Page 1 Troubleshooting Manual Models T350 T500J 3121203 September 7, 2005...
Page 3 REVISION LOG September 7, 2005 - Original Issue Of Manual 3121203 T350 T500J...
Page 4 REVISION LOG T350 T500J 3121203...
Page 5: Section A. Introduction
Ground System Lamp Blinking? Message Tests Troubleshoot by “Ground/ Help Message in Everything OK” Section 2 Possible Causes Component Troubleshoot by Checks function in Section Identify Fault Repair Machine Problem Solved? Done Figure A-1. Troubleshooting Flow Chart 3121203 T350 T500J...
Page 6: Visual Inspection
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 can be read from the green LED on the face of the ground module, see Figure A-2.. Figure A-2. Ground Module Fault LED T350 T500J 3121203...
Page 7: User Fault Codes
Figure A-3.. Refer to A.8 Power Module Flash Codes for fault descriptions. Figure A-3. Power Module Fault LED A.5 USER FAULT CODES Flash Description of Difficulty Code Procedure Vehicle Setup Battery / Charge System Excessive Duty Cycle Start Engine / Turn-Off System Unused Unused Unused Vehicle Requires Service 3121203 T350 T500J...
Page 8: User Fault Code Cross References
Functions At Cutback - Power Module Current Limit ......................... 2-78 Power Module Too Hot - Please Wait ............................2-99 Battery Voltage Too High - System Shutdown ..........................2-41 Battery Voltage Too Low - System Shutdown ..........................2-42 Engine Not Running ..................................2-60 T350 T500J 3121203...
Page 9 Ground Alarm Short To Battery ..............................2-79 Ground Alarm Short To Ground ..............................2-79 Ground Module Failure Ref Voltage Out Of Range ........................2-80 Ground Module Failure Vlow Fet Failure .............................2-80 Hourmeter Short To Battery ................................2-80 Jib Down Solenoid Open Circuit ..............................2-80 3121203 T350 T500J...
Page 10 Throttle Hold Solenoid Short To Battery ........................... 2-114 Throttle Hold Solenoid Short To Ground ........................... 2-114 Throttle Pull Relay Open Circuit ..............................2-115 Throttle Pull Relay Short To Battery ............................2-115 Throttle Pull Relay Short To Ground ............................2-116 A-10 T350 T500J 3121203...
Page 11: Service Fault Code Cross References
2-5 Lift Up Prevented - Lift Down Then Set Outriggers ......................2-93 2-5 Lift Up Prevented - Tilted ...............................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 - Elevated .............................2-97 3121203 T350 T500J A-11...
Page 12 3-3 Lift Up Solenoid Short To Battery ............................2-94 3-3 Lift Up Solenoid Short To Ground ............................2-95 3-3 Optional Ground Alarm Short To Battery ..........................2-96 3-3 Optional Ground Alarm Short To Ground ..........................2-96 3-3 Rear-Left O/R Solenoid Open Circuit ............................ 2-99 A-12 T350 T500J 3121203...
Page 13 9-9 Ground Module Failure Ref Voltage Out Of Range .......................2-80 9-9 Ground Module Failure Vlow Fet Failure ..........................2-80 9-9 Power Module Failure Check Power Circuits Or Mosfet Short Circuit .................2-98 9-9 Power Module Failure Internal Error ............................2-98 3121203 T350 T500J A-13...
Page 14: Power Module Flash Codes
On engine powered machines, battery negative (X100) should be used as the ground reference for voltage measurements, unless stated otherwise. On electric powered machines, the power module B- (X101) terminal should be used as the ground reference for voltage measurements, unless stated otherwise. A-14 T350 T500J 3121203...
Page 15: Control Module Power
Analyzer R S232 Transm it Analyzer X 074 Analyzer G round X075 C onstant Battery (Vbatt) Ignition Pow er from Ignition R elay 87 (Vbatt) G round from Ignition R elay 85 Figure A-4. Basic Electronic Module Connections 3121203 T350 T500J A-15...
Page 16: Tilt
·The vehicle is Elevated AND One Outrigger is Unset AND the vehicle is TILTED ·The vehicle is Elevated AND Two Outriggers are UNSET. A.13 OUTRIGGERS Some machine software may refer to the Outriggers (O/R) as Lifting Jacks (L/J). A-16 T350 T500J 3121203...
Page 17: General
• 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...
Page 18 SAFETY B-18 T350 T500J 3121203...
Page 19: Table Of Contents
Battery Voltage Too Low - System Shutdown ........2-42 CANBUS Failure - Accessory Module Communications Lost ......2-42 3121203 T350 T500J...
Page 20 Function Problem - Level Up And Down Both Selected....... . .2-70 T350 T500J...
Page 21 Outrigger Stow Prevented - Tele In First..........2-97 3121203 T350 T500J...
Page 22 Power Module - Power ............3-126 T350 T500J...
Page 23 CL TELE IN ..............5-138 3121203 T350 T500J...
Page 24 LEVEL DN VALVE ............. .5-146 T350 T500J...
Page 25 R-R OUTRIGGER VALVE OPEN CIRCUIT ......... . .5-152 3121203 T350 T500J...
Page 26 Trailer Wiring ..............7-188 SECTION 8 - HYDRAULIC REFERENCES T350 T500J 3121203...
Page 27 To Connect the JLG Control System Analyzer ........
Page 28 Component Weights - T350 ........
Page 29: Section 1 - Troubleshooting By Function
Voltage between X115 and Go to step 1.2.5 switch X101 =Vbatt? Possible Causes: 4.1.70, 4.1.72, 4.1.12 1.2.5 Engage enable and lift up Voltage between X114 and Possible Causes: 4.1.12 switch X102 =Vbatt? Possible Causes: 4.1.71, 4.1.72, 4.1.12 3121203 T350 T500J 1-29...
Page 30: All Functions Inoperative, Engine Starts And Runs - Engine Models
1.4.4 Plumb a 0 to 5000 PSI (345 While holding enable and lift up Possible Causes: 4.1.40, 4.1.10, 4.1.47 bar) pressure gauge into the switch, does pressure rise Possible Causes: 4.1.37, 4.1.45, 4.1.39 manifold P port above 100PSI (minimum func- tion pressure)? 1-30 T350 T500J 3121203...
Page 31: Battery Charger Not Functioning Properly
1.5.4 Using a hydrometer - Check Is the specific gravity of all bat- Possible Causes: 4.1.8 the specific gravity in each tery cells between 1.155 and Possible Causes: 4.1.4 battery cell. 25% charged is 1.265? 1.155, 100% = 1.265 3121203 T350 T500J 1-31...
