User Guide: Sn1676-1Cb Canbus Control System

User Guide
SN1676-1CB CANBus Control System
July 2010
TEREX P/N 221953
Contents -ER 21872 Rev. B
WARNING: It is the purchaser’s responsibility to determine the suitability of any OEM

Controls, Inc. product for an intended application and to ensure that it is installed and guarded in
accordance with all federal, state, local and private safety and health regulations, codes and
standards.
Due to the unlimited variety of machines, vehicles and equipment on which our control products are
used, and the numerous standards which are frequently the subject of varying interpretation, it is
impossible for OEM Controls, Inc.’ personnel to provide expert advice regarding the suitability of a
given controller for a specific application. The flexibility of our products allows us to offer thousands of
custom configurations. We can advise you of the various features that are available and you can
examine models to see what meets your needs. We believe our customer’s engineering departments
should be qualified experts in their own product field. If the product will be used in a safety critical
application, the customer must undertake appropriate testing and evaluation to prevent injury to the
ultimate user.
Should you have any questions or if any of the above warning is unclear, please contact OEM
Controls, Inc. at 10 Controls Drive, Shelton, CT, 06484, FAX: 203.929.3867, TEL: 203.929.8431
10 Controls Drive, Shelton CT 06484

203.929.8431
www.oemcontrols.com
Contents
Section 1 1
Overview of the CANBus Control System ........................................... 1

About CANBus ............................................................................................................................................... 2
CANBus System Block Diagram ........................................................................................................................... 3
Main Winch and Boom Hoist Control .................................................................................................................... 4
AUX Winch and Swing Control ............................................................................................................................. 5
Boom Extend/Retract Control ................................................................................................................................ 6
OCO2-101 CAN Output Module ............................................................................................................................ 7
Energy Storage Module (ESM-1) ........................................................................................................................... 8
OCI1-107 with (HMI) Module ............................................................................................................................... 9
The HMI Switch Functions ........................................................................................................................... 10
Section 2 11
Getting Started with System Check .................................................. 11

Quick Check of the SN1676-1CB System ............................................................................................................ 11
IF - THEN Test 1: Using CANBus LEDs to Diagnose the System ...................................................................... 12
IF - THEN Test 2: Using the HMI to Check Equipment ...................................................................................... 13
Section 3 16
Testing and Troubleshooting ............................................................. 16

Assessing the CANBus System Health ................................................................................................................ 16
Power Supply Requirements................................................................................................................................. 17
Testing the OCO-2 CAN Module ......................................................................................................................... 17
OCI1-107 CAN Input Module with (HMI) Diagnostic ........................................................................................ 18
Testing with Menu Select and the (HMI) ............................................................................................................. 20
Main Menu Screen ........................................................................................................................................ 20
Run Screen .................................................................................................................................................... 20
Part Number and Serial Number Screen ........................................................................................................ 20
Setup Unlock Screen ..................................................................................................................................... 20
Pass/ Fail Equipment Tests Using the HMI Display ..................................................................................... 22
Restore Factory Defaults Screen ................................................................................................................... 22
Main Winch Boom Hoist Control wiring ............................................................................................................. 23
Aux Winch and Swing Control Test ..................................................................................................................... 25
Aux Winch and Swing Control wiring .......................................................................................................... 25
Boom Extend/ Retract Wiring Test ...................................................................................................................... 26
Energy Storage Module ESM-1 Test .................................................................................................................... 27
Operating voltage 9-24 vdc @ 60000 MFD ......................................................................................................... 27
J1-“A” and J2-“B” Equipment Wiring Check ...................................................................................................... 28
User Notes ............................................................................................................................................................ 31
Section 4 33
Index ................................................................................................... 33
Figures
Figure 1. CANBus Enclosure ................................................................................................................................ 1
Figure 2. CANBus Block Diagram ......................................................................................................................... 3
Figure 3. Main Winch and Boom Hoist Control ..................................................................................................... 4
Figure 4. AUX Winch and Swing Control............................................................................................................. 5
Figure 5. Foot Pedal Control .................................................................................................................................. 6
i
Figure 6. OCO2-101 CAN Output Module ............................................................................................................ 7

Figure 7. Energy Storage Module (ESM-1)............................................................................................................ 8
Figure 8. OCI1-107 Installation in the CANBus System........................................................................................ 9
Figure 9. OCI1-107 Master Module with (HMI) .................................................................................................. 10
Figure 10. CANBus Quick check with LED diagnostics ..................................................................................... 11
Figure 11. OCO-2 CAN Output Module LED Indicator Table for Diagnostics ................................................... 12
Figure 12. Equipment Check Using the HMI ....................................................................................................... 15
Figure 13.OCO2 CAN Output Module LED Indicator table for diagnostics ....................................................... 18
Figure 14. OCI1-107 System Connectors – J1-“A”-J2-“B” ................................................................................. 19
Figure 15. Wiring Configuration for Main Winch Boom Hoist Controller .......................................................... 23
Figure 16. Wiring table for P4 and P7 .................................................................................................................. 24
Figure 17. Wiring table for P3 and P5 .................................................................................................................. 24
Figure 18. Wiring Configuration for AUX Winch and Swing Controller ............................................................ 25
Figure 19. Wiring Tables for the Foot Pedal Controller ....................................................................................... 26
Figure 20. Wiring Configuration for the Energy Storage Module (ESM-1) ......................................................... 27
Figure 21. Wiring Configuration for Connector J1-“A” ....................................................................................... 29
Figure 22. Wiring Configuration for Connector J2-“B” ....................................................................................... 30
Document Revision History
Rev A : 11-22-09*GJO
Rev B : O3-22-10*SJM
ii
Section 1
Overview of the CANBus Control

System
This document is a Manual of Operations and basic troubleshooting guide,
thereby allowing for the proper installation and use of the CANBus system as
designed.
This document provides coverage for the following TEREX Cranes: RT120,
RT200, RT300, RT500, RT600, RT700, T300, T500, and T700.
This section provides an overview of the CANBus Control System.
Energy Storage Module
OCO2-101
CANBus Output
Module
Figure 1. CANBus Enclosure
OCI1-107 Human Machine Interface

