999 SERVICE MANUAL TROUBLESHOOTING

CRANE DIAGNOSTICS Drum 4 (Boom Hoist)

To activate the diagnostic display screens, turn the limit
bypass key clockwise and scroll up at least one screen. 1 2 3 4
Once this step is performed, you can scroll up and down 5 6 DRUM 4
through the diagnostic screens in addition to the normal
operating screens. To deactivate the diagnostic screens, turn
1. The handle command is in percent from neutral (+ raise
the limit bypass key clockwise and scroll down at least one
and - lower). For certain operating conditions the handle
screen. The normal operating screens will remain active.
command can be set to neutral by the controller even if
The diagnostic display provides information about the status the handle is not in neutral.
of all main crane components as well as the controller inputs
2. the pump command is in percent from neutral (+ raise
and outputs during operation. The screen types are:
and - lower).
Screens that display information about particular crane
3. The motor command is in percent (0% is maximum
functions DRUMS 1, 2, 4, and 8, SWING, TRACK,
displacement, 100% is minimum displacement).
RIN, and ACCESSORY SYSTEM.
4. Park brake command (1 release, 0 engage).
Screens that display digital input and output information
A1 (analog handle inputs to crane controller), D1 5. Measured pump pressure (raise) in psi.
(digital outputs from crane controller), and D2 (digital
inputs to crane controller). 6. Measured drum speed in rpm (+ raise and - lower).

Screens that display controller programming information Drum 8 (Auxiliary)

A2, A3, and D3. These screens are for factory use
only, and are not shown. 1 2 3 4
Screens that display hydraulic system calibration 5 6 DRUM 8
information HYD SYSTEM CHECK. Check includes
pressure sender, charge pressure, control calibration,
and pump pressure. 1. The handle command in percent from neutral (+ raise
and - lower). For certain operating conditions the handle
Program screens, SWING SPEED/TORQUE, and command can be set to neutral by the controller even if
DRUM SLIP. the handle is not in neutral.
See Figure 10-2 for Drum and Pump Identification. 2. The pump command is in percent from neutral (+ raise
and - lower).
Drum 1 and 2 (Front and Rear Drum)
3. The motor command is in percent (0% is maximum
displacement, 100% is minimum displacement).
1 2 3 4 5
4. Park brake command (1 release, 0 engage).
6 7 DRUM X
5. Measured pump pressure (raise) in psi.
1. The handle command in percent from neutral (+ raise 6. Measured drum speed in rpm (+ raise and - lower).
and - lower). For certain operating conditions the handle
command can be set to neutral by the controller even if FFall
the handle is not in neutral.
2. The pump command in percent from neutral (+ raise and 1 2 3 4
- lower).
5 6 7 8 FFALL
3. The motor command is in percent (0% is maximum
displacement, 100% is minimum displacement). 1. The drum 1 pedal command is in percent (0% applied,
4. Parking brake command (1 release, 0 engage). 100% fully released).

5. Clutch command (1 release, 0 engage) (applies only to 2. Drum 1 PC output to proportional valve in percent of
drums with free fall, otherwise has no meaning). pressure (0% to 100%).

6. Measured pump pressure (port A) in psi. 3. Drum 1 measured pressure to clutch/brake piston in psi.

7. Measured drum speed in rpm (+ raise and lower). 4. Drum 1 clutch/brake command is (0 disengaged,
1 engaged).
X is where the corresponding drum number appears. 10

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5. Drum 2 pedal command is in percent (0% applied, 100% 6. Measured system pressure left track in psi.
fully released).
7. Parking brake command (1 release, 0 engage).
6. Drum 2 PC output to proportional valve in percent of
pressure (0% to 100%). RIN
7. Drum 2 measured pressure to clutch/brake piston in psi. Depending on the crane configuration, RIN computers are
mounted in the universal boom top junction box, luffing jib top
8. Drum 2 clutch/brake command is (0 disengaged,
junction box, or fixed jib top junction box (Figure 10-1). The
1 engaged).
junction boxes are interconnected in series with electrical
co r d s t h a t r u n u p t h e b o o m to t h e la st a t ta c h me n t
Swing (Crane)
component. The RIN computer in universal boom top
junction box receives inputs from load sensors, limit
1 2 switches, angle sensors, and other RIN computers in series.
The RIN computer in universal boom top junction box
3 4 SWING
transmits output information to crane EPIC computer in
operators cab.
1. The handle command is in percent from neutral (+ right
and - left). For certain operating conditions the handle A1042
command can be set to neutral by the controller even if Luffing Jib Top
Junction Box
the handle is not in neutral.
2. The pump command is in percent from neutral (+ right
and - left).
3. Measured pump pressure swing right (port A) in psi. Fixed Jib Top
Junction Box
4. Measured pump pressure swing left (port B) in psi.

