Page 1 of 7 - JLG Industries

1 SPECIAL INSTRUCTION Reference: SI E0920 June 17, 2009 Attention: This notice is being issued to advise you of new information for certain Caterpillar ( CAT ) Telehandlers that were manufactured by JLG Industries , Inc. ( JLG ). TITLE: Diagnostic Code Information for Transmission and/or Engine control systems used on certain CAT Branded Telehandlers. APPLICABLE PRODUCTS: Model Serial Number Range TH336 TDE00100 & After TH337 TDF00100 & After TH406 TBX00100 & After TH407 TBY00100 & After TH414 TBZ00100 & After TH514 TBW00100 & After TH417 TBT00100 & After INTRODUCTION: The diagnostic code information that follows is utilized by certain CAT Branded Telehandlers that are equipped with Caterpillar electronic controls.

2 Component identifiers, failure mode identifiers, and module identifiers are pieces of information that assist service personnel in diagnosing system problems of the machine. A component identifier (CID) is a diagnostic code that informs the service personnel of the specific circuit or system within which a problem was detected. A failure mode identifier (FMI) is a diagnostic code that informs the service personnel of the type of problem that has been detected within a circuit or system. Event codes identify significant events that occur to the systems of the machine. The ECM stores the data from the events.

3 This function allows tracking of the history of the machine. The data is used as an aid for managers and maintenance personnel. Page 1 of 7 TRANSMISSION RELATED DIAGNOSTICS Details are following for the transmission control system related diagnostics that are supported by the system. This system will support diagnostic reporting in SAE J1939 SPN-FMI format only. SPN SPN Description FMI FMI Description Warning Level 678 ECU 8 Volts DC Supply 3 Voltage Above Normal 2 678 ECU 8 Volts DC Supply 4 Voltage Below Normal 2 168 Electrical Potential (voltage) 3 Valid & Above Normal Range 2 168 Electrical Potential (voltage)

4 4 Valid & Below Normal Range 2 639 J1939 Network #1 9 Abnormal Update 2 525 Transmission Requested Gear 19 Received Network Data in Error 2 683 Disengage Driveline Request 19 Received Network Data in Error 2 177 Transmission Oil Temperature 3 Voltage Above Normal 2 177 Transmission Oil Temperature 4 Voltage Below Normal 2 190 Engine Speed 19 Received Network Data in Error 2 191 Transmission Output Shaft Speed 2 Data Erratic, Intermittent or Incorrect 1 161 Transmission Input Shaft Speed 2 Data Erratic, Intermittent or Incorrect 1 4216 Transmission Reverse solenoid Valve 3 Voltage Above Normal 3 4216 Transmission Reverse solenoid Valve 5 Current Below Normal 2 4216 Transmission Reverse solenoid Valve 6 Current Above Normal 2 741 Transmission Forward solenoid Valve 3 Voltage Above Normal 3 741 Transmission Forward solenoid Valve 5 Current Below Normal 2 741 Transmission Forward solenoid Valve 6 Current Above Normal 2 734 Transmission Range Clutch solenoid #1 3 Voltage Above Normal 3 734 Transmission Range Clutch solenoid #1 5 Current Below Normal 2 734 Transmission

5 Range Clutch solenoid #1 6 Current Above Normal 2 Page 2 of 7 735 Transmission Range Clutch solenoid #2 3 Voltage Above Normal 3 735 Transmission Range Clutch solenoid #2 5 Current Below Normal 2 735 Transmission Range Clutch solenoid #2 6 Current Above Normal 2 736 Transmission Range Clutch solenoid #3 3 Voltage Above Normal 3 736 Transmission Range Clutch solenoid #3 5 Current Below Normal 2 736 Transmission Range Clutch solenoid #3 6 Current Above Normal 2 737 Transmission Range Clutch solenoid #4 3 Voltage Above Normal 3 737 Transmission Range Clutch solenoid #4 5 Current Below Normal 2 737 Transmission Range Clutch solenoid #4 6 Current Above Normal 2 738 Transmission Range Clutch solenoid #5 3 Voltage Above Normal 3 738 Transmission Range Clutch solenoid #5 5 Current Below Normal 2 738 Transmission Range Clutch solenoid #5 6 Current Above Normal 2 2827 Power Up Without Neutral 31 Not Available or Condition Exists 3 4217 Transmission Shift Modulation solenoid Valve 3 Voltage Above Normal 3 4217 Transmission Shift Modulation solenoid Valve 5 Current Below Normal 2 4217 Transmission Shift Modulation solenoid Valve 6 Current Above