Module
Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 1

About CANBus
Your CANBus System is a group of interconnected modules that operate
under a Standard Protocol of the Controller Area Network (CAN). This
System is designed for motion oriented machine control networks.
CANBus allows for communication compatibility between each device, as
well as interoperability and interchangeability of devices. The individual
Modules each have several visual diagnostic tools designed in them and can
be easily troubleshot and diagnosed, and replaced if need be by simply
unplugging and replacing.
CANBus system modules are all interconnected by means of two wires
CANH (CAN High) and CANL (CAN Low).
Different Types of Modules
The CANBus modules you have been supplied with
have been configured to be wired in a specific order based on your
application or types of modules your system could possibly use.
Full Termination : A CAN Module at the end of a cable run
Stub Termination : A CAN module that has been

placed in between the modules with full termination.
ENGINE OPERATORS CURBSIDE WINCH

COMPARTMENT CAB CONTROL STATION
FULL STUB STUB FULL
TERMINATION TERMINATION TERMINATION TERMINATION
2 2 2
START END
Important: The recommended module placement and system wiring

must be followed very closely. Improperly placed/wired CANBus
modules may result in an inoperable system. It is important to
carefully map out how you will route CANH and CANL signals from
module to module so as not to compromise the signal integrity.
2 Section 1 | Overview of the CANBus Control System SN1676-1CB

CANBus System Block Diagram
J2 “B”
Figure 2. CANBus Block Diagram

Main Winch and Boom Hoist Control

The MAIN Winch and Boom Hoist Control (HCJS8M15065)
TEREX P/N 719 0947 is equipped with a CANBus input module
to specifically control the speed and position of the Main Winch
and Boom Hoist. This CANBus element is configured with a
thumper and horn control.
Note: “Thumper” is a tactile indicator that receives electrical pulses from

the Winch Proximity Sensor and converts them into mechanical
movement via a solenoid. The thumping rate increases in direct
proportion to the drum speed –up to a maximum 15 pulses per second at
drum speeds of 60 RPM (600 inches/min) or higher. Thumper indications
relate to inches: approximately 4 ticks = 2 inches of travel.
The Main Winch and Boom Hoist control is configured to operate, in this system,
with a proximity sensor that disables the main winch (Down) when the payout cable
on the Main Winch has less than three (3) wraps left from its fastening point on the
reel. This feature helps protect against dangerous or improper cable extension and
will not allow the Main Winch Boom to proceed down when tripped.
As part of this system, the controller also recognizes a Load Management Interrupt
(LMI) sensor. This sensor is in place to prevent excessive loads placed on the
equipment from damaging this equipment or bringing possible injury to its operators.
An active LMI when tripped will not allow the Boom to lower or the Main Winch to
Payin.
When this Main Winch Control is enabled, - a (Green LED indication) will signify
that the control is operational, and a good voltage and ground connection are in place.
When High speed is required, the top (Red LED indication) switch is used. The
wiring for this unit is shown in the Testing and Trouble Shooting section of this
manual. See Figures 17 and 18.
Figure 3. Main Winch and Boom Hoist Control

AUX Winch and Swing Control

The AUX Winch and Swing Control (HCJS8M15066) TEREX
P/N 719 0948 is equipped with a CANbus input module to
specifically control the Swing and Payout/Retraction of the
AUX Winch Cable. It features a thumper and horn control.
Note: “Thumper” is a tactile indicator that receives electrical

pulses from the Winch Proximity Sensor and converts them
into mechanical movement via a solenoid. The thumping rate
increases in direct proportion to the drum speed –up to a
maximum 15 pulses per second at drum speeds of 60 RPM
(600 inches/min) or higher. Thumper indications relate to
inches: approximately 4 ticks = 2 inches of travel in this
system.
The AUX Winch and Swing Control is configured to operate in this system, with a
proximity sensor that disables the AUX winch (Down) when the payout cable has
less than three (3) wraps left from its fastening point on the reel. This feature helps
protect against dangerous or improper cable extension and will not allow the AUX
Winch Boom to proceed down when tripped.
As part of this system, the controller also recognizes a Load Management Interrupt
(LMI) sensor. This sensor is in place to prevent excessive loads placed on the
equipment from damaging this equipment or bringing possible injury to its operators.
An active LMI will not allow Boom down or Boom extend as well as AUX Winch
up.
When this AUX Winch Control is enabled, - A (Green LED indication) signifies that
the control is operational, and a good voltage and ground connection are in place.
When High speed is required the top (Red LED indication) switch is used. The wiring
for this unit is shown in the Testing and Trouble Shooting section of this manual. See
Figures 17 and 18.
Figure 4. AUX Winch and Swing Control

Boom Extend/Retract Control

The CFP2M14436 (TEREX P/N 724 0266) Boom Extend/Retract is the
The CFP2MI4436
operator’s Foot Pedal Control for retracting or extending the boom. For
Boom Extend Out, the operator’s toe should apply down pressure to the
treadle. For Boom Retract the operator’s heel should apply down pressure
to the treadle.
DT06-3P
The foot pedal control is interconnected to
the SN1676-1CB system by means of two DT04-2P
wires - CANH (CAN High) and CANL
(CAN Low) - plus the addition of a
common shield wire at the DT06-3P
connector. This unit is manufactured to
operate in a CAN type system. It should
never be used otherwise.
These connectors and foot pedal mate with the CANBus harness for
SN1676-1CB. No other type foot pedal should be used for this system.
For complete schematic and connection wiring see Figure 19 in the
Testing and Trouble Shooting section of this manual under Foot Pedal
Control Wiring.
Figure 5. Foot Pedal Control

OCO2-101 CAN Output Module

This Hi Resolution, current regulated Output Module, the OCO2-101,- (TEREX P/N
04219993) serves as the interface between the application software stored in the
programmable Human Machine Interface (HMI) (OCI1-107) and the outside world.
It is configured with (10) ten PWM sourcing outputs and (2) two sourcing digital
inputs.
The OCO-2 CAN Output Module is equipped with a Bi-Color status LED, located
between J1 and J2. This LED provides easy verification of good system bus health or
can provide help as troubleshooting tool. The Bi-Color LED will indicate with Red
and Green on the state of the CANBus control system. See Testing and
Troubleshooting OCO-2 for the LED indication table.
OCO-2 is mounted
with four (4) 8-32 pan
head machine screws
and locking washers,
into the pre-drilled
holes of the enclosure.
1.90
For wiring information and input/output signal
names from J1 and J2, see Figures 21 and 22 in
the Testing and Troubleshooting Section of this
Manual.
Figure 6. OCO2-101 CAN Output Module

