Service Manual 1004 SM01−073−002.

00

Figure 1
Typical Electronic Gauge System Instrument Layouts

provided was taken directly from Dixon NGIt

Electronic Gauges,
Troubleshooting
This document covers the basic troubleshooting of
Dixon NGIt electronic gauges. The information
Technical Manual #072−40336−A. If more detailed
information is required, contact your nearest Link−Belt
distributor.

i
SM01−073−002.00 1004 Service Manual

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Service Manual 1004 SM01−073−002.00
Table Of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Purpose And Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How To Use This Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Definitions And Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Activating The Instrumentation (Initialization) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mode And Set Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Alphanumeric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Normal Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

System Diagnostic Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Auto Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Manual Test Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fault Codes And Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Unacknowledged Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Acknowledged Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Light Bar Telltales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Vehicle Data Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

NGI Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

NGI Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

NGI Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

System Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Alphanumeric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Mode And Set Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Audible Warning Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Gauges, General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Gauge Warning LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LED Steadily On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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SM01−073−002.00 1004 Service Manual
Rapid Flashing LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Slow Flashing LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Data Bus Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Speedometer Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Odometer And Hourmeter Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tachometer Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Analog Input Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Voltmeter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Pressure And Hydraulic Oil Temperature Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Light Bar Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Replacing Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Replacing Other NGI Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Typical Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SCU Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Light Bar Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Service Manual 1004 SM01−073−002.00
1 2 3 4 5 6
Typical Lower
Cab Panel

11 10 9 8 7

12 13 14
Typical Upper
Cab Panel

17 16 15
1. Water Temperature 6. Secondary Air Pressure 10. Voltmeter 14. Voltmeter
2. Oil Pressure 7. Light Bar 11. Fuel Level 15. Hydraulic Oil Temperature
3. Tachometer 8. Alphanumeric Display 12. Tachometer 16. Fuel Level
4. Speedometer 9. Mode And Set Switch 13. Water Temperature 17. Oil Pressure
5. Primary Air Pressure

Figure 2
Typical Panel Layouts

Introduction S Operation − This section describes how to use the

Purpose And Scope
The purpose of this document is to provide the
knowledge required to understand the operation and
functionality of the Next Generation Instrumentation
(NGIt) System.
How To Use This Information
This document is divided into four main sections:
S Introduction − Contains a brief introduction to the
product and to the document itself.
instrumentation and the information it presents.
Anyone who operates the crane should read and
understand this information.
S Functional Description − Describes the compo-
nents that make up the instrumentation and how
they communicate with each other and with other
systems in the crane. Understanding the informa-
tion in this section will help diagnose problems and
isolate instrumentation related problems.
S Service − Describes how to remove and install NGI
modules. It contains complete electrical connec-
tion diagrams.