6 Normal 2 4218 Transmission Shift Rail 1 Position 3 Voltage Above Normal 2 4218 Transmission Shift Rail 1 Position 4 Voltage Below Normal 2 4218 Transmission Shift Rail 1 Position 8 Abnormal Frequency, Pulse Width or Period 2 4219 Transmission Shift Rail 2 Position 3 Voltage Above Normal 2 4219 Transmission Shift Rail 2 Position 4 Voltage Below Normal 2 4219 Transmission Shift Rail 2 Position 8 Abnormal Frequency, Pulse Width or Period 2 4220 Transmission Shift Rail 3 Position 3 Voltage Above Normal 2 4220 Transmission Shift Rail 3 Position 4 Voltage Below Normal 2 4220 Transmission Shift Rail 3 Position 8 Abnormal Frequency, Pulse Width or Period 2 4221 Transmission Directional Shift at High Speed 14 Special Instruction 3 Page 3 of 7 ENGINE RELATED DIAGNOSTICS Note that in some case there are differences in the codes which are transmitted on the J1939 bus and those are transmitted on the CDL bus.

7 Additionally codes may be added on later software that are not present on this table. Type CID/EID J1939 SPN FMI Lamp Flash Code [ future ] Component Description Diagnostic 91 91 2 154 Throttle Position Sensor data erratic intermittent or incorrect Diagnostic 91 91 3 154 Throttle Position Sensor Voltage above normal or shorted high Diagnostic 774 91 3 155 Secondary throttle position sensor Voltage above normal or shorted high Diagnostic 91 91 4 154 Throttle Position Sensor Voltage below normal or shorted low Diagnostic 774 91 4 155 Secondary throttle position sensor Voltage below normal or shorted low Diagnostic 91 91 8 154 Throttle Position Sensor abnormal frequency, pulse width.

8 Or period Diagnostic 774 91 8 155 Secondary throttle position sensor abnormal frequency, pulse width, or period Diagnostic 91 91 12 154 Throttle Position Sensor Bad Device or component Diagnostic 774 91 12 155 Secondary throttle position sensor Bad Device or component Diagnostic 100 100 3 157 Engine Oil pressure Sensor voltage above normal or shorted high Diagnostic 100 100 4 157 Engine Oil pressure Sensor voltage below normal or shorted low Diagnostic 100 100 10 157 Engine Oil pressure sensor Engine oil pressure sensor 5V supply connection open circuit Event 360 100 17 n/a Engine Oil pressure sensor low oil pressure - WARNING Event 360 100 18 n/a Engine Oil

9 Pressure sensor Low oil Pressure - DERATE Event 360 100 1 n/a Engine Oil pressure sensor Low Oil Pressure - SHUTDOWN Event 539 105 15 n/a Inlet Manifold Air Temp Sensor High Intake manifold temperature - WARNING Event 539 105 16 n/a Inlet Manifold Air Temp Sensor High Intake manifold temperature - DERATE Diagnostic 172 105 3 133 Inlet Manifold Air Temp Sensor voltage above normal or shorted high Diagnostic 172 105 4 133 Inlet Manifold Air Temp Sensor voltage below normal or shorted low Page 4 of 7 Diagnostic 1785 106 3 135 Inlet Manifold Pressure Sensor voltage above normal or shorted high Diagnostic 1785 106 4 135 Inlet Manifold Pressure Sensor voltage below normal or shorted low Diagnostic 1785 106 10 135 Inlet Manifold Pressure Sensor Inlet Manifold Pressure Sensor 5V supply connection open circuit Event 361 110 15 n/a Engine Coolant Temp Sensor High coolant temp - WARNING Event 361 110 16 n/a Engine Coolant Temp Sensor High coolant temp - DERATE Diagnostic 110 110 3 169 Engine Coolant Temp Sensor voltage above normal or shorted high Event 361 110 0 n/a Engine Coolant Temp Sensor High coolant temp - SHUTDOWN

10 Diagnostic 110 110 4 169 Engine Coolant Temp Sensor voltage below normal or shorted low Diagnostic 1797 157 3 n/a Fuel Rail pressure sensor Voltage above normal or shorted high Diagnostic 1797 157 4 n/a Fuel Rail pressure sensor Voltage below normal or shorted low Diagnostic 1834 158 2 439 Keyswitch data erratic, intermittent, or incorrect Diagnostic 168 168 0 422 ECM battery power Excessive battery power Diagnostic 168 168 1 422 ECM battery power Low battery power Diagnostic 168 168 2 422 ECM battery power intermittent Diagnostic 190 190 8 141 Speed/Timing sensor abnormal signal frequency Event 362 190 15 n/a Engine Speed Engine Overspeed - WARNING Diagnostic 91 558 2 154 Throttle Position Sensor Idle validation switch Diagnostic 774 558 2 155 Secondary throttle position sensor data erratic, intermittent, or incorrect Diagnostic 268 630 2