JLG T350 - Troubleshoot Manual

Troubleshooting Manual
Models
T350
T500J
3121203
September 7, 2005

Summary

Section A. Introduction

A.1 How to Use This Manual

Explains how to effectively use the troubleshooting manual to isolate problems. Includes guidance on flow charts and step instructions.

A.2 Visual Inspection

Details the importance of performing a thorough visual and hands-on inspection before troubleshooting procedures.

A.4 Reading Fault Codes

Guides on how to read system fault codes from the analyzer and distress lamps.

A.5 User Fault Codes

Lists user fault codes with their corresponding descriptions of difficulty.

A.8 Power Module Flash Codes

Provides a reference for flash codes related to the power module and their troubleshooting steps.

A.10 Control Module Power

Ensures the ground control module is properly powered, detailing pin connections for ground and platform operation.

A.11 Tilt

Explains tilt calculations, outrigger set conditions, and tilt sensor response for orientation.

A.12 Critical Vehicle Interlock Scenarios

Identifies scenarios requiring unique vehicle interlocks like Retrieval-A and Retrieval-B.

Section B. Troubleshooting Safety Precautions

B.1 General

Contains general safety precautions for troubleshooting aerial platforms, emphasizing user responsibility.

B.2 Hydraulic System Safety

Highlights safety considerations for hydraulic systems operating at high pressures.

B.3 Troubleshooting Safety

Lists critical safety precautions that must be followed to avoid machine damage, injury, or death.

Section 1 - Troubleshooting by Function

1.1 All Functions Inoperative

Provides a troubleshooting guide for when all machine functions are inoperative.

1.2 Pump Motor Will Not Operate - DC Powered Models

Details troubleshooting steps for a DC powered machine where the pump motor does not operate.

1.5 Battery Charger Not Functioning Properly

Troubleshooting guide for issues related to the battery charger not functioning as expected.

1.6 Engine Will Not Crank - Engine Models

Troubleshooting steps for engine powered models when the engine will not crank.

1.10 Ground Controls Inoperative

Troubleshooting steps for when the ground controls are not functioning.

1.12 Ground Leveling Not Functioning Properly

Addresses issues where the ground leveling system is not functioning correctly.

1.13 Lift Down Function Inoperative

Troubleshooting guide for when the lift down function is inoperative.

1.14 Lift Up Function Inoperative

Troubleshooting steps for when the lift up function is inoperative.

Section 2 - Troubleshooting by Fault Messages

2.1 Accessory Fault

Details faults related to an attached accessory communicating an error to the ground control.

2.2 Battery Voltage Too High - System Shutdown

Addresses system shutdowns due to excessively high battery voltage.

2.6 CANBUS Failure - Accessory Module Communications Lost

Troubleshooting steps for when the system cannot communicate with an installed accessory via CANBUS.

2.7 CANBUS Failure - Drive Module

Troubleshooting steps for communication failures with the drive module via CANBUS.

2.10 Chassis Tilt Sensor Gain Not Calibrated

Describes issues where chassis tilt sensor calibration data is corrupted.

2.14 Choke Hold Solenoid Open Circuit

Troubleshooting for an open circuit in the engine choke hold solenoid.

2.20 Drive & O;R Prevented - Operate From Platform

Addresses prevention of drive/outrigger operation from the platform due to incorrect platform position.

2.23 Drive Enable Solenoid Short to Battery

Troubleshooting for a short to battery in the drive enable valve PWM output.

2.40 Dump Solenoid Open Circuit

Troubleshooting steps for an open circuit in the dump valve solenoid.

2.44 Engine Not Running

Addresses situations where the control system does not detect the engine is running.

2.54 Function Locked Out - Joystick Not Centered at Startup

Troubleshooting for function lockout when the joystick signal is not at the proper neutral voltage.

2.72 Function Problem - Rotary Selector Switch

Diagnoses issues with the platform rotary selector switch having multiple inputs active simultaneously.

2.78 Function Problem - Telescope Out Permanently Selected

Troubleshooting for a telescope out switch that is stuck closed or shorted.

2.85 Ground Module Failure: Ref Voltage Out of Range

Addresses issues where the ground module detects the +7V reference voltage source is out of range.

2.94 Joystick Faulty - X Axis Wiper Out of Range

Troubleshooting joystick X-axis wiper signal input outside acceptable voltage range.

2.97 Keyswitch Faulty

Diagnoses faults where platform and ground mode keyswitch inputs are active simultaneously.