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SM01−073−002.00
All graphics on for
about 2 seconds Minimum
Scale
Note: For example, if the park brake is
applied when the initialization begins,
the Park Brake telltale will remain on.
Figure 3
System Initialization Sequence
Definitions And Abbreviations
S ECU − Electronic Control Unit
S Ground − Any point that measures less than two
ohms resistance between it and the battery ground
terminal when using a properly zeroed ohmmeter
on its X1 range.
S LC − Liquid Crystal, as in LC display.
S LCD − Liquid Crystal Display
S LED − Light Emitting Diode
S NGI − Next Generation Instrumentation
S SCU − System Control Unit
Note: Throughout this document, the terms public
data bus, vehicle data bus, and public bus refer
specifically to the J1708 data bus.
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1004 Service Manual
During the Initialization:
S Gauge pointers move to just below minimum scale
for 1/2 second, then clockwise to minimum scale.
S Gauge warning LEDs turn on for 1/2 second.
S All Alphanumeric Display graphics turn on for
about 2 seconds.
S SCU lights all Light Bar telltales for three seconds.
After the Initialization:
S Pointers indicate actual readings.
S Alphanumeric Display shows the odometer.
S Light Bar telltales turn off (see note).
S Gauge warning LEDs turn off.
Operation
System Components
The instrumentation system consists of several
gauges, indicators, and telltales mounted in a panel
similar to that shown in Figure 2. The purpose of the
instrumentation is to display the operational status of
the crane. In addition to the gauges and Light Bar, the
instrumentation contains an Alphanumeric Display that
alerts the driver to a condition or event that requires
attention.
Service Manual
Alphanumeric Display
Figure 4
Normal Operation Displays
Activating The Instrumentation
(Initialization)
Turning on the ignition activates the instrumentation
and starts an initialization sequence. This sequence
gives the operator a chance to verify correct operation
of the gauges and indicators. The sequence is
described in Figure 3.
Service the crane if any of the following conditions
occur during or after the initialization:
S A telltale does not light, or is always on
S A 2−inch gauge’s pointer stays at minimum scale
and its warning LED flashes slowly, indicating the
gauge is not receiving data from the vehicle data
bus
S A 2−inch gauge’s pointer goes to full or minimum
scale and its warning LED flashes rapidly, indicat-
ing the gauge has received invalid or out−of−
range data
S Any other symptom not described as part of the in-
itialization or normal operation
Mode And Set Switches
The mode and set switches are buttons in the
speedometer that allow you to select, set, and reset
displays in the Alphanumeric Display. They also allow
you to scroll through active system warning messages.
Alphanumeric Display
The Alphanumeric Display provides mileage, engine
hours, and messages to the driver. Examples of
displays are shown in Figure 4.
1004 SM01−073−002.00
Odometer Warning
(Default display) (Example)
Trip Odo 1 Hourmeter
Trip Odo 2 Diagnostic
Mode
The Alphanumeric Display can be activated in the
following ways (refer to Figure 5):
S Ignition Switch − Turning the ignition on turns on
the display and also starts the initialization se-
quence. The display will remain on as long as the
ignition switch is on.
S Mode or Set Switch − Pressing either switch when
the ignition is off activates the display for 10 sec-
onds, allowing it to be used without an ignition key.
The display will remain active until the 10 seconds
have elapsed after the last press of the mode or set
switch. This method does not start an initialization
sequence.
S Backlighting − Turning the backlighting on acti-
vates the display as long as the backlighting re-
mains on. This method does not start an initializa-
tion sequence.
Normal Operating Mode
After the initialization sequence (or after the mode or
set switch is pressed, or the backlighting is turned on),
the Alphanumeric Display goes into its normal
operation mode (refer to Figure 5). If any
unacknowledged messages exist, they will be
displayed (most recent first). The non−resettable
odometer is displayed next. The display goes from 0 to
999999.9, then from 1000000 to 9999999 (no decimal
point), and then rolls over to 0. Leading zeros are not
displayed.
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SM01−073−002.00 1004 Service Manual

Ignition Initialization
On? YES Sequence

NO
Do unacknow−
ledged warning
Dashlights
On?
YES messages YES
exist?
Display first unac−
NO knowledged warning
message.
NO
Mode or Set
Pressed?
YES
Last
YES One?
NO

10
NO
seconds since
Mode/Set last NO
pressed? Display next
unacknowledged
warning message.
System
YES Off

Toggles odometer and trip

odometer displays between
kilometers and miles

(hold 3 seconds to zero)

to System
Diagnostic
(hold 3 seconds to zero) Test Mode

to Warning
No effect
Messages
Loop

Ignition
On? YES
NO

Figure 5
Normal Operation Mode

The following displays are also available by pressing
the mode switch:
S Trip Odometer − Two independently resettable trip
odometers, each with a maximum display of
9999.9 miles or kilometers.
S Hourmeter − A non−resettable hourmeter that
displays up to 999999 hours.
In addition to these displays, the Alphanumeric Display
can be used to view fault codes and up to the last six
warning messages stored by the SCU. These are
explained in
Fault Codes And Warning Messages"
found later in this document.

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Service Manual 1004 SM01−073−002.00

System
All Gauges Light Bar
Diagnostic
Test Mode

to Manual
Test Function Auto Test Sequence
Note: Light bar telltales will stay on if
the condition that lights them is true.

Displays device codes

for up to 128 faults in
3−second intervals

or

back to Normal
Operation Mode

Figure 6
System Diagnostic Test Loop

System Diagnostic Test Mode Auto Test Sequence

To access the System Diagnostic Test mode, turn the
ignition on and press the mode switch until
DIAGTST"
appears in the display. Then press the set switch to
enter the System Diagnostics Test mode.
AUTO" will
be displayed.
Note: The System Diagnostics Test mode is only
enabled when the ignition is on.
The System Diagnostic Test mode is shown in Figure 6.
Three functions are available:
S Auto − A fully automatic test of all modules, dis-
plays, and telltales
S Manual − Manual selection of individual modules
and telltales to test
S Fault Display − Recalls up to 128 device fault
codes
Pressing the set switch while
AUTO" is displayed
starts the Auto Test sequence. During the Auto Test,
the SCU generates its own pointer positioning data,
warning LED data, and telltale control data. Auto Test
phases are shown in Figure 6. The sequence begins
with all pointers at zero scale and a blank
Alphanumeric Display. The SCU moves the pointers in
unison to mid−scale, full scale, back to mid−scale,
back to zero, and then exits the Normal Operation
mode.
Pressing the mode or set switch during the sequence
halts the sequence and returns the display to
AUTO".
If the instrumentation passes the Auto Test, it is a good
indication that the entire instrumentation system is
functioning properly.

