Jlg 4394RT Service Manual Bedienungsanleitung Seite 163
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SECTION 5 - JLG CONTROL SYSTEM
3121133 – JLG Lift – 5-9
2/5 Flash code 2/5 indicates issues that may cutout functions.
5
ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR
VOLTAGE OUT OF RANGE
Reported when the elevation rotary sensor voltage is outside
the range of acceptable values.
ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when the rotary calibration value does not exist.
ELEVATION PROX SWITCH PERMANENTLY CLOSED Reported when the elevation rotary sensor is reporting above
elevation and the elevation proximity switch is still closed.
ELEVATION PROX SWITCH PERMANENTLY OPEN Reported when the elevation rotary sensor is reporting stowed
and the elevation proximity switch is open.
FRONT LEFT LEVELING JACK PRESSURE TRANS-
DUCER FAILURE
Reported when the front left leveling jack pressure reading is
well below 0PSI.
FRONT RIGHT LEVELING JACK PRESSURE TRANS-
DUCER FAILURE
Reported when the front right leveling jack pressure reading is
well below 0PSI.
REAR LEFT LEVELING JACK PRESSURE TRANS-
DUCER FAILURE
Rep or t ed w hen the rear lef t lev eli ng jack pre ssur e re ading is
well below 0PSI.
REAR RIGHT LEVELING JACK PRESSURE TRANS-
DUCER FAILURE
Reported when the rear right leveling jack pressure reading is
well below 0PSI.
PLATFORM OVERLOAD Reported when the overload is setup and the LSS is reading the
platform is overloaded.
FRONT LEFT LEVELING JACK STOW SWITCH PERMA-
NENTLY CLOSED
Rep or t ed w hen the FRONT LE FT Lev eli ng Jack Stow S witch is
closed and the FRONT LEFT pressure transducer reads "Set"
pressure.
FRONT RIGHT LEVELING JACK STOW SWITCH PER-
MANENTLY CLOSED
Reported when the FRONT RIGHT Leveling Jack Stow Switch
is closed and FRONT RIGHT pressure transducer reads "Set"
pressure.
REAR LEFT LEVELING JACK STOW SWITCH PERMA-
NENTLY CLOSED
Rep or t ed w hen the REAR LEF T Leve lin g Jack Stow Swi tch is
closed and the REAR LEFT pressure transducer reads "Set"
pressure.
REAR RIGHT LEVELING JACK STOW SWITCH PERMA-
NENTLY CLOSED
Rep or t ed w hen the REAR RIGHT Leveling Jack Stow Sw itch is
closed and the REAR RIGHT pressure transducer reads "Set"
pressure.
ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED Reported when elevation height calibration has not been per-
formed or is not logical (increasing voltages from stowed).
Vehicle assumed to be at full height.
ELEV ANGLE SENSOR FAULTY - NOT MOUNTED OR
VOLTAGE OUT OF RANGE
Reported when elevation angle sensor is outside the 0.30V to
4.85V range. Vehicle assumed to be at full height.
ELEV ANGLE SENSOR NOT DETECTING CHANGE Reported when elevation angle sensor voltage does not
change for 5 sec during lift up >20%. Vehicle assumed to be at
full height. Fault cleared only in valid stowed position.
Table 5-1. Fault Code Listing - Software P1.X
Fault Flash
Code
Communicated (Displayed on Analyzer) Fault Description Priority
- October 6, 2008 1
- PRECAUTIONS 3
- REVISION LOG 4
- 5
- TABLE OF CONTENTS 10
- SECTION 1. SPECIFICATIONS 11
- 1.4 TIRES 12
- 1.5 MACHINE DIMENSIONS 12
- 1.6 PRESSURE SETTINGS 12
- 1.7 SERIAL NUMBER LOCATIONS 12
- 1.8 SENSORS 13
- 1.9 CYLINDER SPECIFICATIONS 13
- 1.10 MAJOR COMPONENT WEIGHTS 13
- SECTION 1 - SPECIFICATIONS 14
- 1.13 OPERATOR MAINTENANCE 15
- Regulator 18