Page 32: Engine Will Not Crank - Engine Models
Voltage on X022.6 = Vbatt? wire between X022.6 and solenoid Go to step 1.6.8 1.6.8 While pressing the start button, 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...
Page 33: Engine Cranks But Will Not Start - Engine Models
Lift Up? Possible Causes: Wht/Yel 48-3 wire from X003.11 to X022.4 or X022.4 to X097.1 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...
Page 34: Ground Controls Inoperative
ANALYZER -> DIAGNOSTICS - Go to step 1.12.3 > GROUND -> Outrigger Possible Causes:4.1.20, 4.1.19, 4.1.18, switch indicators agree with O/ 4.1.36 R positions? 1.12.3 Are some outriggers operating Possible Causes:4.1.62, 4.1.10 properly? Possible Causes:4.1.63, 4.1.62, 4.1.10 1-34 T350 T500J 3121203...
Page 35: Lift Down Function Inoperative
Possible Causes: 4.1.49, 4.1.48, 4.1.41 bar) pressure gauge into the while activating lift up at (bar) hose from the lift up cylinder ground controls Below Min. Lift Up Pressure psi Possible Causes: 4.1.42, 4.1.58 cap end. (bar) 3121203 T350 T500J 1-35...
Page 36: Telescope Out Function Inoperative
Possible Causes: 4.1.49, 4.1.48, bar) pressure gauge into the scope cylinder while activating (bar) 4.1.41 hose from the lift up cylinder telescope in at ground controls Below Min. Tele In Pressure psi Possible Causes: 4.1.42, 4.1.51 cap end. (bar) 1-36 T350 T500J 3121203...
Page 37: Swing Left Function Inoperative
Possible Causes: 4.1.49, 4.1.48, bar) pressure gauge into the motor while activating swing psi (bar) 4.1.41 hose from the 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...
Page 38: Platform Leveling Up Function Inoperative
Below Min. Level Up Pressure psi Possible Causes: 4.1.42, 4.1.55, working pressure will still be in pressure before removing the (bar) 4.1.44, 4.1.54 the line. Install a 0 to 5000 PSI gauge. (345 bar) pressure gauge at the manifold GA port 1-38 T350 T500J 3121203...
Page 39: Platform Leveling Down Function Inoperative
Possible Causes: 4.1.42, 4.1.57, ing pressure will still be in the pressure before removing the psi (bar) 4.1.44, 4.1.56 line. Install a 0 to 5000 PSI gauge. (345 bar) pressure gauge at the manifold GB port 3121203 T350 T500J 1-39...
Page 40: Jib Up Function Inoperative
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...
Page 41: Section 2 - Troubleshooting By Fault Messages
Functions Disabled (Electric Powered Machines Only): Lift Up, Lift Down, Swing Left, Swing Right, Telescope In, Telescope Out, Jib Up, Jib Down, Level Up, Level Down, Front Left O/R, Front Right O/R, Rear Left O/R, Rear Right O/R, Set (Extend O/ R), Stow (Retract O/R), Drive Possible Causes: 4.1.2, 4.1.3, 4.1.4 3121203 T350 T500J 2-41...
Page 42: Battery Voltage Too Low - System Shutdown
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? Refer to Information Supplied with Accessory Possible Causes: 4.1.2 2-42 T350 T500J 3121203...
Page 43: Canbus Failure - Drive Module
CAN resistance between Go to step 2.7.11 X007.13.pin and X007.24.pin = 120Ω? 2.7.11 Disconnect X007 Test harness for continuity Possible Causes: 4.1.10 between X007.6.soc and Repair or replace black jumper wire X007.17.soc between X007.6.soc and X007.17.soc 3121203 T350 T500J 2-43...
Page 44: Canbus Failure - Platform Module
CAN resistance between Go to step 2.8.10 X007.13.pin and X007.24.pin = 120Ω? 2.8.10 Disconnect X007 Test harness for continuity Possible Causes: 4.1.10 between X007.6.soc and Repair or replace black jumper wire X007.17.soc between X007.6.soc and X007.17.soc 2-44 T350 T500J 3121203...
Page 45: Canbus Failure - Power Module
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...
Page 46: Chassis Tilt Sensor Not Calibrated
Run the tilt sensor calibra- tion 2.13.3 Has a tilt sensor calibration Possible Causes: 4.1.10 been run recently? Properly secure the ground module with the machine resting on a level surface. Run the tilt sensor calibra- tion 2-46 T350 T500J 3121203...
Page 47: Choke Hold Solenoid Open Circuit
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 2-47...
Page 48: Choke Hold Solenoid Short To Ground
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“ 2-48 T350 T500J 3121203...
Page 49: Choke Pull Relay Short To Battery
2.19.2 Remove wire WHT/YEL 48-4 Rerun System Test Analyzer Message “CHOKE PULL 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...
Page 50: Drive & O/R Prevented - Operate From Platform
In Platform Mode, an attempt was made to operate Drive or Outriggers, but X007.7 is not at Battery Voltage, as it should be when the platform console is plugged into the platform position. Using the JLG Analyzer, view the Platform Position status under DIAGNOSTICS -> SYSTEM. The vehicle must be in “AWP MODE” (not “HOOK MODE”) with PLTPOS1 +B and PLTPOS2 GND.
Page 51: Drive & O/R Prevented - Place Boom On Rest
2.23.3 Remove wire Orn 55-1 from Rerun System Test Analyzer Message “DRV ENABLE Wire Orn 55-1 shorted to battery. X074.11 SHORT TO GROUND OR OPEN Repair or replace CIRCUIT“ Analyzer Message “DRV ENABLE Possible Cause: 4.1.10 VALVE SHORT TO BATTERY“ 3121203 T350 T500J 2-51...
Page 52: Drive Enable Solenoid Short To Ground Or 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...
Page 53: Drive Left Forward Solenoid Short To Battery
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 2-53...
Page 54: Drive Left Reverse Solenoid Open Circuit
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“ or replace Analyzer Message “DRV LEFT Possible Cause: 4.1.10 REV VALVE SHORT TO BAT- TERY“ 2-54 T350 T500J 3121203...
Page 55: Drive Left Reverse Solenoid Short To Ground
X041. When the boom is stowed in transport position, TELE LMT SW input, X004.21 = +B. DRIVE OPTION MACHINES ONLY Functions Disabled (Drive Option Machines Only): Drive See 3.15 Telescope Limit Switch 3121203 T350 T500J 2-55...