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SM01−073−002.00 1004 Service Manual
Manual
Test Function
Displays SCU Displays SCU
version number status

Displays version Displays

number status

Gauge Manual Test Sequence

Pressing MODE ends test and displays module name.

Note: All gauges for which the system is configured will

be tested (excluding mechanical pressure gauges).

Lights each telltale one at a time

back to System
Diagnostic Test
Mode

Figure 7
Using The Manual Test Function
Manual Test Function
Pressing the mode switch while
AUTO" is displayed
activates the Manual Test function and causes

MANUAL" to be displayed. The Manual Test function is
the same as the Auto Test except that the user can
select which modules to test. The Manual Test flow is
shown in Figure 7.
S Use the set switch while
MANUAL" is displayed to
select the module to be tested. The module’s
name will appear in the display, starting with

SCU".
S Press the set switch to start the test, or press the
mode switch to select a different module.
S To end the test and display the module name,
press the mode switch at any time during the se-
quence.
The Manual Test sequence is identical to the Auto Test
sequence except that the user must press the set
switch to move from one phase to the next.

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Service Manual
Fault Codes And Warning Messages
Fault Codes
When a device (or ECU) attached to the vehicle data
bus detects a fault, it can place an active fault code on
the data bus. The active fault code describes a specific
type of failure (for example, low oil pressure). Each
fault code includes a device fault code that identifies
the device which detected the fault. Pressing the set
switch when
FAULTS" is displayed tells the SCU to
send a request over the vehicle data bus for all devices
to send their active fault codes. During this time the
SCU displays
POLLING". After all the active fault
codes have been received, the SCU displays the
device fault codes one−at−a−time in 3−second
intervals. Up to 128 device fault codes can be
displayed. Pressing the mode or set switch during this
time exits the Fault mode.
Note: A device fault code does not contain actual
failure data, only the identification of the device that
detected the fault.
Warning Messages
Unacknowledged Warning Messages
When the SCU receives an active fault code, it displays
a warning message in the Alphanumeric Display, turns
on the buzzer, and turns on the warning LED in the
1004 SM01−073−002.00
appropriate gauge. That warning message overrides
all other displays until it is acknowledged. See

Acknowledged Warning Messages" found later in this
document. Warning messages are listed in Table A.
When the condition resulting in the active fault code is
corrected, the device that detects the condition places
an inactive fault code for that condition on the vehicle
data bus. When the SCU receives an inactive fault
code, it turns off the buzzer and the gauge warning
LED.
Acknowledged Warning Messages
Unless otherwise stated in Table A, the user can
acknowledge an unacknowledged message by
pressing the set switch when the message is visible.
The SCU will turn the buzzer off and display either the
odometer or the next unacknowledged message if one
exists.
The SCU stores the six most recent acknowledged
messages for later viewing. If more than six messages
have been acknowledged, the oldest one will be
detected.
Messages can be viewed and acknowledged using the
mode and set switches as shown in Figure 8. The last
message to be acknowledged will be the first message
to be displayed. If the mode switch is not pressed for
15 seconds, the SCU will display the odometer (or the
next unacknowledged message, if one exists).
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SM01−073−002.00 1004 Service Manual

Any
messages to NO
display?

YES
back to Normal
YES Operation Mode
Last
NO message?

Increment
message
counter

Active or Can message

Lower message’s
Display dismissable NO priority be YES
priority.
Message annunciator? modified?

YES
NO
No effect

Shut off
annunciator.