Energy Storage Module (ESM-1)

The Energy Storage Module conditions the cranes battery power to the CANBus
electronic system in operation during spikes in input voltage.
When the Input voltage drops below the power fail voltage threshold, the charged
Energy Storage Module maintains a constant voltage to the system.
This 60,000 µFD unit should never be used in an environment where it receives more
than 24 volts DC. See the Power Supply Requirements in the Testing and
Troubleshooting section of this manual.
For the system wiring to this

module, see the wiring diagram
Figure 20 in the Testing and
Trouble Shooting section of this
manual under ESM-1
Using the maximum output
current of the OCO2-101 output
module, of (4) Amps (Nominal)
the ESM-1 charge should decay
in approximately 2 to 6 Seconds
with power off
Field harness lengths and wire
sizes will affect this time by
increasing the resistance in the circuit. Status indicator should
show green with a
good input voltage and
Figure 7. Energy Storage Module (ESM-1) ground connection
Tester-Do not probe the wiring in the wire connection block of this
unit with metal objects such as screw drivers, pliers, picks or any tool, un-insulated or
insulated. The resulting shock from this unit can seriously impair the tester even with
power off.
As part of a machine’s safety system, an Emergency Stop switch (E

Stop ) must be installed in series with all CAN modules (OCM, OCI, and OCO) power
line. The “Emergency Stop” must disable the output of the module in the event of failure.

OCI1-107 Master Module with (HMI)
The OCI1-107 –(TEREX P/N 04219995) is a programmable Input Module. It has eight (8)
inputs that can be programmed for analog or digital signals. The HMI (Human Machine
Interface) allows the customer to adjust the functionality with the four (4) button membrane
keypad and view each channels setup through the 2 line by 16 character LCD display.
OC1I-107 is configured with:
Ten (10) proportionally sourced current regulated valve outputs
Frequency from 40-250 Hz
Maximum current output up to 3 amps
The Human Machine Interface (referred to as the HMI ) will allow the operator to monitor or
adjust the following information:
Active Function Being Used
Part Number and Serial Number
Restore the Factory Default Settings Output Calibrations ( Thresh, Max, Ramp. etc)
I-O CANBusStatus (see CANBus Output Module OCO2-101 in this section)
OCI1-107 Module
installed in the SN1676
Enclosure
Figure 8. OCI1-107 Installation in the CANBus

System

A power source between 10-32VDC is

required for proper operation.
The J1 connector of the module provide

the voltage for the command source. The
command source is between 12VDC and
ground. This voltage source is adequate
to power single and multi-axis joysticks,
foot pedals, sensors, etc., (with approx.
100mA). An external signal source (such
as from a PLC) supplying the proper
voltage signal swing can also be used.
J1 J2
Figure 9. OCI1-107 Master Module with (HMI)

The HMI Switch Functions
The following define the membrane switch names and functions of the HMI. For wiring and
software information see the Testing and Trouble Shooting with Menu Select section of this
manual.
MENU <MENU> Enters a new menu screen.

SELECT <SELECT> Selects the flashing item.
<MINUS> Decreases an adjustable parameter such as
time.
<DOWN> Selects the previous item in the current
menu’s list.
<UP> Selects the next item in the current menu’s list.
<PLUS> Increases an adjustable parameter.
SAVE <SAVE> Saves the new data to EEPROM (permanent

EXIT memory storage).
Simultaneously pressing <UP and <DOWN> will reset

the HMI to menu.
+ +
Section 2
Getting Started with System Check

Quick Check of the SN1676-1CB System
Note: System shown without internal wiring for the sake of clarity. External
harnesses and power to this system must be connected in the system to
follow this procedure.
Status indicator LED

should show Green
with a good input
voltage and ground OCI1-107
connection with HMI
CAN Output
Module 3
ESM-1
Energy Source
Module
1
Observe Green
LED status Observe Green
indicator LED status
2 indicator
Figure 10. CANBus Quick check with LED diagnostics
WARNING: Operator; before starting Test, Disable hydraulics and power to all external
equipment. The SN1676-1CB enclosure however, will require the vehicle cabling to be
connected and powered.
Confidential and Proprietary, Property of OEM Controls, Inc.| Section 2 11

IF - THEN Test 1: Using CANBus LEDs to

Diagnose the System
To Start: With power on and vehicle cables connected to the SN1676-1CB.
If - ESM-1 shows a GREEN LED.
1 Then – Good voltage and ground connection and unit is charged.
If – ESM-1 shows a RED LED.
Then – Look for incorrect wiring or improper input voltage source.
If - No LED .
Then - Check for a short to ground, reverse polarity wiring or no input voltage,
see wiring tables for this unit in the Testing and Trouble Shooting
Section.
If - Voltage and wiring are correct and not shorted or broken, Replace ESM-1.
If - OCO-2 CAN Output Module Observe a GREEN LED between J1 and J2 for
2 good voltage and ground connections. See CAN explanation and table that
follows for complete LED diagnostics of the OCO-2 Module.
OCO-2 CAN Output Module BI COLOR (LED) INDICATORS
INDICATION GREEN LED (RUN MODE) RED LED (BUS MODE)

INDICATION INDICATION
OFF BRIEFLY AT POWER UP No Errors

BLINK PRE-OPERATIONAL STATE Configuration Error
ON OPERATIONAL STATE “BUS OFF” ERROR CAUSED
BY > 255 MESSAGE ERRORS
SINGLE FLASH STOPPED STATE “REDUCED BUS” ERROR

2 SECOND ON, 1 OFF CAUSED BY > 96 MESSAGE
ERRORS
DOUBLE FLASH N/A NODE GUARD EVENT HAS
2 SECOND ON/OFF, OCCURRED
1 SECOND OFF
ALTERNATING RED AND GREEN FLASHING: DUAL RED AND GREEN FLASHING:
PROBLEMS (SEE ABOVE FOR EACH DUAL PROBLEMS (SEE
COLOR) ABOVE FOR EACH COLOR)
AMBER INDICATION- TERMINAL DOWNLOAD IN PROGRESS
Figure 11. OCO-2 CAN Output Module LED Indicator Table for Diagnostics
12 Section 2 | Getting Started with System Check

If - OCI1-107 Observe a GREEN LED .