Page 56: Drive Right Forward Solenoid Open Circuit
2.35.3 Remove wire Orn 7-2 from Rerun System Test Analyzer Message “DRV RIGHT Wire Orn 7-2 shorted to battery. Repair X002.9 FWD VALVE OPEN CIRCUIT“ or replace Analyzer Message “DRV RIGHT Possible Cause: 4.1.10 FWD VALVE SHORT TO BAT- TERY“ 2-56 T350 T500J 3121203...
Page 57: Drive Right Forward Solenoid Short To Ground
2.37.3 Replace X074.10 with a Rerun System Test Analyzer Message “DRV RIGHT Wire Orn 8-2 broken. Repair or replace jumper to X074.2 REV VALVE SHORT TO GROUND“ Analyzer Message “DRV RIGHT Possible Cause: 4.1.10 REV VALVE OPEN CIRCUIT“ 3121203 T350 T500J 2-57...
Page 58: Drive Right Reverse Solenoid Short To Battery
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“ or replace Analyzer Message “DRV RIGHT Possible Cause: 4.1.10 REV VALVE SHORT TO GROUND“ 2-58 T350 T500J 3121203...
Page 59: Dump Solenoid Open Circuit
2.41.3 Remove wire Red/Wht 50-1-1 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 battery. Repair or replace Analyzer Message “DUMP VALVE Possible Cause: 4.1.10 SHORT TO BATTERY“ 3121203 T350 T500J 2-59...
Page 60: Dump Solenoid Short To Ground
Possible Cause:4.1.2, 4.1.10 TICS -> ENGINE SPEED > Go to step 2.44.2 0RPM? 2.44.2 Check for continuity Possible Cause:4.1.21, 4.1.21, 4.1.2, between X001.16.soc and 4.1.10 X095 Repair WHT/YEL 48-7 or WHT/YEL 48- 13-1 between X001.16 and X095 2-60 T350 T500J 3121203...
Page 61: Extend O/R Solenoid Open Circuit
2.46.3 Remove wire Orn/Wht 55-3-1 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 2-61...
Page 62: Extend O/R Solenoid Short To Ground
Rerun System Test Analyzer Message “F-L OUTRIG- Wire Orn/Red 49-5 or White wire to to X003.3 GER VALVE SHORT TO GROUND“ X046 broken. Repair or replace Analyzer Message “F-L OUTRIG- Possible Cause: 4.1.10 GER VALVE OPEN CIRCUIT“ 2-62 T350 T500J 3121203...
Page 63: Front-Left O/R Solenoid Short To Battery
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...
Page 64: Front-Right O/R Solenoid Open Circuit
Analyzer Message “F-R OUTRIG- Wire Orn/Red 49-6 or White wire to from X003.6 GER VALVE OPEN CIRCUIT“ X047 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...
Page 65: Front-Right O/R Solenoid Short To Ground
2.54.4 Perform the voltmeter joystick Using a multimeter, is the Possible Causes: 4.1.11 test of 3.10 Joystick Diag- voltage between X061.3 and 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...
Page 66: Function Locked Out - Trigger Permanently Closed
Selected“still present? switches. 2.56.3 Place key switch in the plat- Measured voltage at Possible Causes: Short in Orn/Red 49- form position and pull the X060.14 = Vbatt? 30 wire, 4.1.11 emergency stop switches. Possible Causes: 4.1.11 2-66 T350 T500J 3121203...
Page 67: Function Problem - Engine Choke Permanently Selected
Selected“still present? switches. 2.58.3 Place key switch in the plat- Measured voltage at Possible Causes: Short in Wht/Yel 48- form position and pull the X060.13 = Vbatt? 1 wire, 4.1.11 emergency stop switches. Possible Causes: 4.1.11 3121203 T350 T500J 2-67...
Page 68: Function Problem - Engine Start Permanently Selected
Selected“still present? wire emergency stop switch. 2.60.4 Place key switch in ground Measured voltage at X004.8 Possible Causes: Short in Blue 28-2-1 position and pull the emer- = Vbatt? wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 2-68 T350 T500J 3121203...
Page 69: Function Problem - Jib Up And Down Both Selected
Selected“still present? wire emergency stop switch. 2.62.4 Place key switch in ground Measured voltage at Possible Causes: Short in Blue 27-2-1 position and pull the emer- X004.19 = Vbatt? wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 3121203 T350 T500J 2-69...
Page 70: Function Problem - Level Down Permanently Selected
Go to step 2.64.4 2.64.4 Remove X004.17.soc from Is fault “Function Problem - Possible Causes: 4.1.10 X004 Level Up And Down Both Possible Causes: Short in Pink 25-2-1 Selected“still present? wire or Pink 26-2-1 wire 2-70 T350 T500J 3121203...
Page 71: Function Problem - Level Up Permanently Selected
Selected“still present? emergency stop switch. 2.66.4 Place key switch in ground Measured voltage at Possible Causes: Short in Tan 4-2-1 position and pull the emer- X004.33 = Vbatt? wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 3121203 T350 T500J 2-71...
Page 72: Function Problem - Lift Up And Down Both Selected
Selected“still present? emergency stop switch. 2.68.4 Place key switch in ground Measured voltage at Possible Causes: Short in Tan 3-2-1 position and pull the emer- X004.23 = Vbatt? wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 2-72 T350 T500J 3121203...
Page 73: Function Problem - Outrigger Set And Stow Both Selected
2 wire emergency stop switch. 2.70.4 Place key switch in ground Measured voltage at Possible Causes: Short in Orn/Wht 55- position and pull the emer- X004.20 = Vbatt? 2-1 wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 3121203 T350 T500J 2-73...
Page 74: Function Problem - Outrigger Stow Permanently Selected
JIB/TELE CLOSED and LIFT/SW Possible Causes: Short in Orn/Red 49- Turn the selector switch to the “Closed” status in ANA- CLOSED 28 wire, 4.1.11 right position, JIB/Tele LYZER -> DIAGNOSTICS -> Any other combination Possible Causes: 4.1.11 PLATFORM 2-74 T350 T500J 3121203...
Page 75: Function Problem - Swing Left And Right Both Selected
Go to step 2.73.4 2.73.4 Remove X004.35.soc from Is fault “Function Problem - Possible Causes: 4.1.10 X004 Swing Left And Right Both Possible Causes: Short in White 22-2- Selected“still present? 1 wire or White 21-2-1 wire 3121203 T350 T500J 2-75...