Figure 8
Displaying And Acknowledging Warning Messages

SCU Other Can Be Reset

Meaning Source
Message Indications Acknowledged Message

MID 128, PID 194, PID Buzzer, gauge warning

H2OTEMP Coolant temperature high Yes None
110, FMI 00 LED

MID 128, PID 194, PID Buzzer, gauge warning

OIL PSI Oil pressure low No None
100, FMI 01 LED

Buzzer, gauge warning

LO AIR1 Primary air psi under 65 psi Analog input No None
LED

Buzzer, gauge warning

LO AIR2 Secondary air psi under 65 psi Analog input No None
LED

Buzzer, gauge warning

HYDTEMP Hydraulic oil temperature over 200° F Analog input No None
LED

LO FUEL Fuel level under 1/8 tank Analog input Gauge warning LED Yes FUEL OK

Battery voltage under 10 volts or over 15

VOLTS Analog input Gauge warning LED Yes None
volts

NO SPDO No public bus speed data for 15 seconds SCU None No None

NO DATA No public bus data at all for 15 seconds SCU None No None

NO ODO Odometer data not present SCU None No None

No public bus engine hour data for 15

NO HR SCU None No None
seconds

Table A
Warning Messages

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Service Manual 1004 SM01−073−002.00

Cruise Engine
Control Torque Limit
On Reached

Park Brake Check ABS

Engaged System

Figure 9
Light Bar Telltales
Light Bar Telltales but from individual switches connected directly to the
The Light Bar contains 13 telltales as shown in Light Bar.
Figure 9. Telltale control does not come from the SCU,

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SM01−073−002.00 1004 Service Manual

Analog Inputs to SCU Lower Cab Panel

for Gauges:
Fuel Level Speedometer
Primary Air Pressure with SCU
Secondary Air Pressure
Hydraulic Oil Temperature
Voltage NGI Bus

Vehicle
Data Bus
Data Bus Inputs to
SCU for Gauges:
Crane Speed and Total Miles
Engine RPM and Hours
Engine Oil Pressure
Coolant Temperature

Backlight (+)
Backlight Ground
Battery (+)
Battery Ground
Ignition (+)

Ignition (+)
Battery Ground

13 Switched Inputs:
Left Turn
Inter−Cab Cable
Trans Oil Temp
Cruise
Upper Cab Panel
Engine Torque Limit
High Beam
Wait To Start
Service Engine
Left Turn
Rear Axle Unlocked
Park Brake
Check Engine
Stop Engine
ABS

Notes: Gauge complement may differ

from that shown. Order of connections
on NGI bus is for illustration only and
may not reflect actual order in crane.

Figure 10
System Block Diagram

Functional Description Vehicle Data Bus

The vehicle data bus is a two−wire bus that transfers
This section provides a more detailed understanding of
information to and from the crane’s electronic control
how the system works. Reading and understanding
units (ECU). Examples of ECUs are the engine ECU,
this section can help troubleshoot and service the
ABS ECU, and the instrumentation system control unit
system. Figure 10 shows how the instrumentation
(SCU) that is built into the speedometer. The SCU
connects to the rest of the crane.
receives road speed, engine RPM, engine hours,
engine oil pressure, and water temperature data from
the vehicle data bus.