Swing Speed/Torque
See Swing Speed/Torque Adjustment instructions in
Operators Manual. Universal Boom Top
Junction Box
Drum Slip
See Free Fall Drum Slip Adjustment instructions in FIGURE 10-1
Operators Manual.
The RIN diagnostic screen is to assist in troubleshooting the
Track boom top, luffing jib or fixed jib electrical system.

1 2 3 4 1 2 3 4
5 6 7 TRACK 5 6 7 8 RIN

1. The right handle/pedal command is in percent from

The following voltages can be displayed on the first six banks
neutral (+ forward, - backward). For certain operating
of the RIN diagnostic screen. These voltage values can be
conditions the handle command can be set to neutral by
compared with the voltages shown on the LMI (Rated
the controller even if the handle is not in neutral.
Capacity Indicator/Limiter) diagnostic screen.
2. The right pump command is in percent from neutral
If the voltages do not match, the EPIC computer and the LMI
(+ forward, - backward).
are not communicating properly.
3. The left handle/pedal command is in percent from
neutral (+ forward, - backward). For certain operating Bank 1 Boom Angle
conditions the handle command can be set to neutral by
Bank 2 Luffing Jib Angle
the controller even if the handle is not in neutral.
Bank 3 Lower Boom Point
4. Left pump command in percent from neutral (+ forward,
Bank 4 Upper Boom Point
backward).
Bank 5 Lower Luffing Jib Point
5. Measured system pressure right track in psi. Bank 6 Upper Luffing Jib Point or Fixed Jib Point

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999 SERVICE MANUAL TROUBLESHOOTING

1. Rear drum/accessory system pump command in

Bank 7 indicates the RIN digital inputs. For example, if Bank percent from neutral (+ retract mast cylinders; extend
7 displays the number 72, see Table 10-3 and the shaded mast cylinders).
boxes in row 72. This indicates that Jib Maximum Up 2. Desired accessory system pressure in psi.
Working Limit (8) and Block-Up Limit Luffing Jib Point (64)
inputs (8 + 64 = 72) are active. 3. Actual accessory system pressure in psi.
4. Rear drum measured pump pressure (hoist) in psi.
1 Block-Up Limit (Boom Point) 5. The boom hoist pump command in percent from neutral
2 Block-Up Limit (Boom Point) (+ lower mast; raise mast).
4 Jib Max Down Limit 6. Boom hoist measured pump pressure (hoist) in psi.
8 Jib Max Up 1 Limit 7. Accessory system switches:
16 Jib Max Up 2 Limit 1 - Raise Gantry Remote Switch
32 Block-Up Limit (Luffing Jib/Fixed Jib Point) 2 - Lower Gantry Remote Switch
64 Block-Up Limit (Luffing Jib Point) 4 - Mast Raise Switch
8 - Mast Lower Switch
128 Block-Up Limit (Fixed Jib on Luffing Jib Point) 16 - Boom Hinge Pins In Switch
To end the RIN circuit at the last used junction box, a 32 - Boom Hinge Pins Out Switch
shorting plug must be plugged into junction box jib cable 64 - Accessory System Enable Switch
receptacle. If shorting plug is not installed, the RIN computer 128 - Spare
sees an open circuit and assumes the electrical cable to next
junction box is open. The RIN circuit turns off one or more
A1 (Handles)
block-up limit identifiers (switches) depending on where the The variable control handle output voltage is represented in
open circuit exists. With an open RIN circuit at boom top the controller by a number between 0 (0 Volts) and 255 (10
junction box jib cable receptacle, Bank 7 numbers 32, 64, Volts). Diagnostic screen A1 displays this number for each of
and 128 are off. With an open RIN circuit at luffing jib top the control handles/pedals. The normal operating outputs of
junction box jib cable receptacle, Bank 7 number 128 is off. the handles range from:
Bank 8 indicates the status of each RIN computer as shown Approximately 38 (1.5 Volts) to 120 (4.7 Volts) for lower/
below. reverse/right.
Approximately 136 (5.3 Volts) to 215 (8.5 Volts) for raise/
0 EPIC computer is communicating with boom top forward/left.
RIN computer.
NOTE: Some dual-axis handles (joysticks) are internally
1 EPIC computer is communicating with boom top limited and will not put out the full range stated.
RIN computer, but there is a communication fault
internal to universal boom top junction box RIN A switch opens when the handle is in the neutral range of
computer. (4.7 5.3 volts). In the neutral range, the screen reads 0
2 EPIC computer is communicating properly with volts.
boom top RIN computer and boom top RIN
computer is communicating properly with at least
one other RIN computer in series.
1 2 3 4 5

