 X051 X052 or repair CAN defective wiring 4 1 15 Black ground wire from battery X100 may be cut Check continuity to X100 and repair wire or connectors 4 1 16 On board system memory may have been corrupted Check correctall settings and re cycle power to clear difficulty 4 1 17 Integrated Tilt sensor may be defective Contact Factory 4 1 18 Switch may be defective Repair or replace 4 1 19 Switch may be stuck Check for obstructions and switch freedom of motion 4 1 20 Limit Switch may be out of adjustment Adjustthe switch to the specified trip level and retighten 4 1 21 Engine speed pickup may be defective Repair or replace 4 1 22 Joystick may be defective 3 10 Joystick Diagnostics or Repair or replace 4 1 23 Intermittent voltage fluctuation Checkthe Help Log for recent recorded problems Test all conditions 4 1 24 Hourmeter may be defective Repair or replace 4 1 25 Alarm may be defective Repair or replace 4 1 26 Joystick calibration may be corrupt Calibrate 4 1 27 LED or LED module may be defective Repair or replace 4 1 28 Engine Start Charge Fuse may be blown See Engine Owner s Manual for fuse replacement 4 1 29 Engine Charge coil may be defective Repair or
190. e dece equ eran Mo ted qe e 5 152 5 170 START GL endis eek TG NET RE dai T ec ne ede 5 152 2START SOLENOID 2420 testet 5 153 5 172 START SOLENOID OPEN CIRCUIT 5 153 5 173 START SOLENOID SHORT TO BATTERY 5 153 5 174 START SOLENOID SHORT TO GROUND 5 153 5175 START SWITCH CL cots oth h tua rin aq A RON ELE RO ded 5 153 5 176 SWINGEEET GL x Si 5 153 5 177 SWING LEFT VALVE OPEN 5 153 5 178 SWING LEFT VALVE SHORT TO 5 153 5 179 SWING LEFT VALVE SHORT TO 5 154 5 180 SWING ET VALVE cepere a m ence RID e PARC e ect Ul rege 5 154 5 181 SWINGRIGHT CL 3 2 2 Rp nn 5 154 5 182 SWING RIGHT VALVE OPEN 1 5 154 5 183 SWING RIGHT VALVE SHORT TO 5 154 5 184 SWING RIGHT VALVE SHORT TO 5 154 5 185 SWING RT VALVE iud RR EUR pa p epe EP 5 154 5 186 SYSTEM DISTRES
191. e at Yes Possible Causes Short in Pink 25 2 1 position and pull the emer X004 17 Vbatt wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 66 FUNCTION PROBLEM LIFT DOWN PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground lift down switch was closed when the machine was powered The switch could be accidentally held mechani cally stuck or electrically shorted Functions Disabled at Ground Only Lift Down Step Pretest Instructions Test Result Corrective Action 2 66 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 66 2 2 66 2 DisconnectX031 Placekey Is fault Function Problem Yes Goto step 2 66 3 Switch in ground position and Lift Down Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present switch 2 66 3 Remove X014 22 pin from Is fault Function Problem Yes Goto step 2 66 4 X014 Place key switch in Lift Down Permanently No Possible Causes Shortin Tan 4 2 wire ground position and pullthe Selected still present emergency stop switch 2 66 4 Place key switch in ground Measured voltage at Yes Possible Causes Short in Tan 4 2 1 position and pull the emer X004 33 Vbatt wire 4 1 10 gency stop switch No Possible Causes 4 1 10 3121203 T350 T500J 2 71 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 67 FUNCTION PROBLEM LIFT UP AND DOWN BOTH SELECTED ADE Code 2 3 The
192. e boom is stowed in transport position TRANS LMT SW input X004 11 B DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive See 3 17 Transport Limit Switch 2 32 DRIVE PREVENTED STOW OUTRIGGERS Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive but at least one outrigger was detected to be set All outriggers must be unset before drive will function Outrigger status can be viewed on the ground control panel LEDs or with the Ana lyzer in Diagnostics gt Ground DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Stow all outriggers If message is still present See 3 12 Outrigger Switches All Stowed 2 33 DRIVE PREVENTED TELESCOPE IN Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive but the boom was not detected to be telescoped in by the Tele scope limit switch at 041 When the boom is stowed in transport position TELE LMT SW input X004 21 B DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive See 3 15 Telescope Limit Switch 3121203 T350 T500J 2 55 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 34 DRIVE RIGHT FORWARD SOLENOID OPEN CIRCUIT Distress Lamp 9 defective DRIVE OPTION MACHINES ONLY ADE Code 3 3 Drive module feedback shows that the Drive Right Forward Valve PWM output may be disconnected or the solenoid may be Functions Disabled Dri
193. e gauge into the manifold P port Engage the enable and Lift up switch Check pressure at manifold P port Above Min Lift Up Pressure psi bar Below Min Lift Up Pressure psi bar Possible Causes 4 1 38 4 1 45 4 1 74 4 1 40 4 1 10 4 1 43 Possible Causes 4 1 10 4 1 46 4 1 47 4 1 74 4 1 45 4 1 39 1 14 5 Plumb a0 to 5000 PSI 345 bar pressure gauge into the Check pressure at lift cylinder while activating lift up at Above Min Lift Up Pressure psi bar Possible Causes 4 1 49 4 1 48 4 1 41 hose from the liftup cylinder ground controls Below Min LiftUp Pressure Possible Causes 4 1 42 4 1 58 end bar 3121203 T350 T500J 1 35 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 15 TELESCOPE OUT FUNCTION INOPERATIVE bar pressure gauge into the hose from the lift up cylinder cap end scope cylinder while activating telescope out at ground con trols bar Below Min Tele Out Pressure psi bar Step Pretest Instructions Test Result Corrective Action 1 15 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 15 2 Engage enableandtelescope DC Is pump motor running Yes Goto step 1 15 3 out switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 15 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 15 3 Install a 0 to 5000 PSI
194. e ground and plat between X058 and X054 form emergency stop switches and place key switch inthe platform position 2 124 5 Remove X059 J With t he Is the voltage on X059 J soc Yes Possible Cause Shorted Blu BIk console inthe platform posi VBatt between X059 J and X059 H groung ano plat No Possible Cause Shorted Blu BIk gt between X059 and X058 switches and place key switch inthe platform position 2 124 6 Withtheconsoleintheplat Is the voltage onX054 9 Yes Possible Cause Broken wire form position pull the ground VBatt between 054 and X019 and platform emergency stop No Goto step 2 124 7 switches and place key switch in the platform position 2 124 7 Withthe console inthe plat Is the voltage on X058 K Yes Possible Cause Broken Orn BIk wire form position pullthe ground VBatt between X058 and X054 and platform emergency stop No Goto step 2 124 8 switches and place key switch inthe platform position 2 124 8 Withtheconsoleintheplat Is the voltage on X059 K Yes Possible Cause Broken Orn BIk wire form position pullthe ground VBatt between X059 and X058 and platform emergency stop No Possible Cause Broken Orn BIk wire Switches and placekey switch between X059 K and X059 D or see inthe platform position 3 13 Platform Module Power 2 125 POWER MODULE FAILURE CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT Distress Lamp 9 ADE Code 9 9 The Power Mod
195. e ground panel Level Down switch Release the switch at the ground panel to test the switch input and continue the test 9 138 LEVEL UP System test prompt to open the ground panel Level Up switch Release the switch at the ground panel to test the switch input and continue the test 5 139 LIFT DOWN System test prompt to open the ground panel Lift Down switch Release the switch at the ground panel to test the switch input and continue the test 5 140 LIFT UP System test prompt to open the ground panel Lift Up switch Release the switch at the ground panel to test the switch input and continue the test 5 141 O R SET System test prompt to open the ground panel Outrigger Set switch Release the switch at the ground panel to test the switch input and continue the test 9 142 0 STOW System test prompt to open the ground panel Outrigger Stow switch Release the switch at the ground panel to test the switch input and continue the test 9 143 START System test prompt to open the ground panel engine Start switch Release the switch at the ground panel to test the switch input and continue the test 9 144 START SWITCH System test prompt to open the platform panel engine Start switch Release the switch at the platform panel to test the switch input and continue the test 9 145 SWING LEFT System test prompt to open the ground panel Swing Left switch Release the switch at the ground panel
196. e switch input and continue the test 5 40 CL LEVEL DOWN System test prompt to close the Platform Levelling Down switch Push the Platform Levelling switch at the ground panel to the Down position to test the switch input and continue the test 3121203 T350 T500J 5 137 SECTION 5 SYSTEM TEST MESSAGES 5 41 CL LEVEL UP System test prompt to close the Platform Levelling Up switch Push the Platform Levelling switch at the ground panel to the Up position to test the switch input and continue the test 5 42 CL LIFT DOWN System test prompt to close the Lift Down switch Push the Lift switch at the ground panel to the Down position to test the switch input and continue the test 9 43 CL LIFT UP System test prompt to close the Lift Up switch Push the Lift switch at the ground panel to the Up position to test the switch input and continue the test 5 44 CL 0 SET System test prompt to close the ground panel Outrigger Set switch Push the Outrigger switch at the ground panel to the Set position to test the switch input and continue the test 5 45 CL 0 STOW System test prompt to close the ground panel Outrigger Stow switch Push the Outrigger switch at the ground panel to the Stow position to test the switch input and continue the test 9 46 CL START ENGINE POWERED MACHINES ONLY System test prompt to close the ground Start switch Push the Start button at the ground panel to test the Start switch input and continue the test
197. e wires GER VALVE OPEN CIRCUIT Analyzer Message R R OUTRIG Goto step 2 134 2 GER VALVE SHORT TO GROUND 2 134 2 Remove wire Orn Red 49 8 Rerun System Test Analyzer Message R R OUTRIG Wire Orn Red 49 8 or White wire from X003 10 GER VALVE OPEN CIRCUIT between X020 and X049 shorted to ground Repair or replace Possible Cause 4 1 10 2 135 RETRACT O R SOLENOID OPEN CIRCUIT Distress Lamp 9 be defective ADE Code 3 3 Ground module feedback shows that the Retract Stow Outriggers digital output may be disconnected or the solenoid may Functions Disabled Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 135 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise goto step 2 135 2 No Goto step 2 135 2 2 135 2 Disconnect solenoid atX085 Rerun System Test Analyzer Message RETRACT Replace solenoid and or connector Short X085 1 soc to VALVE SHORT TO GROUND 085 2 30 Analyzer Message RETRACT Gotostep2 135 3 VALVE OPEN CIRCUIT 2 135 3 Replace X003 14 witha Rerun System Test Analyzer Message RETRACT Wire Orn Wht55 4 1 orOrn Wht 55 4 jumper to X003 3 VALVE SHORT TO GROUND broken Repair or replace Analyzer Message RETRACT Possible Cause 4 1 10 VALVE OPEN CIRCUIT 2 102 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 136 RETRACT 0 R SO
198. ectifier Throttle Relay X041 X056 E T500J Only n Jib Down Valve M m 9 80 057 x098 X040 039 Lift Down Valve 9 80 X Rear Left Outrigger Limit Switch See Rear Left Outrigger View X047 for Detail gt oe gt _ 927 5 lt 048 Rear Left Outrigger Valve 7 20 X046 Front Left Outrigger Valve Power Module X013 X019 Electric Powered Only X014 X020 X015 X021 X016 X054 X017 X055 X018 Figure 7 1 Frame Connector Layout 3121203 T350 T500J Main Harness X011 Electric Pwr Only c ONU T X010 gt SM 087 MODELS DUMP VALVE 6 0 Q X084 X080 LEVEL UP LIFT UP 00 X081 LEVEL DOWN X086 8 0 rid X08 8 0 TELE OUT 8 0 X083 TELE 8 0 0 X078 SWING 8 085 0 0 n L J STOW SWING LF 0 9 8 0 X079 T500 ONLY JIB UP 8 0 Figure 7 2 Ground Control Valve Connections 7 162 SECTION 7 ELECTRICAL REFERENCE 3121203
199. ective Action 2 161 1 Run system test Do other functions fail sys Yes Check 4 1 15 4 1 1 otherwise go to tem test step 2 161 2 No Goto step 2 161 2 2 161 2 Disconnect relay atX091 At Rerun System Test Analyzer Message THROTTLE Replace solenoid and or connector harness end short X091 86 PULL RELAY SHORT TO WHT YEL 48 4 to X091 85 GROUND BLACK wire Analyzer Message THROTTLE Goto step 2 161 3 PULL RELAY OPEN CIRCUIT 2 161 3 Replace X003 9 with ajumper Rerun System Test Analyzer Message THROTTLE Wire WHT YEL 48 2 broken Repair or to X003 3 PULL RELAY SHORT TO replace GROUND Analyzer Message THROTTLE Possible Cause 4 1 10 PULL RELAY OPEN CIRCUIT Ground module feedback shows that the Engine Throttle Pull digital output may be shorted to battery or other function ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Throttle Pull 2 115 Step Pretest Instructions Test Result Corrective Action 2 162 1 Run system test Do other functions fail sys Yes Possible Cause 4 1 15 4 1 1 other tem test wise go to step 2 162 2 No Go to step 2 162 2 2 162 2 Disconnect relay atX091 and Rerun System Test Analyzer Message THROTTLE Replace solenoid isolate wires PULL RELAY OPEN CIRCUIT Analyzer Message THROTTLE step 2 162 3 PULL RELAY SHORT TO BAT TERY 2 162 3 Remove wire WHT YEL 48 2 Rerun System Test Analyz
200. el Above Min Level Up Pressure psi Goto step 1 19 5 bar pressure gauge atthe Up switch Checkthe pressure bar manifold G port Below Min Level Up Pressure psi Goto step 1 19 4 bar 1 19 4 Plumb a 0 to 5000 PSI 345 Engagethe enable and Level Above Min Level Up Pressure psi Possible Causes 4 1 38 4 1 45 bar pressure gauge intothe Up switch Checkpressureat bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port manifold P port Below Min Level Up Pressure psi Possible Causes 4 1 46 4 1 47 bar 4 1 74 4 1 45 4 1 39 4 1 10 1 19 5 Putboomintransport and Engage the enable and Level Above Min Level Up Pressure psi Possible Causes 4 1 49 4 1 48 activate Platform Level Down to relieve pressure Some working pressure will still be in the line Install a0 to 5000 PSI 345 bar pressure gauge at the manifold GA port Up switch Check pressure at manifold GA port Relieve the pressure before removing the gauge bar Below Min Level Up Pressure psi bar 4 1 41 Possible Causes 4 1 42 4 1 55 4 1 44 4 1 54 1 38 T350 T500J 3121203 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 20 PLATFORM LEVELING DOWN FUNCTION INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 20 1 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 20 2 Engage enable and LevelUp DC Ispump motor running Yes Goto step 1 20 3 S
201. elected ener tnnt netten nennen Function Problem Engine Start Permanently Selected Function Problem Jib Down Permanently Selected sess Function Problem Jib Up Permanently Selected en soe dee e dee ada a eee e ee a Function Problem Level Down Permanently Selected Function Problem Level Up Permanently Selected 02 11 20 22000 2 0000000000000000000000000000 nennen eren Function Problem Lift Down Permanently Selected 2222 42 1 600000000000000000000000 Function Problem Lift Up Permanently Selected isses enne 4 Function Problem Outrigger Set Permanently Selected Function Problem Outrigger Stow Permanently Selected Function Problem Swing Left Permanently Selected Function Problem Swing Right Permanently Selected Function Problem Telescope In Permanently Selected Function Problem Telescope Out Permanently Selected Joystick Moved But Trigger Switch Open Trigger Closed Too Long While In Neutral ee e P PH d eed ede diee 2 Drive amp O R Prevented Operate From Platform 2 50 Drive amp O R Prevented Place Boom On Rest eere ce een hr rete e Ie ede As sirat 2 51 Drive amp O R Prevented Set Hand Brake eese e
202. em test broken 4 1 1 otherwise go to step 2 38 2 No Goto step 2 38 2 2 38 2 Disconnect solenoid atX070 Rerun System Test Analyzer Message DRVRIGHT Replace solenoid and isolate wires REV VALVE OPEN CIRCUIT Analyzer Message DRVRIGHT Gotostep 2 38 3 REV VALVE SHORT TO BAT TERY 2 38 3 Remove wire Orn 8 2 from Rerun System Test Analyzer Message DRVRIGHT Wire Orn 8 2 shorted to battery Repair X074 10 REV VALVE OPEN CIRCUIT orreplace Analyzer Message DRV RIGHT Possible Cause 4 1 10 REV VALVE SHORT TO BAT TERY 2 39 DRIVE RIGHT REVERSE SOLENOID SHORT TO GROUND Distress Lamp 9 tive ADE Code 3 3 Drive module feedback shows that the drive right reverse digital output may be shorted to ground or the relay may be defec DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Right Reverse Step Pretest Instructions Test Result Corrective Action 2 39 1 Disconnect solenoid atX070 Rerun System Test Analyzer Message DRV RIGHT Repair Replace solenoid and isolate wires REV VALVE OPEN CIRCUIT Analyzer Message DRVRIGHT Gotostep 2 19 2 REV VALVE SHORT TO GROUND 2 39 2 Remove wire Orn 8 2 from Rerun System Test Analyzer Message DRV RIGHT Wire Orn 8 2 shorted to ground Repair X074 10 REV VALVE OPEN CIRCUIT orreplace Analyzer Message DRVRIGHT Possible Cause 4 1 10 REV VALVE SHORT TO GROUND 2 58 T350 T500J
203. enoid Short To 1 2 81 Jib Down Solenoid Short To Ground 2 4 2 81 Jib Up Solenoid Open 2 40 2 82 Jib Up Solenoid Short To 2 2 82 Jib Up Solenoid Short To Ground 7 212 2 2 83 Joystick Faulty X axis Wiper Out Of Range 2 83 Joystick Faulty Y axis Wiper Out Of Range 2 84 Joystick Moved But Trigger Switch 2 85 KeySwitch Faultyz es ERI RCRUM LIE ee 2 86 Level Down Solenoid Open 2 87 Level Down Solenoid Short To 2 87 Level Down Solenoid Short To Ground 2 88 Level Up Solenoid Open 2 88 Level Up Solenoid Short To 2 89 Level Up Solenoid Short To 2 89 Lift Down Prevented Tele In 2 90 Lift Down Solenoid Open