- 1.14 TORQUE CHARTS 20
- SECTION 2. GENERAL 27
- 2.2 SERVICE AND GUIDELINES 28
- Safety and Workmanship 28
- Cleanliness 28
- SECTION 2 - GENERAL 29
- Hydraulic System 30
- Hydraulic Oil 30
- Changing Hydraulic Oil 30
- Lubrication Specifications 30
- 2.4 CYLINDER DRIFT TEST 31
- Platform Drift 31
- Cylinder Drift 31
- REPAIR GUIDELINES 31
- INSPECTION SCHEDULE 32
- 3121133 – JLG Sizzor – 3-1 37
- 0.50v-1.0v x-xxv 38
- Elevation Sensor Calibration 39
- (Software P1.20 & Higher) 39
- Joystick Calibration 39
- Tilt Sensor Calibration: 39
- 3-4 – JLG Sizzor – 3121133 40
- Tilt Sensor, JLG P/N 4000006: 42
- Tilt Sensor, JLG P/N 4000021: 43
- Roll Test 44
- Leak Test 44
- 3121133 – JLG Sizzor – 3-9 45
- Disconnect Mechanism 46
- Gearbox Disassembly 47
- 3-12 – JLG Sizzor – 3121133 48
- Gearbox Assembly 49
- 3-14 – JLG Sizzor – 3121133 50
- 3121133 – JLG Sizzor – 3-15 51
- 3-16 – JLG Sizzor – 3121133 52
- 3121133 – JLG Sizzor – 3-17 53
- 3-18 – JLG Sizzor – 3121133 54
- Motor Disassembly 55
- 3-20 – JLG Sizzor – 3121133 56
- 3121133 – JLG Sizzor – 3-21 57
- 3-22 – JLG Sizzor – 3121133 58
- 3121133 – JLG Sizzor – 3-23 59
- 3-24 – JLG Sizzor – 3121133 60
- Motor Assembly 61
- 3-26 – JLG Sizzor – 3121133 62
- 3121133 – JLG Sizzor – 3-27 63
- 3-28 – JLG Sizzor – 3121133 64
- 3121133 – JLG Sizzor – 3-29 65
- 3.5 DUAL FUEL/LPG SYSTEM 66
- 3.6 FORD EFI ENGINE 67
- Performing Diagnostics 67
- EFI Diagnostics 67
- ECM and Sensors 67
- 3-32 – JLG Sizzor – 3121133 68
- 3121133 – JLG Sizzor – 3-33 69
- 3121133 – JLG Sizzor – 3-35 71
- 3-36 – JLG Sizzor – 3121133 72
- ENGINE CONTROL MODULE (ECM) 72
- 3121133 – JLG Sizzor – 3-37 73
- ECM INPUTS/OUTPUTS 73
- ECM SERVICE PRECAUTIONS 73
- THROTTLE POSITION (TP) SENSOR 73
- USE OF CIRCUIT TESTING TOOLS 73
- Fuel System 74
- 3121133 – JLG Sizzor – 3-39 75
- FUEL METERING SYSTEM PURPOSE 75
- 3121133 – JLG Sizzor – 3-41 77
- 3-42 – JLG Sizzor – 3121133 78
- ELECTRONIC IGNITION 78
- IGNITION COIL 78
- 3.7 GENERATOR - FORD ENGINE 79
- PRESENT) 80
- 3121133 – JLG Sizzor – 3-45 81
- 3-46 – JLG Sizzor – 3121133 82
- 3121133 – JLG Sizzor – 3-47 83
- 3-48 – JLG Sizzor – 3121133 84
- 3121133 – JLG Sizzor – 3-49 85
- 3-50 – JLG Sizzor – 3121133 86
- 3121133 – JLG Sizzor – 3-51 87
- 3-52 – JLG Sizzor – 3121133 88
- 3121133 – JLG Sizzor – 3-53 89
- 3-54 – JLG Sizzor – 3121133 90
- 3121133 – JLG Sizzor – 3-55 91
- 3-56 – JLG Sizzor – 3121133 92
- 3.9 GENERATOR - DUETZ ENGINE 93
- Maintenance of the Drive Belt 94
- Changing The Engine Oil 95
- 3.11 GENERATOR - GM ENGINE 96
- Fuel Filter 97
- Electric Lock Off 97
- EPR Assembly 98
- Low Pressure Regulator (LPR) 98
- Air Fuel Mixer 99
- Engine Control Module 100
- 3121133 – JLG Sizzor – 3-65 101
- Propane Fuel System Leak Test 102
- Assembly Replacement 103
- (TMAP) Sensor 104
- 3121133 – JLG Sizzor – 3-69 105
- Coolant Hose Replacement 106
- Vapor Hose Replacement 106
- Mixer Replacement 106
- Replacement 107
- DIAGNOSIS 108
- Fuel System Description 108
- Diagnostic Aids 108
- 3121133 – JLG Sizzor – 3-73 109
- 3-74 – JLG Sizzor – 3121133 110
- 3121133 – JLG Sizzor – 3-75 111
- 3.15 JOYSTICK CONTROLLER 112
- 3121133 – JLG Sizzor – 3-77 113
- 3-78 – JLG Sizzor – 3121133 114
- 3121133 – JLG Sizzor – 3-79 115
- 3-80 – JLG Sizzor – 3121133 116
- 3121133 – JLG Sizzor – 3-81 117
- 3-82 – JLG Sizzor – 3121133 118