4 Shorting plug is installed to cable connector end at 6 7 8 9 A1

boom limit junction box or at cable reel to bypass
operating limit fault(s). Handle 1 Front Drum
8 No communication, all boom top operating limits Handle 2 Rear Drum
are activated when a drum control handle is moved
from neutral. Handle 3 Boom Hoist
Handle 4 Swing
Accessory System
Handle 5 Right Track
1 2 3 4 Handle 6 Left Track
5 6 7 ACC Handle 7 Auxiliary Drum
Pedal 1 Right Track 10

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TROUBLESHOOTING
Pedal 2 Left Track
D1, D2, and D3 (Digital Outputs and Inputs)
The status of the digital outputs from the controller and the
inputs to the controller is displayed in several banks in
screens D1, D2, and D3. Each bank can indicate the state of
up to nine individual digital inputs or outputs.
1 2 3 4 5 component description for the identifiers in Table 10-2, Bank
6 7 8 9 DX
1 9 is the bank number.
X corresponds to digital screen number (1, 2, or 3).
Each individual input/output is assigned a number (identifier)
in the binary system (powers of two). The identifiers of all
inputs/outputs that are ON (active), are added to a total in
each bank. Thus, the number displayed for each bank is the
sum of all identifiers of the inputs/outputs that are ON (0
255). With this system, each possible ON/OFF combination
per bank has a unique total.
For identification of the digital outputs and inputs (and the
crane components connected to them) see Tables 10-1 and
10-2.
To determine the state of the individual inputs/outputs in a
bank, find the number displayed for the bank in the first
column in Table 10-3. In the corresponding row the identifier
numbers that are ON (active) in the bank are shaded. Use
Tables 10-1 and 10-2 to identify the crane components
associated with the identifiers for the corresponding bank.
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999 SERVICE MANUAL
If number displayed for short bank is more than the total of all
bank identifiers, add missing identifier numbers (64 + 128=
192) and subtract from displayed number to obtain
remaining identifier number(s).
Example 1: The number displayed in Bank 4 of screen D2 of
the digital display is 41. Go to row number 41 in Table 10-3.
The boxes for identifiers 1, 8 and 32 are shaded in this row,
indicating that the corresponding inputs are active. Find the
4. In this example, the inputs for Front Drum Brake Switch
(1), Display Scroll Up (8) and Gantry Lower Switch (32) are
active.
Example 2: You want to know if the controller output for the
rear drum clutch is ON. In Table 10-1 you will find Rear Drum
Clutch in Bank 1 (identifier 64). Look up the current number
for Bank 1 in screen D1 on the digital display (e.g. 152). Then
go to the corresponding row number (152) in Table 10-3.
Identifier 64 box is not shaded in this row, indicating that the
controller output to the rear drum clutch is OFF.
NOTE: All numbers in screen D1, and the pump/motor
command values in screens DRUM, SWING and
TRACK represent controller commands to the
corresponding output devices only. The state of a
certain output port on the controller may not
necessarily correspond to the actual state of the
associated crane component (brake valve, clutch
valve, etc.), since the connection between the
controller and the component may be faulty due to
loose connections, corroded terminals, broken
wiring, or improperly operating components.
999 SERVICE MANUAL TROUBLESHOOTING