3 Then - Good voltage and ground connections are in place.
If – OCI1 shows a RED LED.
Then – Look for incorrect wiring or improper input voltage source.
If - No LED .
Then - Check for a short to ground, or no input voltage, see wiring tables for this
unit in the Testing and Trouble Shooting Section.
If - Voltage, wiring is correct and not shorted or broken, Replace OCI1.
IF - THEN Test 2: Using the HMI to Check

Equipment
WARNING: Operator; before starting Test, Disable hydraulics and power to all external
equipment. The SN1676-1CB unit however, will require the vehicle cabling to be connected
and powered.
Operator - For instructions on the HMI usage-

see Testing and Trouble Shooting under Testing
Using Menu Select and the HMI.
After power on, the Main Menu RUN screen is
displayed. Press the key <UP> or <DOWN> to
display all menu branches available through the
MAIN menu: Stop at the I/O Test Menu.
PWM 01 PWM 02
45.5 % 100.0%
EQUIPMENT CHECK USING THE HMI DISPLAY

FUNCTION For HMI DISPLAY IF THEN
Boom Extend @ AI-13 See 5.0v INCORRECT LMI Switch is tripped
On the Control to .48v Threshold OPERATION OR NO Check for 2600Ω at A and
28% Max 65.0. If RESPONSE B of DT06-3S
Toe Down, Hold
Not or 0v go to IF -
@ HMI Display Check for +/-12v @ 1,2
THEN
DT04-2S
PWM-09
Check Wiring /Replace Unit


FUNCTION FOR HMI DISPLAY IF THEN
Boom Retract @ AI-13 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
to 9.50v Threshold NO RESPONSE for 2600Ω at A and B from
On the Control
28% Max 65.0. If the foot pedal side.
Heel Down, Hold
Not or 0v go to IF- Check for +/-12v @ 1,2
@ HMI Display THEN DTO4-2S – Power Side
AI-13 Check Wiring/Replace Unit
Boom Hoist Up @ AI-10 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
to .48v Threshold NO RESPONSE for 2600Ω at A and B from
Right (MAIN)
28% Max 55.0 If the foot pedal side.
control for Hoist
Up @ HMI Not or 0v go to IF- Check for +/-12v @ 1,2
Display AI-10 THEN DT04-6S - Power Side
Check Wiring/Replace Unit
Boom Hoist Dwn @ AI-10 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
to .9.50v NO RESPONSE for 2600Ω at A and B from
Right (MAIN)
Threshold 28% the foot pedal side.
control for Hoist
Max 55.0 If Check for +/-12v @ 1,2
@ HMI Display
Not or 0v go to IF- DT04-6S - Power Side
AI-10
THEN Check Wiring/Replace Unit
Main Winch Up @ AI-11 See 5.0v INCORRECT OP OR Disconnect DT06-3S check

Right (MAIN)
28% Max 64.9. If the joystick side.
control for Up
@ HMI Display
THEN DT04-6S - Power Side
AI-11
Main Winch Dwn @ AI-11 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
Right (MAIN)
control for Down CHECK LMI
Not or 0v go to IF- SWITCH Check for +/-12v @ 1,2
@ HMI Display
THEN DT04-6S - Power Side
AI-11
AUX Winch Dwn @ AI-08 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
Left (AUX)
Control for Down CHECK LMI SWITCH
Not or 0v go to IF- FOR OVERLOAD Check for +/-12v @ 1,2
@ HMI Display
THEN DT06-6S – Power Side
AI-08 rd
Check 3 WRAP SWITCH
14 Section 2 | Getting Started with System Check


FUNCTION FOR HMI DISPLAY IF THEN
AUX Winch Up @ AI-08 See 5.0v INCORRECT OP OR LMI Switch is tripped
Left (AUX)Control to 9.50v Threshold NO RESPONSE Check ARM SW closed at
for Up 28% Max 64.9. If CHECK LMI 1 and 2 of DT06-2S
Not or 0v go to IF- SWITCH FOR
@ HMI Display Disconnect DT06-3S check
THEN
AI-08
OVERLOAD for 120Ω at A and B from
the joystick side.
Check for +/-12v @ 1,2
DT06-6S – Power Side
Swing Left @ AI-07 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
Left (AUX) control
28% Max 55.0 If the joystick side.
for swing left
@ HMI Display
AI-07
Swing Right @ AI-07 See 5.0v INCORRECT OP OR Disconnect DT06-3S check
Left (AUX) control
for swing right
@ HMI Display
AI-07
Note: At rest (Centered) with power on the Control Joysticks, and Foot Pedal
Control; - the OCI1 display should read 5.0v for each.
Figure 12. Equipment Check Using the HMI
If a wiring problem is suspected in the - Check Wiring Block – See Testing and Trouble
Shooting Section for all wiring information for this unit. Refer to Figures 14, 16, 17, 21 and 22.

Section 3
Testing and Troubleshooting
This section will cover basic issues of the CANBus System architecture and does not attempt
to substitute as a Maintenance Manual. The intent of this section is to provide the user with a
basic system understanding and a procedure that troubleshoots by identifying a defective
component. It does contain detailed signal and wiring information of the system.
With the CANBus architecture, configuration data is stored in the Master Module and can be
accessed through the (HMI) Human Machine Interface Module database. The HMI provides
a consistent, user-friendly interface to access the configuration data in the database.
This Section covers:
How to Assess the CANBus System Health
System Connector information with signal names
The CANBus Block Diagram
Operator; before starting Testing and Troubleshooting,

Disable hydraulics and power to all external equipment. The SN1676-1CB enclosure,
however, will require the vehicle cabling to be connected.
Assessing the CANBus System Health

The System is equipped to diagnose its internal
CAN Output Module wiring and component status with a quick procedure.
Note: Power to this controller is required and

all external connections to the system must be
made to follow this procedure.
Note: In most cases, grounding the valve coils to

the vehicle frame will not cause a problem. But in
using an external battery to “jump” power into the
system with the coils frame grounded, be sure to
connect the external battery negative to the frame of
the vehicle being jumped. This is to keep the
external battery ground and the vehicle frame at the
J2 same ground potential.
J1
For wiring information to these (2) connectors J1/J2 and
signal names see the tables at figures 21 and 22
16 Section 3 | Confidential and Proprietary, Property of OEM Controls, Inc.