- 3121133 – JLG Sizzor – 3-83 119
- 3-84 – JLG Sizzor – 3121133 120
- 3121133 – JLG Sizzor – 3-85 121
- 3-86 – JLG Sizzor – 3121133 122
- 3121133 – JLG Sizzor – 3-87 123
- 3-88 – JLG Sizzor – 3121133 124
- SECTION 4. HYDRAULICS 125
- Steer Cylinder 126
- Oscillating Axle Lockout Test 126
- 4.5 CYLINDER REPAIR 127
- Disassembly 127
- SECTION 4 - HYDRAULICS 128
- Cleaning and Inspection 129
- Assembly 130
- PROCEDURES AND 134
- RECOMMENDATIONS 134
- 4.8 HYDRAULIC GEAR PUMP 135
- Pump Disassembly 135
- Parts Inspection 136
- Pump Reassembly 136
- 4.9 MAIN VALVE 138
- Pressure Setting Procedures 139
- 4.12 HEADER VALVES (4WD) 141
- 4.13 DIRECTIONAL VALVE 142
- Pressure Setting Procedure 142
- 4.16 HYDRAULIC PUMP 144
- Auxiliary Pump Motor 145
- 4.17 CYLINDER ASSEMBLIES 146
- 3121133 – JLG Lift – 4-25 149
- 4-26 – JLG Lift – 3121133 150
- 4-28 – JLG Lift – 3121133 152
- 3121133 – JLG Lift – 4-29 153
- OSCILLATING AXLE 154
- OSCILLATING AXLE CYLINDER 154
- 5.1 HAND HELD ANALYZER 155
- Using the Analyzer: 156
- Analyzer: 157
- Analyzer 158
- Machine Setup 158
- 3121133 – JLG Lift – 5-5 159
- 5-6 – JLG Lift– 3121133 160
- 3121133 – JLG Lift – 5-7 161
- 5-8 – JLG Lift– 3121133 162
- 3121133 – JLG Lift – 5-9 163
- 5-10 – JLG Lift– 3121133 164
- 3121133 – JLG Lift – 5-11 165
- 5-12 – JLG Lift– 3121133 166
- 3121133 – JLG Lift – 5-13 167
- 4150588 D 167
- CONT’D ON SHEET 2 168
- FROM SHEET 1 169
- TO SHEET 3 169
- FROM SHEET 2 170
- 3121133 – JLG Lift – 5-17 171
- 4150389 D 171
- 5-18 – JLG Lift– 3121133 172
- 3121133 – JLG Lift – 5-19 173
- 4150390 J 173
- 5-24 – JLG Lift– 3121133 178
- 3121133 – JLG Sizzor – 6-1 179
- 6-2 – JLG Sizzor – 3121133 180
- 3121133 – JLG Sizzor – 6-3 181
- Procedure 182
- Requirements: 182
- 3121133 – JLG Sizzor – 6-5 183
- 3121133 – JLG Sizzor – 6-7 185
- Wedge Lock 186
- Service - Voltage Reading 187
- DT/DTP Series Assembly 188
- DT/DTP Series Disassembly 188
- HD30/HDP20 Series Assembly 188
- HD30/HDP20 Series Disassembly 189
- 6.5 SWITCHES 190
- Basic check 190
- Limit Switches 190
- Automatic Switches 191
- 6.6 SCHEMATICS 192
- 3121133 – JLG Sizzor – 6-15 193
- 6-16 – JLG Sizzor – 3121133 194
- 1870143 H 194
- 3121133 – JLG Sizzor – 6-17 195
- 6-18 – JLG Sizzor – 3121133 196
- 3121133 – JLG Sizzor – 6-19 197
- 1870153 G 198
- 3121133 – JLG Sizzor – 6-21 199
- 6-22 – JLG Sizzor – 3121133 200
- 3121133 – JLG Sizzor – 6-23 201
- 6-24 – JLG Sizzor – 3121133 202
- 3121133 – JLG Sizzor – 6-25 203
- 6-26 – JLG Sizzor – 3121133 204
- 6-28 – JLG Sizzor – 3121133 206
- 3121133 – JLG Sizzor – 6-29 207
- 6-30 – JLG Sizzor – 3121133 208
- 1870190 D 208
- 3121133 – JLG Sizzor – 6-31 209
- 6-32 – JLG Sizzor – 3121133 210
- 3121133 – JLG Sizzor – 6-33 211
- 6-34 – JLG Sizzor – 3121133 212
- 3121133 – JLG Sizzor – 6-35 213
- 6-36 – JLG Sizzor – 3121133 214
- 3121133 – JLG Sizzor – 6-37 215
- 6-38 – JLG Sizzor – 3121133 216
- 3121133 – JLG Sizzor – 6-39 217
- 6-40 – JLG Sizzor – 3121133 218
- 3121133 – JLG Sizzor – 6-41 219
- 6-42 – JLG Sizzor – 3121133 220
- 3121133 – JLG Sizzor – 6-43 221
- 6-44 – JLG Sizzor – 3121133 222
- 3121133 – JLG Sizzor – 6-45 223
- 6-46 – JLG Sizzor – 3121133 224
- 3121133 – JLG Sizzor – 6-47 225
- 6-48 – JLG Sizzor – 3121133 226
- JLG Worldwide Locations 228
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