Table 10-1 D1 (Crane Digital Outputs) Table 10-2 D2 (Crane Digital Inputs)
Identifier* Component Identifier* Component
Bank 1 Bank 1
1 Auxiliary Drum Pawl Enabled 1 Travel Detent Set/Cancel
2 Auxiliary Drum Pawl Disabled 2 Front Drum Maximum Bail Limit
4 Boom Hoist Park Brake 4 Front Drum Minimum Bail Limit
8 Travel Park Brake 8 Spare
16 Remote Output Node Communication 16 Boom/Jib Maximum Angle Bypass
32 Front Drum Proportional Valve 32 Mast Raise Switch
64 Rear Drum Proportional Valve 64 Rear Drum Maximum Bail Limit
128 Front Drum Brake 128 Rear Drum Minimum Bail Limit
Bank 2 Bank 2
1 Rear Drum Brake 1 Crane Mode Select
2 Engine Throttle Output 2 Crane Mode Confirm
Bank 3 4 Mast Lower Switch
1 Auxiliary Drum Park Brake 8 Boom Maximum Up Limit
2 Boom Hinge Pins Retract 16 Remote Output Node Feedback
4 Motion Alarm 32 Spare
8 Front Drum Enable Valve Bank 3
16 Rear Drum Enable Valve 1 Spare
32 Gantry Cylinders Extend 2 Hydraulic Fluid Level
64 Gantry Cylinders Retract 4 Spare
128 Mast Cylinders Extend 8 Spare
Bank 4 16 Spare
1 Mast Cylinders Retract 32 Spare
2 Boom Hinge Pins Extend 64 Rear Drum Brake Switch
128 Gantry Up Limit
Bank 5
1 Counterweight Pins Retract Bank 4
2 Front Drum Rotation Indicator 1 Front Drum Brake Switch
4 Rear Drum Rotation Indicator 2 Rated Capacity Indicator/Limiter
8 Boom Drum Rotation Indicator 4 Limit Bypass
16 Auxiliary Drum Rotation Indicator 8 Display Scroll Up
32 High Speed Travel 16 Gantry Raise Switch
64 Front Drum Pawl Enabled 32 Gantry Lower Switch
128 Front Drum Pawl Disabled Bank 5
Bank 6 1 Counterweight Pins Extend Switch
1 Rear Drum Pawl Enabled 2 Counterweight Pins Retract Switch
2 Rear Drum Pawl Disabled 4 Boom Hinge Pins Extend Switch
8 Boom Hinge Pins Retract Switch
Bank 7 16 Display Scroll Down
1 Boom Drum Pawl Enabled 32 Seat Safety Switch
2 Boom Drum Pawl Disabled 64 High Speed Travel Switch
4 Rotating Bed Auto-Lube 128 Accessory Pressure Switch
8 Swing Auto-Lube
16 Travel Auto-Lube Bank 6
32 Auxiliary Drum Pump Control Up ** 1 Front Drum Park Switch
64 Auxiliary Drum Pump Control Down ** 2 Rear Drum Park Switch
128 Not Used 4 Boom Hoist Drum Park Switch
8 Travel Park Brake Switch
Bank 8 16 Auxiliary Drum Park Switch
Not used 32 Auxiliary Drum Minimum Bail Limit
* Binary Bank 7
** These digital ports are pulsed for auxiliary pump 1 Spare
control. For both ports a digital ON is displayed when 2 Swing Park Brake Switch
pulsing, to prevent a flickering number for the 4 Spare
corresponding bank. 8 Main Charge Filters Switch
16 Auxiliary Drum Charge Filter Switch
*** Bank 9 inputs are from RIN computer, not system 32 Free-Fall Filters Switch
computer. 64 Spare
128 Engine Oil Pressure Switch
Bank 8
1 Engine Temperature Switch
2 Not Used
4 Not Used
8 Not Used
16 Not Used
32 Not Used
10

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Table 10-2 D2 (Crane Digital Inputs)

Drum Identification
Identifier* Component
Bank 9*** Drum
1 Block Up Limit (Boom Top) Crane
Number 8
2 Block Up Limit (Boom Top)
1 Front Load Drum
4 Jib Minimum Down Working Limit
8 Jib Maximum Up Working Limit 2 Rear Load Drum 1
16 Jib Maximum Up Stop
4 Boom Hoist
32 Block Up Limit (Luffing Jib/Fixed Jib Top)
64 Block Up Limit (Luffing Jib Top) 2
128 Block Up Limit (Fixed Jib on Luffing Jib Top) Auxiliary Load Drum
* Binary 8
(in boom butt)
** These digital ports are pulsed for auxiliary pump 4
control. For both ports a digital ON is displayed when
pulsing, to prevent a flickering number for the
corresponding bank. FIGURE 10-2
*** Bank 9 inputs are from RIN computer, not system
computer.