2.112 Lift Up Prevented - Lift Down Then Set Outriggers

Explains why lift up is prevented until all outriggers are set or stowed.

2.125 Power Module Failure: Check Power Circuits or Mosfet Short Circuit

Troubleshooting power module errors related to power wiring or MOSFET short circuits.

2.129 Rear-Left O;R Solenoid Open Circuit

Troubleshooting an open circuit in the rear-left outrigger digital output.

2.134 Rear-Right O;R Solenoid Short to Ground

Troubleshooting a short to ground in the rear-right outrigger digital output.

2.138 Running at Creep - Material Hook Mode

Addresses function speed limitations to creep when operating in Ground Mode with Material Hook in use.

2.141 Start Solenoid Open Circuit

Troubleshooting an open circuit in the engine start digital output.

2.144 Swing Left Solenoid Open Circuit

Troubleshooting an open circuit in the swing left digital output.

2.147 Swing Right Solenoid Open Circuit

Troubleshooting an open circuit in the swing right digital output.

2.150 Tele Out Prevented - Set Outriggers

Explains prevention of telescope out function due to improperly set outriggers.

2.152 Telescope In Solenoid Open Circuit

Troubleshooting an open circuit in the telescope in digital output.

2.155 Telescope Out Solenoid Open Circuit

Troubleshooting an open circuit in the telescope out digital output.

2.158 Throttle Hold Solenoid Open Circuit

Troubleshooting an open circuit in the engine throttle hold digital output.

2.161 Throttle Pull Relay Open Circuit

Troubleshooting an open circuit in the engine throttle pull digital output.

2.164 Trigger Closed Too Long While In Neutral

Addresses trigger switch closure for too long while joystick is neutral.

Section 3 - Component Checks

3.1 DC Powered Machine - Hydraulic Pump

Checks related to the hydraulic pump on DC powered machines.

3.2 DC Powered Machine - Power

Power checks for DC powered machines.

3.3 DC Powered Machine - Power Module

Examines the power module, including theory of operation and diagnostic issues.

3.5 Drive Sensor Reset

Procedure to reset turntable position and hand brake sensors.

3.10 Joystick Diagnostics

Details how to diagnose joystick functionality using an analyzer.

3.15 Telescope Limit Switch

Checks and troubleshooting for the telescope limit switch.

3.17 Transport Limit Switch

Procedures for checking the transport limit switch function.

Section 4 - Possible Causes

4.1 Possible Causes

Lists potential causes for various system issues and their corresponding solutions.

Section 5 - System Test Messages

5.1 Battery 1;4 Lamp On

System test response indicating the platform battery indicator is illuminated.

5.5 Battery Voltage Too High

System test prompt indicating battery voltage is too high.

5.6 Battery Voltage Too Low

System test prompt indicating battery voltage is too low.

5.7 Check Choke Switch

System test response for choke switch input status.

5.8 Check Ground;Platform Select

System test response for ground/platform mode selection.

5.15 Check Outrigger Set Switch

System test response for ground outrigger set switch status.

5.16 Check Outrigger Stow Switch

System test response for ground outrigger stow switch status.

5.20 Check Swing Left Switch

System test response for ground swing left switch status.

5.22 Check Telescope In Switch

System test response for ground telescope in switch status.

5.25 Choke CL

System test response for platform choke switch closure.

5.30 Choke Pull

System test prompt for testing the choke pull circuit.

5.37 CL Drive Switch

System test prompt to test the platform drive switch input.

5.41 CL Level Up

System test prompt to test the platform level up switch input.

5.44 CL O;R Set

System test prompt to test the ground outrigger set switch input.

5.46 CL Start

System test prompt to test the ground engine start switch input.

5.53 Drive Switch CL

System test response indicating platform drive switch closed unexpectedly.

5.55 DRV Enable Short to Ground or Open Circuit

System test detects open circuit or short to ground in drive enable valve circuit.

5.60 DRV Left FWD Valve Short to Ground

System test detects short to ground in drive left forward valve circuit.

5.64 DRV Left Rev Valve Short to Ground

System test detects short to ground in drive left reverse valve circuit.

5.73 Dump Valve

System test prompt for testing the dump valve circuit.

5.83 F-L Outrigger Lamp On

System test prompt to check if the front-left outrigger lamp is illuminated.

5.88 F-R Outrigger Lamp On

System test prompt to check if the front-right outrigger lamp is illuminated.

5.92 Ground Alarm On

System test indicates the ground alarm is sounding.