Page 76: Function Problem - Swing Left Permanently Selected
2.75.4 Place key switch in ground Measured voltage at Possible Causes: Short in White 22-2- position and pull the emer- X004.35 = Vbatt? 1 wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 2-76 T350 T500J 3121203...
Page 77: Function Problem - Telescope In And Out Both Selected
2.77.4 Place key switch in ground Measured voltage at X004.7 Possible Causes: Short in Brown 13- position and pull the emer- = Vbatt? 2-1 wire, 4.1.10 gency stop switch. Possible Causes: 4.1.10 3121203 T350 T500J 2-77...
Page 78: Function Problem - Telescope Out Permanently Selected
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...
Page 79: Functions Locked Out - Power Module Software Version Improper
Wire Orn/Red 49-11 or black ground wire shorted to ground. Repair or replace Go to step 2.84.3 2.84.3 Remove X002.19 from X002 Is the fault removed? Wire Orn/Red 49-11-1 shorted to ground. Repair or replace Possible Causes: 4.1.10 3121203 T350 T500J 2-79...
Page 80: Ground Module Failure: Ref Voltage Out Of Range
X019 and X055. Repair or replace Go to step 2.88.4 2.88.4 Short X002.20.pin to B- Is the fault removed? Blue 28-3-1 or black wire broken between X002 and X019. Repair or replace Possible Causes: 4.1.10 2-80 T350 T500J 3121203...
Page 81: Jib Down Solenoid Short To Battery
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 “JIB DOWN Possible Cause: 4.1.10 VALVE SHORT TO GROUND“ 3121203 T350 T500J 2-81...
Page 82: Jib Up Solenoid Open Circuit
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...
Page 83: Jib Up Solenoid Short To Ground
2.94.6 Place key switch in platform Measured voltage between 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? Possible Cause: 4.1.22 3121203 T350 T500J 2-83...
Page 84: Joystick Faulty - Y Axis Wiper Out Of Range
2.95.6 Place key switch in platform Measured voltage between 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? Possible Cause: 4.1.22 2-84 T350 T500J 3121203...
Page 85: Joystick Moved But Trigger Switch Open
= Vbatt? Possible Cause: Open in wire Yel/Red gency stop switches. 2-19 2.96.8 Disconnect X061. Engage and Test for continuity between Possible Cause: Open in wire Yel/Red hold the trigger. X061.5.pin and X061.6.pin. 2-17 Possible Causes: 4.1.22 3121203 T350 T500J 2-85...
Page 86: Keyswitch Faulty
2.97.5 Extract X007.1. Switch Key to Is the fault removed? Possible Causes: Short in Yel/Red 2- Ground Mode and pull the 44, 4.1.10 ground emergency stop Possible Causes: Short in Yel/Red 2- switch 9, 4.1.10 2-86 T350 T500J 3121203...
Page 87: Level Down Solenoid Open Circuit
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...
Page 88: Level Down Solenoid Short To Ground
2.101.3 Replace X002.5 with a jumper 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...
Page 89: Level Up Solenoid Short To Battery
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...
Page 90: Lift Down Prevented - Tele In First
X016.2.pin X016 and X039. Repair or replace Go to step 2.105.3 2.105.3 Short X002.22.pin to B- Is the fault removed? Tan 4-3-1 or black wire broken between X002 and X016. Repair or replace Possible Causes: 4.1.10 2-90 T350 T500J 3121203...
Page 91: Lift Down Solenoid Short To Battery
4.5 degrees? machine before lifting or telescoping out. Go to step 2.108.2 2.108.2 ANALYZER -> DIAGNOS- See 3.16 Tilt Sensor TICS -> SYSTEM -> TILT Possible Causes: 4.1.10 >= 4.5 DEG (platform tilt LED illuminated) 3121203 T350 T500J 2-91...
Page 92: Lift Up & Tele Out Prevented - Tilted,Unset,& Above Elevation
Functions Disabled: Lift Up Step Pretest Instructions Test Result Corrective Action 2.111.1 Is the boom elevated? See 2.110 Lift Up & Tele Out Prevented - Unset & Above Elevation 3.17 Transport Limit Switch 2-92 T350 T500J 3121203...
Page 93: Lift Up Prevented - Lift Down Then Set Outriggers
Is the machine tilted more Level the machine and try again than 2 degrees? Go to step 2.113.2 2.113.2 Analyzer DIAGNOSTICS -> See 3.16 Tilt Sensor SYSTEM -> TILT >= 2 DEG Possible Causes: 4.1.10 (platform tilt LED illumi- nated) 3121203 T350 T500J 2-93...
Page 94: Lift Up Solenoid Open Circuit
2.115.3 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 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...
Page 95: Lift Up Solenoid Short To Ground
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...
Page 96: Open-Circuit Pump Motor Wiring
Wire Yel/Red 2-13 or black ground wire shorted to ground. Repair or replace Go to step 2.121.3 2.121.3 Remove X002.8 from X002 Is the fault removed? Wire Yel/Red 2-13 shorted to ground. Repair or replace Possible Causes: 4.1.10 2-96 T350 T500J 3121203...
Page 97: Outrigger Stow Prevented - Tele In First
Go to step 2.124.4 console in the platform posi- = VBatt? Possible Cause: Shorted Blu/Blk 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...
Page 98: Power Module Failure: Check Power Circuits Or Mosfet Short Circuit
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 Module's prior to V1.10, a Power Wiring Issue, 4.1.12 2-98 T350 T500J 3121203...
Page 99: Power Module Failure: Personality Range Error
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.
Page 100: Rear-Left O/R Solenoid Short To Battery
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 ground. Repair or replace Analyzer Message “R-L OUTRIG- Possible Cause: 4.1.10 GER VALVE SHORT TO GROUND“ 2-100 T350 T500J 3121203...
Page 101: Rear-Right O/R Solenoid Open Circuit
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...
Page 102: Rear-Right O/R Solenoid Short To Ground
2.135.3 Replace X003.14 with a Rerun System Test Analyzer Message “RETRACT Wire Orn/Wht 55-4-1 or Orn/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...
Page 103: Retract O/R Solenoid Short To Battery
2.137.2 Remove wire Orn/Wht 55-4-1 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...
Page 104: Running At Creep - Material Hook Mode
Is the platform elevated? Go to step 2.140.2 See 3.17 Transport Limit Switch 2.140.2 Are any outriggers unset? Retract, lower the boom and level the machine before trying again See 3.11 Outrigger Switches - All Set 2-104 T350 T500J 3121203...