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Service Manual
NGI Bus
The NGI bus is an internal six−wire bus that originates
at the SCU and is connected to all NGI components. It
contains a pair of wires for module power and ground,
a pair for backlight power and ground, and a pair that
carries pointer destination and gauge warning LED
data to gauges.
The NGI bus connects to the Alphanumeric Display
and is then brought outside the speedometer housing
on two six−pin connectors that are wired in parallel.
Each NGI module has a pair of these six−pin NGI
connectors.
NGI Cable Assemblies
NGI cable assemblies distribute the NGI bus, module
power and ground, and module backlighting power
and ground to every display module in the system.
Because all NGI modules are connected to each other
by the NGI cable assemblies, a fault in any one of these
modules can affect the operation of some, or all, of the
others. For example, if the wire that carries backlight
power to the gauges is broken, the gauges between
the break and the speedometer will have backlighting
while the remaining modules will not. Or, a short circuit
from one data line to the other in one of the modules will
disable all modules (including the Alphanumeric
Display) connected to the NGI bus.
NGI Modules
System Control Unit
The SCU is mounted inside the speedometer housing
and is connected to the vehicle data bus and the NGI
bus. A block diagram showing how the SCU is
connected is provided in Figure 11.
The SCU performs the following functions:
S Receives, conditions, and processes vehicle data
bus information into pointer destination data for the
data bus gauges
S Receives, conditions, and processes analog input
signals from external sensors into pointer destina-
tion data for the analog gauges
S Controls gauge warning LEDs
S Requests crane mileage and engine hour data
upon power−up
S Calculates odometer and trip odometer values
S Controls the Alphanumeric Display and monitors
the mode and set switches
1004 SM01−073−002.00
S Periodically compares calculated odometer data
with total crane miles
S Stores gauge configuration and parameters
(range, pointer sweep, zero point)
S Compares input data to stored gauge confirmation
data to determine out−of−range conditions
S Supplies power and backlight power to the gauges
S Supplies test data to modules during the Auto Test
and Manual Test functions
S Controls the buzzer
Alphanumeric Display
The Alphanumeric Display is a seven−digit,
multi−segment, backlit, LC display. It contains a
microprocessor that receives data from the SCU over
the NGI bus. During the power−on initialization
sequence (see Figure 3), this microprocessor
momentarily turns on all display segments and icons
for visual verification.
Mode And Set Switches
The Alphanumeric Display also receives inputs from
the mode and set switches. The mode and set
switches are normally open and apply ground to the
Alphanumeric Display when pressed. The driver uses
them to select displays, reset the trip odometers, scroll
through diagnostic messages, and to perform the
diagnostic test described in
Manual Test Function"
found earlier in this document.
Audible Warning Device
Sometimes called the buzzer, the warning device is
mounted inside the speedometer housing and is
controlled by the SCU.
Gauges, General Information
Each gauge contains a microprocessor, a stepper
motor, a red warning LED (except the tachometer and
speedometer), and a pair of NGI bus connectors that
are wired in parallel.
Applying power to a gauge causes its microprocessor
to re−zero the pointer and momentarily turn on its
warning LED. This action is not initiated by the SCU but
by the gauge’s microprocessor. Because power is
applied to all gauges (through their NGI bus
connections) when the ignition is switched on, all
pointers and LEDs will act in unison. Gauge operation
can also be checked through the SCU by using the
mode and set switches as described elsewhere in this
document.
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SM01−073−002.00 1004 Service Manual
Tachometer
Speedometer
µP Pointer
Battery +
Power Self Test
Battery − Supply Circuitry LED

EEPROM Oil Pressure

Switched Inputs µP Pointer

Input
Conditioners
Analog Inputs NGI Bus LED
µP

Vehicle Bus
Data Bus Transceiver Temperature
NGI
Power & Pointer
Ground µP

Backlight Power Backlight LED

Backlight Ground Power
Conditioner
Fuel Level
+12V from
Buffer Speedometer
Ignition
Pointer µP Pointer
Mode Button
LED

Set Button µP
LCD Voltmeter
Backlighting

µP
Buzzer Pointer

Figure 11
Block Diagram For SCU
The SCU tells the gauge microprocessor where to
rotate the pointer, and updates the information often
enough to provide smooth pointer operation. The
gauge microprocessor converts the point destination
into stepper motor drive signals, and warning LED data
into LED−on, LED−off signals.
Gauge Warning LEDs
LED Steadily On
This is the LED’s primary function. When it is on
steadily, it indicates that a condition exists in the crane
that requires the driver’s attention (high temperature,
low oil pressure, low fuel, and voltage too high or too
low).
Rapid Flashing LED
If the SCU detects that the data it receives for a
particular gauge is beyond that gauge’s display range,
it will flash that gauge’s warning LED rapidly and
position its pointer to zero (if the input is too low) or full
scale (if the input is too high).
Slow Flashing LED
If a gauge does not receive any data from the SCU, it
will flash its warning LED slowly (about once per
second) and position its pointer to zero.

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Service Manual 1004 SM01−073−002.00

Speedometer with SCU

SE3
SE4
1 System
Control Tach.
2 Unit

NGI Bus
SE5
5,6
Water
Speedo. Oil PSI
Temp.

J1708 Bus
to/from other devices

from Speed Sensor

Engine
ECU
= NGI System from RPM Sensor

The engine ECU generates speed, odome-

Coolant ter, ROM, pressure, temperature, and gauge
Oil PSI LED data that the SCU uses to position the
Temperature
Sensor gauge pointers and control the gauge LEDs.
Sensor