204. ep Pretest Instructions Test Result Corrective Action 1 6 1 Do panel indicator lights blink Yes Goto step 1 6 2 at power on Ground controller not powered Perform component check 3 7 Engine Powered Machine Power 1 6 2 Is Analyzer DIAGNOSTICS gt Yes Goto step 1 6 3 SYSTEM gt BATTERY atleast No Possible Causes 4 1 4 9 Volts 1 6 3 Voltage at X096 6 Yes Goto step 1 6 4 No Replace engine solenoid fuse at X088 1 6 4 Does engine turn with manual Yes Goto step 1 6 5 recoil No Possible Causes 4 1 76 1 6 5 Analyzer DIAGNOSTICS gt Yes Goto step 1 6 6 ENGINE gt SPEED 0 RPM No Possible Causes 4 1 82 Remove X001 16 to verify 4 1 21 4 1 30 4 1 10 1 6 6 While pressing the start button Yes Possible Causes 4 1 77 Voltage on X089 starter sole No Goto step 1 6 7 noid Vbatt 1 6 7 While pressingthe startbutton Yes Possible Cause Broken Wht Yel 48 6 Voltage on X022 6 Vbatt wire between X022 6 and solenoid Goto step 1 6 8 1 6 8 While pressingthe startbutton Yes Possible Cause Broken Wht Yel 48 6 Voltage on X002 23 Vbatt wire between X002 23 and X022 6 Possible Causes 4 1 2 4 1 10 1 32 T350 T500J 3121203 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 7 ENGINE CRANKS BUT WILL NOT START ENGINE MODELS Step Pretest Instructions Test Result Corrective Action 1 7 1 Basic check of likely causes Possible Causes 4 1 83 4 1 84 4 1 85 4 1 86 4 1 87 4 1 88 4 1 91 1 7
205. er Message THROTTLE Wire WHT YEL 48 2 shorted to bat from X003 9 PULL RELAY OPEN CIRCUIT tery Repair or replace Analyzer Message THROTTLE Possible Cause 4 1 10 PULL RELAY SHORT TO BAT TERY 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 163 THROTTLE PULL RELAY SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Throttle Pull digital output may be shorted to ground or the relay may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Throttle Pull Step Pretest Instructions Test Result Corrective Action 2 163 1 Disconnect solenoid atX091 RerunSystem Test Analyzer Message THROTTLE Repair Replace solenoid andisolate wires PULL RELAY OPEN CIRCUIT Analyzer Message THROTTLE Goto step 2 163 2 PULL RELAY SHORT TO GROUND 2 163 2 Remove wire WHT YEL 48 2 Rerun System Test Analyzer Message THROTTLE Wire WHT YEL 48 2 shortedto from X003 9 PULL RELAY OPEN CIRCUIT ground Repair or replace Analyzer Message THROTTLE Possible Cause 4 1 10 PULL RELAY SHORT TO GROUND 2 164 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL Distress Lamp 1 ADE Code 2 2 The Trigger Switch in the Platform Control Box was closed for more than seven seconds while the Joystick was in the neutral position centered Release switch or repair the switch wiring to clear the difficulty F
206. ered Machine Poweror3 7 Engine Pow ered Machine Power 1 11 PLATFORM CONTROLS INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 11 1 Do panel indicator lights blink Yes Goto step 1 11 2 at power on Normal 3 sec No Platform controller not powered Per ond wakeup alarm should also form component check 3 13 Platform sound Module Power 1 11 2 Place key switch in platform Measured voltage atX061 6 Yes Possible Causes 4 1 38 Rotary Select position and pull the emer Vbatt switch may be defective See 2 96 Joy gency stop switches Engage stick Moved But Trigger Switch Open and hold the trigger No Joystick trigger switch may be defective See 2 96 Joystick Moved But Trigger Switch Open 1 12 GROUND LEVELING NOT FUNCTIONING PROPERLY The ground module uses its embedded tilt sensor and feedback from the outrigger switches to automatically level the machine when the outrigger extend switch is held It will first try extending the appropriate outriggers to achieve level If the switch is still held and level is not yet achieved it will try retracting the appropriate outriggers to achieve level If the ground is too uneven or the slope is too great the outriggers will not be able to level the machine Step Pretest Instructions Test Result Corrective Action 1 12 1 Basic check of likely causes Possible Causes 4 1 37 4 1 34 4 1 36 4 1 35 1 12 2 ANALYZER gt
207. erri tenes 5 156 5 203 THROTTLE PULL RELAY OPEN CIRCUIT 2 5 156 5 204 THROTTLE PULL RELAY SHORT TO BATTERY 5 156 5 205 THROTTLE PULL RELAY SHORT TO GROUND 5 157 5 206 EAMP ON Br qaad es P I De ME recede 5 157 SECTION 6 CALIBRATION MESSAGES SECTION 7 ELECTRICAL REFERENCE SECTION 7 ELECTRICAL REFERENCE 7 1 Gonnector Index ete ln uta bep dre dated doeet sede i aad 7 166 SECTION 7 ELECTRICAL REFERENCE 7 2 Ground Module Connector Pinouts 7 169 7 3 Platform Module Connector 7 174 7 4 drive Module Connector 7 175 7 5 Connector Loading 7 176 7 6 Working with 4 4 7 181 7 7 Working with Deutsch 7 186 7 8 Trailer Wiring crm pH Eee era Ra EDDA S DEIN E NEP ER 7 188 SECTION 8 HYDRAULIC REFERENCES 26 T350 T500J 3121203 5 8 1 8 2 SECTION 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 Solenoids a NE 8 191 Minimum
208. etween X015 and X040 Repair or replace No Goto step 3 17 6 3 17 6 Voltage on X040 1 Vbatt Yes Possible Cause 4 1 18 No Goto step 3 17 7 3 17 7 Voltage onX015 1 Vbatt Yes White wire broken between X015 and X040 Repair or replace No Goto step 3 17 8 3 17 8 Voltage on X004 25 Yes Wire Yel Red 2 26 1 or Yel Red 2 26 Vbatt broken Repair or replace No Possible Cause 4 1 10 3 128 T350 T500J 3121203 SECTION 4 POSSIBLE CAUSES SECTION 4 POSSIBLE CAUSES 4 1 POSSIBLE CAUSES Item Possible Cause Possible Solution 4 1 1 Bad contacts at connector Repair or replace 4 1 2 System Setup information may be incorrect Make sure the setup displayed on the analyzer matches the machine 4 1 3 Battery or charger may be installed incorrectly Check battery wiring and polarity 4 1 4 Improper battery level Charge or replace batteries 4 1 5 Black battery ground wire may be damaged between Repair or replace X008 1 and B engine X100 or electric X101 4 1 6 Ignition relay at X009 may be defective Repair or replace 4 1 7 X009 86 may be shorted to battery Isolate wire shorted to battery and repair Check Yel Red 2 5 Yel Red 2 10 Yel Red 2 7 Yel Red 2 44 Yel Red 2 9 4 1 8 Battery Charger may be defective Contact Factory 4 1 9 Drive module may be defective Contact Factory 4 1 10 Ground module may be defective Contact Factory 4 1 11 Platform mo
209. evel menu is selected a new set of menu items may be offered for example PLATFORM GROUND PUMP ENGINE SYSTEM VALVES DATALOG VERSIONS Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases such as DRIVE the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus while in access level 2 Remember you may always cancel a selected menu item by pressing the ESC key SECTION 9 JLG ANALYZER 9 4 CHANGING THE ACCESS LEVEL OF THE HAND HELD ANALYZER When the analyzer is first connected you will be in access level 2 which enables you to only view most settings which cannot be changed until you enter a password to advance to a lower level This ensures that a setting 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 2 N AES MENU ACCESS LEVEL 2 A e 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
210. fec ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 41 1 Run system test Do other functions sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 41 2 No Goto step 2 41 2 2 41 2 Disconnectsolenoid atX087 Rerun System Test Analyzer Message DUMP VALVE Replace solenoid andisolate wires OPEN CIRCUIT Analyzer Message DUMP VALVE Goto step 2 41 3 SHORT TO BATTERY 2 41 3 Remove wire Red Wht50 1 1 Rerun System Test Analyzer Message DUMP VALVE Wire Red Wht50 1 1 or Red Wht50 1 from X002 9 OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message DUMP VALVE Possible Cause 4 1 10 SHORT TO BATTERY 3121203 T350 T500J 2 59 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 42 DUMP SOLENOID SHORT TO GROUND ADE Code 3 3 Distress Lamp 9 Ground module feedback shows that Dump Valve PWM output may be shorted to ground or the solenoid may be defective ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up
211. g Input 6 SPARE INPUT 3 Analog Input 7 DRIVE LEFT FORWARD Analog Output PWM 8 DRIVELEFT REVERSE Analog Output PWM 9 DRIVE RIGHT FORWARD Analog Output PWM 10 DRIVE RIGHT REVERSE Analog Output PWM 11 DRIVE ENABLE Analog Output PWM 12 SPAREOUTPUT5 Analog Output Table 7 10 X075 J2 Drive Module Pinout PIN T SERIES FUNCTION TYPE 0 RANGE 1 5 ANALOG REFERENCE Power Output 5VDC 2 SPARE ANALOG 0 Analog Output 3 ANALOG GROUND Analog Output OVDC 4 ANALYZER 5 REF Power Output 5VDC 5 SPARE ANALOG 1 Analog Output 6 ANALYZER GROUND Power Output OVDC 7 SPARE ANALOG 2 Analog Output 8 SPARE ANALOG 3 Analog Output 9 CANBUS CANH Serial VO Serial 10 CANBUS CANL Serial VO Serial 11 ANALYZER 3 Serial VO Seria 12 ANALYZER PIN 2 Serial VO Seria 7 175 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE 7 5 CONNECTOR LOADING DIAGRAMS Table 7 11 Connector Loading Diagrams ID Description Diagram 4 Amp 4 position plug AN350P Anderson Power Con nector J BA mc AS14P Ampseal 14 position 1 SN OO ON 9000 m Sickest Reet inset AS351P Ampseal 35 position Black 5352 127 T OOOOOOCK PP OO 24 35 2 5355 Socket
212. gger Set 8 0 X087 Dump Valve Engine Pow 6 0 ered X046 Front Left Outrigger 7 2 X047 Front Right Outrigger 7 2 X048 Rear Left Outrigger 7 2 X049 Rear Right Outrigger 7 2 X067 Drive Left Forward Solenoid 9 8 X068 Drive Right Forward Solenoid 9 8 X069 Drive Left Reverse Solenoid 9 8 X070 Drive Right Reverse Solenoid 9 8 X071 Drive Enable Solenoid 7 2 8 2 MINIMUM OPERATING PRESSURE Function T350 Minimum Pressure For Operation T500J Minimum Pressure For Operation Swing Left Min Swing Left Pressure psi bar Min Swing Left Pressure psi bar Swing Right Min Swing Right Pressure psi bar Min Swing Right Pressure psi bar Jib Up T500J Min Jib Up Pressure psi bar Min Jib Up Pressure psi bar Jib Down T500J Min Jib Down Pressure psi bar Min Jib Down Pressure psi bar Level Up Min Level Up Pressure psi bar Min Level Up Pressure psi bar Level Down Min Level Down Pressure psi bar Min Level Down Pressure psi bar Telescope Out Min Tele Out Pressure psi bar Min Tele Out Pressure psi bar Telescope In Min Tele In Pressure psi bar Min Tele In Pressure psi bar Lift Up Min Lift Up Pressure psi bar Min Lift Up Pressure psi bar Lift Down Min Lift Down Pressure psi bar Min Lift Down Pressure psi bar Outrigger Stow Min O R Stow Pressure psi bar Min O R Stow Pressure psi bar Outrigger Set Min O R Set Pressure psi bar Min O R Set Pressure psi bar
213. gger Switches All Set 2 110 LIFT UP amp TELE OUT PREVENTED UNSET amp ABOVE ELEVATION Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the lift up or telescope out position but RETRIEVAL B is active with at least two outriggers unset and the machine elevated While RETRIEVAL B is active the boom cannot be lifted up or telescoped out any further to prevent further destabilization Functions Disabled Lift Up Telescope Out Step Pretest Instructions Test Result Corrective Action 2 110 1 Is the boom elevated Yes Goto step 2 110 2 No 3 17 Transport Limit Switch 2 110 2 Are outriggers unset Yes Retract lower the boom and level the machine before trying again No See 3 11 Outrigger Switches All Set 2 111 LIFT UP PREVENTED CHECK OUTRIGGERS Distress Lamp 2 ADE Code 2 5 The ground module senses the control in the lift up position but the machine is elevated and all four outriggers are unset If all four outriggers are unset the control system allows lift up to function up to the elevation switch point for moving the plat form to a safe position for boarding Once the boom lifts beyond the transport switch position opening the transport switch lift up is prevented Lift down will operate at creep speed till back in transport position Lift down set the outriggers and level the machine before attempting to lift beyond the transport switch positi
214. hat the Application s Constant Data Version did not match the version embedded in Constant Data s Flash Structure The control system may resume operation once the difficulty has been corrected Functions Disabled Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Possible Causes 4 1 10 2 81 FUNCTIONS LOCKED OUT PLATFORM MODULE SOFTWARE VERSION IMPROPER Distress Lamp 9 ADE Code 9 9 The Platform Module reported a Software Major Version that was not compatible with the rest of the system The control sys tem may resume operation once the difficulty has been corrected Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Engine Start Engine Throttle Pull Engine Throttle Hold Engine Choke Pull Engine Choke Hold Possible Causes 4 1 13 4 1 11 2 78 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 82 FUNCTIONS LOCKED OUT POWER MODULE SOFTWARE VERSION IMPROPER Distress Lamp 9 ADE Code 9 9 The Power Module reported a Software Major Version that was not compatible
215. he switch Stuck No Goto step 2 68 2 2 68 2 DisconnectX031 Placekey Is fault Function Problem Yes Goto step 2 68 3 switch in ground position and Lift Up Permanently No Possible Causes 4 1 18 pullthe emergency stop Selected still present on Switch 2 68 3 Remove X014 23 pin from Is fault Function Problem Yes Goto step 2 68 4 X014 Place key switch in Lift Up Permanently No Possible Causes Shortin Tan 3 2 wire ground position and pullthe Selected still present emergency stop switch 2 68 4 Place key switch in ground Measured voltage at Yes Possible Causes Short in Tan 3 2 1 position and pull the emer X004 23 Vbatt wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 72 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 69 FUNCTION PROBLEM OUTRIGGER SET AND STOW BOTH SELECTED Distress Lamp 9 ADE Code 2 3 The digital inputs from both O R stow and O R set ground panel switches are active Functions Disabled Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 69 1 DisconnectX023 Pullthe Is fault Function Problem Yes Goto step 2 69 2 ground emergency stop Outrigger Set And Stow Both No Possible Causes 4 1 18 switch and place key switch in Selected still present the ground position 2 69 2 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Orn Wht 55 enable switch X014 5 pin and X01
216. hines the power module B X101 terminal should be used as the ground reference for voltage measurements unless stated otherwise A 14 T350 T500J 3121203 INTRODUCTION A 10 CONTROL MODULE POWER Always make sure that the ground control module is properly powered 1 For Ground operation Pins J001 24 X007 3 and X008 2 should have a voltage of Vbatt Pin X008 1 should be grounded 2 For Platform operation Pins J001 24 X007 1 X007 2 X008 2 and X060 1 should have a voltage of Vbatt Pins X008 1 and X060 2 should be grounded CAN communication wires should have 60 Ohms resistance between CAN HI and CAN LO whenever connected or 120 Ohms when disconnected A CAN termination 120 Ohm resistor is located at both ends of the CAN bus One is in the wire harness near the platform at X057 The other terminator is embedded in the power module for electric powered machines or the ground module for engine powered machines The jumper in the engine powered machine harness between X007 6 and X007 17 enables the ground module termination resistor Ground Module i Power Module Electric Powered Machines Only 1 Ignition Power for Power Module Vbatt Electric Only 3 1 X010 11 10 ____ Terminator Terminators X007 6 amp Terminator X007 17 if Power Module is 1 20 O iR i ma i See CAN HI CAN HI Platform CAN LO CAN Shield 1
217. ight switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 182 SWING RIGHT VALVE OPEN CIRCUIT The system test detected an open in the Swing Right valve circuit See 2 147 Swing Right Solenoid Open Circuit 9 183 SWING RIGHT VALVE SHORT TO BATTERY The system test detected a short to battery in the Swing Right valve circuit See 2 148 Swing Right Solenoid Short To Battery 5 184 SWING RIGHT VALVE SHORT TO GROUND The system test detected a short to ground in the Swing Right valve circuit See 2 149 Swing Right Solenoid Short To Ground 5 185 SWING RT VALVE System test prompt indicating that it is currently testing this circuit 9 186 SYSTEM DISTRESS LAMP ON System test prompt to check that the system distress lamp is illuminated Step Pretest Instructions Test Result Corrective Action 5 186 1 Does this indicator illuminate Yes Press ENTER onthe analyzerto con properly tinuethe system test Goto step 5 186 2 5 186 2 Do other indicators illuminate Yes Possible Causes Check wiring instead No Goto step 5 186 3 5 186 3 Which testis running Ground System Test Possible Causes Brn Wht 47 20 wire broken 4 1 27 4 1 10 Platform System Test Possible Causes 4 1 11 5 154 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 9 187 TELE IN CL System test response indicating that the ground Telescope In s