5.93 High Tilt Angle

System test prompt for unsafe tilt angle reported by tilt sensor.

5.95 Jib Down CL

System test response for ground Jib Down switch closure.

5.104 Joystick Forward to Max

System test prompt to move platform joystick forward for voltage check.

5.113 Level Up CL

System test response for ground level up switch closure.

5.118 Lift Dn Valve

System test prompt for testing the lift down valve circuit.

5.128 Multiple Closure

System test response indicating multiple switches closed when one was expected.

5.130 O;R Set Lamp On

System test prompt to check platform outrigger set lamp illumination.

5.132 Op Choke

System test prompt to open ground panel engine choke switch.

5.134 Op Drive Switch

System test prompt to open platform panel drive switch.

5.136 Op Jib Up

System test prompt to open ground panel Jib Up switch.

5.147 Op Tele In

System test prompt to open ground panel Telescope In switch.

5.150 Opt Ground Alarm On

System test indicates the optional ground alarm is sounding.

5.157 R-L Outrigger Lamp On

System test prompt to check ground rear-left outrigger lamp illumination.

5.165 R-R Outrigger Lamp On

System test prompt to check ground rear-right outrigger lamp illumination.

5.170 Start CL

System test response for ground start switch closure.

5.175 Start Switch CL

System test response indicating platform start switch closed unexpectedly.

5.177 Swing Left Valve Open Circuit

System test detects an open circuit in the swing left valve.

5.181 Swing Right CL

System test response indicating ground swing right switch closure.

5.186 System Distress Lamp On

System test prompt to check if the system distress lamp is illuminated.

5.197 Tests Complete

System test message indicating that testing is completed.

5.198 Throttle Hold

System test prompt for testing the engine throttle hold circuit.

Section 7 - Electrical Reference

7.1 Connector Index

An index of all connectors used in the system, with descriptions and locations.

7.2 Ground Module Connector Pinouts

Detailed pinout information for the Ground Module connectors (X001, X002, X003, X004, X007, X008).

7.3 Platform Module Connector Pinout

Pinout details for the Platform Module connector (X060).

7.4 Drive Module Connector Pinout

Pinout details for the Drive Module connectors (X074, X075).

7.5 Connector Loading Diagrams

Visual diagrams illustrating the loading and configuration of various connector types.

7.6 Working with AMP Connectors

Guidelines for applying Silicone Dielectric Compound to AMP connectors.

7.7 Working with Deutsch Connectors

Procedures for assembling and disassembling Deutsch DT/DTP and HD30/HDP series connectors.

7.8 Trailer Wiring

Electrical schematic diagrams for trailer wiring configurations.

Section 8 - Hydraulic References

8.1 Solenoids

Lists solenoid connectors and their nominal resistance values.

8.2 Minimum Operating Pressure

Provides minimum operating pressure specifications for various hydraulic functions.

Section 9 - JLG Analyzer

9.1 Introduction

Introduces the JLG Control System analyzer and its capabilities for fault indication.

9.2 To Connect the JLG Control System Analyzer

Provides instructions on connecting the analyzer to the machine's controller.

9.3 Using the Analyzer

Explains how to navigate and use the analyzer menus and displays.

9.4 Changing the Access Level of the Hand Held Analyzer

Details the process of accessing and changing settings by entering a password.

9.5 Adjusting Parameters Using the Hand Held Analyzer

Describes how to adjust personality settings and values using the analyzer.

9.6 Machine Setup

Guides on adjusting machine digit items and selecting machine models for personality settings.

9.7 System Test

Instructions for performing platform and ground system tests using the analyzer.

9.8 User Fault Codes

Lists single-digit fault codes displayed on control panels for operator alerts.

Section 10 - Multimeter Basics

10.1 Introduction

Introduction to multimeters (VOMs) and their use in circuit measurements.

Section 11 - Specifications

11.1 Introduction

Provides additional information for proper operation and maintenance of the machine.

11.2 Operating Specifications

Lists key operating specifications for T350 and T500J models, including weight and dimensions.

Component Weights

Details the weight specifications for various components of the T350 and T500J models.

Lubrication

Information regarding hydraulic oil type and specifications.

Hydraulic Oil

Provides details on hydraulic oil requirements and recommendations.

JLG T350 Specifications

General

Platform Height	35 ft
Working Height	41 ft
Horizontal Outreach	20 ft
Platform Capacity	500 lbs
Horizontal Reach	20 ft
Fuel Type	Electric
Power Source	Battery
Tire Type	Solid