Handle/Pedal Identification
Handle Crane
Number (All Modes)
1 Front Load Drum
Rear Load Drum or
2
Luffing Hoist*
Boom Hoist or
3
Luffing Hoist**
4 Swing 2 1
3 4
5 Right Crawler
4
6 Left Crawler 1 2
3
Auxiliary Load Drum
7 (in butt) or
Luffing Hoist**
Pedal
Number
1 Right Crawler 6 5
2 Left Crawler 7
3 Front Drum Brake
4 Rear Drum Brake
* Activated only in luffing jib Mode.
** Special handle arrangement activated
only in luffing jib Mode. A817 FIGURE 10-3

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999 SERVICE MANUAL TROUBLESHOOTING

CRANE
Pump Identification Pump Port Identification
Pump Pump
Number Crane Number Port A Port B 2 10

0 Front Load Drum 0, 1, 2,

Raise Lower Super Charge
Rear Load Drum or 10 Pump
1 3
Luffing Hoist 3 Right Left
2 Boom Hoist 4 Forward Reverse 0
3 Swing 5 Forward Reverse
4 Right Crawler 5
5 Left Crawler 4

Auxiliary Load Drum

10 A817
(in butt) 1

FIGURE 10-4

10

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Table 10-3 8-Bit Binary System

128

128

128
16
32
64

16
32
64

16
32
64
1
2
4
8

1
2
4
8

1
2
4
8
1 44 87
2 45 88
3 46 89
4 47 90
5 48 91
6 49 92
7 50 93
8 51 94
9 52 95
10 53 96
11 54 97
12 55 98
13 56 99
14 57 100
15 58 101
16 59 102
17 60 103
18 61 104
19 62 105
20 63 106
21 64 107
22 65 108
23 66 109
24 67 110
25 68 111
26 69 112
27 70 113
28 71 114
29 72 115
30 73 116
31 74 117
32 75 118
33 76 119
34 77 120
35 78 121
36 79 122
37 80 123
38 81 124
39 82 125
40 83 126
41 84 127
42 85 128
43 86 129

Dark shaded boxes indicate ON; white boxes OFF.

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Table 10-3 8-Bit Binary System (continued)

128

128

128
16
32
64

16
32
64

16
32
64
1
2
4
8

1
2
4
8

1
2
4
8
130 173 216
131 174 217
132 175 218
133 176 219
134 177 220
135 178 221
136 179 222
137 180 223
138 181 224
139 182 225
140 183 226
141 184 227
142 185 228
143 186 229
144 187 230
145 188 231
146 189 232
147 190 233
148 191 234
149 192 235
150 193 236
151 194 237
152 195 238
153 196 239
154 197 240
155 198 241
156 199 242
157 200 243
158 201 244
159 202 245
160 203 246
161 204 247
162 205 248
163 206 249
164 207 250
165 208 251
166 209 252
167 210 253
168 211 254
169 212 255
170 213
171 214
172 215

Dark shaded boxes indicate ON; white boxes OFF.

10

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Appendix - Abbreviations and Symbols

Abbreviations PCP Pressure Controller Pilot (Motor)
pot Potentiometer
A (amp) Ampere
psi Pounds Per Square Inch
AC Alternating Current
psia Pounds Per Square Inch Absolute
aux. Auxiliary
Reg. Regulated
DC Direct Current
RPM (rpm) Revolutions Per Minute
EDC Electric Displacement Control (Pump)
SAE Society of Automotive Engineers
ft. lbs. Foot Pounds
TB Terminal Block
GND Ground
V Volts
gpm Gallons Per Minute
VAC Volts Alternating Current
LED Light Emitting Diode
VDC Volts Direct Current
L/m Liters Per Minute
Symbols
LMI Rated Capacity Indicator/Limiter
max Maximum
+/- Positive or negative numerical value
min Minimum
+ Positive voltage
mm Millimeter
- Negative voltage
N/C Normally Closed (Switch)
% Percent
Nm Newton Meters
Angular degrees
N/O Normally Open (Switch)
F Degrees Fahrenheit
No. Number
OEM Original Equipment Manufacturer
PC Programmable Controller

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