218. ilization Functions Disabled Lift Up Telescope Out Step Pretest Instructions Test Result Corrective Action 2 108 1 Is the machine tilted more Yes Retract lower the boom and level the than 4 5 degrees machine before lifting or telescoping out No Goto step 2 108 2 2 108 2 ANALYZER gt DIAGNOS Yes See 3 16 Tilt Sensor TICS gt SYSTEM gt TILT N Possibl 4 1 1 gt 4 5DEG platformtilt ae EN LED illuminated 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 109 LIFT UP amp TELE OUT PREVENTED TILTED UNSET amp ABOVE ELEVATION Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the lift up or telescope out position but RETRIEVAL B is active with one outrigger unset and the machine elevated and tilted While RETRIEVAL B is active the boom cannot be lifted up or telescoped out any further to prevent further destabilization Functions Disabled Lift Up Telescope Out Step Pretest Instructions Test Result Corrective Action 2 109 1 Is the machine tilted more Yes Goto step 2 109 3 than 2 degrees No Goto step 2 109 2 2 109 2 ANALYZER gt DIAGNOS Yes See 3 16 Tilt Sensor TICS gt SYSTEM gt TILT Possible Causes 4 1 1 gt 2 DEG platform tilt LED BED illuminated 2 109 3 Have any outriggers come Yes Retract lower the boom and level the unset machine before lifting or telescoping out No See 3 11 Outri
219. is illuminated If lamp is illuminating properly press ENTER on the analyzer to continue the system test Otherwise see possible cause 4 1 11 9 78 EXTEND VALVE System test prompt indicating that it is currently testing this circuit 9 79 EXTEND VALVE OPEN CIRCUIT The system test detected an open in the extend valve circuit See 2 45 Extend O R Solenoid Open Circuit 9 80 EXTEND VALVE SHORT TO BATTERY The system test detected a short to battery in the extend valve circuit See 2 46 Extend O R Solenoid Short To Battery 9 81 EXTEND VALVE SHORT TO GROUND The system test detected a short to ground in the extend valve circuit See 2 47 Extend O R Solenoid Short To Ground 5 82 F L O R VALVE System test prompt indicating that it is currently testing this circuit 5 142 T350 T500J 3121203 5 83 F L OUTRIGGER LAMP ON System test prompt to check that the ground F L Outrigger lamp is illuminated SECTION 5 SYSTEM TEST MESSAGES Step Pretest Instructions Test Result Corrective Action 5 83 1 Does this indicator illuminate Yes Press ENTER onthe analyzerto con properly tinuethe system test No Goto step 5 83 2 5 03 2 Do other indicators illuminate Yes Possible Causes Check wiring Instead No Goto step 5 83 3 5 83 3 Voltage atX030 2 12VDC Yes Possible Causes 4 1 27 Goto step 5 83 4 5 83 4 Voltage atX004 13 Yes Possible Causes Check wires Brn 12VDC Wht 47 25 Brn Wht 47 25 1 and Black No
220. l be a cut back in output any time the charger is below 108 VAC ANY interruption where there is power loss causes the charger to reset If left plugged in the charger will restart in 30 days or when the Voltage drops Battery Charge Level and Normal Charging Time Number of Cycles Battery Charge Level Recharge time hours 15 7596 24 8V 12 30 5096 24 2V 13 1 50 2096 23 4V 14 7 66 0 less than 23 2V 15 Step Pretest Instructions Test Result Corrective Action 1 5 1 Does charger go through Yes Goto step 1 5 2 proper LED sequencing upon No Check AC power supply start up 1 5 2 Is the red LED on Yes Possible Causes 4 1 1 4 1 3 4 1 4 No Do some function to cause draw on the battery then start again Otherwise goto step 1 5 3 1 5 3 Check the voltage on each bat Do all batteries have at least Yes Goto step 1 5 4 tery 25 6 12 V 100 6 12V No Possible Causes 4 1 4 6 32V ADU 1 5 4 Usingahydrometer Check Is the specific gravity of all bat Yes Possible Causes 4 1 8 the specific gravity in each tery cells between 1 155 and Possible Causes 4 1 4 battery cell 25 chargedis 1 265 1 155 100 1 265 3121203 350 T500J 1 31 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 6 ENGINE WILL NOT CRANK ENGINE MODELS Engine starting is only allowed for engine powered machines when the engine speed feedback is zero St
221. lay Short To Battery 5 156 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 205 THROTTLE PULL RELAY SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the Engine Throttle Pull circuit See 2 163 Throttle Pull Relay Short To Ground 5 206 LAMP ON System test prompt to check that the platform tilt lamp is illuminating properly If the lamp is illuminating properly press ENTER on the analyzer to continue the system test Otherwise see possible cause 4 1 11 3121203 T350 T500J 5 157 SECTION 5 SYSTEM TEST MESSAGES 5 158 T350 T500J 3121203 SECTION 6 CALIBRATION MESSAGES SECTION 6 CALIBRATION MESSAGES This section is reserved for messages related to the calibration process using the analyzer 3121203 T350 T500J 6 159 SECTION 6 CALIBRATION MESSAGES 6 160 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE SECTION 7 ELECTRICAL REFERENCE 3121203 T350 T500J 7 161 SECTION 7 ELECTRICAL REFERENCE ll PLATFORM CONTROL PANEL Boom AREA GROUND CONTROL PANEL OUTRIGGERS B HYDRAULIC VALVES ELECTRIC Power Gas ENGINE OPT X088 Sol Fuse X089 Starter Sol X092 Oil Level Switch X095 Eng Speed 7 DRIVE AND SET x X098 090 Platform Module Choke Solenold Ss Eng Stop Relay X097 DNE xis Q Throttle Solenoid x Choke Relay X096 n y R
222. le Cause 4 1 26 4 1 23 extent Using the analyzer between 2 75 and 4 25 No Goto step 2 95 4 navigate to DIAGNOSTICS gt Volts PLATFORM gt Y JOYSTK 2 95 4 Place key switch in platform Measured voltage between Yes Goto step 2 95 6 position and pull the emer X061 1 and X061 2 5V No Goto step 2 95 5 gency stop switches 2 95 5 DisconnectX061 Placekey Measuredvoltage between Yes Possible Cause Short or Open in Yel switch in platform position X060 5 and X60 7 5V Red 2 18 or Black joystick ground and the emergency stop 4 1 22 Switches No Possible Cause 4 1 11 2 95 6 Place key switch in platform Measured voltage between Yes Possible Cause Short or Open in Orn position and pull the emer X060 8 and X060 7 between Red 49 21 gency stop switches 2 75 and 4 25 Volts No Possible Cause 4 1 22 2 84 T350 T500J 3121203 2 96 JOYSTICK MOVED BUT TRIGGER SWITCH OPEN Distress Lamp 1 ADE Code None SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES The platform module senses the joystick is out of center but did not first sense the trigger switch This could be due to improper operation or a problem with the trigger switch joystick or rotary function select switch Functions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract
223. losure ENGINE POWERED MACHINES ONLY See 2 58 Function Problem Engine Start Permanently Selected 9 20 CHECK SWING LEFT SWITCH System test response indicating that the ground module input from the ground swing left switch was closed when the sys tem test began testing switch inputs This may indicate a permanent switch closure See 2 74 Function Problem Swing Left Permanently Selected 9 21 CHECK SWING RIGHT SWITCH System test response indicating that the ground module input from the ground swing right switch was closed when the sys tem test began testing switch inputs This may indicate a permanent switch closure See 2 75 Function Problem Swing Right Permanently Selected 9 22 CHECK TELESCOPE IN SWITCH System test response indicating that the ground module input from the ground telescope in switch was closed when the sys tem test began testing switch inputs This may indicate a permanent switch closure See 2 77 Function Problem Telescope In Permanently Selected 5 23 CHECK TELESCOPE OUT SWITCH System test response indicating that the ground module input from the ground telescope out switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure See 2 78 Function Problem Telescope Out Permanently Selected 3121203 T350 T500J 5 135 SECTION 5 SYSTEM TEST MESSAGES 9 24 CHECKING INPUTS System test status message indicating that it has begun testing digital inpu
224. lt Corrective Action 2 19 1 DisconnectsolenoidatX093 Rerun System Test Analyzer Message CHOKE PULL Repair Replace solenoid andisolate wires RELAY OPEN CIRCUIT Analyzer Message CHOKE PULL Goto step 2 19 2 RELAY SHORT TO GROUND 2 19 2 Remove wire WHT YEL48 4 Rerun System Test Analyzer Message CHOKEPULL Wire WHT YEL 48 4 shorted to from X003 4 RELAY OPEN CIRCUIT ground Repair or replace Analyzer Message CHOKE PULL Possible Cause 4 1 10 RELAY SHORT TO GROUND 3121203 T350 T500J 2 49 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 20 DRIVE amp 0 R PREVENTED OPERATE FROM PLATFORM Distress Lamp 2 ADE Code 2 5 In Platform Mode an attempt was made to operate Drive or Outriggers but X007 7 is not at Battery Voltage as it should be when the platform console is plugged into the platform position Using the JLG Analyzer view the Platform Position status under DIAGNOSTICS gt SYSTEM The vehicle must be in AWP not HOOK MODE with PLTPOS1 and PLTPOS2 GND DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Step Pretest Instructions Test Result Corrective Action 2 20 1 15 platform console Yes Goto step 2 20 2 plugged into the platform No Connectthe platform console atthe platform position and try again 2 20 2 Using the JLG Analyzer view Is PLTPOS1 B Yes Possible Cause 4 1 10 the Platfor
225. ltage atX097 2 Wht Yes Goto step 1 8 3 position and pull the emer Yel 48 2 1 Vbatt momen No Goto step 1 8 2 gency stop Engine Running _ tarily when operating Lift Up 1 8 2 Turn key switch to ground Does voltage at X091 86 Wht Yes Possible Causes Fusible link from B position and pull the emer Yel 48 2 Vbatt momentarily toX091 30 broken Throttle Pull Diode at gency stop when operating Lift Up X097 Bad 4 1 80 No Possible Causes Wht Yel 48 2 wire from X003 9 to 022 3 or X022 3 to X091 86 broken 4 1 10 1 8 3 Turn key switch to ground Does voltage atX097 1 Wht Yes Possible Causes Throttle cable froze or position and pull the emer Yel 48 3 Vbatt when operat binding Engine throttle stuck 4 1 78 gency stop ing Lift Up No Possible Causes Wht Yel 48 3 wire from X003 11 to X022 4 or X022 4 to 097 1 broken 4 1 10 1 9 ENGINE LOW IDLE INOPERATIVE ENGINE MODELS Possible Causes 4 1 83 4 1 84 4 1 85 4 1 86 4 1 90 4 1 89 4 1 93 3121203 T350 T500J 1 33 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 10 GROUND CONTROLS INOPERATIVE Step Pretest Instructions Test Result Corrective Action 1 10 1 Do panel indicator lights blink Yes Possible Causes Checkthe Analyzer at power on Normal 3 sec connection and look for faults again ond wakeup alarm should also 4 1 18 4 1 10 sound No Ground controller not powered Perform component check 3 2 DC Pow
226. ltage on X041 2 Vbatt Yes Black wire broken between X018 and X041 Repair or replace No Goto step 3 15 6 3 15 6 Voltage on X041 1 Vbatt Yes Possible Cause 4 1 18 No Goto step 3 15 7 3 15 7 Voltage on X018 1 Vbatt Yes White wire broken between X018 and X041 Repair or replace No Goto step 3 15 8 3 15 8 Voltage on X004 25 Yes Wire Yel Red 2 26 1 or Yel Red 2 26 Vbatt broken Repair or replace No Possible Cause 4 1 10 3 16 TILT SENSOR Step Pretest Instructions Test Result Corrective Action 3 16 1 Is the ground module se Yes Possible Causes 4 1 17 4 1 10 ITUR Mount ground module securely to frame level and inthe upright posi tion as in Figure 7 1 3121203 T350 T500J 3 127 SECTION 3 COMPONENT CHECKS 3 17 TRANSPORT LIMIT SWITCH Step Pretest Instructions Test Result Corrective Action 3 17 1 Stowthe boom ANALYZER gt DIAGNOS OP Goto step 3 17 2 TICS gt SYSTEM gt L Possibl 4 1 TRANS LMT SW C ossible Cause 4 1 23 4 1 10 3 17 2 Does the Transportlimit Yes Goto step 3 17 3 switch X040 spring pullthe No Possible Cause 4 1 19 4 1 18 lever againstthe cylinder 3 17 3 Voltage on X004 11 Yes Possible Cause 4 1 10 Goto step 3 17 4 3 17 4 Voltage 015 2 Yes Wire Orn Red 49 53 broken Repair or replace No Goto step 3 17 5 3 17 5 Voltage on X040 2 Vbatt Yes Black wire broken b
227. lve circuit See 2 129 Rear Left O R Solenoid Open Circuit 9 159 R L OUTRIGGER VALVE SHORT TO BATTERY The system test detected a short to battery in the Rear Left Outriggers valve circuit See 2 130 Rear Left O R Solenoid Short To Battery 9 160 R L OUTRIGGER VALVE SHORT TO GROUND The system test detected a short to ground in the Rear Left Outriggers valve circuit See 2 131 Rear Left O R Solenoid Short To Ground 5 161 ROTARY TO JIB TELE Platform system test prompt to turn the rotary select switch to the Jib Telescope position 5 162 ROTARY TO LEVEL Platform system test prompt to turn the rotary select switch to the Platform Leveling position 5 163 ROTARY TO LIFT SWING Platform system test prompt to turn the rotary select switch to the Lift Swing position 3121203 T350 T500J 5 151 SECTION 5 SYSTEM TEST MESSAGES 5 164 R R 0 VALVE System test prompt indicating that it is currently testing this circuit 9 165 R R OUTRIGGER LAMP ON System test prompt to check that the ground Rear Right Outrigger lamp is illuminated Step Pretest Instructions Test Result Corrective Action 5 165 1 Does this indicator illuminate Yes Press ENTER onthe analyzerto con properly tinuethe systemtest No Goto step 5 165 2 5 165 2 Do other indicators illuminate Yes Possible Causes Check wiring instead No Goto step 5 165 3 5 165 3 Voltage at X030 7 12VDC Yes Possible Causes 4 1 27 No Go to step 5 165 4 5 165 4 Voltage
228. m Position status No Goto step 2 20 3 under DIAGNOSTICS gt SYS The vehicle must be in AWP MODE not HOOK MODE with PLTPOS1 and PLTPOS2 GND 2 20 3 With the console in the plat Is the voltage onX059 D pin Yes Goto step 2 20 4 form position pullthe ground VBatt No Possible Cause and platform emergency stop switches and place key switch in the platform position 2 20 4 With the console inthe plat Is the voltage on X059 K Yes Goto step 2 20 5 form position pull the ground VBatt No See 2 124 Platform Position Detec and platform emergency stop tion Faulty switches and place key switch in the platform position 2 20 5 Remove X058 K Witht he Is the voltage on X058 K soc Yes Goto step 2 20 6 console inthe platform posi VBatt No See 2 124 Platform Position Detec tion pull the ground and plat tion Faulty form emergency stop switches and place key switch inthe platform position 2 20 6 Remove X054 10 Withthe Is the voltage on Yes Goto step 2 20 7 console inthe platform posi X054 10 soc VBatt No See 2 124 Platform Position Detec tion pull the ground and plat tion Faulty form emergency stop switches and place key switch inthe platform position 2 20 7 Remove X019 10 Withthe Isthe voltage onX019 10 pin Yes Possible Cause Orn Red 49 10 wire console inthe platform posi VBatt open or swapped with Orn Red 49 9 tion pull the ground and plat wire form emergency stop
229. 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 WARNING 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 15 MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY TROUBLESHOOTING DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICE AND OPERA TORS MANUALS KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED A machine that is damaged or malfunctioning should immediately be tagged and removed from service Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform any troubleshoot ing procedure with the machine parked on a flat level surface boom
230. n be read from the green LED on the face of the ground module see Figure A 2 Figure A 2 Ground Module Fault LED A 6 T350 T500J 3121203 INTRODUCTION On electric powered machines power module flash codes can be read from the flashing of the green LED located on the power module as seen in Figure A 3 Refer to A 8 Power Module Flash Codes for fault descriptions A 5 USER FAULT CODES 3121203 Figure A 3 Power Module Fault LED Flash Code Description of Difficulty a Procedure Vehicle Setup Battery Charge System Excessive Duty Cycle Start Engine Turn Off System Unused Unused Unused N oy Vehicle Requires Service T350 T500J INTRODUCTION A 6 USER FAULT CODE CROSS REFERENCES CODE MESSAGE PAGE NO 0 Chassis Tilt Sensor Out Of Range reat tn sue ruine earn doe dn an doe 2 46 R nning At Greep Material HOOK eee pere ep prep Et a a a a es Pe debe obse 2 104 1 Function Locked Out Joystick Not Centered At Startup Function Locked Out Trigger Permanently Closed sese eterne nennen inrer enne Function Problem Engine Choke Permanently S
231. nction Possible Causes Shortin wire Orn Red 49 26 4 1 11 Repair shortin wire Orn Red 49 31 Possible Cause 4 1 11 2 56 FUNCTION PROBLEM ENGINE CHOKE PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 2 The platform engine choke switch was closed when the platform was powered The switch could be accidentally held mechanically stuck or electrically shorted ENGINE POWERED MACHINES ONLY Functions Disabled at Platform Only Engine Choke Pull Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 56 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 56 2 2 56 2 DisconnectX064 Place key Isfault FunctionProblem Yes Goto step 2 56 3 switch in the platform position Engine Choke Permanently No Possible Causes 4 1 18 and pullthe emergency stop Selected still present switches 2 56 3 Place key switchintheplat Measured voltage at Yes Possible Causes Short in Orn Red 49 form position and pull the X060 14 Vbatt 30 wire 4 1 11 emergency stop switches No Possible Causes 4 1 11 2 66 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 57 FUNCTION PROBLEM ENGINE CHOKE PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground engine choke switch was closed when the machine was powered The switch could be accidentally held mechanically stuck or electrically shorted ENGINE POWERED MACH