Page 105: Start Solenoid Open Circuit
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 battery. Repair or replace Analyzer Message “START Possible Cause: 4.1.10 SOLENOID SHORT TO BATTERY“ 3121203 T350 T500J 2-105...
Page 106: Start Solenoid Short To Ground
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- jumper to 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...
Page 107: Swing Left Solenoid Short To Battery
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...
Page 108: Swing Right Solenoid Open Circuit
Rerun System Test Analyzer Message “SWING Wire White 22-3-1 or White 22-3 from X002.35 RIGHT 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...
Page 109: Swing Right Solenoid Short To Ground
Is the machine tilted more Level the machine and try again than 2 degrees? Go to step 2.113.2 2.151.2 Analyzer DIAGNOSTICS -> See 3.16 Tilt Sensor SYSTEM -> TILT >= 2 DEG Possible Causes: 4.1.10 (platform tilt LED illumi- nated) 3121203 T350 T500J 2-109...
Page 110: Telescope In Solenoid Open Circuit
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...
Page 111: Telescope In Solenoid 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...
Page 112: Telescope Out Solenoid Open Circuit
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...
Page 113: Telescope Out Solenoid Short To Ground
2.158.3 Replace X003.11 with a Rerun System Test Analyzer Message “THROTTLE Wire WHT/YEL 48-3 broken. Repair or jumper to 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...
Page 114: Throttle Hold Solenoid Short To Battery
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...
Page 115: Throttle Pull Relay Open Circuit
2.162.3 Remove wire WHT/YEL 48-2 Rerun System Test Analyzer 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 2-115...
Page 116: Throttle Pull Relay Short To Ground
Turn the select Selector Switch switch to the Lift/Swing Posi- “JIB/TELE SELECT” See 2.72 Function Problem - Rotary tion. Do NOT hold the joystick. Selector Switch “TRIGGER OPEN” See 2.72 Function Problem - Rotary Selector Switch 2-116 T350 T500J 3121203...
Page 117: Section 3 - Component Checks
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 T350 T500J 3-117...
Page 118 Open-Circuit between M1 Terminal and Pump Motor Positive Terminal This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP , the JLG Analyzer will show PUMP PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.
Page 119 Short-Circuit between Pump Motor Positive and Negative Terminals This issue will prevent the Pump Motor from operating. Under DIAGNOSTICS -> PUMP , the JLG Analyzer will show an erratic reading for PUMP PWM% and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode.
Page 120: Drive Module - Power
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...
Page 121 -> Drive Possible Causes: Orn/Red 57-1 wire broken, 4.1.18 Possible Causes: Switch 3.5.9 Is hand brake applied? obstructed, Orn/Red 56-1 wire bro- ken, brake cable broken, 4.1.20, 4.1.18 Place boom on rest and try again 3121203 T350 T500J 3-121...
Page 122: Engine Powered Machine - Hydraulic Pump
3.8.2 Test for continuity between See 3.2 DC Powered Machine - X008.1 and B- (X101 for Power or 3.7 Engine Powered electric, X100 for engine) Machine - Power Repair black ground wire between X008.1 and B- 3-122 T350 T500J 3121203...
Page 123: Ignition Relay - Power
Otherwise, go to step 3.9.9 switch in ground position Vbatt Repair open in YEL/RED 2-1 or YEL/ RED 2-2 Check Voltage on X013.1 Possible Causes: 4.1.64 3.9.9 Otherwise, repair open between X013.1 and B+ Vbatt Repair open in Red 1-1 3121203 T350 T500J 3-123...
Page 124: Joystick Diagnostics
Go to step 3.11.7 3.11.6 Disconnect X020 Test for continuity between Possible Causes: Broken Orn/Red 49- X020.1 and X020.4 3 or Yel/Red 2-6 Wire, 4.1.10 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...
Page 125: Outrigger Switches - All Stowed
Possible Causes: 4.1.23, 4.1.10 GROUND -> R-R O/R SET Go to step 3.12.8 3.12.8 Disconnect X020.5 Voltage on X020.5.soc = 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...
Page 126: Platform Module - Power
Possible Causes: 4.1.72, 4.1.12 luminated? stop switch and place key Go to step 3.14.3 switch in ground position 3.14.3 Measured voltage between Possible Causes: 4.1.12 X102 (B+) and X101 (B-) = See 3.2 DC Powered Machine - Vbatt? Power 3-126 T350 T500J 3121203...
Page 127 Corrective Action 3.16.1 Is the ground module se- Possible Causes: 4.1.17, 4.1.10 curely mounted in a level po- Mount ground module securely to sition? frame, level, and in the upright posi- tion as in Figure 7-1 3121203 T350 T500J 3-127...
Page 128 Voltage on X015.1 = Vbatt? Yes White wire broken between X015 and X040. Repair or replace Go to step 3.17.8 3.17.8 Voltage on X004.25 = Wire Yel/Red 2-26-1 or Yel/Red 2-26 Vbatt? broken. Repair or replace Possible Cause: 4.1.10 3-128 T350 T500J 3121203...
Page 129 4.1.34 The ground may be too uneven for proper outrigger Find a more even and/or level area deployment and leveling 4.1.35 The ground module may not be mounted properly Level and properly mount the ground module 3121203 T350 T500J 4-129...
Page 130 Black Pump Motor Negative wire may be cut Repair or replace 4.1.72 Power wire terminals may be corroded or loose Clean terminals and tighten if loose 4.1.73 Hydraulic pump engine coupling may be defective Repair or replace 4-130 T350 T500J 3121203...
Page 131 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 T350 T500J 4-131...
Page 132 SECTION 4 - POSSIBLE CAUSES 4-132 T350 T500J 3121203...
Page 133 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...
Page 134 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...
Page 135 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...
Page 136 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...
Page 137 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...
Page 138 5.50 CL TELE IN System test prompt to close the Telescope In switch. Push the Telescope switch at the ground panel to the In position to test the switch input and continue the test. 5-138 T350 T500J 3121203...
Page 139 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...
Page 140 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...
Page 141 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...
Page 142 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...
Page 143 Go to step 5.88.2 5.88.2 Do other indicators illuminate Possible Causes: Check wiring instead? Go to step 5.88.3 5.88.3 Voltage at X030.6 = 12VDC? Yes Possible Causes: 4.1.27 Go to step 5.88.4 3121203 T350 T500J 5-143...