Figure 12
Block Diagram For Vehicle Data Bus Gauges
Data Bus Gauges
The speedometer, tachometer, engine oil pressure,
and coolant temperature gauges all obtain their pointer
data from the vehicle data bus through the SCU and
the NGI bus. They are sometimes referred to as
data
bus gauges". Figure 12 shows the information flow for
data bus gauges.
Speedometer Gauge
The speedometer houses the SCU, Alphanumeric
Display, and the speedometer pointer drive
electronics. The SCU receives current crane speed
data (MID 128, PID 84) from the engine ECU and sends
it to the speedometer over the (internal) NGI bus. The
SCU updates the speedometer pointer data every 0.3
seconds.
Odometer And Hourmeter Displays
Each time power is applied to the instrumentation, and
periodically thereafter, the SCU requests and receives
total travel distance (MID 128, PID 245) and total
engine hours data (MID 128, PID 247) from the engine
ECU. Upon receipt, the SCU sends the data to the
Alphanumeric Display over the NGI bus. The odometer
data is updated every three seconds, the hourmeter
data every 10 seconds.
Tachometer Gauge
The tachometer receives engine RPM data from the
engine ECU (MID 128, PID 190). The SCU updates the
tachometer pointer destination often enough to ensure
smooth operation.
Engine Oil Pressure Gauge
The engine oil pressure gauge receives its pointer and
warning LED data (MID 128, PID 100) from the engine
ECU. If the SCU receives an active fault code of MID
128, PID 194, PID 100, FMI 01, it will turn on the LED in
the oil pressure gauge, display
OIL PSI" in the
Alphanumeric Display, and sound the buzzer. If the
SCU does not receive any more of these active fault
codes during the next 30 seconds, or if the SCU
receives an inactive fault code for oil pressure, the SCU
will turn the LED and the buzzer off and will display
whatever it was displaying when the active fault code
was detected. The oil pressure fault cannot be
acknowledged.
Coolant Temperature Gauge
The coolant temperature gauge receives its pointer
and warning LED data (MID 128, PID 110) from the
engine ECU. If the SCU receives an active fault code of
MID 128, PID 194, PID 110, FMI 01, it will turn on the
LED in the coolant temperature gauge, display

H2OTEMP" in the Alphanumeric Display, and sound
the buzzer. If the SCU does not receive any more of
these active fault codes during the next 30 seconds, or
if the SCU receives an inactive fault code for coolant
temperature, or if the SCU’s message is
acknowledged, the SCU will turn the LED and the
buzzer off and will display whatever it was displaying
when the active fault code was detected.

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SM01−073−002.00 1004 Service Manual

Speedometer with SCU

SE3

1 System SE4 Volt- Fuel

Control meter Level
2 Unit

SE5
SE6 NGI Bus
to other
NGI Modules
2
Fuel Level
Analog Input:
33 ohms (Full)
240 ohms (Empty)

The fuel level sensor on the fuel tank provides a

resistance signal to the SCU to drive the Fuel
Level pointer and LED.
= NGI System Fuel The SCU drives the voltmeter pointer position
and LED state from the voltage at SE3 pin 1.

Figure 13
Block Diagram For Fuel Level And Voltmeter Gauges
Analog Input Gauges
Fuel Level Gauge
The fuel level sensor output varies according to the fuel
level in the tank. This analog signal is connected to an
analog input at the SCU. The SCU converts the analog
signal into digital format and places the resulting
pointer destination data on the NGI bus. The data flow
for the fuel level gauge is shown in Figure 13.
When the SCU detects the fuel level is less than 1/8
tank, it will turn on the warning LED in the fuel level
gauge and display
LO FUEL" in the Alphanumeric
Display. It does not turn the buzzer on. When the fuel
level rises above 1/8 tank, the SCU turns the LED in the
fuel level gauge off and sends
FUEL OK" to the
Alphanumeric Display.
The SCU compensates for the effects of fuel slosh
inside the tank so the LED does not flash erratically
when the fuel level is near 1/8 tank.
Voltmeter Gauge
The SCU uses its own battery (+) connection as an
analog signal input for the voltmeter gauge. It converts
this analog voltage into digital format and places the
resulting pointer drive data on the NGI bus. The data
flow for the voltmeter gauge is shown in Figure 13.
When the voltage at the SCU’s battery (+) connection
is less than 10 volts or more than 15 volts, the SCU will
turn on the warning LED in the voltmeter gauge and
display
VOLTS" in the Alphanumeric Display. It will not
turn the buzzer on. When the voltage at that point is
within 10 to 15 volts, the SCU will turn off the voltmeters
gauge’s warning LED and will display whatever it was
displaying when the active fault code was detected.