232. nctions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 147 2 No Goto step 2 147 2 2 147 2 Disconnect solenoid Short Rerun System Test Analyzer Message SWING Replace solenoid and or connector X078 1 soc to X078 2 soc RIGHT VALVE SHORT TO GROUND Analyzer Message SWING Goto step 2 147 3 RIGHT VALVE OPEN CIRCUIT 2 147 3 Replace X002 35 witha Rerun System Test Analyzer Message SWING Wire White 22 3 1 or White 22 3 bro jumperto X002 14 RIGHT VALVE SHORT TO ken Repair or replace GROUND Analyzer Message SWING Possible Cause 4 1 10 RIGHT VALVE OPEN CIRCUIT 2 148 SWING RIGHT SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Swing Right digital output may be shorted to battery or other function Functions Disabled Swing Right Step Pretest Instructions Test Result Corrective Action 2 148 1 Runsystem test Do other functions failsys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 148 2 No Goto step 2 148 2 2 148 2 Disconnect solenoid atX078 Rerun System Test Analyzer Message SWING Replace solenoid RIGHT VALVE OPEN CIRCUIT Analyzer Message SWING Goto step 2 148 3 RIGHT VALVE SHORT TO BAT TERY 2 148 3 Remove wire White 22 3 1 Rerun System Test Analyzer Message SWING Wire White 22 3 1 or White 22 3 from X002 35 R
233. ne Will Not Crank Engine Models or 1 7 Engine Cranks But Will Not Start Engine Models ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Step Pretest Instructions Test Result Corrective Action 2 44 1 Start Engine ANALYZER gt DIAGNOS Yes Possible Cause 4 1 2 4 1 10 TICS gt ENGINESPEED gt 0 Goto step 2 44 2 ORPM 2 44 2 Check for continuity Yes Possible Cause 4 1 21 4 1 21 4 1 2 between X001 16 soc and 4 1 10 X095 No Repair WHT YEL 48 7 or WHT YEL 48 13 1 between X001 16 and X095 2 60 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 45 EXTEND 0 R SOLENOID OPEN CIRCUIT Distress Lamp 9 be defective Functions Disabled Set Extend O R ADE Code 3 3 Ground module feedback shows that Extend Outrigger digital output may be disconnected from the relay or the relay may Analyzer Message EXTEND VALVE OPEN CIRCUIT Step Pretest Instructions Test Result Corrective Action 2 45 1 Runsystem test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise Goto step 2 45 2 No Goto step 2 45 2 2 45 2 Disconnect solenoid atX086 Rerun System Test Analyzer Message EXTEND Re
234. ne the Hand Brake Sensor wiring and adjustment When the hand brake is applied BRAKE1 input 074 5 and BRAKE2 input X074 6 OV This could be caused by the brake linkage or cable not being properly adjusted an obstruction over the switch the switch adjusted too far from the cylinder should be within 0 188 of the extended cylinder or a faulty switch If an error has been detected the switch must be reset before drive will function DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive See 3 5 Drive Sensor Reset 2 23 DRIVE ENABLE SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Enable Valve PWM output may be shorted to battery or the solenoid may be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Step Pretest Instructions Test Result Corrective Action 2 23 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 23 2 No Goto step 2 23 2 2 23 2 Disconnect solenoid at Rerun System Test Analyzer Message DRVENABLE Replace solenoid X07 1andisolate wires SHORT TO GROUND OR OPEN CIRCUIT Analyzer Message DRVENABLE Goto step 2 23 3 VALVE SHORT TO BATTERY 2 23 3 Remove wire Orn 55 1 from Rerun System Test Analyzer Message DRVENABLE Wire Orn 55 1 shorted to battery X074 11 SHORT TOGROUND
235. nector If this difficulty is present examine wiring at the connectors leading to the pins on the Ground Module and wiring within the Platform Console Functions in Creep Mode Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Step Pretest Instructions Test Result Corrective Action 2 124 1 Withthe console inthe plat Is the voltage onX019 10 Yes Goto step 2 124 2 form position pull the ground VBatt No Goto step 2 124 6 and platform emergency stop switches and place key switch in the platform position 2 124 2 Remove X019 9 With the Is the voltage on X019 9 pin Yes Goto step 2 124 3 console in the platform posi VBatt No Possible Cause Orn Red 49 9 tion pull the ground and plat shorted 4 1 31 4 1 10 form emergency stop switches and place key switch inthe platform position 2 124 3 Remove X054 9 With t he Isthe voltage on X054 9 soc Yes Goto step 2 124 4 console inthe platform posi No Possible Cause Shorted Blu BIk tion pull the ground and plat between X054 and X019 form emergency stop switches and place key switch in the platform position 3121203 T350 T500J 2 97 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES Step Pretest Instructions Test Result Corrective Action 2 124 4 Remove X058 J With t he Isthe voltage on X058 J soc Yes Goto step 2 124 5 SOSSE NED EOS ie No Possible Cause Shorted Blu BIk tion pullth
236. negative terminal of the pump connects to the P Terminal of the Power Module which switches current through MOSFET transistors to the Battery Negative For variable speed pump operation the MOSFET transistors switch On and Off at high frequencies 16kHz The Duty Cycle is varied to control the voltage applied to the pump motor When the MOSFET s spend 50 of the period On and 50 Off 3121203 350 T500J 3 117 3 approximately 1 2 of the available Battery Voltage will be applied to the pump motor Similarly the MOSFET On continu ously 10096 Duty Cycle to apply all available Battery Voltage to the pump motor Line Contactor 24V Series DC Pump Motor Power Module Ignition Power X002 3 CANHI CANLO Figure 3 1 Power Module Circuit When the Control System is energized the voltage at the P Terminal will be approximately 24V referenced to B when the pump is static The M2 Terminal will be approximately at 1V referenced to B when the pump is running at full speed Common Difficulties The following difficulties can be examined using the JLG Analyzer a voltmeter and simple hand tools Unless otherwise noted the Control System shall be energized in Ground Mode during testing The vehicle should be placed on a firm level surface for all analysis Ground Module Interlocks There are a variety of interlocks that prevent Lift Up due to sys
237. nne enne 6 6 6 CANBUS Failure Accessory Module Communications Lost essent nennen ener ener nene 2 42 6 6 CANBUS Failure Drive Module ep E HEREIN 2 43 6 6 CANBUS Failure Platform Module eese een entente nne ettet rennen nete 2 44 6 6 CANBUS Failure Power Module esee eene entree 2 45 6 T ACCEss ry Fault 2 22 22 een is a e erre rae e de aed ee Dee ates 2 41 7 7 7 Open Circuit Pump Motor Wiring 2 96 8 8 1 Chassis Tilt Sensor Not Calibrated rete EE innen 2 46 9 9 9 Chassis Tilt Sensor Gain Not Calibrated 9 9 Chassis Tilt Sensor Gain Out Of Range ssssssseseseeeseeeeeeeeetn enne tentent nne nnns 9 9 EEPROM Failure Check All Settings teen teo e e e be eo pe dye rr ib ee erstes 9 9 Functions Locked Out Constant Data Version Improper 9 9 Functions Locked Out Platform Module Software Version Improper 9 9 Functions Locked Out Power Module Software Version Improper i 9 9 Ground Module Failure Ref Voltage Out Of Range 9 9 Ground Module Failure Vlow Fet Failure
238. noid and or connector X003 2 Short X046 1 soc to GER VALVE SHORT TO GROUND 046 2 50 Analyzer Message F L OUTRIG Goto step 2 48 3 GER VALVE OPEN CIRCUIT 2 48 3 Replace X003 2 with a jumper Rerun System Test Analyzer Message F L OUTRIG Wire Orn Red 49 5 or White wire to X046 broken Repair or replace Possible Cause 4 1 10 2 62 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 49 FRONT LEFT 0 SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Front Left Outrigger Valve digital output may be shorted to battery or the solenoid may be defective Functions Disabled Front Left O R Analyzer Message F L OUTRIG GER VALVE SHORT TO BAT TERY Step Pretest Instructions Test Result Corrective Action 2 49 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 49 2 No Goto step 2 49 2 2 49 2 Disconnectsolenoid atX046 Rerun System Test Analyzer Message F L OUTRIG Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message F L OUTRIG Goto step 2 49 3 GER VALVE SHORT TO BAT TERY 2 49 3 Remove wire Orn Red 49 5 Rerun System Test Analyzer Message F L OUTRIG Wire Orn Red 49 5 or White wire to from X003 2 GER VALVE OPEN CIRCUIT X046 shorted to battery Repair or replace Possible Cause 4
239. ns fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2144 2 Goto step 2 144 2 2 144 2 Disconnect solenoid Short Rerun System Test Analyzer Message SWING LEFT Replace solenoid and or connector X077 1 soc to X077 2 soc VALVE SHORT TO GROUND Analyzer Message SWING LEFT Goto step 2 144 3 VALVE OPEN CIRCUIT 2 144 3 Replace X002 34 with a Rerun System Test Analyzer Message SWING LEFT Wire White 21 3 1 or White 21 3 bro jumperto X002 14 VALVE SHORT TO GROUND ken Repair or replace Analyzer Message SWING LEFT Possible Cause 4 1 10 VALVE OPEN CIRCUIT 2 106 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 145 SWING LEFT SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Swing Left digital output may be shorted to battery or other function Functions Disabled Swing Left Step Pretest Instructions Test Result Corrective Action 2 145 1 system test Dootherfunctionsfailsys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise 0010 step 2 145 2 No Goto step 2 145 2 2 145 2 Disconnect solenoid atX077 Rerun System Test Analyzer Message SWING LEFT Replace solenoid VALVE OPEN CIRCUIT Analyzer Message SWING LEFT Goto step 2 145 3 VALVE SHORT TO BATTERY 2 145 3 Remove wire White 21 3 1 Rerun System Test Analyzer Message SWING LEFT Wire
240. nt entree stets tr tennenntne trennen erret treten treten enn 2 96 3 3 Re r Left O R Solenoid Open Circus o eee ete E ite dett de dee rr e qued edere 2 99 A 12 T350 T500J 3121203 INTRODUCTION 3 3 Rear Left O R Solenoid Short To Battery sese nennen 2 100 3 3 Rear Left O R Solenoid Short To Ground s eene entente nennen reiner erre then 2 100 3 3 Rear Right O R Solenoid Open Circuit a e EEE E EEEE I E 2 101 3 3 Rear Right O R Solenoid Short To Battery nennen ener ettet nnne 2 101 3 3 Rear Right O R Solenoid Short To Ground sse eene entente nenne ten nene 2 102 3 3 Retract O R Solenoid Open Circuit 3 3 Retract O R Solenoid Short To Battery 3 3 Retract O R Solenoid Short To Ground 3 3 Start Solenoid Open Circuit E 3 3 Start Solenoid Short To Battery 5 eed Meee nie et dl etre oid Raster acti 3 3 startsol enoide hort Lo Ground Lc eoe Me ELE 3 3 Swing Left Solenoid Open Circuit sese ennemi trennen trennen enne 3 3 Swing Left Solenoid Short To Battery sese eee rennen innere inniti netten entente nennen nennen 3 3 Swing Left Solenoid Short To Ground eee eese eeeeeeeee
241. ntente nennen nennen eene etr ene tenete tenent ten ener ennt 2 51 Diive Prevented LEift Down he ER IHE eet n deed ode om m e ask De Drive Prevented Stow Outriggers Drive Prevented Telescope In Lift Down Prevented Tele In First 2 Lift Up amp Tele Out Prevented Tilted amp Above Elevation rennen entretenir enne 2 91 Lift Up amp Tele Out Prevented Tilted Unset amp Above Elevation eese eee ntt nennen nennen enne 2 92 Lift Up amp Tele Out Prevented Unset amp Above Elevation tnn 2 92 LiftUp Prevert d Check Outriggers Bu ee C D ee E e e HERE 2 92 Lift Up Prevented Lift Down Then Set Outriggers 2 93 Laft Up Pr vented Tilted nnd eget soe AV AAS hand eee vedete e eese ete hated 2 93 Model Changed Hydraulics Suspended Cycle EMS 2 95 Outrigger Stow Prevented Tele In First u 2 97 Outriggers Prevented Elevated 2 97 Running At Creep Tilted amp Above Elevation 2 104 Running At Creep Unset amp Above Elevation esses eene nennen 2 104 Tele Out Prevented Set Outriggers
242. ntil 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 7 14 DT DTP Contact Removal 1 Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out 2 To remove the contacts gently pull wire backwards while at the same time releasing the locking finger by moving it away from the contact with a screwdriver 3 Hold the rear seal in place as removing the contact may displace the seal HD30 HDP20 Series Assembly Figure 7 15 HD HDP Contact Installation 1 Grasp contact about 25mm behind the contact crimp barrel 2 Hold connector with rear grommet facing you 3121203 350 T500J 7 186 SECTION 7 ELECTRICAL REFERENCE 3 Push contact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place LOCKING FINGERS CONTACT CONTACT INSERTION Ebo UNLOCKED POSITION CONTACT LOCKED IN POSITION Figure 7 16 HD HDP Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly Figure 7 17 HD HDP Contact Remo
243. o B X011 black wire to B 4 1 65 30A fuse in ground control box blown Replace fuse 4 1 66 Key switch not on Turnto either ground or platform control 4 1 67 Emergency stop switch is pushed Pull ground emergency stop switch for ground operation or both ground and platform emergency stop switches for platform operation 4 1 68 Enable switch is not held Hold enable switch while operating 4 1 69 Hydraulic Pump Motor may be defective Repair or replace 4 1 70 Red Pump Motor Positive wire may be cut Repair or replace 4 1 71 Black Pump Motor Negative wire may be cut Repair or replace 4 1 72 Power wire terminals may be corroded or loose Cleanterminals and tighten if loose 4 1 73 Hydraulic pump engine coupling may be defective Repair or replace 4 130 T350 T500J 3121203 SECTION 4 POSSIBLE CAUSES 4 1 POSSIBLE CAUSES Item Possible Cause Possible Solution 4 1 74 Gas Only Dump Valve may be defective Repair or replace 4 1 75 Gas Only High Idle Inoperable See1 8 Engine High Idle Inoperative Engine Models 4 1 76 Gas Only Engine may be mechanically defective Contact Factory 4 1 77 Gas Only Engine start solenoid may be defective Repair or replace 4 1 78 Gas Only Engine throttle pull solenoid may be defec Repair or replace tive 4 1 79 Gas Only Engine start motor may be defective Repair or replace 4 1 80 Gas Only Engine throttle relay may be defective Repair or replace
244. o Side to Side tilt of the vehicle while the Y Axis responds to Front to Back tilt of the vehicle The following table is offered to clarify orientation Orientation Response Raise Tongue of Vehicle Y Axis Lower Tongue of Vehicle Y Axis Raise Left Side of Vehicle X Axis Raise Right Side of Vehicle X Axis A 12 CRITICAL VEHICLE INTERLOCK SCENARIOS The following scenarios have been identified that require unique vehicle interlocks For readability the circumstances involved with entering and leaving these situations have been isolated here RETRIEVAL A Retrieval A forces the user to stow the boom if the Tilt Warning is ignored and critical stability situations are reached This scenario is INACTIVE at Power up It becomes ACTIVE when the machine is ELEVATED transport switch OPEN AND CRITICALLY TILTED 4 5 degrees or more It is INACTIVE otherwise RETRIEVAL B Retrieval B forces the user to stow the boom if the Outrigger Unset Warning is ignored and critical stability situations are reached This scenario is INACTIVE at Power up It becomes ACTIVE under the following circumstances It is INACTIVE otherwise vehicle is Elevated AND One Outrigger is Unset AND the vehicle is TILTED vehicle is Elevated AND Two Outriggers are UNSET A 13 OUTRIGGERS Some machine software may refer to the Outriggers O R as Lifting Jacks L J A 16 T350 T500J 3121203
245. odule feedback shows that the hourmeter output may be shorted to battery or another function Open Circuit and Short to Ground detection are disabled since they cannot be detected reliably with this style load All Functions Operable Possible Causes Short in Brn Wht 47 7 1 Short in Brn Wht 47 7 4 1 24 4 1 10 2 88 JIB DOWN SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Jib Down PWM output may be disconnected or the solenoid may be defective T500J MODELS ONLY Functions Disabled Jib Down Step Pretest Instructions Test Result Corrective Action 2 88 1 ShortX056 1 soc to Is the fault removed Yes Repair Replace solenoid 056 2 50 Goto step 2 88 2 2 88 2 ShortX055 11 pinto Is the fault removed Yes Yel Blk or Brn Blk boom wire broken X055 12 pin between X055 and X056 Repair or replace No Goto step 2 88 3 2 88 3 ShortX019 11 socto Is the fault removed Yes Yel Blk or Brn Blk boom wire broken X019 12 soc between X019 and X055 Repair or replace No Goto step 2 88 4 2 88 4 ShortX002 20 pinto B Is the fault removed Yes Blue 28 3 1 or black wire broken between X002 and X019 Repair or replace No Possible Causes 4 1 10 2 80 T350 T500J 3121203 2 89 JIB DOWN SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES Ground module feedback shows that Lift Down PWM output may be shorted to bat
246. of likely causes Possible Causes 4 1 33 4 1 37 4 1 49 1 22 2 Does Manual Descentlower Yes Possible Causes 4 1 38 4 1 61 the jib 4 1 48 4 1 10 Possible Causes 4 1 41 4 1 47 4 1 10 1 23 OUTRIGGER SET FUNCTION INOPERATIVE See 1 12 Ground Leveling Not Functioning Properly 1 24 OUTRIGGER STOW FUNCTION INOPERATIVE See 1 12 Ground Leveling Not Functioning Properly 1 40 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 1 ACCESSORY FAULT Distress Lamp 9 ADE Code 6 7 An attached accessory is communicating a fault to the ground control Step Pretest Instructions Tet Corrective Action 2 1 1 Is an accessory installed Yes Referto Information Supplied with Accessory No Possible Causes 4 1 2 2 2 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN Distress Lamp 3 ADE Code 4 4 The system detected a battery voltage above 36 Volts for an electric powered machine ELECTRIC POWERED MACHINES ONLY Functions Disabled Electric Powered Machines Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O Stow Retract O R Drive Possible Causes 4 1 2 4 1 3 4 1 4 2 3 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN Distress Lamp 5 ADE Code 4 4 The system detected a battery volt