Page 144 Make sure the correct switch is being activated or check the switch wiring. 5.96 JIB DOWN VALVE OPEN CIRCUIT The system test detected an open in the Jib Down valve circuit. See 2.88 Jib Down Solenoid Open Circuit 5-144 T350 T500J 3121203...
Page 145 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...
Page 146 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...
Page 147 See 2.114 Lift Up Solenoid Open Circuit 5.126 LIFT UP VALVE SHORT TO BATTERY The system test detected a short to battery in the Lift Up valve circuit. See 2.115 Lift Up Solenoid Short To Battery 3121203 T350 T500J 5-147...
Page 148 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...
Page 149 5.146 OP SWING RIGHT System test prompt to open the ground panel Swing Right switch. Release the switch at the ground panel to test the switch input and continue the test. 3121203 T350 T500J 5-149...
Page 150 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...
Page 151 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...
Page 152: R-R Outrigger Valve Short To Battery
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...
Page 153: Start Solenoid
See 2.144 Swing Left Solenoid Open Circuit 5.178 SWING LEFT VALVE SHORT TO BATTERY The system test detected a short to battery in the Swing Left valve circuit. See 2.145 Swing Left Solenoid Short To Battery 3121203 T350 T500J 5-153...
Page 154: Swing Left Valve Short To Ground
5.186.2 Do other indicators illuminate Possible Causes: Check wiring instead? Go to step 5.186.3 5.186.3 Which test is 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...
Page 155: Tele In Cl
See 2.156 Telescope Out Solenoid Short To Battery 5.196 TELESCOPE OUT VALVE SHORT TO GROUND The system test detected a short to ground in the Telescope Out valve circuit. See 2.157 Telescope Out Solenoid Short To Ground 3121203 T350 T500J 5-155...
Page 156: Tests Complete
See 2.161 Throttle Pull Relay Open Circuit 5.204 THROTTLE PULL RELAY SHORT TO BATTERY ENGINE POWERED MACHINES ONLY The system test detected a short to battery in the Engine Throttle Pull circuit. See 2.162 Throttle Pull Relay Short To Battery 5-156 T350 T500J 3121203...
Page 157: Throttle Pull Relay Short To Ground
5.206 TILT LAMP ON System test prompt to check that the platform tilt lamp is illuminating properly. If the lamp is illuminating properly, press ENTER on the analyzer to continue the system test. Otherwise, see possible cause 4.1.11 3121203 T350 T500J 5-157...
Page 158 SECTION 5 - SYSTEM TEST MESSAGES 5-158 T350 T500J 3121203...
Page 159: Section 6 - Calibration Messages
SECTION 6 - CALIBRATION MESSAGES CALIBRATION MESSAGES SECTION 6. This section is reserved for messages related to the calibration process using the analyzer. 3121203 T350 T500J 6-159...
Page 160 SECTION 6 - CALIBRATION MESSAGES 6-160 T350 T500J 3121203...
Page 161: Section 7 - Electrical Reference
SECTION 7 - ELECTRICAL REFERENCE ELECTRICAL REFERENCE SECTION 7. 3121203 T350 T500J 7-161...
Page 162 Ω (8.0 ) X015 X021 SWING LF. Ω (8.0 ) X016 X054 X017 X055 X115 X079 X114 X018 T500 ONLY JIB UP 8.0 Ω Figure 7-1. Frame Connector Layout Figure 7-2. Ground Control / Valve Connections 3121203 T350 T500J 7-162...
Page 163 FOR TROUBLE SHOOTING THE MACHINE ONLY. X022 = 8 POS. CONNECTOR AT FRONT LEFT OUTRIGGER. 12V ENGINE X020 = 12 POS. CONN. OUTRIGGER VALVE/ LIMIT SWITCH TO CHARGE COIL BATTERY GROUND BOLT ON X095 ENGINE HOUSING Figure 7-3. Electrical Schematic 3121203 T350 T500J 7-163...
Page 164 LIGHT HYDRAULIC O/R JACK O/R JACK RELAY JACK JACK LIMIT LIMIT BATTERY STARTER RIGHT BRAKES RIGHT SIDE VALVE VALVE SWITCH SWITCH TAILLIGHT (ENGINE POWERED) (ENGINE POWERED) MARKER LIGHT Ref. 1870172 Rev C Figure 7-4. Electrical Diagram 3121203 T350 T500J 7-164...
Page 165 6. Brake Release Cylinder 2. Drive Enable Valve 7. Drive Engage Cylinder 3. Proximity Sensor 8. Friction Drive Wheel 4. Propulsion Module 9. Drive Directional Valve 5. Drive Engagement Release Valve 10. Drive Motor Figure 7-5. Drive and Set 3121203 T350 T500J 7-165...
Page 166: Connector Index
Figure: 7-1 X043 F/R Outrigger Limit Sw No Drawing Figure: 7-1 X044 R/L Outrigger Limit Sw No Drawing Figure: 7-1 X045 R/R Outrigger Limit Sw No Drawing Figure: 7-1 X046 F/L Outrigger Valve Solenoid DT02P Figure: 7-1 3121203 T350 T500J 7-166...
Page 167 No Drawing Figure: 7-1 X089 Starter Sol. No Drawing Figure: 7-1 X090 Engine Stop Relay No Drawing Figure: 7-1 X091 Throttle Pull Relay No Drawing Figure: 7-1 X092 Engine Oil Level Switch No Drawing Figure: 7-1 7-167 T350 T500J 3121203...
Page 168 X112 6V Batt 4, Pos. No Drawing X113 6V Batt 4, Neg. No Drawing X114 Electric Pump Neg. No Drawing Figure: 7-2 X115 Electric Pump Pos. No Drawing Figure: 7-2 X116 Battery Charger AC Cord No Drawing 3121203 T350 T500J 7-168...
Page 169: Ground Module Connector Pinouts
Output 9.5VDC RS-232 RECEIVE Serial Input Digital Comm. RS-232 TRANSMIT Serial Output Digital Comm. ANALYZER RETURN Power Output 0VDC Depopulated Power Output GROUND Power Output 0VDC NOT USED Digital Input ELECTRIC POWER MODE (FUTURE) Digital Input 7-169 T350 T500J 3121203...
Page 170 SYSTEM DISTRESS INDICATOR Digital Output Vbatt GROUND Power Output 0VDC GROUND Power Output 0VDC GROUND Power Output 0VDC Depopulated HOUR METER Digital Output 12VDC NOT USED Digital Output SWING LEFT Digital Output 12VDC SWING RIGHT Digital Output 12VDC 3121203 T350 T500J 7-170...
