Jlg 4394RT Service Manual Bedienungsanleitung Seite 165
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SECTION 5 - JLG CONTROL SYSTEM
3121133 – JLG Lift – 5-11
2/6 LEVELING JACK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
leveling jack extend valve is short to ground.
6
LEVELING JACK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
leveling jack extend valve is short to battery.
LEVELING JACK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
leveling jack retract valve is open circuit.
LEVELING JACK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
leveling jack retract valve is short to ground.
LEVELING JACK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
leveling jack retract valve is short to battery.
FRONT DECK EXTEND VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
front deck extend valve is open circuit.
FRONT DECK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
front deck extend valve is short to ground.
FRONT DECK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
front deck extend valve is short to battery.
FRONT DECK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
front deck retract valve is open circuit.
FRONT DECK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
front deck retract valve is short to ground.
FRONT DECK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
front deck retract valve is short to battery.
REAR DECK EXTEND VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
rear deck extend valve is open circuit.
REAR DECK EXTEND VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
rear deck extend valve is short to ground.
REAR DECK EXTEND VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
rear deck extend valve is short to battery.
REAR DECK RETRACT VALVE OPEN CIRCUIT Reported by the I/O module and during system test when the
rear deck retract valve is open circuit.
REAR DECK RETRACT VALVE SHORT TO GROUND Reported by the I/O module and during system test when the
rear deck retract valve is short to ground.
REAR DECK RETRACT VALVE SHORT TO BATTERY Reported by the I/O module and during system test when the
rear deck retract valve is short to battery.
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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