247. on Functions Disabled Lift Up Step Pretest Instructions Test Result Corrective Action 2 111 1 Is the boom elevated Yes See 2 110 LiftUp amp Tele Out Prevented Unset amp Above Elevation No 3 17 Transport Limit Switch 2 92 T350 T500J 3121203 2 112 UP PREVENTED DOWN THEN SET OUTRIGGERS SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES Distress Lamp 2 ADE Code 2 5 The ground module senses the controls in the lift up position but the platform is stowed and the outriggers are not com pletely set or stowed Lift up is prevented until all outriggers are either set or stowed While outriggers are stowed functions should only be used for aligning the boom for transport Functions Disabled Lift Up 2 113 LIFT UP PREVENTED TILTED Distress Lamp 2 ADE Code 2 5 Lift Up is being attempted while the Platform is Stowed all four Outriggers are Set but the vehicle is Tilted Step Pretest Instructions Test Result Corrective Action 2 112 1 Are all outriggers set Yes 3 11 Outrigger Switches All Set No Goto step 2 112 2 2 112 2 Are alloutriggers stowed Yes See 3 12 Outrigger Switches All Stowed No Goto step 2 112 3 2 112 3 Are you attempting to align Yes Stow all outriggers and try again the boom for transport No Set all outriggers and try again The ground module senses the controls in the lift up position the platform is stowed and the outrigger
248. on Problem Yes Goto step 2 73 2 ground emergency stop Swing Left And Right Both No Possible Causes 4 1 18 switch and place key switch in Selected still present 27 the ground position 2 73 2 DisconnectX014 Holdthe Measure continuity between Yes Possible Causes Short in White 22 2 enable switch X014 18 pin and X014 1 pin wire No Goto step 2 73 3 2 73 3 DisconnectX014 Holdthe Measure continuity between Yes Possible Causes Short in White 21 2 enable switch X014 19 pin and X014 1 pin wire No Goto step 2 73 4 2 73 4 Remove X004 35 soc from Is fault Function Problem Yes Possible Causes 4 1 10 004 Swing LeftAndRightBoth Possible Causes Short in White 22 2 Selected still present 1 wire or White 21 2 1 wire 3121203 350 T500J 2 75 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 74 FUNCTION PROBLEM SWING LEFT PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground swing left switch was closed when the machine was powered The switch could be accidentally held mechani cally stuck or electrically shorted Functions Disabled at Ground Only Swing Left Step Pretest Instructions Test Result Corrective Action 2 74 1 Is the switch mechanically Yes Repair or replace the switch Stuck No Goto step 2 74 2 2 74 2 DisconnectX024 ls fault Function Problem Yes Goto step 2 74 3 switch in ground position and Swing Left Permanently No Possible Cau
249. ontrolinoperable Goto step 1 3 3 1 3 3 Is the hydraulic pump turning Yes Goto step 1 3 4 with the engine No Perform component check 3 6 Engine Powered Machine Hydraulic Pump 1 3 4 Connecta 0 5000 PSI pres While holding enable andliftup Yes Possible Causes 4 1 37 4 1 47 sure gauge atthe manifold G switch does pressure rise No Goto step 1 3 5 port above 100PSI minimum func tion pressure 1 3 5 Plumb a 0to 5000 PSI 345 While holding enable and Yes Possible Causes 4 1 40 4 1 10 4 1 47 bar pressure gaugeintothe switch does pressure rise No Possible Causes 4 1 37 4 1 45 4 1 74 manifold P port above 100PSI minimum func tion pressure 4 1 75 4 1 39 1 4 ALL FUNCTIONS INOPERATIVE PUMP MOTOR RUNS DC POWERED MODELS Step Pretest Instructions Test Result Corrective Action 1 4 1 Basic check of likely causes Possible Causes 4 1 68 1 4 2 Try both ground and platform One set of controls functions See 1 10 Ground Controls Inoperative or controls 1 11 Platform Controls Inoperative Both sets of control inoperable Goto step 1 4 3 1 4 3 Connecta 0 5000 PSI pres While holding enable and Yes Possible Causes 4 1 37 4 1 47 sure gauge atthe manifold G switch does pressure rise No Goto step 1 4 4 port above 100PSI minimum func en tion pressure 1 4 4 Plumb a 0to 5000 PSI 345 While holding enable andliftup Yes Possible
250. or Red Blk power wires emergency stop switches and X057 H Vbatt between X059 and X057 place key switch in the plat No Repair Blue or Red BIk power wires form position between X057 and X055 3 14 POWER MODULE POWER Step Pretest Instructions Test Result Corrective Action 3 14 1 Pullthe ground emergency Is the power module fault Yes See A 8 Power Module Flash Codes stop switch and place key LED flashing No Goto step 3 14 2 switch in ground position 22 3 14 2 Pullthe ground emergency Is the power module LED il Yes Possible Causes 4 1 72 4 1 12 stop switch and place key luminated No Goto step 3 14 3 switch in ground position Xu 3 14 3 XU between Yes Possible Causes 4 1 12 RAUL Ng See 3 2 DC Powered Machine Power 3 126 T350 T500J 3121203 3 15 TELESCOPE LIMIT SWITCH SECTION 3 COMPONENT CHECKS Step Pretest Instructions Test Result Corrective Action 3 15 1 ANALYZER gt DIAGNOS OP Goto step 3 15 2 TICS gt SYSTEM TELE i L Possibl 4 1 23 4 1 1 LMTSW ossible Cause 3 0 3 15 2 Does the Telescope limit Yes Goto step 3 15 3 switch X041 spring pull the No Possible Cause 4 1 19 4 1 18 lever into the slot in the boom 3 15 3 Voltage on X004 21 Yes Possible Cause 4 1 10 Vbatt No Goto step 3 15 4 3 15 4 Voltage on X018 2 Vbatt Yes Wire Orn Red 49 72 broken Repair or replace No Goto step 3 15 5 3 15 5 Vo
251. or example 7 S ALE GROUND RLRRR 2 00 710 Amar GROUND ALARM 2 MOTION The effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when lifting down There are certain settings allowed to install optional features or select the machine model When selection the machine model to match the size of the machine the personality settings will all default to the factory recommended setting NOTE Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings 3121203 T350 T500J SECTION 9 JLG ANALYZER 9 206 SECTION 9 JLG ANALYZER ud adigd3AO TY 9 3 1 4 TFAAFIOLNV JezAjeuy 2 6 NOLLOIN C INHOSSQ I G 11SNI LON 0 INDOWO ISNV I VITVALSNV r VSI T VSN ISNV 0 LINUVIN SHA I ON 0 3IvHarivo HNIONH T ORILOATA 0 HOSN3S eg uodn Buipuedep jou suaaJos jeu ejou 9seald 25 JazAjeue ejqissod sapnjoul umoys jnoKe 21 9 6 4 14
252. ort To Ground 2 83 Joystick Faulty X axis Wiper Out Of Range 2 83 Joystick Faulty Y axis Wiper Out Of Range 2 84 Keyswitch Faulty 2 2 86 Level Down Solenoid Open Circuit 2 87 Level Down Solenoid Short To Battery essere 2 87 Level Down Solenoid Short To eae eee tea vas tea HR RR Ede ed EIE 2 88 Up Solenoid Open Circuits 2 eee dena terere dete ete p e eed as e tes e ete haa dea 2 88 Level Up Solenoid Short To Battery 2 89 Level Up Solenoid Short To Ground 2 89 Lift Down Solenoid Open Circullt 22020 2 90 Lift Down Solenoid Short To Battery 2 91 Lift Down Solenoid Short To Ground E Hears de der bee 2 91 Lift Up Solenoid Open Circuit o e eti IE ke ead 2 94 Lift Up Solenoid Short To Battery 22 52 2 94 Lift Up Solenoid Short To Ground ns 2 95 Open Circuit Pump Motor Wiring 1 1 11 202000 00 0000000000000000000 05 00 00 tnt netten
253. ort To Ground 5 113 LEVEL UP CL System test response indicating that the ground level up switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 114 LEVEL UP VALVE System test prompt indicating that it is currently testing this circuit 9 115 LEVEL UP VALVE OPEN CIRCUIT The system test detected an open in the Level Up valve circuit See 2 101 Level Up Solenoid Open Circuit 5 116 LEVEL UP VALVE SHORT TO BATTERY The system test detected a short to battery in the Level Up valve circuit See 2 102 Level Up Solenoid Short To Battery 5 146 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 9 117 LEVEL UP VALVE SHORT TO GROUND The system test detected a short to ground in the Level Up valve circuit See 2 103 Level Up Solenoid Short To Ground 9 118 LIFT DN VALVE System test prompt indicating that it is currently testing this circuit 5 119 LIFT DOWN CL System test response indicating that the ground lift down switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 120 LIFT DOWN VALVE OPEN CIRCUIT The system test detected an open in the Lift Down valve circuit See 2 105 Lift Down Solenoid Open Circuit 5 121 LIFT DOWN VALVE SHORT TO BATTERY The system test detected a short to battery in the Lift Down valve circuit See 2 106 Lift Down Solenoid
254. osure MODEL T500J ONLY See 2 60 Function Problem Jib Down Permanently Selected 5 10 CHECK JIB UP SWITCH System test response indicating that the ground module input from the ground panel jib up switch was closed when the sys tem test began testing switch inputs This may indicate a permanent switch closure MODEL T500J ONLY See 2 62 Function Problem Jib Up Permanently Selected 5 11 CHECK LEVEL DOWN SWITCH System test response indicating that the ground module input from the ground level down switch was closed when the sys tem test began testing switch inputs This may indicate a permanent switch closure See 2 63 Function Problem Level Down Permanently Selected 5 12 CHECK LEVEL UP SWITCH System test response indicating that the ground module input from the ground level up switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure See 2 65 Function Problem Level Up Permanently Selected 9 13 CHECK LIFT DOWN SWITCH System test response indicating that the ground module input from the ground lift down switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure See 2 66 Function Problem Lift Down Permanently Selected 5 14 CHECK LIFT UP SWITCH System test response indicating that the ground module input from the ground lift up switch was closed when the system test began testing switch inputs This may indica
255. oto step 2 101 3 VALVE OPEN CIRCUIT 2 101 3 Replace X002 5 with ajumper Rerun System Test Analyzer Message LEVEL UP Wire Pink 25 3 1 or Pink 25 3 broken to X002 14 VALVE SHORT TO GROUND Repair or replace Analyzer Message LEVEL UP Possible Cause 4 1 10 VALVE OPEN CIRCUIT 2 88 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 102 LEVEL UP SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Platform Level Up digital output may be shorted to battery or other function Functions Disabled Level Up Step Pretest Instructions Test Result Corrective Action 2 102 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 102 2 No Goto step 2 102 2 2 102 2 Disconnect solenoid at X080 Rerun System Test Analyzer Message LEVEL UP Replace solenoid andisolate wires VALVE OPEN CIRCUIT Analyzer Message LEVEL UP Goto step 2 102 3 VALVE SHORT TO BATTERY 2 102 3 Remove wire Pink 25 3 1 Rerun System Test Analyzer Message LEVEL UP Wire Pink 25 3 1 or Pink 25 3 shorted from X002 5 VALVE OPEN CIRCUIT to battery Repair or replace Analyzer Message LEVEL UP Repair Replace wire Pink 25 3 1 VALVE SHORT TO BATTERY 2 103 LEVEL UP SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the
256. ound Alarm Short To 2 96 Outrigger Stow Prevented Tele In 2 97 T350 T500J 21 TABLE OF CONTENTS Continued 2 123 Outriggers Prevented 1 2 97 2 124 Platform Position Detection 2 97 2 125 Power Module Failure Check Power Circuits Or Mosfet Short Circuit 2 98 2 126 Power Module Failure Internal 2 98 2 127 Power Module Failure Personality Range 2 99 2 128 Power Module Too Hot Please 2 99 2 129 Rear Left O R Solenoid Open Circuit 2 99 2 130 Rear Left O R Solenoid Short To Battery 2 100 2 131 Rear Left O R Solenoid Short To Ground ses 2 100 2 132 Rear Right O R Solenoid Open 2 4 2 101 2 133 Rear Right O R Solenoid Short To 2 101 2 134 Rear Right O R Solenoid Short To Ground 1 2 102 2 135 Retract O R Solenoid Open
257. ow Chart Platform Tests and go through the compo nent tests Hit the ESC key during any part of the test to return to the main menu without completing all tests or wait until all tests are complete During the TEST ALL INPUTS sequence the analyzer allows control switches to be operated and shows if they are closed CL or open OP 3 Pull out the Emergency Stop switch and Start the engine 3121203 350 T500J 9 210 SECTION 9 JLG ANALYZER Wuviv WHOSLV1d na v AH3LIVg 2 1 Z AMALIVE vn AMALIA SSIULSIA 1591 WJONEId 1591 16 6 6 6 OL 1 MOLLSAOL OL 1331 MOLLSAOL 3MOHO 9339981 40 SNIMS 14 OL 1no dil 331 air GION3IOS OL AHVIOH MOHI NI 3I3L ONIMS 14 OL 1 TINd MOHI OL 1 F1LLOUHL 93991 N3dO 439914 35079 39914 N3dO LL H3MOd OL NYO 8 H3MOd 23H92 WHOdLV ld OL MOSHO HOIH 001 3OVLIOA AHaLivg MOI 001 ADVLIOA 15 LHOIU ONIMS 14391 9NIMS 13437 GIONGIOS G10H IN31SAS AH3LIva wea xe Er wu 1 A i i dNLUVLS MOLLSAOP 2 SISAL 3NISN3 SISAL INVA a 4N13S 3NIHOVIA NNAW T3A31 dO LXAN JHL OL 31VAL
258. ow Min Tele In Pressure psi Goto step 1 16 4 bar 1 16 4 Plumb a 0 to 5000 PSI 345 Engage the enable and Tele Above Min Tele In Pressure psi Possible Causes 4 1 38 4 1 45 bar pressure gauge intothe scope in switch Checkpres bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port sure at manifold P port Below Min Tele In Pressure psi Possible Causes 4 1 10 4 1 46 bar 4 1 47 4 1 74 4 1 45 4 1 39 1 16 5 Plumb a 0 to 5000 PSI 345 Check pressure atthe tele Above Min Tele In Pressure psi Possible Causes 4 1 49 4 1 48 bar pressure gauge into the hose fromthe lift up cylinder end scope cylinder while activating telescope in at ground controls bar Below Min Tele In Pressure psi bar 4 1 41 Possible Causes 4 1 42 4 1 51 1 36 T350 T500J 3121203 1 17 SWING LEFT FUNCTION INOPERATIVE SECTION 1 TROUBLESHOOTING BY FUNCTION Step Pretest Instructions Test Result Corrective Action 1171 Basic check of likely causes Possible Causes 4 1 32 4 1 33 4 1 37 1 17 2 Engage enable and swing left DC Is pump motor running Yes Goto step 1 17 3 Switch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 17 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 17 3 Install a0 to 5000 PSI 345 Engage the enable and swing Above Min Swing LeftPressure Goto step 1 17
259. place or repair select switch in to Ground Mode and pullthe 0 ground panel ground emergency stop No Replace or repair Yel Red 2 4 wire switch 2 97 3 Find diode atX009 connected Is the fault removed Yes Replace the diodes at X009 to Yel Red 2 7 Yel Red 2 44 No Goto step 2 97 4 and Yel Red 2 9 Disconnect m this diode from X009 and the other diode Switch Key to Ground Mode and pull the ground emergency stop switch 2 97 4 ExtractX019 6 Switch Key to Is the fault removed Yes Possible Causes Shortin Yel Red 2 4 Ground Mode and pull the or Orange or Yellow Boom wires ground emergency stop No Goto step 2 97 5 switch 2 97 5 ExtractX007 1 Switch Key to Is the fault removed Yes Possible Causes Shortin Yel Red 2 Ground Mode and pull the 44 4 1 10 ground emergency stop No Possible Causes Shortin Yel Red 2 switch 9 4 1 10 2 86 T350 T500J 3121203 2 98 LEVEL DOWN SOLENOID OPEN CIRCUIT ADE Code 3 3 Ground module feedback shows that the Platform Level Down digital output may be disconnected or the solenoid may be Distress Lamp 9 defective Functions Disabled Level Down SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES Step Pretest Instructions Test Result Corrective Action 2 98 1 Run system test Do other functions fail sys Yes Possible Causes Black ground wire tem test broken 4 1 1 otherwise Goto step 2 98 2 No Goto step 2 98 3 2 98 2 Disconnectsolenoid Short RerunSystem Test Analyzer Message L
260. place solenoid and or connector Short X086 1 soc to VALVE SHORT TO GROUND 086 2 50 Analyzer Message EXTEND Goto step 2 45 3 VALVE OPEN CIRCUIT 2 45 3 Replace X003 13 witha Rerun System Test Analyzer Message EXTEND Wire Orn Wht55 3 1 orOrn Wht 55 3 jumper to X003 3 VALVE SHORT TO GROUND broken Repair or replace Possible Cause 4 1 10 2 46 EXTEND 0 R SOLENOID SHORT TO BATTERY Distress Lamp 9 may be defective Functions Disabled Set Extend O R ADE Code 3 3 Ground module feedback shows that the Extend Outrigger Valve digital output may be shorted to battery or the solenoid 2 61 Step Pretest Instructions Test Result Corrective Action 2 46 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 46 2 No Goto step 2 46 2 2 46 2 Disconnectsolenoid atX086 Rerun System Test Analyzer Message EXTEND Replace solenoid andisolate wires VALVE OPEN CIRCUIT Analyzer Message EXTEND Goto step 2 46 3 VALVE SHORT TO BATTERY 2 46 3 Remove wire Orn Wht55 3 1 Rerun System Test Analyzer Message EXTEND Wire Orn Wht 55 3 1 or Orn Wht 55 3 from X003 13 VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message EXTEND Possible Cause 4 1 10 VALVE SHORT TO BATTERY 3121203 T350 T500J SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 47 EXTEND 0 R SOLENOID SHORT TO GROUND
261. properly the analyzer will display the following MENU HELP PRESS ENTER PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS SYSTEM TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS view only If you press ENTER at the HELP PRESS ENTER display and a fault is present the analyzer display will scroll the fault across the screen If there was no fault detected the display will read HELP EVERYTHING OK If powered up at the ground station the display will read GROUND OK 9 203 T350 T500J 3121203 3121203 If ENTER is pressed again the display moves to the fol lowing display a N ED HELP 1 STARTUP 211 M E L Mn 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 1005 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 l
