SENB8550-02-04a - 44550 Cat NR
SENB8550-02-04a - 44550 Cat NR
SENB8550-02-04a - 44550 Cat NR
Troubleshooting Schematics
4: Appendix
Troubleshooting Schematics
PDMM-0057 4-39
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
DISPLAY 6 9
DISPLAY
350A TP2 SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
1 FU8
150A 1 L1 2 10 SHIELD
TP7
H-BRIDGE CONTROL
10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT LIMIT
P FW-2 4 4 H-BRIDGE 1 1
A2
3 2
9 5
FW-B+
T2
CONTROL 8 8
FORWARD
FIELD PWM
MODULE
7 6 MODULE 7 7
FU6
1
MD CR1 5 7
FW-2 (HCM) 6 6
PGND
450A +12 +12V
FW-1 3 8 9
TP3 R1 A1 S2 T4 PGND
2 T5 1 9
FW-1
6 10
2 FW-B- LOOP
1S 2 11
T1 I-LIMIT
T2 T3 T4
JP 1
B+
S
JPS12-
5
B1 B2 B1 B2 4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
CHOPPER CONTROL
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIMIT
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPERATURE
8 8
B CHOPPER PWM
MODULE
e 8 7 7
C1 B-DRIVE PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
3 2 2
POWER PANEL
FU2 B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
DRIVER
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
4
7
A B C D
4-40 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE DIRA
TRAC TEMP
LIFT TEMP
24
23
24
23
B+KEY
B+F
2
4
5
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
4 6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-41
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
FU8
8 5
10
1
ALARM
SHIELD
150A 1 L1 2
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP
B-
2
3 6
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1
8 6 6
5
PGND
+12V
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
8 JPF3-
5 JPF2-
14
8 8
7
JPS10-
8
7
PC-CONTACTOR
B-PC B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6
1S-SENSE 4 15
14
15
14
PC-SENSE
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 3 X Y
1
P P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
LINE
2 B CNTR
2 P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
Figure 4-23: Schematic - Turning Key Switch ON, Before SelfTest (Sheet 1 of 2)
4-42 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
8 AGND
11 11
CONTROL HANDLE
15 15 S20
LIFT
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3
DIRB SOL
9
DIRB
CONTROL HANDLE
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
ENTER
AGND
AGND
3
2
8 +12V
DEADMAN
2
3
COM NO
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
25 25
5
1 1 2
PRESSURE DIRA
TRAC TEMP
LIFT TEMP
24
23
24
23
B+KEY
B+F
2
4
1
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
4 REACH EN
REMOTE EPO
17
16
17
16
2ND TS21- RED
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
5 SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
7 3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
Figure 4-23: Schematic - Turning Key Switch ON, Before SelfTest (Sheet 2 of 2)
PDMM-0057 4-43
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1 PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
FU2
1 3
2
3
2
B+KEY
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+
FILT
B+
FILT
X
1S
Y
4 1S CNTR
2
F2 F1 PC
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
Figure 4-24: Schematic - Turning Key Switch ON, After SelfTest (Sheet 1 of 2)
4-44 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
Figure 4-24: Schematic - Turning Key Switch ON, After SelfTest (Sheet 2 of 2)
PDMM-0057 4-45
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
PC FU5
350A
3 TP2
OPERATOR
DISPLAY
4
6
2
9
DATA LATCH
DATA IN
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 SHIELD
150A 1 L1 2
6 10
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4
4 7
8
PGND
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
6 C1 e
B 8