Page 171 REAR-LEFT O/R Digital Output 12VDC THROTTLE PULL RELAY Digital Output 12VDC REAR-RIGHT O/R Digital Output 12VDC THROTTLE HOLD SOLENOID Digital Output 12VDC GROUND Power Output 0VDC EXTEND O/R Digital Output 12VDC RETRACT O/R Digital Output 12VDC 7-171 T350 T500J 3121203...
Page 172 Output Vbatt 30 TELESCOPE OUT Digital Input Vbatt 31 GROUND Power Output 0VDC 32 GROUND Power Output 0VDC 33 LIFT DOWN Digital Input Vbatt 34 SWING LEFT Digital Input Vbatt 35 SWING RIGHT Digital Input Vbatt 3121203 T350 T500J 7-172...
Page 173 Table 7-7. X008 (J8) Ground Module Pinout T-SERIES FUNCTION TYPE RANGE (V) GROUND FROM B- Power Input 0VDC IGN PWR FROM IGN RELAY 87 Power Input Vbatt GROUND FOR PLATFORM MODULE Power Output 0VDC IGN PWR FOR PLATFORM MODULE Power Output Vbatt 7-173 T350 T500J 3121203...
Page 174: Platform Module Connector Pinout
Vbatt SWITCH GROUND Power Output 0VDC PLATFORM ALARM Analog Output 0VDC START SWITCH Digital Input Vbatt CHOKE / GLOW SWITCH Digital Input Vbatt ROTARY POSITION 3 Digital Input Vbatt DRIVE & SET SWITCH Digital Input Vbatt 3121203 T350 T500J 7-174...
Page 175: Drive Module Connector Pinout
ANALYZER GROUND Power Output 0VDC SPARE ANALOG 2 Analog Output SPARE ANALOG 3 Analog Output CANBUS CANH Serial Serial 10 CANBUS CANL Serial Serial 11 ANALYZER PIN #3 Serial Serial 12 ANALYZER PIN #2 Serial Serial 7-175 T350 T500J 3121203...
Page 176: Connector Loading Diagrams
AN350P Anderson Power Con- nector AS14P Ampseal 14 position Socket Rear Insert AS351P Ampseal 35 position (Black) AS352P (Neutral) AS354P (Gray) AS355P Socket Rear Insert (Blue) DHD14P Deutsch 14 position HD series alum. Plug Rear View 3121203 T350 T500J 7-176...
Page 177 Socket Rear Insert DT02P Deutsch 2 position DT series plug DT02R Deutsch 2 position DT series receptacle DT03P Deutsch 3 position DT series plug DT04P Deutsch 4 position DT series plug DT04R Deutsch 4 position DT series receptacle 7-177 T350 T500J 3121203...
Page 178 DT06R Deutsch 6 position DT series receptacle DT08AP Deutsch 8 position DT series plug DT08AR Deutsch 8 position DT series receptacle DT12AP Deutsch 12 position DT series plug DT12AR Deutsch 12 position DT series receptacle 3121203 T350 T500J 7-178...
Page 179 A DTM12BP Deutsch 12 position DT 10 11 12 series mini plug with B DTP02P Deutsch 2 position DTP series plug DTP02R Deutsch 2 position DTP series receptacle E06P Eaton Toggle Switch 7-179 T350 T500J 3121203...
Page 180 Molex 4 position MMF08P Molex Mini Fit 8 position plug Rear View MMF10P Molex Mini Fit 10 posi- tion plug MMF12P Molex Mini Fit 12 posi- tion plug MMF16P Molex Mini Fit 16 posi- tion plug 3121203 T350 T500J 7-180...
Page 181: Working With Amp Connectors
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...
Page 182 1. To 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 lbs. to be sure the retention fingers are holding the contact (See Fig- ure 7-8.). Figure 7-7. AMP Connector 3121203 T350 T500J 7-182...
Page 183 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.). Figure 7-9. Connector Assembly Figure 3 7-183 T350 T500J 3121203...
Page 184 The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. 3121203 T350 T500J 7-184...
Page 185 This nullifies the effectiveness of the connector seals and could result in system failure. Figure 7-12. Connector Installation 7-185 T350 T500J 3121203...
Page 186: Working With Deutsch Connectors
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 T350 T500J 7-186...
Page 187 2. Slide tool along into the insert cavity until it engages contact and resistance is felt. 3. Pull contact-wire assembly out of connector. Figure 7-18. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. 7-187 T350 T500J 3121203...
Page 188: Trailer Wiring
SECTION 7 - ELECTRICAL REFERENCE 7.8 TRAILER WIRING Figure 7-19. Electrical Schematic (Trailer) 3121203 T350 T500J 7-188...
Page 189 SECTION 7 - ELECTRICAL REFERENCE 7-189 T350 T500J 3121203...
Page 190: Section 8 - Hydraulic References
SECTION 8 - HYDRAULIC REFERENCES HYDRAULIC REFERENCES SECTION 8. 3121203 T350 T500J 8-190...
Page 191: Solenoids
Drive Right Reverse Solenoid X070 X071 Drive Enable Solenoid 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.
Page 192 SECTION 8 - HYDRAULIC REFERENCES Hydraulic Test Ports MAIN VALVE BLOCK DRIVE DIRECTIONAL VALVE DRIVE ENABLE VALVE Figure 8-1. Hydraulic Test Ports 3121203 T350 T500J 8-192...
Page 193: Hydraulic Schematic - Electric Powered Machines (Sheet 2 Of 2)
SECTION 8 - HYDRAULIC REFERENCES Hydraulic Schematic - Electric Powered Machines Figure 8-2. Hydraulic Schematic - Electric Powered Machines (Sheet 1 of 2) 8-193 T350 T500J 3121203...
Page 194 SECTION 8 - HYDRAULIC REFERENCES 2792642 F Figure 8-3. Hydraulic Schematic - Electric Powered Machines (Sheet 2 of 2) 3121203 T350 T500J 8-194...
Page 195: Hydraulic Schematic - Engine Powered Machines (Sheet 1 Of 2)
SECTION 8 - HYDRAULIC REFERENCES Hydraulic Schematic - Engine Powered Machines Figure 8-4. Hydraulic Schematic - Engine Powered Machines (Sheet 1 of 2) 8-195 T350 T500J 3121203...