262. r Function Problem Level Up And Down Both Selected 2 2 001 0 0000000000000000000000000000050 ener etre Function Problem Lift Up And Down Both Selected Function Problem Outrigger Set And Stow Both Selected Function Problem Rotary Selector Switch m Function Problem Swing Left And Right Both Selected esses eerte nennen entrent Function Problem Telescope In And Out Both Selected sss eene eerte tenente enne Functions Locked Out Constant Data Version Improper sse etn nennen Functions Locked Out Platform Module Software Version Improper sess enne enne 2 78 Functions Locked Out Power Module Software Version Improper sss eere ener eret ener 2 79 Ground Alarm Short To Battery a pee eden den i tuta Ground Alarm Short To Ground Ground Module Failure Ref Voltage Out Of Range Ground Module Failure Vlow Fet Failure Hourmeter Short To Battery Jib Down Solenoid Open Circuit 3121203 T350 T500J A 9 INTRODUCTION Jib Down Solenoid Short To Battery 2 81 Jib Down Solenoid Short To Ground 2 81 Jib Up Solenoid Open Circuit 2 82 Jib Up Solenoid Short To Battery 2 82 Jib Up Solenoid Sh
263. r 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 3121203 350 T500J 7 184 SECTION 7 ELECTRICAL REFERENCE Service Voltage Reading A 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 WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA i CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 7 12 Connector Installation 7 185 T350 T500J 3121203 SECTION 7 ELECTRICAL REFERENCE 7 1 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly Figure 7 13 DT DTP Contact Installation 1 Grasp crimped contact about 25mm behind the contact barrel 2 Hold connector with rear grommet facing you 3 Push contact straight into connector grommet u
264. raulic 71 7 3 117 3 2 DC Powered Machine 4 3 117 3 3 DC Powered Machine Power 2 3 117 3 4 Drive Module Power 2223222 ee ip ER x eoe RR eR ee RAT den 3 120 3 5 Drive Sensor Reset asi u dilute dX Ei ds eder x M 3 120 3 6 Engine Powered Machine Hydraulic 3 122 3 7 Engine Powered Machine 3 122 3 8 Ground Module 1 3 122 3 9 Ignition Relay 2 3 123 3 10 Joystick 2 2 2 2 4 2 4 5 65 rn 3 124 3 11 Outrigger Switches All Set 3 124 3 12 Outrigger Switches All 3 125 3 13 Platform Module 1 3 126 3 14 Power Module Power 2 4 4 3 126 22 T350 T500J 3121208 5 3 15 3 16 3 17 SECTION 4 4 1 SECTION 3121203 Telescope Limit Switch Jes RS UNA Boa be RE e yee SIS d kr 3 127 Till SensQr
265. re tem test broken 4 1 1 otherwise goto step 2 92 2 No Goto step 2 92 2 2 92 2 Disconnectsolenoid atX079 Rerun System Test Analyzer Message JIB UP VALVE Replace solenoid and isolate wires OPEN CIRCUIT Analyzer Message JIB UP VALVE Goto step 2 92 3 SHORT TO BATTERY 2 92 3 Remove wire Blue 27 3 1 Rerun System Test Analyzer Message JIB UP VALVE Wire Blue 27 3 1 or Blue 27 3 shorted from X002 12 OPEN CIRCUIT to battery Repair or replace Analyzer Message JIB UP VALVE Possible Cause 4 1 10 SHORT TO BATTERY 2 82 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 93 JIB UP SOLENOID SHORT TO GROUND Distress Lamp 9 T500J MODELS ONLY Functions Disabled Jib Up ADE Code 3 3 Ground module feedback shows that Jib Up digital output may be shorted to ground or the solenoid may be defective from X002 12 OPEN CIRCUIT Analyzer Message JIB UP VALVE SHORT TO GROUND Step Pretest Instructions Test Result Corrective Action 2 93 1 DisconnectsolenoidatX079 Rerun System Test Analyzer Message JIB UP VALVE Repair Replace solenoid andisolate wires OPEN CIRCUIT Analyzer Message JIB UP VALVE Goto step 2 93 2 SHORT TO GROUND 2 93 2 Remove wire Blue 27 3 1 Rerun System Test Analyzer Message UP VALVE Wire Blue 27 3 1 or Blue 27 3 shorted to ground Repair or replace Possible Cause 4 1 10 2 94 JOYSTICK FAULTY X AXIS WIPER OUT OF RANGE
266. replace See Engine Owner s Manual for more information 4 1 30 Engine Voltage Rectifier may be defective Repair or replace See Engine Owner s Manual for more information 4 1 31 Optional Lift Hook harness may be defective Checkfor shorts opens and miswired connectors 4 1 32 The boom may be latched to the trailer Engage lift down telescope in and platform leveling until relieved of pressure unlatch boom andtry the function again 4 1 33 The ground control is being operated without enable Use enable and try again 4 1 34 The ground may be too uneven for proper outrigger Find amore even and or level area deployment and leveling 4 1 35 The ground module may not be mounted properly Level and properly mountthe ground module 3121203 350 T500J 4 129 SECTION 4 POSSIBLE CAUSES 4 1 POSSIBLE CAUSES Item Possible Cause Possible Solution 4 1 36 The outrigger switch or solenoid wires may be Assure thatthe outriggers are wired correctly swapped 4 1 37 Hydraulic fluid level may be low Check for leaks Fill hydraulic reservoir to recommended level 4 1 38 Personality may need to be increased to initiate flow Increase the personality using the analyzer as described in the Operators Manual 4 1 39 Pump may be defective Repair or replace 4 1 40 Oil filter may be restricted Replace oil filter 4 1 41 Cylinder may be
267. ric Machine 24 volts 24 Volts Electrical System Voltage Gas Machine 12 volts 12 Volts Gross Machine Weight Plattorm Empty 3330 Ibs 1510 kg 4750105 2155 kg DO NOT exceed axle rating or GVW rating 3121203 350 T500J 11 218 SECTION 11 SPECIFICATIONS Dimensional Data Table 11 1 Dimensional Data T350 T500J Overall Length Surge Brake 2 ball 20 ft5 in 6 2 m 26 ft 9 75 8 2 m Surge Brake 2 ball w rotator 20 ft 11 in 6 4 m Electric brake 2 ball 20 ft3 in 6 2 m 26 ft 8 in 8 1 m Electric brake 2 ball w rotator 20 ft9in 6 3 Surge Brake Combination 2 20ft11in 6 4m 26ft10 25in 8 2m Overall Height ANSI CSA 6 ft6 25 in 2m 6ft7 25in 2 Overall Height CE 7 ft0 5 in 2 1 Overall Width outriggers up 4ft11 25in 1 5m 5ft10 25 in 1 8 Overall Width outriggersdown 10ft5 5in 3 2m 12 7 75 3 9 ANSI Overall Width outriggers down 11 ft3in 3 4m 13 ft5 25 in 4 1m CE Fluid Capacities Table 11 2 Fuel Tank 1 6 Gal 6 01 Hydraulic Tank Filling Volume 4 4 Gallon 16 65 Liters Usable Volume 4 0 Gallon 15 1 Liters Engine Crankcase 1 16 qt 1 0 Liter Electric Power Unit Table 11 3 Electric Power Unit Specifications 740PSI 1500PSI 3000PSI 51 Bar 103 Bar 207 Bar Motor Power 3 0 kW 3 0 kW 3 0 kW Voltage 24VDC 24V
268. rompt indicating that it is currently testing this circuit 5 70 DRV RIGHT REV VALVE OPEN CIRCUIT DRIVE OPTION MACHINES ONLY The system test detected an open circuit in the drive right reverse valve circuit See 2 37 Drive Right Reverse Solenoid Open Circuit 5 71 DRV RIGHT REV VALVE SHORT TO BATTERY DRIVE OPTION MACHINES ONLY The system test detected a short to battery in the drive right reverse valve circuit See 2 38 Drive Right Reverse Solenoid Short To Battery 5 72 DRV RIGHT REV VALVE SHORT TO GROUND DRIVE OPTION MACHINES ONLY The system test detected a short to ground in the drive right reverse valve circuit See 2 39 Drive Right Reverse Solenoid Short To Ground 9 73 DUMP VALVE ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 74 DUMP VALVE OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open circuit in the dump valve circuit See 2 40 Dump Solenoid Open Circuit 3121203 T350 T500J 5 141 SECTION 5 SYSTEM TEST MESSAGES 5 75 DUMP VALVE SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the dump valve circuit See 2 41 Dump Solenoid Short To Battery 5 76 DUMP VALVE SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the dump valve circuit See 2 42 Dump Solenoid Short To Ground 5 77 ENABLE LAMP ON System test prompt to check that the platform enable lamp
269. ry indicator illumi Yes Press ENTER onthe analyzerto con nate properly tinuethe system test No Possible Causes 4 1 11 9 2 BATTERY 1 2 LAMP ON See 5 1 BATTERY 1 4 LAMP ON 5 3 BATTERY 3 4 LAMP ON See 5 1 BATTERY 1 4 LAMP ON 5 4 BATTERY FULL LAMP ON See 5 1 BATTERY 1 4 LAMP ON 5 5 BATTERY VOLTAGE TOO HIGH System test prompt that the battery voltage is too high See 2 3 Battery Voltage Too High System Shutdown 9 6 BATTERY VOLTAGE TOO LOW System test prompt that the battery voltage is too low See 2 4 Battery Voltage Too Low System Shutdown 5 7 CHECK CHOKE SWITCH System test response indicating that the module input from the choke switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure ENGINE POWERED MACHINES ONLY See 2 56 Function Problem Engine Choke Permanently Selected 9 8 CHECK GROUND PLATFORM SELECT System test response indicating that the ground module inputs for ground mode and platform mode are both or neither true A properly wired and functioning machine will show either ground or platform mode true not both See 2 97 Keyswitch Faulty 3121203 T350 T500J 5 133 SECTION 5 SYSTEM TEST MESSAGES 5 9 CHECK JIB DOWN SWITCH System test response indicating that the ground module input from the ground panel jib down switch was closed when the system test began testing switch inputs This may indicate a permanent switch cl
270. s FWD VALVE OPEN CIRCUIT Analyzer Message DRVRIGHT Goto step 2 35 3 FWD VALVE SHORT TO BAT TERY 2 35 3 Remove wire Orn 7 2 from Rerun System Test Analyzer Message DRVRIGHT Wire Orn 7 2 shorted to battery Repair 002 9 FWD VALVE OPEN CIRCUIT or replace Analyzer Message DRVRIGHT Possible Cause 4 1 10 FWD VALVE SHORT TO BAT TERY 2 56 T350 T500J 3121203 2 36 DRIVE RIGHT FORWARD SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES Drive module feedback shows that the drive right forward digital output may be shorted to ground or the relay may be defec tive DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Right Forward Step Pretest Instructions Test Result Corrective Action 2 36 1 DisconnectsolenoidatX068 Rerun System Test Analyzer Message DRV RIGHT Repair Replace solenoid and isolate wires FWD VALVE OPEN CIRCUIT Analyzer Message DRVRIGHT Goto step 2 36 2 FWD VALVE SHORT TO GROUND 2 36 2 Remove wire WHT YEL48 4 Rerun System Test Analyzer Message DRV RIGHT Wire WHT YEL 48 4 shorted to from X074 9 FWD VALVE OPEN CIRCUIT ground Repair or replace Analyzer Message DRVRIGHT Possible Cause 4 1 10 FWD VALVE SHORT TO GROUND 2 37 DRIVE RIGHT REVERSE SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Right
271. s are all set but the vehicle is tilted Lift up is prevented until all outriggers are either set or stowed While outriggers are stowed functions should only be used for aligning the boom for transport Functions Disabled Lift Up SYSTEM gt TILT gt 2DEG platform tilt LED illumi nated Step Pretest Instructions Test Result Corrective Action 2 113 1 Is the machine tilted more Yes Level the machine and try again than 2 degrees No Goto step 2 113 2 2 113 2 Analyzer DIAGNOSTICS gt Yes 3 16 Tilt Sensor Possible Causes 4 1 10 3121203 T350 T500J 2 93 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 114 LIFT UP SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Lift Up digital output may be disconnected or the solenoid may be defective Functions Disabled Lift Up Step Pretest Instructions Test Result Corrective Action 2 114 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 114 2 No Goto step 2 114 2 2 114 2 Disconnect solenoid at X084 Rerun System Test Analyzer Message LIFT UP Replace solenoid and or connector ShortX084 1 soc to VALVE SHORT TO GROUND 084 2 50 Analyzer Message LIFT UP Goto step 2 114 3 VALVE OPEN CIRCUIT 2 114 3 Replace X002 11 witha Rerun System Test Analyzer Message LIFT UP Wire Tan 3 3 1 or Tan 3
272. sage THROTTLE Goto step 2 158 3 HOLD SOLENOID OPEN CIR CUIT 2 158 3 Replace X003 11 with a Rerun System Test Analyzer Message THROTTLE Wire WHT YEL 48 3 broken Repair or jumperto X003 3 HOLD SOLENOID SHORT TO replace GROUND Analyzer Message THROTTLE Possible Cause 4 1 10 HOLD SOLENOID OPEN CIR CUIT 3121203 T350 T500J 2 113 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 159 THROTTLE HOLD SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Throttle Hold digital output may be shorted to battery or other function ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Throttle Hold Step Pretest Instructions Test Result Corrective Action 2 159 1 Run system test Do other functions fail sys Yes Possible Cause 4 1 15 4 1 1 other tem test wise go to step 2 159 2 No Goto step 2 159 2 2 159 2 Disconnect solenoid atX097 Rerun System Test Analyzer Message THROTTLE Replace solenoid and isolate wires HOLD SOLENOID OPEN CIR CUIT Analyzer Message THROTTLE step 2 159 3 HOLD SOLENOID SHORT TO BATTERY 2 159 3 Remove wire WHT YEL 48 3 Rerun System Test Analyzer Message THROTTLE Wire WHT YEL 48 3 shorted to bat from X003 11 HOLD SOLENOID OPEN CIR tery Repair or replace CUIT Analyzer Message THROTTLE Possible Cause 4 1 10 HOLD SOLENOID SHORT TO BATTERY
273. sconnect solenoid atX047 Rerun System Test Analyzer Message F R OUTRIG Replace solenoid and or connector ShortX047 1 soc to GER VALVE SHORT TO GROUND 047 2 50 Analyzer Message OUTRIG Goto step 2 51 3 GER VALVE OPEN CIRCUIT 2 51 3 Replace X003 6 with a jumper Rerun System Test Analyzer Message F R OUTRIG Wire Orn Red 49 6 or White wire to to X003 3 GER VALVE SHORT TO GROUND Analyzer Message F R OUTRIG GER VALVE OPEN CIRCUIT X047 broken Repair or replace Possible Cause 4 1 10 2 52 FRONT RIGHT 0 R SOLENOID SHORT TO BATTERY Distress Lamp 9 may be defective ADE Code 3 3 Ground module feedback shows that the Front Right Outrigger Valve digital output may be shorted to battery or the solenoid Functions Disabled Front Right O R Step Pretest Instructions Test Result Corrective Action 2 52 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 52 2 No Goto step 2 52 2 2 52 2 Disconnect solenoid atX047 Rerun System Test Analyzer Message F R OUTRIG Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message F R OUTRIG Goto step 2 52 3 GER VALVE SHORT TO BAT TERY 2 52 3 Remove wire Orn Red 49 6 Rerun System Test Analyzer Message F R OUTRIG Wire Orn Red 49 6 or White wire to from X003 6 GER VALVE OPEN CIRCUIT X04
274. scope In Telescope Out Step Pretest Instructions Test Result Corrective Action 2 139 1 Is the platform elevated Yes Goto step 2 139 2 No See 3 17 Transport Limit Switch 2 139 2 Is the machine tilted more Yes The machine will operate at lower than 2 degrees speed while tilted and elevated No Goto step 2 139 3 2 139 3 ANALYZER gt DIAGNOS 5 See 3 16 Tilt Sensor 5 gt SYSTEM gt TILT yo Possible Causes 4 1 10 gt 2 DEG platform tilt LED illuminated 2 140 RUNNING AT CREEP UNSET amp ABOVE ELEVATION Distress Lamp 2 ADE Code None All function speeds are limited to creep because the outriggers are not completely set and the platform is elevated Functions in Creep Mode Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Step Pretest Instructions Test Result Corrective Action 2 140 1 Is the platform elevated Yes Goto step 2 140 2 No See 3 17 Transport Limit Switch 2 140 2 Are outriggers unset Yes Retract lower the boom and level the machine before trying again No See 3 11 Outrigger Switches All Set 2 104 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 141 START SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Engine Start digital output may be disconnected or the solenoid may be defective The start solenoid fuse should be checked ENGINE POW
275. ses 4 1 18 pull the emergency stop Selected still present Switch 2 74 3 Remove X014 19 pin from Is fault Function Problem Yes Goto step 2 74 4 X014 Place key switch in Swing Left Permanently No Possible Causes Short in White 21 2 ground position and pullthe Selected still present wire emergency stop switch 2 74 4 Place key switch in ground Measured voltage at Yes Possible Causes Short in White 21 2 position and pull the emer X004 34 Vbatt 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 75 FUNCTION PROBLEM SWING RIGHT PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground swing right switch was closed when the machine was powered The switch could be accidentally held mechan ically stuck or electrically shorted Functions Disabled at Ground Only Swing Right Step Pretest Instructions Test Result Corrective Action 2 75 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 75 2 2 75 2 DisconnectX024 Placekey Is fault Function Problem Yes Goto step 2 75 3 switch in ground position and Swing Right Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 75 3 Remove X014 18 pin from Is fault Function Problem Yes Goto step 2 75 4 X014 Place key switch in Swing Right Permanently No Possible Causes Short in White 22 2 ground position and pullthe Selected still present
276. shorted to Analyzer Message R L OUTRIG GER VALVE SHORT TO GROUND ground Repair or replace Possible Cause 4 1 10 2 100 T350 T500J 3121203 SECTION 2 TROUBLESHOOTING FAULT MESSAGES 2 132 REAR RIGHT SOLENOID OPEN CIRCUIT Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Rear Right Outrigger digital output may be disconnected or the solenoid may be defective Functions Disabled Rear Right O R jumperto X003 3 Step Pretest Instructions Test Result Corrective Action 2 132 1 Run system test Do other functions failsys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 132 2 No Goto step 2 132 2 2 132 2 Disconnect solenoid at X049 Rerun System Test Analyzer Message R R OUTRIG Replace solenoid and or connector ShortX049 1 soc to GER VALVE SHORT TO GROUND 049 2 50 Analyzer Message R R OUTRIG Goto step 2 132 3 GER VALVE OPEN CIRCUIT 2 132 3 Replace X003 10 with a Rerun System Test Analyzer Message R R OUTRIG Wire Orn Red 49 8 or White wire GER VALVE SHORT TO GROUND Analyzer Message R R OUTRIG GER VALVE OPEN CIRCUIT between X020 and X049 broken Repair or replace Possible Cause 4 1 10 2 133 REAR RIGHT 0 R SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Rear Right Outrigger digital output may be shorted to ba