Power Supply Requirements

Typical Supply Voltage: 8-15 VDC
The OCI Modules can withstand the following conditions without any
permanent damage;
Reverse Polarity: The V-Bat and Ground terminals can be
INTERCHANGED
Short Circuit: Any Input or Output from the system can be shorted to
V-Bat or Ground.
Over Voltage: The CANBus system is able to withstand Transient
Voltage levels to 30VDC
Testing the OCO-2 CAN Module

The OCO-2-107 CAN Output Module is equipped with a Bi-Color status LED,
located between J1 and J2.
This LED provides easy verification of good system bus health (Red and Green
constant) or can provide help as a troubleshooting tool. The Bi-Color LED will
indicate with Red and Green. Amber indicates Download in progress.
In many cases the Bi-Color LED will indicate (2) bits of information.
Example: Green LED is constant, Red LED is flashing: (2 seconds on 2 on/off)

The Output Module is operational-(Green)- but a CANBus Node
Guard (Bus Open) error has occurred (Red).
When the Output Module is first powered

up it enters the Pre-Operational state,
with a (Green Blink) indication.
If there are no bus open messages within
(5) seconds, the OCO-2 switches to
stopped, with (Red) LED constant ON.
For output signals and
During normal operation, if no CANBus wire connection
open messages are received within (75) Bi-Color LED information see J1/J2
milliseconds, the OCO-2 turns off all of Figures 21/22
its local outputs.
After (1) second the OCO-2 enters the stopped state with the (Red) LED on
indication.
Testing and Trouble Shooting | Section 3 17

There are four states – the (3) above plus initializing which occurs at Power On
Reset. The OEM CAN modules automatically transition to pre-operational state
(Green Blink) after reset.
The OCO-2 provides additional bus information for the tester that is listed in the
Table below.
OCO-2 CAN Output Module BI COLOR (LED) INDICATORS
INDICATION GREEN LED (RUN MODE) RED LED (BUS MODE)

INDICATION INDICATION
OFF BRIEFLY AT POWER UP No Errors

BLINK PRE-OPERATIONAL STATE Configuration Error
ON OPERATIONAL STATE “BUS OFF” ERROR CAUSED
BY > 255 MESSAGE ERROR
SINGLE FLASH STOPPED STATE “REDUCED BUS” ERROR

2 SECOND ON, 1 OFF CAUSED BY > 96 MESSAGE
ERROR
DOUBLE FLASH N/A CANBUS MESSAGE FOR BUS
2 SECOND ON/OFF, OPEN (NON-COMMUNICATION)
1 SECOND OFF AT SOME POINT ON THE BUS
ALTERNATING RED AND GREEN DUAL PROBLEMS RED AND GREEN DUAL
(SEE ABOVE FOR EACH COLOR) PROBLEMS (SEE ABOVE FOR
EACH COLOR)
AMBER INDICATION- TERMINAL DOWNLOAD IN PROGRESS
Figure 13.OCO2 CAN Output Module LED Indicator table for diagnostics
OCI1-107 CAN Input Module with (HMI)

Diagnostic
Note: The OCI1-101 is sensitive to interference; mobile radios, high power AC
equipment and transmission lines are potential sources of interference. A
shielded system cable and a connection to chassis ground from the
SN1676-1CB enclosure is recommended.
Warning: Before disconnecting internal harnesses, be sure the external
battery negative is to the frame of the vehicle. This is to keep the external
battery ground and the vehicle frame at the same ground potential.

Before Starting: Observe a Green LED between

J1 and J2 for good voltage and ground connections,
or Red LED for incorrect wiring or improper
voltage source. IF the Red LED is lighted do the
recommended Voltage Check.
A power source between 9-14VDC is required for
proper operation. The power supply must be clean
and free of spikes and DC ripple. A dedicated
direct connection from the battery, fuse block or
power supply is strongly recommended to ensure
a clean supply with low voltage drop.
The power wiring to the system should be sized
appropriately to handle the maximum current
draw anticipated.
J1 J2 Contact OEM Controls for assistance as required.
When using the HMI display to check your equipment, the tester will require this
table to relate to what the HMI display is showing, and where that signal is coming
from or being sent to in the equipment.
Example: The HMI display shows DI 04. This means the proximity sensor is not
engaged, so the cable is not completely “payed out”, and using the table, verify the
wiring to J2-4 is good, and the switch is good.
Figure 14. OCI1-107 System Connectors – J1-“A”-J2-“B”

The table, (Figure 14), shows the wiring from the OCI1-107 to the field connectors with
identification signal names (see J1 “A” J2 “B” tables, Figures 21 and 22 ) *DI- Digital Input
-** DO- Digital Output ***AI- Analog Input.
Testing with Menu Select and the (HMI)

Warning: Operator; before starting Testing and Troubleshooting, Disable
any and all systems external to this controller. The system however will
require the external cables to be connected with power on to this unit.
Main Menu Screen

After power on, the Main menu RUN screen is displayed. Press the key <UP> or <DOWN> to
display all menu branches available through the MAIN menu:
1. Run Screen
2. Part Number and Serial Number Screen
3. Setup Unlock Screen
4. I/O Test Menu
5. Restore Factory Defaults Screen
Run Screen
This screen displays the output level for the channel function that is activated.
No Channel Active Last Channel Active
RUN MODE: NORMAL RUN: RETRACT

FUNCTIONS OFF Fn 1A 50.5%
Part Number and Serial Number Screen (for Master Module

only)
This screen displays the OCI1-107 Master Module software part number, version number
‘nnn’, and serial number.
XXXXX-101.nnn
SN: 000000001
Setup Unlock Screen
This menu allows the operator to unlock adjustments for a period of time OR tells the
operator that the setup and configuration menus are UNLOCKED.
Displayed if setup is UNLOCKED
SETUP UNLOCKED
PRESS + OR -