Page 196: Hydraulic Schematic - Engine Powered Machines (Sheet 2 Of 2)
SECTION 8 - HYDRAULIC REFERENCES 2792642 F Figure 8-5. Hydraulic Schematic - Engine Powered Machines (Sheet 2 of 2) 3121203 T350 T500J 8-196...
Page 197: Hydraulic Schematic - Engine Powered Drive Option (Sheet 1 Of 2)
SECTION 8 - HYDRAULIC REFERENCES Hydraulic Schematic - Engine Powered Drive Option Figure 8-6. Hydraulic Schematic - Engine Powered Drive Option (Sheet 1 of 2) 8-197 T350 T500J 3121203...
Page 198: Hydraulic Schematic - Engine Powered Drive Option (Sheet 2 Of 2)
SECTION 8 - HYDRAULIC REFERENCES 2792642 F Figure 8-7. Hydraulic Schematic - Engine Powered Drive Option (Sheet 2 of 2) 3121203 T350 T500J 8-198...
Page 199: Hydraulic Schematic - Electric Powered Drive Option (Sheet 1 Of 2)
SECTION 8 - HYDRAULIC REFERENCES Hydraulic Schematic - Electric Powered Drive Option Figure 8-8. Hydraulic Schematic - Electric Powered Drive Option (Sheet 1 of 2) 8-199 T350 T500J 3121203...
Page 200: Hydraulic Schematic - Electric Powered Drive Option (Sheet 2 Of 2)
SECTION 8 - HYDRAULIC REFERENCES 2792642 F Figure 8-9. Hydraulic Schematic - Electric Powered Drive Option (Sheet 2 of 2) 3121203 T350 T500J 8-200...
Page 201 SECTION 8 - HYDRAULIC REFERENCES 8-201 T350 T500J 3121203...
Page 202: Section 9. Jlg Analyzer
(Analyzer Kit, JLG part no. 2901443) which will display two lines of information at a The JLG Control System controller has a built in LED to time, by scrolling through the program. indicate any faults. The system stores recent faults which may be accessed for troubleshooting.
Page 203: To Connect The Jlg Control System Analyzer
SECTION 9 - JLG ANALYZER 9.2 TO CONNECT THE JLG CONTROL SYSTEM 9.3 USING THE ANALYZER ANALYZER With the machine power on and the analyzer connected properly, the analyzer will display the following: 1. Connect the cable supplied with the analyzer, to the...
Page 204: Changing The Access Level Of The Hand Held Analyzer
SECTION 9 - JLG ANALYZER 9.4 CHANGING THE ACCESS LEVEL OF THE If ENTER is pressed again, the display moves to the fol- lowing display: 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.
Page 205: Adjusting Parameters Using The Hand Held Analyzer
SECTION 9 - JLG ANALYZER 9.5 ADJUSTING PARAMETERS USING THE Once the correct password is displayed, press ENTER. The access level should display the following, if the pass- HAND HELD ANALYZER word was entered correctly: Once you have gained access to level 1, and a personality...
Page 206: Machine Setup
SECTION 9 - JLG ANALYZER 9.6 MACHINE SETUP When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: GROUND ALARM: 2 = MOTION The effect of the machine digit value is displayed along with its value.
Page 207 SECTION 9 - JLG ANALYZER 9-207 T350 T500J 3121203...
Page 208 SECTION 9 - JLG ANALYZER 3121203 T350 T500J 9-208...
Page 209 SECTION 9 - JLG ANALYZER 9-209 T350 T500J 3121203...
Page 210: System Test
SECTION 9 - JLG ANALYZER 9.7 SYSTEM TEST 4. The analyzer screen should read: The Control System Incorporates a built-in system test to check the system components and functions. To use this function, use the following procedures. Platform Test 1. Position the Platform/Ground select switch to the Platform position.
Page 211 SECTION 9 - JLG ANALYZER 9-211 T350 T500J 3121203...
Page 212: User Fault Codes
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 component tests. Hit the ESC key during any part of 1. Position the Platform/Ground select switch to the the test to return to the main menu without complet- Ground position.
Page 213 SECTION 9 - JLG ANALYZER 9-213 T350 T500J 3121203...
Page 214: Section 10 - Multimeter Basics
VOM con- • 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 T350 T500J 10-214...
Page 215: Resistance Measurement
• Disconnect component from circuit before testing • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity Figure 10-3. Continuity Measurement 10-215 T350 T500J 3121203...
Page 216 • Be sure to connect the meter leads to the correct jacks for the cur- rent range you have selected • If meter is not auto ranging, set it to the correct range (See multi meter’s operation manual) • Use firm contact with meter leads Figure 10-4. Current Measurement (DC) 3121203 T350 T500J 10-216...
Page 217 SECTION 10 - MULTIMETER BASICS 10-217 T350 T500J 3121203...
Page 218: 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 & T500J Operation and Safety Manual ....3121197 T350 Service and Maintenance Manual ...... 3121198 T500J Service and Maintenance Manual ....3121200 T350 &...
Page 219: Dimensional Data
Voltage 24 VDC 24 VDC 24 VDC Amperage Speed 4000 rpm 3600 rpm 2900 rpm Pump Flow Rate 3.0 gpm 2.7 gpm 2.2 gpm (11.3 (10.2 (8.3 lpm) lpm) lpm) Displace- 0.192 cu.in. ment (3.15 cc) 11-219 T350 T500J 3121203...
Page 220: Light Bulb Information
SECTION 11 - SPECIFICATIONS Taillight and Marker Light Bulb Information Table 11-4. Light Bulb Information Bulb JLG Part # Stop/Turn/Taillight 7026341 Side Marker 7026342 Boom Taillight 7016626 Side Marker Light 7027717 Tires Table 11-5. Tire Specifications T350 T500J (ANSI) (CE)
Page 221 Greater or Equal to 6 Volts Life Cycle Rating 600 Cycles Internal Resistance No more than 2.5 mOhms @ 70° F (21° C) / 4.0 m Ohms @ 0° F (-18°C) Battery Weight (minimum allowable) 61 lbs. (27.7 kg) 11-221 T350 T500J 3121203...
Page 222: Hydraulic Oil
(+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.
Page 223 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.
Page 225 Fax: (61) 2 65 810122 England 20010 Pregnana Milanese Latino Americana Brazil 2132 HJ Foofddorp JLG Industries (Norge AS) Ltda. Phone: (55) 19 3295 0407 The Netherlands Sofeimyrveien 12 Rua Eng. Carlos Steven- Fax: (55) 19 3295 1025 Phone: (31) 23 565 5665...

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