277. sor calibra tion 2 13 3 Has a tilt sensor calibration Yes Possible Causes 4 1 10 been run recently No Properly secure the ground module with the machine resting on a level surface Run the tilt sensor calibra tion 2 46 T350 T500J 3121203 2 14 CHOKE HOLD SOLENOID OPEN CIRCUIT ADE Code 3 3 Ground module feedback shows that the Engine Choke Hold digital output may be disconnected from solenoid or the sole Distress Lamp 9 noid may be defective SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES ENGINE POWERED MACHINES ONLY Functions Disabled Engine Powered Machines Only Engine Choke Hold Step Pretest Instructions Test Result Corrective Action 2 14 1 Runsystem test Do other functions fail sys Yes Check 4 1 15 4 1 1 otherwise go to tem test step 2 14 2 No Goto step 2 14 2 2 14 2 Disconnect solenoid atX098 Rerun System Test Analyzer Message CHOKE Replace solenoid and or connector On harness end short X098 HOLD SOLENOID SHORT TO WHT YEL 48 5 to X098 GROUND BLACK wire Analyzer Message CHOKE Goto step 2 14 3 HOLD SOLENOID OPEN CIR CUIT 2 14 3 Replace X003 7 with a jumper Rerun System Test Analyzer Message CHOKE Wire WHT YEL 48 5 broken Repair or to X003 3 HOLD SOLENOID SHORT TO replace GROUND Analyzer Message CHOKE Possible Cause 4 1 10 HOLD SOLENOID OPEN CIR CUIT 2 15 CHOKE HOLD SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE
278. st Do other functions fail sys Yes Possible Cause Black Ground wire tem test broken 4 1 1 otherwise go to step 2 130 2 No Goto step 2 130 2 2 130 2 Disconnect solenoid atX048 Rerun System Test Analyzer Message R L OUTRIG Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message R L OUTRIG Goto step 2 130 3 GER VALVE SHORT TO BAT TERY 2 130 3 Remove wire Orn Red 49 7 Rerun System Test Analyzer Message R L OUTRIG Wire Orn Red 49 7 or White wire from X003 8 GER VALVE OPEN CIRCUIT between X020 and X048 shorted to Analyzer Message R L OUTRIG GER VALVE SHORT TO BAT TERY 2 131 REAR LEFT 0 R SOLENOID SHORT TO GROUND battery Repair or replace Repair Replace wire Orn Red 49 7 Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Rear Left Outrigger digital output may be shorted to ground or the solenoid may be defective Functions Disabled Rear Left O R Step Pretest Instructions Test Result Corrective Action 2 131 1 Disconnect solenoid 1 048 Rerun System Test Analyzer Message R L OUTRIG Repair Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message R L OUTRIG Goto step 2 131 2 GER VALVE SHORT TO GROUND 2 131 2 Remove wire Orn Red 49 7 Rerun System Test Analyzer Message R L OUTRIG Wire Orn Red 49 7 or White wire from X003 8 GER VALVE OPEN CIRCUIT between X020 and X048
279. step 2 63 2 2 63 2 DisconnectX034 Placekey Is fault Function Problem Yes Goto step 2 63 3 switch in ground position and Level Down Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 63 3 Remove X014 26 pin from Is fault Function Problem Yes Goto step 2 63 4 X014 Place key switch in ground position and pull the emergency stop switch 2 63 4 Place key switch in ground Measured voltage atX004 5 Yes position and pull the emer Vbatt gency stop switch No Level Down Permanently Possible Causes Short in Pink 26 2 Selected still present wire Possible Causes Short in Pink 26 2 1 wire 4 1 10 Possible Causes 4 1 10 2 64 FUNCTION PROBLEM LEVEL UP AND DOWN BOTH SELECTED Distress Lamp 9 ADE Code 2 3 The digital inputs from both level up and level down ground panel switches are active Functions Disabled at Ground Only Level Up Level Down Step Pretest Instructions Test Result Corrective Action 2 64 1 Disconnect X034 Pull the Is fault Function Problem Yes Go to step 2 64 2 ground emergency stop Level Up And Down Both No Possible Causes 4 1 18 switch and place key switch in Selected still present the ground position 2 64 2 DisconnectX014 Hold the Measure continuity between Yes Possible Causes Short in Pink 25 2 enable switch 014 27 and X014 1 pin wire No Goto step 2 64 3 2
280. t Both Selected 2 75 Function Problem Swing Left Permanently 2 76 Function Problem Swing Right Permanently Selected 2 76 Function Problem Telescope In And Out Both Selected 2 77 Function Problem Telescope In Permanently 2 77 Function Problem Telescope Out Permanently Selected 2 78 Functions At Cutback Power Module Current 2 78 Functions Locked Out Constant Data Version 2 78 Functions Locked Out Platform Module Software Version 2 78 Functions Locked Out Power Module Software Version 2 79 Ground Alarm Short To 2 79 Ground Alarm Short To 2 79 Ground Module Failure Ref Voltage Out 2 80 Ground Module Failure Vlow Fet 2 80 Hourmeter Short To Battery 2 80 Jib Down Solenoid Open 30 2 80 Jib Down Sol
281. t Corrective Action 3 9 1 Pullthe ground emergency Check Voltage on X009 87 OV Goto step 3 9 2 stop switch and place Key Vbatt Possible Causes 4 1 6 4 1 7 Switch in the OFF position 3 9 2 Pullthe ground emergency Check Voltage on X009 86 OV Go to step 3 9 4 stop switch and place key Vbatt Goto step 3 9 3 switch in ground position 3 9 3 Pull the ground emergency Check Voltage on X009 30 OV Go to step 3 9 8 stop switch and place key Vbatt Repair Replace Ignition Relay switch in ground position 3 9 4 Pull the ground emergency Check Voltage at X007 3 OV Goto step 3 9 5 Stop switch and place key Vbatt Repair Replace diode at X009 86 switch in ground position 3 9 5 Pullthe ground emergency Check Voltage at X014 16 0 Goto step 3 9 6 stop switch and place key Switch in ground position Vbatt Repair open in YEL RED 2 5 or YEL RED 2 10 3 9 6 Pullthe ground emergency Check Voltage at X026 3 0 Goto step 3 9 7 Stop switch and place key Vbatt Repair open in YEL RED 2 5 Switch in ground position 3 9 7 Pullthe ground emergency Check Voltage at x026 2 0 Goto step 3 9 8 Stop switch and place key Vbatt Repair Replace key switch switch in ground position 3 9 8 Pullthe ground emergency Check Voltage at X037 ground OV Possible Causes 4 1 65 stop switch and place key EMS switch Otherwise go to step 3 9 9 switch in ground position Vbatt Repair open in YEL RED 2 1 or YEL RED 2 2 3 9 9 Check Voltage on X013 1 0 Possible Causes 4 1 64 Otherwise
282. t is currently testing this circuit 5 153 RETRACT VALVE OPEN CIRCUIT The system test detected an open in the Retract Outriggers valve circuit See 2 135 Retract O R Solenoid Open Circuit 5 154 RETRACT VALVE SHORT TO BATTERY The system test detected a short to battery in the Retract Outriggers valve circuit See 2 136 Retract O R Solenoid Short To Battery 5 155 RETRACT VALVE SHORT TO GROUND The system test detected a short to ground in the Retract Outriggers valve circuit See 2 137 Retract O R Solenoid Short To Ground 5 150 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 9 156 R L 0 R VALVE System test prompt indicating that it is currently testing this circuit 9 157 R L OUTRIGGER LAMP ON System test prompt to check that the ground Rear Left Outrigger lamp is illuminated Step Pretest Instructions Test Result Corrective Action 5 157 1 Does this indicator illuminate Yes Press ENTER onthe analyzerto con properly tinuethe system test No Goto step 5 157 2 5 1572 Dootherindicators illuminate Yes Possible Causes Check wiring Instead No Goto step 5 157 3 5 157 3 Voltage atX030 3 12VDC Yes Possible Causes 4 1 27 No Goto step 5 157 4 5 157 4 Voltage atX004 29 Yes Possible Causes Check wires Brn 12VDC Wht 47 24 Brn Wht 47 24 1 and Black No Possible Causes 4 1 10 9 158 R L OUTRIGGER VALVE OPEN CIRCUIT The system test detected an open in the Rear Left Outriggers va
283. tart Permanently No Possible Causes Shortin Wht Yel 48 ground position and pullthe Selected still present 1 wire emergency stop switch 2 59 4 Place key switch in ground Measured voltage at X004 4 Yes Possible Causes Short in Wht Yel 48 position and pull the emer Vbatt 1 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 60 FUNCTION PROBLEM JIB DOWN PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground jib down switch was closed when the machine was powered The switch could be accidentally held mechani cally stuck or electrically shorted T500J MODELS ONLY Functions Disabled at Ground Only Jib Down Step Pretest Instructions Test Result Corrective Action 2 60 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 60 2 2 60 2 DisconnectX032 Placekey Is fault Function Problem Yes Goto step 2 60 3 switch in ground position and Jib Down Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present nz switch 2 60 3 Remove X014 24 pin from Is fault Function Problem Yes Goto step 2 60 4 X014 Place key switch in Jib Down Permanently No Possible Causes Short in Blue 28 2 ground position and pullthe Selected still present wire emergency stop switch 2 60 4 Place key switch in ground Measured voltage atX004 8 Yes Possible Causes Shortin Blue 28 2 1 position and pull the emer Vbatt wire
284. te a permanent switch closure See 2 68 Function Problem Lift Up Permanently Selected 9 15 CHECK OUTRIGGER SET SWITCH System test response indicating that the ground module input from the ground outrigger set switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure See 2 70 Function Problem Outrigger Set Permanently Selected 5 16 CHECK OUTRIGGER STOW SWITCH System test response indicating that the ground module input from the ground outrigger stow switch was closed when the system test began testing switch inputs This may indicate a permanent switch closure See 2 71 Function Problem Outrigger Stow Permanently Selected 5 134 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES CHECK POWER amp CAN WIRING TO DRIVE MODULE DRIVE OPTION MACHINES ONLY System test cannot communicate with the drive module See 2 7 CANBUS Failure Drive Module 9 17 CHECK POWER amp CAN WIRING TO PLATFORM System test cannot communicate with the platform module See 2 8 CANBUS Failure Platform Module 5 18 CHECK POWER amp CAN WIRING TO POWER MODULE ELECTRIC POWERED MACHINES ONLY System test cannot communicate with the power module See 2 8 CANBUS Failure Platform Module 9 19 CHECK START SWITCH System test response indicating that the ground module input from the ground start switch was closed when the system test began testing switch inputs This may indicate a permanent switch c
285. ted amp Above Elevation 2 104 0 Running At Creep Unset amp Above Elevation 2 104 2 2 1 KeyswilchFaully eet HEU eR ER Se n ai de e UR UE VR UD XU 2 1 Platform Position Detection Faulty seen nennen tentent treni tri 00 nennen 2 2 Function Locked Out Joystick Not Centered At Startup 2 2 Function Locked Out Trigger Permanently Closed 2 2 Function Problem Engine Choke Permanently Selected 2 2 Function Problem Engine Start Permanently Selected 2 2 Function Problem Rotary Selector Switch 2 2 Joystick Faulty X axis Wiper Out Of Range sess 2 2 Joystick Faulty Y axis Wiper Out Of Range 2 2 Trigger Closed Too Long While In Neutral 2 er eerte Pee pe 2 3 Function Problem Engine Choke Permanently Selected 2 3 Function Problem Engine Start Permanently Selected 2 3 Function Problem Jib Down Permanently Selected 2 3 Function Problem Jib Up And Down Both Selected 2 3 Function Problem Jib Up Permanently Selected 2 3 Function Problem Level Down Permanently Selected 2 3 Function Problem Level Up And Down
286. tem events Tilted Tilt Sensor Not Calibrated etc Before investigating Pump System issues examine the JLG Analyzer s HELP Menu while attempting to Lift Up from Ground Mode Refer to Section 2 Troubleshooting by Fault Messages for explanations of the Help Messages Power Module Diagnostic Issues The Power Module executes a self test during every power up to ensure proper functionality If a Diagnostic Issue is detected the Power Module will not energize the Line Contactor Instead it will flash the Green LED Open Circuit between M1 Terminal and Pump Motor Positive Terminal This issue will prevent the Pump Motor from operating Under DIAGNOSTICS gt PUMP the JLG Analyzer will show PUMP PWM 100926 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode The voltage measured between the Pump Motor Positive Terminal and Ground Reference should be 24V If it is not examine the cable between the terminal and the Power Module compartment Inspect crimps for corrosion and ensure that bolted connections are tight Ensure that the cable is not crushed Open Circuit between Pump Motor Negative Terminal and M2 Terminal This issue will prevent the Pump Motor from operating Under DIAGNOSTICS gt PUMB the JLG Analyzer will show PUMP PWM 100 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode After ensuring there is not an Open Circuit between the M1 Terminal and Pump Motor Positive Terminal check that the volt age measured between
287. tery or other function T500J MODELS ONLY Functions Disabled Jib Down Step Pretest Instructions Test Result Corrective Action 2 89 1 Disconnect solenoid atX056 Rerun System Test Analyzer Message JIB DOWN Repair Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message JIBDOWN Goto step 2 89 2 VALVE SHORT TO BATTERY 2 89 2 Remove wire Blue 28 3 1 Rerun System Test Analyzer Message Wire Blue 28 3 1 or Yel Blk boom wire from X002 20 VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message JIB DOWN Possible Cause 4 1 10 VALVE SHORT TO BATTERY 2 90 JIB DOWN SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that Jib Down PWM output may be shorted to ground or the solenoid may be defective T500J MODELS ONLY Functions Disabled Jib Up Step Pretest Instructions Test Result Corrective Action 2 90 1 Disconnect solenoid atX056 Rerun System Test Analyzer Message JIB DOWN Repair Replace solenoid and isolate wires VALVE OPEN CIRCUIT Analyzer Message JIBDOWN Gotostep 2 90 2 VALVE SHORT TO GROUND 2 90 2 Remove wire Blue 28 3 1 Rerun System Test Analyzer Message JIB DOWN Wire Blue 28 3 1 or Blue 28 3 shorted from X002 20 VALVE OPEN CIRCUIT to ground Repair or replace Analyzer Message JIBDOWN Possible Cause 4 1 10 VALVE SHORT TO GROUND 3121203 T3
288. tion Problem Jib Up Permanently Selected 2 69 Function Problem Level Down Permanently 2 70 Function Problem Level Up And Down Both 2 70 T350 T500J 3121203 5 2 65 2 66 2 67 2 68 2 69 2 70 2 71 2 72 2 73 2 74 2 75 2 76 2 77 2 78 2 79 2 80 2 81 2 82 2 83 2 84 2 85 2 86 2 87 2 88 2 89 2 90 2 91 2 92 2 93 2 94 2 95 2 96 2 97 2 98 2 99 2 100 2 101 2 102 2 103 2 104 2 105 2 106 2 107 2 108 2 109 2 110 2 111 2 112 2 113 2 114 2 115 2 116 2 117 2 118 2 119 2 120 2 121 2 122 3121203 Function Problem Level Up Permanently Selected 2 71 Function Problem Lift Down Permanently Selected 2 71 Function Problem Lift Up And Down Both Selected 2 72 Function Problem Lift Up Permanently Selected 2 72 Function Problem Outrigger Set And Stow Both Selected 2 73 Function Problem Outrigger Set Permanently Selected 2 73 Function Problem Outrigger Stow Permanently Selected 2 74 Function Problem Rotary Selector Switch 2 74 Function Problem Swing Left And Righ
289. tivated or check the switch wiring 5 130 O R SET LAMP ON System test prompt to check that the platform outriggers set lamp is illuminated If lamp is illuminating properly press ENTER on the analyzer to continue the system test Otherwise see possible cause 4 1 11 5 131 0 R STOW CL System test response indicating that the ground Outrigger Stow switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 132 OP CHOKE System test prompt to open the ground panel engine Choke switch Release the switch at the ground panel to test the switch input and continue the test 5 133 OP CHOKE SWITCH System test prompt to open the platform panel engine Choke switch Release the switch at the platform panel to test the switch input and continue the test 5 134 OP DRIVE SWITCH System test prompt to open the platform panel drive switch Release the switch at the platform panel to test the switch input and continue the test 5 135 OP JIB DOWN System test prompt to open the ground panel Jib Down switch Release the switch at the ground panel to test the switch input and continue the test 5 136 OP JIB UP System test prompt to open the ground panel Jib Up switch Release the switch at the ground panel to test the switch input and continue the test 5 148 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 137 LEVEL DOWN System test prompt to open th
290. tiye Preverted Dift Down iac nier ER pe re eb nd E 2 5 Drive Prevented Stow Outriggers o edere eo bee aee pha nee ba m a e ae pa HO dod dede iret ida 2 5 Drive Prevented Telescope In sisse eene entretenir entrent tet 2 5 Lift Down Prevented Tele In First nennen senken ene inp sehe dne te Ge ote ica e cesa 2 5 Lift Up amp Tele Out Prevented Tilted amp Above Elevation 2 91 2 5 Lift Up amp Tele Out Prevented Tilted Unset amp Above Elevation esses ener enne 2 92 2 5 Lift Up amp Tele Out Prevented Unset amp Above Elevation 2 92 2 5 Lift Up Prevented Check Outriggers 2 92 2 5 Lift Up Prevented Lift Down Then Set Outriggers 2 93 2 5 Lift Up Preyented Tilted nn et 2 93 2 5 Model Changed Hydraulics Suspended Cycle EMS 2 95 2 5 Outrigger Stow Prevented Tele In First 2 97 2 5 Outriggers Prevented Elev ted en es erinnere ne sorte eae ue SE ocean 2 97 3121203 T350 T500J A 11 INTRODUCTION 2 5 Tele Out Prevented Set Outriggers 2 5 Pele Out Prevented Tilted ee cete ts recon eens 3 3 3 Choke Hold Solenoid Open Circuit 3 3 Choke Hold Solenoid Short To Battery 3 3 Choke Hold