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Service Manual 1004 SM01−073−002.00

Speedometer with SCU

SE3 = NGI System

1 System SE4 Hyd. Oil

Control Temp.
2 Unit

SE6
NGI Bus SE5
1
3
4 Air 1 Air 2
PSI PSI
Data
Collector

The SCU turns on the air pressure LEDs

when the analog input represents less
than 65 psi (448kPa). The SCU turns on
the hydraulic oil temperature warning LED
when the analog input represents greater
than 200° F (93° C).

Hydraulic Oil Primary Air Secondary Air

Temperature Sensor
315 ohms = 120° F (49° C)
147 ohms = 200° F (93° C)
PSI Sensor PSI Sensor
10 ohms = 0 psi (0kPa)
52 ohms = 29 psi (200kPa)
88 ohms = 58 psi (400kPa)
124 ohms = 87 psi (600kPa)

Figure 14
Air Pressure And Hydraulic Oil Temperature Gauges

Air Pressure And Hydraulic Oil Temperature Gauges
Sensors for hydraulic oil temperature and air pressure
are connected to a data collector. The analog outputs
from the data collector (which is not part of the
instrument system) are connected to the SCU. The
SCU processes the analog signals into gauge pointer
data and places the data on the NGI bus to drive the
hydraulic oil temperature and the primary and
secondary air pressure gauge pointers. The data flow
for the air pressure and hydraulic oil temperature
gauges is shown in Figure 14.
When the SCU detects the air pressure is lower than 65
psi (448kPa) in either of the air systems, it will turn on
the warning LED in the appropriate air pressure gauge,
display
LO AIR1" or
LO AIR2" in the Alphanumeric
Display, and sound the buzzer. When the air pressure
rises to 65 psi (448kPa) or more, the SCU turns the
buzzer and the gauge LED off. This warning message
cannot be acknowledged.
When the SCU detects the hydraulic oil temperature is
200° F (93° C) or more, it will turn on the warning LED in
the hydraulic oil temperature gauge, display

HYDTEMP" in the Alphanumeric Display, and sound
the buzzer. When the temperature drops below 200° F
(93° C), the SCU will turn the buzzer and the gauge
LED off. This warning message cannot be
acknowledged.

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SM01−073−002.00 1004 Service Manual

SE3 Speedometer with SCU

2
1
System SE4
Control NGI Bus
Unit
Air 1
PSI
SE5
Ignition
Switch

ON
Low from
Switch closure activates telltale. Engine ECU
= NGI System

LBE3
18 19 21 10 7 6 8 17 9

Air 2
PSI
LBE2 LBE1

15 21 4 5 16 1
LBE3

Low from Low from

Engine ECU ABS ECU

Figure 15
Light Bar Module

Light Bar Module
The light bar contains 13 individually controlled
telltales, each illuminated by an LED. Individual
switched inputs to the light bar control the telltales.
Light bar power is routed through the ignition switch
rather than to the battery. The light bar interacts with
the NGI System and crane as shown in Figure 15.

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Service Manual 1004 SM01−073−002.00

Cutouts (2)

3
2

1
Remove
4

Alignment Tab

Notch

1. Clamp Ring
2. Wave Spring Lock Tabs (2)
3. Panel
4. Gauge

Figure 16
Gauge Replacement

Service Procedures
All NGI modules are easily replaceable in the field. This
section describes the correct method of removing and
replacing them. For a functional description of the
instrumentation, see
Functional Description" section
found earlier in this document.
Note: NGI modules are not repairable in the field.
Replace them if defective. Opening any of the com-
ponents voids the warranty.
Replacing Gauge
Refer to Figure 16.
To remove:
1. Gain access to the rear of the panel.
2. Unplug the connectors from the rear of the gauge.
The connectors have locking tabs that must be de-
pressed to release the plug.
3. Push the clamp ring up against the wave spring.
Twist it counterclockwise about 1/16 in (1.58mm),
then pull it off the rear of the gauge.
4. Remove the gauge from the front of the panel.
To install:
1. Insert the gauge through the front of the panel,
making sure the alignment tab on the bottom near
the bezel fits into the notch in the gauge mounting
hole.
2. Install the wave spring followed by the clamp ring.
Align the tab with the cutouts in the gauge housing.
3. Press the clamp ring against the wave spring and
twist clockwise about 1/16 in (1.58mm) until it locks
into place.
4. Plug the connectors into the rear of the gauge. The
connectors have locking tabs that must lock.