B-DRIVE 7
6
7
6
CHOPPER PWM
PGND
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
2
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
6 6
13
11
B- 6 B-PC
FU1
B-PCF
5
4
5
4
P-CONTACTOR
1S-CONTACTOR
B+PC +12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
1S
B+ B+
B+ F1
X Y
3
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-46 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
LOWER
12
13
12
13
S21 B+PCF
1 7
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND
1 DEADMAN
2ND EN
11
10
11
10 S/S PGND
JPN11-
3
JPZ-
1 T˚
9 9 ON
EQ EN 2 PT
8 8 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
DIRA EN
21
20
21
20 EQ 7
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2 8
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-47
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
4
JPH2- JPS2-
FW-B+
FIELD 7 JPD1-
10
11
JPH1-
1
2
T1
5
4
5
4
REVERSE
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT L
P FW-2 4 4 H-BRIDGE 1 1
A2
3 2
MD
9
7
5
6
FW-B+
T2
CONTROL
MODULE
8
7
8
7
FORWARD
FIELD PWM
FU6
450A 1
FW-1
CR1 5
3
7
8
FW-2
+12
(HCM) 6 6
9
PGND
+12V 5
TP3 R1 A1 S2 T4 PGND
2
2
FW-B-
T5 1
6
9
10
FW-1
LOOP
6
1S 2 11
T1 I-LIMIT
T2 T3 T4
JP 1
B+
S
JPS12-
10
5
S
B1 B2 B1 B2 4
3
B-
B+ 13
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
JP
B-
2 8 PGND
RESISTOR ASSEMBLY
14
4 JPT1-
4 B+KEY 14
CHOPPER JPT2- JPS1- 9
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
CHOPPER ENABL
TP5
D2 Q1
C 6
C-DRIVE 1 9
8
9
8
HEATSINK TEMPE
4 e
B 8
B-DRIVE 7 7
CHOPPER PWM
C1
2 6 6
5
PGND
+12V
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
3
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
11 8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-48 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-49
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABL
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
6
TP7 10 5
JPD1- JPH1- JPH2- JPS2-
FW-B+ 10 1 5 5
FIELD T1 REVERSE
11 2 4 4
1 WIRING FW-B- FIELD CURRENT
(FW) 12 3 2 2
S1 T3 FIELD CURRENT
P FW-2 4 4 H-BRIDGE 1 1
A2
3 2
FU6 MD
9
7
5
6
FW-B+
T2
FW-2
CONTROL
MODULE
8
7
8
7
FORWARD
FIELD PWM
PGND
1 CR1 5 7 (HCM) 6 6
450A +12 +12V
FW-1 3 8 9
TP3 R1 A1 S2 T4 PGND
2 T5 1 9
FW-1
6 10
2 FW-B- LOOP
1S 2 11
T1 I-LIMIT
T2 T3 T4
JP 1
B+
S
JPS12-
B1 B2 B1 B2
1 5
4 B-
S B+
3
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4
4 7
8
PGND
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 3
JPT1-
7 4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT L
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMP
8 8
9 C1 e
B 8
B-DRIVE 7
6
7
6
CHOPPER PWM
PGND
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-50 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2 2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-51
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT L
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1 PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-52 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-53
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8
1 150A 1 L1 2 10 SHIELD
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1 PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-54 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
VEHICLE
GND
3
MANAGER 2 HORN
2 2
S3 9
DIRB
CONTROL HANDLE
DIRB SOL
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
SSHIFT LEFT
4 4
S8
7
9
7 SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9-
13
8 JPN14-
13
REACH PGND
2 2
DT
ON
MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
3 HORN EN
DIRB EN
7
6
7
6
TILT
LIFT TEMP
JPN9-
S/S EN
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
4 REACH EN
REMOTE EPO
17
16
15
17
16
15
2ND TS21- RED