291. trically shorted T500J MODELS ONLY Functions Disabled at Ground Only Jib Up Step Pretest Instructions Test Result Corrective Action 2 62 1 Is the switch mechanically Yes Repair or replace the switch stuck No Go to step 2 62 2 2 62 2 DisconnectX032 Placekey Is fault Function Problem Yes Goto step 2 62 3 switch in ground position and Jib Up Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 62 3 Remove X014 25 pin from Is fault Function Problem Yes Go to step 2 62 4 014 Place key switch Jib Up Permanently No Possible Causes Shortin Blue 27 2 ground position and pullthe Selected still present wire emergency stop switch 2 62 4 Place key switch in ground Measured voltage at Yes Possible Causes Shortin Blue 27 2 1 position and pull the emer X004 19 Vbatt wire 4 1 10 gency stop switch No Possible Causes 4 1 10 3121203 T350 T500J 2 69 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 63 FUNCTION PROBLEM LEVEL DOWN PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground level down switch was closed when the machine was powered The switch could be accidentally held mechan ically stuck or electrically shorted Functions Disabled at Ground Only Level Down Step Pretest Instructions Test Result Corrective Action 2 63 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto
292. ts to the module being tested ground or plat form 5 25 CHOKE CL ENGINE POWERED MACHINES ONLY System test response indicating that the ground choke switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 26 CHOKE HOLD ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 27 CHOKE HOLD SOLENOID OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open circuit in the choke hold circuit See 2 14 Choke Hold Solenoid Open Circuit 5 28 CHOKE HOLD SOLENOID SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the choke hold circuit See 2 15 Choke Hold Solenoid Short To Battery 5 29 CHOKE HOLD SOLENOID SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the choke hold circuit See 2 16 Choke Hold Solenoid Short To Ground 5 30 CHOKE PULL ENGINE POWERED MACHINES ONLY System test prompt indicating that it is currently testing this circuit 5 31 CHOKE PULL RELAY OPEN CIRCUIT ENGINE POWERED MACHINES ONLY The system test detected an open circuit in the choke pull circuit See 2 17 Choke Pull Relay Open Circuit 5 136 T350 T500J 3121203 SECTION 5 SYSTEM TEST MESSAGES 5 32 CHOKE PULL RELAY SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the choke p
293. ttery or other function Functions Disabled Rear Right O R Step Pretest Instructions Test Result Corrective Action 2 133 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 133 2 No Goto step 2 133 2 2 133 2 Disconnect solenoid atX049 Rerun System Test Analyzer Message R R OUTRIG Replace solenoid and isolate wires GER VALVE OPEN CIRCUIT Analyzer Message R R OUTRIG Go to step 2 133 3 GER VALVE SHORT TO BAT TERY 2 133 3 Remove wire Orn Red 49 8 Rerun System Test Analyzer Message R R OUTRIG Wire Orn Red 49 8 or White wire from X003 10 GER VALVE OPEN CIRCUIT between X020 and X049 shorted to battery Repair or replace Analyzer Message R R OUTRIG Repair Replace wire Orn Red 49 8 GER VALVE SHORT TO BAT TERY 3121203 T350 T500J 2 101 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 134 REAR RIGHT SOLENOID SHORT TO GROUND Distress Lamp 9 be defective ADE Code 3 3 Ground module feedback shows that the Rear Right Outrigger digital output may be shorted to ground or the solenoid may Functions Disabled Rear Right O R Analyzer Message R R OUTRIG GER VALVE SHORT TO GROUND Step Pretest Instructions Test Result Corrective Action 2 134 1 Disconnect solenoid at X049 Rerun System Test Analyzer Message R R OUTRIG Repair Replace solenoid andisolat
294. tuck No Goto step 2 58 2 2 58 2 DisconnectX065 Placekey Is fault Function Problem Yes Goto step 2 58 3 switch in the platform position Engine Start Permanently N 0 Possible Causes 4 1 18 andpullthe emergency stop Selected still present switches 2 58 3 Place key switch in the plat Measured voltage at Yes Possible Causes Short in Wht Yel 48 form position and pull the X060 13 Vbatt 1 wire 4 1 11 emergency stop switches No Possible Causes 4 1 11 3121203 T350 T500J 2 67 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGES 2 59 FUNCTION PROBLEM ENGINE START PERMANENTLY SELECTED Distress Lamp 1 ADE Code 2 3 The ground engine start switch was closed when the machine was powered The switch could be accidentally held mechanically stuck or electrically shorted ENGINE POWERED MACHINES ONLY Functions Disabled Engine Start Engine Throttle Pull Engine Throttle Hold Step Pretest Instructions Test Result Corrective Action 2 59 1 Is the switch mechanically Yes Repair or replace the switch Stuck No Goto step 2 59 2 2 59 2 DisconnectX036 Placekey Isfault FunctionProblem Yes Goto step 2 59 3 switch in ground position and Engine Start Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present Switch 2 59 3 Remove X014 14 pin from Is fault Function Problem Yes Goto step 2 59 4 X014 Place key switch in Engine S
295. ule detected an error in the Power Wiring for the Pump Alternately the Power Module has failed a self test Check wiring and motor or replace the Power Module Re cycle power to clear difficulty 3 Flashes on Power Module may indicate a Short Circuit in the Armature Wiring or a faulty Power Module No Flashes on Power Module may indicate a faulty Power Module Functions Disabled Electric Powered Machines Only Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Check all power wiring see Power Module Electrical Evaluation and Pump Motor Electrical Evaluation in 3 3 DC Powered Machine Power Module Possible Cause Pump Wiring Shorted 4 1 39 4 1 12 2 126 POWER MODULE FAILURE INTERNAL ERROR Distress Lamp 9 ADE Code 9 9 The Power Module detected an internal error Alternately the Power Module has failed a self test Check all power wiring see Power Module Electrical Evaluation and Pump Motor Electrical Evaluation in 3 3 DC Powered Machine Power Module Re cycle power to clear difficulty Functions Disabled Electric Powered Machines Only Lift Up Swing Left Swing Right Telescope In Telescope Out Jib Up Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R Possible Causes Line Contactor solenoid is Open Circuit in Power
296. ull circuit See 2 18 Choke Pull Relay Short To Battery 5 33 CHOKE PULL RELAY SHORT TO GROUND ENGINE POWERED MACHINES ONLY The system test detected a short to ground in the choke pull circuit See 2 19 Choke Pull Relay Short To Ground 5 34 CHOKE SWITCH CL ENGINE POWERED MACHINES ONLY System test response indicating that the platform choke switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 35 CL CHOKE ENGINE POWERED MACHINES ONLY System test prompt to close the ground panel choke switch Push the choke button at the ground panel to test the choke switch input and continue the test 9 36 CL CHOKE SWITCH ENGINE POWERED MACHINES ONLY System test prompt to close the platform panel choke switch Push the choke button at the platform panel to test the choke switch input and continue the test 9 37 CL DRIVE SWITCH DRIVE OPTION MACHINES ONLY System test prompt to close the platform panel drive switch Push the drive button at the platform panel to test the drive switch input and continue the test 5 38 CL JIB DOWN T500J ONLY System test prompt to close the ground panel Jib down switch Push the Jib switch at the ground panel to the Down position to test the switch input and continue the test 9 39 CL JIB UP T500J ONLY System test prompt to close the ground panel Jib up switch Push the Jib switch at the ground panel to the Up position to test th
297. unctions Disabled at Platform Only Lift Up Lift Down Swing Left Swing Right Telescope In Telescope Out Jib Up Jib Down Level Up Level Down Front Left O R Front Right O R Rear Left O R Rear Right O R Set Extend O R Stow Retract O R 2 116 Step Pretest Instructions Test Result Corrective Action 2 164 1 Was the switch held for more Yes Release switch and try again than 7 seconds No Goto step 2 164 2 2 164 2 Switch Key to Platform Mode Analyzer DIAGNOSTICS gt LIFT SWING SEL Possible Cause 4 1 19 4 1 18 and pull the ground and plat PLATFORM gt Shorted Yel Red2 17 4 1 22 4 1 11 form emergency stop LEVEL SELECT See 2 72 Function Problem Rotary switches Turn the select Selector Switch switch to the Lift Swing Posi tion Do NOT hold the joystick JIB TELE SELECT See 2 72 Function Problem Rotary Selector Switch TRIGGER OPEN 2 72 Function Problem Rotary Selector Switch T350 T500J 3121203 SECTION 3 COMPONENT CHECKS 3 1 DC POWERED MACHINE HYDRAULIC PUMP SECTION 3 COMPONENT CHECKS Step Pretest Instructions Test Result Corrective Action 3 1 1 Voltage between B and B Yes Goto step 3 1 2 102andX101 Vbatt See3 2 DC Powered Machine Power 3 1 2 Engage enable and lift up Voltage between M1andM2 Yes Goto step 3 1 3 switch X1 03andX1 04 Vbatt No Possible Causes 4 1 12 3 1 3
298. val 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 CONTACT REMOVAL TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 7 18 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 7 187 T350 T500J 3121203 7 8 TRAILER WIRING AUSTRALIAN amp CE SPECS WITH ELECTRIC BRAKES SECTION 7 ELECTRICAL REFERENCE CHARGER RED TURN IN SIGNAL RED e SIDE WR RIGHT Ba AMBER BRAKE 4 H RTAL EJ LIGHT zn m E Boot ge 18 5 a AL LIGHT a AND GD WHITE 6D 80 WHITE WHITE WHITE TM Brown m Mm BROWN BROWN BROWN U gt YELLOW YELLOW YELLOW Bf RT GREEN RT RT GREEN GREEN GREEN 1 CENTER 1 1 BRAKE LIGHT Se 5 Bog ED ez E 5 BLACK
299. ve Option Machines Only Drive Right Forward Step Pretest Instructions Test Result Corrective Action 2 34 1 Runsystem test Do other functions fail sys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise Goto step 2 34 2 No Goto step 2 34 2 2 34 2 ShortX068 1 soc to Rerun System Test Analyzer Message DRV RIGHT Replace solenoid and or connector X068 2 soc FWD VALVE SHORT TO GROUND Analyzer Message DRVRIGHT Gotostep 2 34 3 FWD VALVE OPEN CIRCUIT 2 34 3 Replace X074 9 with ajumper Rerun System Test Analyzer Message DRV RIGHT Wire Orn 7 2 broken Repair or replace to X074 2 FWD VALVE SHORT TO GROUND Analyzer Message DRV RIGHT Possible Cause 4 1 10 FWD VALVE OPEN CIRCUIT 2 35 DRIVE RIGHT FORWARD SOLENOID SHORT TO BATTERY Distress Lamp 9 be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Right Forward ADE Code 3 3 Drive module feedback shows that the Drive Right Forward Valve PWM output may be shorted to battery or the solenoid may Step Pretest Instructions Test Result Corrective Action 2 35 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise 0010 step 2 41 2 No Goto step 2 35 2 2 35 2 Disconnectsolenoid atX068 Rerun System Test Analyzer Message RIGHT Replace solenoid and isolate wire
300. verse Step Pretest Instructions Test Result Corrective Action 2 28 1 Runsystemtest Do other functions fail sys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise Goto step 2 28 2 No Goto step 2 28 2 2 28 2 ShortX069 1 soc to Rerun System Test Analyzer Message DRV LEFT Replace solenoid and or connector X069 2 soc REV VALVE SHORT TO GROUND Analyzer Message DRV LEFT Goto step 2 28 3 REV VALVE OPEN CIRCUIT 2 28 3 Replace X074 8 with ajumper Rerun System Test Analyzer Message DRV LEFT Orn 8 4 wire broken Repair or replace to X074 2 REV VALVE SHORT TO GROUND Analyzer Message DRV LEFT Possible Cause 4 1 10 REV VALVE OPEN CIRCUIT 2 29 DRIVE LEFT REVERSE SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Drive module feedback shows that the Drive Left Reverse Valve PWM output may be shorted to battery or the solenoid may be defective DRIVE OPTION MACHINES ONLY Functions Disabled Drive Option Machines Only Drive Left Reverse Step Pretest Instructions Test Result Corrective Action 2 29 1 Run system test Do other functions fail sys Yes Possible Cause Black ground wire tem test broken 4 1 1 otherwise go to step 2 29 2 No Goto step 2 29 2 2 29 2 Disconnectsolenoid atX069 Rerun System Test Analyzer Message DRV LEFT Replace solenoid and isolate wires REV VALVE OPEN CIRCUIT Analyzer Message DRV LEFT Goto step 2 29 3 REV VALVE
301. witch No See 1 2 Pump Motor Will Not Operate DC Powered Models Gas Is engine running athigh Yes Goto step 1 20 3 idle No See 1 8 Engine High Idle Inoperative Engine Models 1 20 3 Install a0 to 5000 PSI 345 Engage the enable and Level Above Min Level Down Pressure Goto step 1 20 5 bar pressure gauge at the Down switch Check the pres psi bar manifold G port Sure Below Min Level Down Pressure Goto step 1 20 4 psi bar 1 20 4 Plumb a 0 to 5000 PSI 345 Engage the enable and Level Above Min Level Down Pressure Possible Causes 4 1 38 4 1 45 bar pressure gaugeintothe Down switch Check pressure psi bar 4 1 74 4 1 40 4 1 10 4 1 43 manifold P port at manifold P port Below Min Level Down Pressure Possible Causes 4 1 46 4 1 47 psi bar 4 1 74 4 1 45 4 1 39 4 1 10 1 20 5 Putboom in transport and Engage the enable and Level Above Min Level Down Pressure Possible Causes 4 1 49 4 1 48 activate Platform Level Upto Down switch Check pressure psi bar 4 1 41 relieve pressure Some work atmanifold GB port Relievethe Min Level Down Pressure Possible Causes 4 1 42 4 1 57 ing pressure will still be inthe pressure before removing the 2 psi bar 4 1 44 4 1 56 line Install a0 to 5000 PSI gauge 345 bar pressure gauge at the manifold GB port 3121203 T350 T500J 1 39 SECTION 1 TROUBLESHOOTING BY FUNCTION 1 21 JIB UP FUNCTION INOPERATIVE Step Pretest Instructions
302. witch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 9 188 TELE IN VALVE System test prompt indicating that it is currently testing this circuit 9 189 TELE OUT CL System test response indicating that the ground Telescope Out switch has been closed when a different switch was expected Make sure the correct switch is being activated or check the switch wiring 5 190 TELE OUT VALVE System test prompt indicating that it is currently testing this circuit 9 191 TELESCOPE IN VALVE OPEN CIRCUIT The system test detected an open in the Telescope In valve circuit See 2 152 Telescope In Solenoid Open Circuit 9 192 TELESCOPE IN VALVE SHORT TO BATTERY The system test detected a short to battery in the Telescope In valve circuit See 2 153 Telescope In Solenoid Short To Battery 9 193 TELESCOPE IN VALVE SHORT TO GROUND The system test detected a short to ground in the Telescope In valve circuit See 2 154 Telescope In Solenoid Short To Ground 5 194 TELESCOPE OUT VALVE OPEN CIRCUIT The system test detected an open in the Telescope Out valve circuit See 2 155 Telescope Out Solenoid Open Circuit 9 195 TELESCOPE OUT VALVE SHORT TO BATTERY The system test detected a short to battery in the Telescope Out valve circuit See 2 156 Telescope Out Solenoid Short To Battery 9 196 TELESCOPE OUT VALVE SHORT TO GROUND The system test detected a short
303. y stuck or electrically shorted Functions Disabled at Ground Only Telescope Out Step Pretest Instructions Test Result Corrective Action 2 78 1 Is the switch mechanically Yes Repair or replace the switch stuck No Goto step 2 78 2 2 78 2 DisconnectX033 Placekey Is fault Function Problem Yes Goto step 2 78 3 switch in ground position and Telescope Out Permanently No Possible Causes 4 1 18 pull the emergency stop Selected still present switch 2 78 3 Remove X014 21 pin from Is fault Function Problem Yes Goto step 2 78 4 X014 Place key switch in Telescope Out Permanently No Possible Causes Short in Brown 14 2 ground position and pullthe Selected still present wire emergency stop switch 2 78 4 Place key switch in ground Measured voltage at Yes Possible Causes Shortin Brown 14 position and pull the emer X004 30 Vbatt 2 1 wire 4 1 10 gency stop switch No Possible Causes 4 1 10 2 79 FUNCTIONS AT CUTBACK POWER MODULE CURRENT LIMIT Distress Lamp 4 ADE Code 4 2 The Power Module is approaching its thermal limit and must reduce output to continue operation The Power Module LED is Flashing 8 Controller Hot ELECTRIC POWERED MACHINES ONLY All Functions Operable but output from power module is at reduced power Possible Causes 4 1 1 4 1 39 4 1 12 2 80 FUNCTIONS LOCKED OUT CONSTANT DATA VERSION IMPROPER Distress Lamp 9 ADE Code 9 9 Ground Module detected t
304. yzer Message TELESCOPE Goto step 2 152 3 IN VALVE OPEN CIRCUIT 2 152 3 Replace X002 4 with a jumper Rerun System Test Analyzer Message TELESCOPE Wire Brown 13 3 1 or Brown 13 3 toX002 14 IN VALVE SHORT TO GROUND broken Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 IN VALVE OPEN CIRCUIT 2 153 TELESCOPE IN SOLENOID SHORT TO BATTERY Distress Lamp 9 ADE Code 3 3 Ground module feedback shows that the Telescope In digital output may be shorted to battery or other function Functions Disabled Telescope In Step Pretest Instructions Test Result Corrective Action 2 153 1 Run systemtest Dootherfunctionsfailsys Yes Possible Cause Black ground wire temtest broken 4 1 1 otherwise 0010 step 2 153 2 No Goto step 2 153 2 2 153 2 Disconnect solenoid atX083 Rerun System Test Analyzer Message TELESCOPE Replace solenoid IN VALVE OPEN CIRCUIT Analyzer Message TELESCOPE Goto step 2 153 3 IN VALVE SHORT TO BATTERY 2 153 3 Remove wire Brown 13 3 1 Rerun System Test Analyzer Message TELESCOPE Wire Brown 13 3 1 or Brown 13 3 from X002 4 IN VALVE OPEN CIRCUIT shorted to battery Repair or replace Analyzer Message TELESCOPE Possible Cause 4 1 10 IN VALVE SHORT TO BATTERY 2 110 T350 T500J 3121203 2 154 TELESCOPE SOLENOID SHORT TO GROUND Distress Lamp 9 ADE Code 3 3 SECTION 2 TROUBLESHOOTING BY FAULT MESSAGE

Troubleshooting 3121203 09-07-05 Global English

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