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SM01−073−002.00 1004 Service Manual
4
3

Alignment Tab
4

3
Notch

2
1

Alignment Tab

1. #10 Torx Screw Notch

2. U−Clamp
3. Panel
4. Module

Figure 17
Additional NGI Module Replacement

Replacing Other NGI Modules To install:

Refer to Figure 17.
To remove:
1. Gain access to the rear of the panel.
2. Unplug the connectors from the rear of the module.
All connectors have locking tabs that must be de-
pressed to release the plug.
3. Use a #10 Torx driver to remove the two U−clamp
screws.
4. Remove the module from the front of the panel.
1. Insert the module through the front of the panel,
making sure the alignment tab on the bottom near
the bezel fits into the notch in the mounting hole.
Note: Align the module by inserting its align-
ment tab (behind the bezel) into the small cutout
in the mounting panel.
2. Use a #10 Torx driver to install the two U−clamp
screws.
3. Plug the connectors into the rear of the module. All
connectors have locking tabs that must be locked
to secure the plug.

18 of 22
 Figure 18
Lower Cab Panel
E1 E2 E1 E2 E1 E2 E1 E2
SE3

Typical Panel Wiring

E1 E2

SE6
Light Bar

E5 E1 E2 E1 E2
LBE3 E4
E2 E1
Service Manual

From Crane To Upper

Harness Cab Panel
1004

Upper Cab Panel

E2 E2 E2 E2 E2 E2

E1 E1 E1 E1 E1 E1

Pin 1 Marker
Pin 1

Length (L) in Inches

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SM01−073−002.00
SM01−073−002.00 1004 Service Manual
Pin # Signal Pin # Signal

Battery (+)
1 6 J1708 Bus (−)
(9−32VDC)

2 Battery (−) 7 No Connection

1
3 Ignition (+) (switched) 8 No Connection
SE3
4 Backlight (+) 9 No Connection

5 J1708 Bus (+) 10 Backlight Ground

7
5 Mating Connector Manufacturer’s Part Numbers
1
Connector: JAE IL−AG5−10S−S3C1
E5 SE6 Pins: JAE IL−AG5−C1−5000
E4

Table C
Speedometer Connector SE3
16 8

Pin # Signal

1 Fuel Level (analog)

2 Primary Air PSI

Figure 19
SCU Connections 3 Secondary Air PSI

4 Hydraulic Oil Temperature

SCU Connections 5 Analog Ground

6−16 No Connection
Pin # Signal
Mating Connector Manufacturer’s Part Numbers
1 NGI Power (+7.6VDC) Connector: JAE IL−AG5−16S−D3C1−A
2 NGI Ground Pins: JAE IL−AG5−C1−5000

3 NGI Bus Positive (+) Table D

4 NGI Bus Negative (−)
Speedometer Connector SE6

5 Backlight Ground

6 Backlight Power

E1/E2 and E4/E5 are internally connected in parallel.

Table B
NGI Bus Connections (E1, E2, E4, And E5)

20 of 22
Service Manual 1004 SM01−073−002.00
Light Bar
Telltale Positions 22 11

E2
TT1 TT2 TT3 TT4 TT5 TT6 TT7 TT8

TT9 TT10 TT11 TT12 TT13 TT14 TT15 TT16

E1

12 1

Figure 20
Light Bar Connections

Light Bar Connections

Telltale Location Function Pin # Activation
TT1 Left Turn Indicator 18 Switch to +12V
TT2 Transmission Oil Temperature 19 Switch to +12V
TT3 Cruise 21 Ground from Engine ECU
TT4 Engine Torque Limit 10 Switch to +12V
TT5 High Beam Indicator 7 Switch to +12V
TT6 Wait To Start 6 Ground from Engine ECU
TT7 Service Engine 8 Ground from Engine ECU
TT8 Right Turn Indicator 17 Switch to +12V
TT9 Not Used
TT10 Rear Axle Unlocked 15 Switch to +12V
TT11 Park Brake 12 Switch to +12V
TT12 Not Used
TT13 Not Used
TT14 Check Engine 4 Ground from Engine ECU
TT15 Stop Engine 5 Ground from Engine ECU
TT16 ABS 16 Ground from ABS ECU
− Battery Ground 1 Battery negative
− Ignition +12V 9 Switched battery
Mating Connector Manufacturer’s Part Numbers
Connector: JAE IL−AG5−22S−D3C1
Pins: JAE IL−AG5−C1−5000

Table E
Light Bar Connector LBE3

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SM01−073−002.00 1004 Service Manual

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