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-55
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LIM
TP6 SENSOR 1 1
TP5 CHOPPER ENABLE
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPER
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1 PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-56 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3
DIRB SOL
9
DIRB
CONTROL HANDLE
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
Figure 4-30: Schematic - Sideshift (Sheet 2 of 2)
PDMM-0057 4-57
A B C D
2 JPI-
1
JPS8-
5
CONTROL LATCH
2 4
MEMORY ENABLE
3 3
DATA LATCH
PC FU5 OPERATOR 4 2
DATA IN
350A TP2 DISPLAY 6 9
SHIFT CLOCK
(OD) 7 8
DATA OUT
1 2 8 7
PGND
9 6
+12V
5 1
ALARM
FU8 10 SHIELD
150A 1 L1 2
TP7
ECODER
ON A+
2
MP MX 1 MD DE 1
A-
TM1 TM2 +5V
A A R4 7
PGND
8
PGND
JP 2
B-
RESISTOR ASSEMBLY
4 JPT1-
4 B+KEY
CHOPPER JPT2- JPS1-
CONTROL 4 4
MODULE ARM CURRENT
7 3 3
REC1 +12 (CCM) TEMP LIMIT
2 2
10 ARM CURRENT LI
TP6 SENSOR 1 1
TP5 CHOPPER ENABL
C 6 9 9
D2 Q1 C-DRIVE HEATSINK TEMPE
8 8
B 8 CHOPPER PWM
e B-DRIVE 7 7
C1 PGND
6 6
+12V
5
TP4 E 2 PGND
HT E-DRIVE
T˚
JPF4- 3
HEATSINK
E
B+KEY
JPF3- JPS10-
5 JPF2-
14 B-PC
8
7
8
7
PC-CONTACTOR
B-CONTACTOR
13 6 6
B- FU1 P-CONTACTOR
5 5
11 B-PC B-PCF 1S-CONTACTOR
B+PC 4 4
+12V
3 3
B+KEY
FU2 2 2
B+KEY
B- B-F 1 1
B+KEY
6 15 15
PC-SENSE
1S-SENSE 14 14
B-SENSE
8 FU3 13 13
B-SENSE P-SENSE
B+PC B+PCF 12 12
7 1S-SENSE
P-SENSE 11 11
B-F
9 10 10
PC-SENSE FU4 B-F AGND
9 9
10 B+ B+F B-F
B+ SHIELD
5 B+KEY
POWER PANEL
X Y DRIVER ASSY
3
PC PC CNTR (PPDA)
6 X
P
Y
1 P CNTR
B+ F1 1S
B+ B+ X Y
FILT 4
FILT 1S 1S CNTR
PC
F2 F1
2 B CNTR
LINE P
REMOTE EPO
FILTER B-
B+KEY
B+PCF
B+ F2
B-PCF
B+F
B-F
JPF1-
1 2 3 4 5 6
A B C D
4-58 PDMM-0057
E F G H
+12V
JPS4-
9
14
JPC1-
9
14
2
THROTTLE VR1
11 11
AGND
15 15
CONTROL HANDLE
LIFT S20
1 1 JPN1-
GND
12 12 1
S21 B+PCF
LOWER
13 13
GND
VEHICLE 2 2
MANAGER HORN S3 9
CONTROL HANDLE
DIRB SOL DIRB
8 8
(VM) REACH S4 1 2
7 7
RETRACT S5
6 6 8
TILT UP S6 DIRA SOL DIRA
5 5 1 2
TILT DOWN S7
4 4
SSHIFT LEFT S8
7
SSHIFT RIGHT
AGND
3
10
3
10
S9 EQ SOL
1
EQ
2
3
SHIELD
3
B+KEY
5
L/H SOL L/H
1 2
RUN PROGRAM JS3-
OUTPUT#1 6 PN3-
OUTPUT#2 7 1 6
B+KEY
OUTPUT#3 9 2 2ND SOL 2ND
B+PCF
EXPANSION
ANALOG #1 5 OPTTVL 3 1 2
B-PCF
ANALOG #2 4 OPTLIPT JPN6-
ANALOG #3 8 1 S2
+12V COM NO
AGND 3 2
ENTER DEADMAN
AGND 2 3
PGND IN
+12V 1
SHIELD 4 H1 NEG
B- F H
HORN + 5
VEHICLE H2 POS
FUNCTION
CONTROLLER
(VFC)
HYDRAULIC
4
DRIVER
ASSEMBLY
(HDA)
JPN10- JPM-
3 1 T˚
JPS9- JPN14- REACH PGND
ON
DT
13 13 2 2 MD
+12V TRAC TEMP
12 12
PGND JPN11- JPZ-
11 11
DEADMAN
10 10 S/S PGND
3 1 T˚
2ND EN ON
9 9 PT
EQ EN
8 8 2 2 MP
HORN EN LIFT TEMP
DIRB EN
7
6
7
6
TILT
S/S EN JPN9-
5 5
UNNESTED 3
4 4 PGND
REMOTE 2 0
MASTSW2
3 3 DIRB PRESSURE
1 +
PRESS
2 2 +12V
LIFT INHBT
1 1 S1
MASTSW1 JPN4-
HYDRAULIC DRIVER
25 25
5
1 1 2
PRESSURE
TRAC TEMP
24 24 DIRA B+KEY
2
23 23 B+F
LIFT TEMP 4
22 22 REMOTE
SPARE 1
21 21
DIRA EN
20 20 EQ
L/H
19 19
TILT EN TS19- BLACK
18 18
INHBTBYP
REACH EN
17
16
17
16
2ND TS21- RED
REMOTE EPO
15 15
REMOTE LWR 5 BLACK 5
14 14 B+KEY
REMOTE LFT
POWER SUPPLY
(PS) SHIELD
L/H SOL 6
3 WHITE 3 2 REACH 1
REACH SOL
SOL 8
B+ FILTERED
+5V
B+
SOL 7
1 RED 1 WHITE 2 TILT 1
TILT SOL
JPP1-
1 2 3 4 5 6
REMOTE EPO
4 ORANGE 4 6
6 BLUE 6
REMOTE EPO
JPS11- B-PCF
6 5 4 3 2 1
B+PCF
B+KEY
ON CARRIAGE
B-PCF
B+F
B-F
JS6-
3
Tracing Legend - Electrical
DIAGNOSTIC
SENSE 6 5 4 3 2 1 JPN5-
1
OUT
4
IN
2
PORT
AGND
Positive Circuit
Negative Circuit
Detect/Signal Lines
7
NOTE: The schematics in this section are for Theory of Operation only.
Refer to the Appendix when troubleshooting and for maintenance.
E F G H
PDMM-0057 4-59
Troubleshooting CATERPILLAR® Reach Service Manual
Troubleshooting Schematics
4-60 PDMM-0057