Service Manual Instruction Manual
Table Of Contents
- Section A. Introduction - Maintenance Safety Precautions
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires And Wheels
- 3.2 Torque Hub
- Oil Information
- Roll and Leak Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Output Carrier Disassembly
- Input Carrier Disassembly
- Hub-Spindle Disassembly
- Spindle-Brake Disassembly
- Cover Disassembly
- Cover Assembly
- Input Carrier Sub-Assembly
- Output Planet Gear Sub-Assembly
- Spindle - Brake Sub-Assembly
- Hub-Spindle Sub-Assembly
- Cover Sub-Assembly
- Main Assembly
- Integral Brake Check
- 3.3 Free Wheeling Option
- 3.4 Drive Motor
- 3.5 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.6 Steer Adjustments
- 3.7 Swing Drive
- 3.8 Swing Bearing
- 3.9 Swing Brake - Mico
- 3.10 Rotary Coupling
- 3.11 Generator
- 3.12 Deutz D2.9 L4 Engine
- 3.13 Deutz D2011 Engine
- 3.14 Spark Arrester Cleaning Instructions
- 3.15 Glow Plugs
- 3.16 Deutz EMR 2
- 3.17 Bio Fuel in Deutz Engines
- 3.18 GM Engine General Maintenance
- 3.19 GM Engine Dual Fuel System
- Fuel Filter
- Direct Electronic Pressure Regulator (DEPR)
- Air Fuel Mixer
- Electronic Throttle Control (ETC)
- Electric Lock Off
- Engine Control Module (ECM)
- Heated Exhaust Gas Oxygen Sensor
- Gasoline Multi Point Fuel Injection System (MPFI)
- Gasoline Fuel Pump
- Gasoline Pressure And Temperature Sensor Manifold
- Fuel Filter
- Fuel Injector Rail
- Fuel Injector
- 3.20 GM Engine Fuel System Repair
- Propane Fuel System Pressure Relief
- Propane Fuel System Leak Test
- Propane Fuel Filter Replacement
- Direct Electronic Pressure Regulator (DEPR) Maintenance And Inspection
- Check/Drain Oil Build-Up In 2-Stage Vaporizer
- Air Fuel Mixer/Throttle Control Device Maintenance And Inspection
- Exhaust System And Catalytic Converter Inspection And Maintenance
- Temperature Manifold Absolute Pressure (TMAP) Sensor
- Throttle Body (ETC) Replacement
- Mixer Replacement
- Electronic Pressure Regulator (EPR) Replacement
- Regulator Replacement
- Coolant Hose Replacement
- Vapor Hose Replacement
- Engine Control Module Replacement
- Heated Exhaust Gas Oxygen Sensor Replacement
- 3.21 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- 5.1 O-Ring Lubrication
- 5.2 Cylinders - Theory of Operation
- 5.3 Cylinder Checking Procedure
- 5.4 Cylinder Removal and Installation
- Cylinder Locations
- Main Boom Telescope Cylinder Removal
- Main Boom Telescope Cylinder Installation
- Main Boom Lift Cylinder Removal
- Main Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- 5.5 Hydraulic Cylinder repair
- Tower Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Upright Level Cylinder
- Cleaning and Inspection
- Assembly
- Master Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Lift Cylinder
- Cleaning and Inspection
- Assembly
- Main Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Tower Boom Telescope Cylinder
- Cleaning and Inspection
- Assembly
- Platform Level (Slave) Cylinder
- Cleaning and Inspection
- Assembly
- Jib Lift Cylinder (AJ Only)
- Cleaning and Inspection
- Assembly
- Steer Cylinder
- Cleaning and Inspection
- Assembly
- Axle Lockout Cylinder
- 5.6 Hydraulic Pump (Gear)
- 5.7 Variable Pump
- 5.8 Hydraulic Component Start-Up
- 5.9 Pressure Setting Procedures
- Section 6. JLG Control System
- Section 7. Basic Electrical Information & Schematics

SECTION 3 - CHASSIS & TURNTABLE
3121616 – JLG Lift – 3-103
562 System Voltage Low 168 17
563 System Voltage High 168 15
601 Flash Checksum Invalid 628 13
604 RAM Failure 630 12
606 COP Failure 629 31
642 External 5V Reference Low 1079 4
643 External 5V Reference High 1079 3
685 Power Relay Open 1485 5
686 Power Relay Shor ted 1485 4
687 Power Relay Shor t to Power 1485 3
1111 Fuel Rev Limit 515 16
1112 Spark Rev Limit 515 0
1151 Closed Loop Multiplier High LPG 520206 0
1152 Closed Loop Multiplier Low LPG 520206 1
1155 Closed Loop Multiplier High Gasoline 520204 0
1156 Closed Loop Multiplier Low Gasoline 520204 1
1161 Adaptive Learn High LPG 520202 0
1162 Adaptive Learn Low LPG 520202 1
1165 LPG Cat Monitor 520213 10
1171 LPG Pressure Higher Than Expected 520260 0
1172 LPG Pressure Lower Than Expected 520260 1
1173 EPR Comm Lost 520260 31
1174 EPR Voltage Supply High 520260 3
1175 EPR Voltage Supply Low 520260 4
1176 EPR Internal Actuator Fault 520260 12
1177 EPR Internal Circuitry Fault 520260 12
1178 EPR Internal Comm Fault 520260 12
1612 RTI 1 loss 629 31
1613 RTI 2 Loss 629 31
1614 RTI 3 Loss 629 31
1615 A/D Loss 629 31
1616 Invalid Interrupt 629 31
1625 Shutdown Request 1384 31
1626 CAN Tx Failure 639 12
1627 CAN Rx Failure 639 12
1628 CAN Address Conflict Failure 639 13
1629 Loss of TSC 1 639 31
2111 Unable to Reach Lower TPS 51 7
2112 U nabl e to Re ac h H igh er T PS 51
2135 TPS 1/2 Simultaneous Voltages 51 31
2229 BP Pressure High 108 0
Table 3-12. DTC to SPN/FMI Cross Reference Chart
DTC Description SPN Code FMI Code