“PRESS <+ >or < ->” is blinking. Press <+> or <-> key to select the next or previous menu.
Setup and Configuration changes are allowed.
Displayed if setup is LOCKED UNLOCK SETUP?
PRESS SELECT
PRESS + OR -
Warning : Changes must be made by carefully trained personnel, authorized to
do so by the manufacturer of this equipment. If done incorrectly, changing the
setting or functionality of this equipment could result in serious injury or death.
The following instructions apply to an extreme circumstance where your system
requires emergency help in the field due to a loss of the factory program settings.
“PRESS SELECT” is blinking. Press <SELECT> key to enter the password entry sub-menus.
Setup and Configuration changes are
NOT allowed. ENTER PASSWORD
0 * *
1st digit is set to 0 and is blinking. Press <+> or <-> key and 1st digit increases or decreases
with each press from 0 thru 9 with rollover at the end-points.
Press <SELECT> key to select the displayed digit.
Press <EXIT> key to exit the ENTER PASSWORD menu without selecting the 1st digit.
2nd digit is set to 0 and is blinking. 1st digit remains as previously selected. Press <+> or <->
key and 2nd digit increases or decreases with each press from 0 thru 9 with rollover at the end-
points. Press <SELECT> key to select the displayed digit.
Press <EXIT> key to return to the 1st digit screen.
3rd digit is set to 0 and is blinking. 1st and 2nd digits remain as previously selected. Press <+>
or <-> key and 3rd digit increases or decreases with each press from 0 thru 9 with rollover at
the end-points.
Press <SELECT> key to select the displayed 3-digit password and attempt to unlock the
Setup Menus.
Press <EXIT> key to return to the 1st digit screen.
If the Password is incorrect, the UNLOCK SETUP? Menu is displayed again. If the Password
is correct, the SETUP UNLOCKED menu is displayed and the unlock timer is started. The
Unlock Timer is reset each time an HMI key is pressed. The Unlock Timer times 10 minutes
of inactivity and locks the HMI. At Power On, the HMI is always locked
1. Continue Scrolling through the <MENU SELECT> either with the plus or minus keys
to check Digital Inputs, Analog Inputs and VDD Status
DI 10 11 12 DI 35 36 37
1 1 1 0 0 0 5.0
5.0

See the Table at Figure 14 for definitions and wire locations
AI 11 AI 12 VDD POWER SUPPLY

45.5 % 100.0% 12.34 Volts
Pass/ Fail Equipment Tests Using the HMI Display

To use the HMI to check for correctness of Boom EXTEND, RETRACT, AUX Winch
UP, DOWN, Swing LEFT/RIGHT, Main Winch UP/DOWN, Boom Hoist UP/DOWN,
values and operation parameters see the Table at Figure 12. This is found in the
Getting Started Section of this Manual.
For Specific wiring for these units See Main and AUX Winch wiring diagrams and
Boom Extend/Retract wiring in this section.
Restore Factory Defaults Screen
This screen is used to restore the OCI1-107 to factory Defaults.
Press the <UP> or <DOWN> key to select YES if you wish to actually restore all
adjustments to their factory default settings. Then press the <SELECT> key.
If “YES” was selected, you will see the following animated screen.
RESTORE DEFAULTS RESTORING NOW !

YES or NO? ………
Note: See the Table: Equipment Check Using the HMI Display at Figure 14. To
relate the HMI display nomenclature (viewed) to a word definition and a
wire input/output of the HMI at J1 and J2.

Main Winch Boom Hoist Control wiring

The Main Boom Winch Controller : - (TEREX P/N 719 0947) HCJS8M15065 is part
of the CANBus system. To check for its correct operation use the HMI display.
Moving the controller and following the test plan will confirm whether the controller
is operating correctly. See Pass/ Fail Equipment Test Table, in the Getting Started
section.
Quick Test: With No power on the control stick, disconnect DT06-3P and check for
resistance at (Pins) A and B -Stub Terminator resistance: - There should be 2600Ω
resistance on the control stick side. If control stick switches do not light when
enabled, and power is on, check the input voltage as shown. For operation problems,
use the HMI display in the Pass/Fail Equipment test.
Note: This wiring diagram is provided

only as reference material to explain
If ..voltage, ground & CANBus testing and show the controller
connection is good & control is connector. See Schematic D16551,
enabled, see a Red lighted control provided separately, for a detailed
button. If not… understanding of this system.
Then… Disconnect this connector and read +12v, -12v at
Power side (socket) of 1 and 2. If no voltage, trace back
through wiring to incoming power from ESM-1.
See wire tables Figure 16 for all signals
Note: The control sticks and foot pedal

control are all interconnected by means
of two wires - CANH (CAN High) and
CANL (CAN Low) - plus the addition
DT06-3S J1
“A” See Table of a common shield wire. It is
Figure 21 for all important to the operation of the
signals CANBus system that the recommended
placement and system wiring be
followed very closely. Improperly
Figure 15. Wiring Configuration for Main Winch Boom Hoist Controller placed/wired CANBus modules may
DT06-3S DT04-6S result in an inoperable system. It is
important to carefully map out how you
will route the CANH and CANL signals
from control to control so as not to
compromise the signal Integrity.

