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 6 - JLG CONTROL SYSTEM
6-18 – JLG Lift – 3121616
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description Priority
None No flash code is indicated for the following help messages. They are intended to
hint at a possible problem if vehicle is not behaving as expected.
1
EVERYTHING OK The “normal” help message in platform mode
GROUND MODE OK The “normal” help message in ground mode
FSW OPEN A drive or boom function has been selected but footswitch is open.
RUNNING AT CREEP – CREEP
SWITCH OPEN
All function speeds are limited to creep because creep switch is open.
RUNNING AT CREEP – TILTED
AND ABOVE ELEVATION
All boom function speeds are limited to creep because vehicle is tilted and
above elevation.
RUNNING AT CUTBACK – ABOVE
ELEVATION
Drive speed is limited to “ELEVATED MAX” because vehicle is above elevation.
TI LT S ENS OR OU T OF RANG E Th e tilt sens or has indi cate d a t ilt a ngl e grea ter than 19 d egre es fo r mor e t han 4
seconds. Not reported during 2 second power-up.
LOAD SENSOR READING UNDER
WEIGHT
The loa d sen sor is re adin g 20% or more under t he cal ibra te d zer o poi nt. T his
fault may occur if platform is resting on the ground. Not reported during 2 sec-
ond power-up.
1/1 Flash code 1/1 indicates a “sleep” mode.
NOT REQUIRED
2/1 Flash code 2/1 indicates problems with footswitch. 2
FSW FAULTY The two footswitch inputs have read the same state for more than one second.
KEYSWITCH FAULTY Both platform and ground modes are selected simultaneously
2/2 Flash code 2/2 indicates problems with drive & steer selection. Except where
noted, these faults are not reported during 2 second power-up sequence.
3
DRIVE LOCKED – JOYSTICK
MOVED BEFORE FOOTSWITCH
Drive was selected before and during footswitch closure. Can be reported dur-
ing power-up sequence.
FSW INTERLOCK TRIPPED Footswitch was closed for seven seconds with no function selected. Can be
reported during power-up sequence.
STEER LOCKED – SELECTED
BEFORE FOOTSWITCH
Steer was selected before and during footswitch closure.
STEER SWITCHES FAULTY Both steer switches are active together.
DRIVE / ST EER W ITH NO QPR OX T his f ault only o cc urs with ind uct ive j oy sticks. It occu rs if the joystic k is m oved
out of the neutral position with no Qprox sensors active.
D/S JOY. QPROX BAD These faults only occur with inductive joysticks. They indicate that the Q-Prox
sensor is reading above 3.18 volts.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
Inductive joysticks: The trigger points for these faults are dependent on the
centertap voltage reading. These faults will be triggered when the voltage is
less than the centertap voltage minus half the center tap voltage minus 0.3
volts. If the centertap is at the high end of the range, these faults will be trig-
gered below 1.05 volts. If the centertap is at the low end of the range, these
faults will be triggered below 0.79 volts.