MAIN WINCH BOOM HOIST CONNECTOR DT04-3P

PIN WIRE FUNCTION COLOR FROM
A DATA SIGNAL Brown J1 – Pin 13
B DATA SIGNAL White J1 – Pin 14
C SHIELD Shield J1 – PIN 15
Figure 16. Wiring table for P4 and P7
AUX WINCH CONNECTER DT04-6P

1 +12 VDC Red/Wht J1 – Pin 8
2 -12V NEG. BATTERY AND TACK SHIELD Black J1 – Pin 6
3 N/U
4 N/U
5 TACK SIGNAL INPUT FOR THUMPER Red/CBL J1 – Pin 19
AUX WINCH CONNECTOR DT04-3P

A DATA SIGNAL Brown J1 – Pin 13
B DATA SIGNAL White J1 – Pin 14
C SHIELD Shield J1 – Pin 15
Figure 17. Wiring table for P3 and P5
MAIN WINCH BOOM HOIST CONNECTER DT04-6P

2 -12V NEG. BATTERY AND TACK SHIELD Black J1 – Pin 5
3 N/U
4/6 N/U
5 TACK SIGNAL INPUT FOR THUMPER Red/CBL J1 – Pin 16

Aux Winch and Swing Control Test

Aux Winch and Swing Control wiring
The AUX Winch Cable Controller: (TEREX P/N 719 0948) HCJS8M15066 is part of
the CANBus system. To check for its correct operation use the HMI display. Moving
the controller and following the test plan will confirm whether the controller is
operating correctly. See Using the HMI function Pass/Fail Equipment Test Table in
the Getting Started section.
Quick Test: With No power on the control stick, disconnect DT06-3S at A and B
check for the Full Terminator Bus resistance: - There should be 120Ω resistance on
the control stick side.
If ...voltage, ground & CANBus connection is

good & control is enabled, see a Red lighted
control button. if not… J1 “A” See
Table Figure
Then… Disconnect this connector and read 21 for all
+12v, -12v at socket side, pins 1 and 2. See signals
wire tables Figure 16 for all signals
Arm Switch must be closed

for operation
Note: This wiring

DT06-3S diagram is provided
only as reference
material to explain
Figure 18. Wiring Configuration for AUX Winch and Swing Controller testing and show the
DT06-3S Arm Switch DT04-6S Controller connector.
Please use the complete
schematic, provided
separately, from this manual.
See D16551 (supplied) for a
detailed understanding of the
system.

Boom Extend/ Retract Wiring Test

This foot pedal controller: (TEREX P/N 724 0266) CFP2M14436) is part of the
CANBus system; to check for its correct operation use the HMI display. Pushing on
the controller and following the test plan will confirm whether the controller is
operating correctly. See the HMI function Pass/Fail Equipment Test Table in the
Getting Started section.
Quick Test: With No power on the Foot Pedal Control disconnect DT06-3S at A and
B check for the Stub Terminator resistance: - There should be 2600Ω resistance at the
control side.
With power on, read +/- 12v on the input socket connector shown below.
Note: This wiring

diagram is provided
only as reference
material to explain
testing.
To J1
“A”
Figure 19. Wiring Tables for the

Foot Pedal Controller
Disconnect this connector and read +12v, Connected to

-12v at socket side pins 1 and 2. See wire Control sticks
table that follows for all signals
This wiring diagram is provided only as reference material to explain testing

and show the Controller connector. See Schematic D16551, provided
separately, for a detailed understanding of the system.
BOOM EXTEND/RETRACT CONNECTOR (P9) DT04-3S

A DATA SIGNAL CAN HI SIGNAL Brown J1 – Pin 13
B DATA SIGNAL CAN LO SIGNAL White J1 – Pin 14
C SHIELD Shield J1 – PIN 15

Energy Storage Module ESM-1 Test

Vehicle Battery J1 “A” See Table
Supply Figure 21 for all
signals
Status indicator
should show Green
Figure 20. Wiring Configuration for the Energy Storage Module (ESM-1) with a good input
voltage and ground
Operating voltage 9-24 vdc @ 60000 µFD
connection. A Red
Warning: Avoid this units wiring connections with fingers or metal LED indication
objects. Even with power removed, the ESM-1 holds a significant denotes a reversed
charge with no load and can cause injury. polarity.
This is a non- repairable item. If defective, it should be returned to OEM
Controls Inc.
Note: This wiring diagram is See Schematic D16551, provided

provided only as reference material separately, for a detailed understanding
to explain testing. of this system.

J1-“A” and J2-“B” Equipment Wiring Check
See Wiring Tables with signal names for J1 and J2- Figures 21,
22
Note: In most cases, grounding the valve coils to the vehicle frame will not cause a
problem. But in using an external battery to “jump” power into the system with the coils
frame grounded, be sure to connect the external battery negative to the frame of the vehicle
being jumped. This is to keep the external battery ground and the vehicle frame at the same
ground potential.
J1 “A” PN DRC12-24PA J2 “B” PN DRC12-24PB

SN1676B -1B FIELD CONNECTER “A” J1 – DRC12-24PA
J1 Field Wire Function Color Connect To
1 +12 BATTERY – FROM IGNITION SWITCH Red POS BUS 3

2 +12 BATTERY – FROM IGNITION SWITCH Red POS BUS 3
3 -12V NEG BATTERY TERMINAL Blk NEG BUS 1
4 -12V NEG BATTERY TERMINAL Blk NEG BUS 2
5 NEG TO BOOM/WINCH CONTROLLER Blk NEG BUS 1
HANDLE
6 NEG TO SWING/AUXWINCH CONTROLLER Blk NEG BUS 1
7 +12V BATTERY – FROM IGNITION SWITCH Red/Wht POS BUS 4
10 N/U
11 +12V SOURCE TO BOOM Red/Wht POS BUS 4
EXTEND/RETRACT (FOOT PEDAL)
12 NEG TO BOOM EXTEND/RETRACT (FOOT Blk NEG BUS 2
PEDAL)
13 CANBUS SIGNAL (TWISTED PAIR) –(HI) Brn OCO2 J1- 3
14 CANBUS SIGNAL (TWISTED PAIR) –(LO) Wht OCO2 J1-10
15 CANBUS SIGNAL SHIELD Shield
16 MAIN TACH SIGNAL IN FOR THUMPER Red FIELD J2-6
17 MAIN TACH SIGNAL IN FOR THUMPER Shield NEG BUS 2
18 N/U
19 AUX TACH SIGNAL IN FOR THUMPER Red FIELD J2-5
20 AUX TACH SIGNAL IN FOR THUMPER Shield FIELD J2-23
21 HORN Org OCO1 J1-11
22,24 N/U
23 LMI INTERRUPT Blu/Blu OCO1 J2-11
Figure 21. Wiring Configuration for Connector J1-“A”

SN1676B -1B FIELD CONNECTER “B” J2-DRC-24PB
J2 Field Wire Function Color Connect To
1 +12 VDC Red FIELD J1 - 1

2 +12 VDC Red FIELD J1 - 2
3 -12V NEG. Blk FIELD J1 - 3
4 -12V NEG. Blk FIELD J1 - 4
5 AUX WINCH TACH THUMPER SIGNAL Blk/Yel FIELD J1 - 19
6 MAIN WINCH TACH THUMPER SIGNAL Blu/Vio FIELD J1 - 16
RD
7 AUX 3 WRAP SIGNAL (INPUT OC1 D1-04) Blk/Org OCO1 J2 - 4
RD
8 MAIN 3 WRAP SIGNAL (INPUT OC1 D1-06) Blk/Blu OCO1 J2 - 8
9 NU
10 NU
11 BOOM HOIST UP (OUTPUT OC0-2 PWM-01) Brn/Wht OCO2 J2 - 1
12 BOOM HOIST DWN (OUTPUT OC0-2 PWM-02) Brn/Blk OCO2 J2 - 12
13 NU
14 SWING LEFT (OUTPUT OC0-2 PWM-03) Gry/Blk OCO2 J2 - 14
15 MAIN WINCH UP (OUTPUT OC0-2 PWM-07) Org/Wht OCO2 J2 - 4
16 MAIN WINCH DWN (OUTPUT OC0-2 PWM-08) Org/Blk OCO2 J2 - 9
17 MAIN WINCH HI SPEED (INPUT D0-21 ) Vio/Wht OCO2 J1 - 6
18 AUX WINCH UP (OUTPUT OC0-2 PWM-05) Grn/Wht OCO2 J2 - 3
19 AUX WINCH DWN (OUTPUT OC0-2 PWM-06) Grn/Blk OCO2 J2 - 10
20 AUX WINCH HI SPEED (INPUT D0-22 ) Blu/Wht OCO2 J1 - 7
21 BOOM EXT OUT (OUTPUT OC0-2 PWM-09) Yel/Wht OCO2 J2 - 5
22 BOOM EXT IN (OUTPUT OC0-2 PWM-10) Yel/Blk OCO2 J2 - 8
23 AUX TACH SIGNAL IN FOR THUMPER Shield FIELD J1 - 20
24 MAIN TACH SIGNAL IN FOR THUMPER Shield FIELD J1 - 17
Figure 22. Wiring Configuration for Connector J2-“B”

User Notes


Section 4
Index
A- J1-A J2-B, 20
Aux Boom Winch Controller, 25, 26 M-

C- Main Boom Winch Controller, 23
CANBus, 2, 23 Membrane Switch Functions, 10
CANBus Control System, 1 module, 2, 23
CANH, 2, 6, 23 O-
CANL, 2, 6, 23 OCI module, 17
Controller Area Network module (CAN), 18 Over Voltage, 17
Current Source, 7 Overview of the CANBus Control System, 1
E- P-
ESM-1, 8 Pre-operational, 18
F- R-
Factory Default Settings, 9 Reverse polarity, 17
Full Termination, 2 S-
H- Short Circuit, 17
Hi Resolution, 7 Stub Termination, 2
HMI, 9 Supply Voltage, 17
HMI Switch Functions, 10 System Check, 11
Human Machine Interface, 9 Testing and Troubleshooting, 16
J-

If you have any questions regarding this product, we will be happy to assist you.
Please contact us at:
OEM Controls Inc.

10 Controls Drive
Shelton, CT 06484
(203) 929-8431
Fax: (203) 929-3867
www.oemcontrols.com

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10 Controls Drive, Shelton CT 06484

Overview of the CANBus Control System ........................................... 1

Getting Started with System Check .................................................. 11

Testing and Troubleshooting ............................................................. 16

Figure 6. OCO2-101 CAN Output Module ............................................................................................................ 7

Document Revision History

Overview of the CANBus Control

Figure 1. CANBus Enclosure

OCI1-107 Human Machine Interface

Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 1

Full Termination : A CAN Module at the end of a cable run

Stub Termination : A CAN module that has been

ENGINE OPERATORS CURBSIDE WINCH

Important: The recommended module placement and system wiring

2 Section 1 | Overview of the CANBus Control System SN1676-1CB

CANBus System Block Diagram

Figure 2. CANBus Block Diagram

Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 3

Main Winch and Boom Hoist Control

Note: “Thumper” is a tactile indicator that receives electrical pulses from

Figure 3. Main Winch and Boom Hoist Control

4 Section 1 | Overview of the CANBus Control System SN1676-1CB

AUX Winch and Swing Control

Note: “Thumper” is a tactile indicator that receives electrical

Figure 4. AUX Winch and Swing Control

Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 5

Boom Extend/Retract Control

Figure 5. Foot Pedal Control

6 Section 1 | Overview of the CANBus Control System SN1676-1CB

OCO2-101 CAN Output Module

Figure 6. OCO2-101 CAN Output Module

Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 7

Energy Storage Module (ESM-1)

For the system wiring to this

As part of a machine’s safety system, an Emergency Stop switch (E

8 Section 1 | Overview of the CANBus Control System SN1676-1CB

OCI1-107 Master Module with (HMI)

Figure 8. OCI1-107 Installation in the CANBus

Confidential and Proprietary, Property of OEM Controls, Inc. | Section 1 9

A power source between 10-32VDC is

The J1 connector of the module provide

Figure 9. OCI1-107 Master Module with (HMI)

MENU <MENU> Enters a new menu screen.

SAVE <SAVE> Saves the new data to EEPROM (permanent

Simultaneously pressing <UP and <DOWN> will reset

Getting Started with System Check

Status indicator LED

Figure 10. CANBus Quick check with LED diagnostics

Confidential and Proprietary, Property of OEM Controls, Inc.| Section 2 11

IF - THEN Test 1: Using CANBus LEDs to

INDICATION GREEN LED (RUN MODE) RED LED (BUS MODE)

OFF BRIEFLY AT POWER UP No Errors

SINGLE FLASH STOPPED STATE “REDUCED BUS” ERROR

12 Section 2 | Getting Started with System Check

If - OCI1-107 Observe a GREEN LED .

IF - THEN Test 2: Using the HMI to Check

Operator - For instructions on the HMI usage-