Jlg 460SJ Service Manual User Manual Page 341
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SECTION 6 - JLG CONTROL SYSTEM (S/N 61718 TO PRESENT)
3120895 – JLG Lift – 6-25
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 at the same time.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE LOW Resistive joysticks: These faults do not occur.
D/S JOY. OUT OF RANGE HIGH Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
D/S JOY. CENTER TAP BAD Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt
range around these values where the fault may be indicated.
WAITING FOR FSW TO BE OPEN Footswitch was closed when platform mode was selected. Can be reported
during power-up sequence.
FOOTSWITCH SELECTED BEFORE
START
The user attempted to start the machine with the
footswitch engaged.
2/3 Flash code 2/3 indicates problems with boom function selection. 3
LIFT/SWING LOCKED — JOYSTICK
MOVED BEFORE FOOTSWITCH
Platform upper lift or swing was selected before and during footswitch closure.
PUMP SWITCHES FAULTY — CHECK
DIAGNOSTICS/BOOM
A boom function (lower lift, telescope, basket level, basket rotate, jib) has both
directions selected together.
PUMP SWITCHES LOCKED —
SELECTED BEFORE FOOTSWITCH
A platform boom function (lower lift, telescope, basket level, basket rotate, jib)
was selected before key switch or footswitch closure.
PUMP SWITCHES LOCKED —
SELECTED BEFORE AUX POWER
A ground boom function (lower lift, telescope, basket level, basket rotate, jib)
was selected before aux power.
l/s joy. out of range low Resistive joysticks: These faults do not occur.
l/s joy. out of range high Resistive joysticks: These faults do not occur if the Vref voltage is below 8.1
volts. If Vref is above 7.7 volts, Vref is operating out of tolerance or a short to
battery has occurred.
l/s joy. center tap bad Resistive joysticks: These faults occur when the center tap voltage is not
between 3.08 volts and 3.83 volts. Due to resistor tolerances there is a +/-.1 volt
range around these values where the fault may be indicated.
PUMP SWITCHES LOCKED —
SELECTED BEFORE START SWITCH
This fault occurs when a hydraulic function switch is closed before the start
switch is closed.
FOOTSWITCH SELECTED BEFORE
START
The user attempted to start the machine with the footswitch engaged.
2/4 Flash code 2/4 indicates that steering digital inputs are faulty.
NOT REQUIRED
Table 6-3. Help Fault Codes, Displayed Faults, and Descriptions - S/N 66995 to Present
Fault Flash
Code
Communicated (Displayed on
Analyzer) Fault
Description Priority
- P/N - 3120895 1
- A GENERAL 3
- B HYDRAULIC SYSTEM SAFETY 3
- CMAINTENANCE 3
- REVISON LOG 4
- 10
- TABLE OF CONTENTS 11
- LIST OF FIGURES 13
- LIST OF TABLES 19
- SECTION 1. SPECIFICATIONS 21
- 1.3 TIRES 22
- 1.5 TORQUE REQUIREMENTS 23
- SECTION 1 - SPECIFICATIONS 24
- 1.10 CYLINDER SPECIFICATIONS 25
- 1.11 LUBRICATION 25
- Hydraulic Oil 25
- 1.13 SERIAL NUMBER LOCATION 26
- LUBRICATION 27
- Regulator 30
- SOCKET HEAD CAP SCREWS 34
- Magni Coating (Ref 4150701)* 38
- SECTION 2. GENERAL 39
- 2.2 SERVICE AND GUIDELINES 40
- Safety and Workmanship 40
- Cleanliness 40
- SECTION 2 - GENERAL 41
- AMBIENT AIR 49
- TEMPERATURE 49
- 3120895 – JLG Lift – 3-1 53
- 3120895 – JLG Lift – 3-3 55
- 3-4 – JLG Lift – 3120895 56
- 3120895 – JLG Lift – 3-5 57
- Final Assembly 58
- 3120895 – JLG Lift – 3-7 59
- 3-8 – JLG Lift – 3120895 60
- Hub-Spindle Disassembly 61
- Cover Disassembly 61
- Carrier Disassembly 61
- Assembly of the Carrier 62
- 3120895 – JLG Lift – 3-11 63
- Cover Sub-Assembly 64
- Hub-Spindle Sub-Assembly 65
- 3-14 – JLG Lift – 3120895 66
- Main Assembly 67
- 3-16 – JLG Lift – 3120895 68
- 3120895 – JLG Lift – 3-17 69
- 3-18 – JLG Lift – 3120895 70
- 3120895 – JLG Lift – 3-19 71
- Tool List 72
- COUPLING 73
- Equipment Required 73
- 3.6 DRIVE BRAKE 74
- Pre-Installation Checks 74
- Maintenance 75
- Examination 75
- 3-24 – JLG Lift – 3120895 76
- 3.7 DRIVE MOTOR 77
- Description 77
- Shaft Seal Replacement 77
- Loop Flushing Valve 78
- Troubleshooting 79
- 3120895 – JLG Lift – 3-29 81
- 3-30 – JLG Lift – 3120895 82
- 3120895 – JLG Lift – 3-31 83
- Slipper retainer 85
- Ball guide 85
- (47-61 Nm) 89
- 35-45 ft.lbs 89
- Initial Start-up Procedures 91
- 3.8 ADJUSTMENT PROCEDURE FOR 92
- LOCKOUT VALVE 92
- 3.9 TOE-IN ADJUSTMENT 92
- 3.10 2WD HUB 93
- Removal & Disassembly 93
- Cleaning & Inspection 93
- Assembly & Installation 94
- PROCEDURE 95
- 3.13 SWING BEARING 96
- Wear Tolerance 97
- Replacement of Swing Bearing 98
- Swing Bearing Torque Value 99
- Swing Drive Installation 99
- 3-48 – JLG Lift – 3120895 100
- 3120895 – JLG Lift – 3-49 101
- Installation 102
- Brake Disassembly 102
- Assembly Information 102
- 3120895 – JLG Lift – 3-51 103
- Assembly 104
- Disassembly 104
- 3.16 SWING DRIVE TORQUE HUB 106
- Disassembly Procedure 106
- 3120895 – JLG Lift – 3-55 107
- 3-56 – JLG Lift – 3120895 108
- 3120895 – JLG Lift – 3-57 109
- 3-58 – JLG Lift – 3120895 110
- 3120895 – JLG Lift – 3-59 111
- 3-60 – JLG Lift – 3120895 112
- 3.17 SEMI-TRACK 113
- Testing the Track 113
- Removing the Track 114
- Assuming Normal Wear 114
- Adjustment 114
- 3120895 – JLG Lift – 3-63 115
- 3-64 – JLG Lift – 3120895 116
- 3120895 – JLG Lift – 3-65 117
- 3-66 – JLG Lift – 3120895 118
- INSPECTING BRUSH POSITION 118
- INSPECTING BRUSHES 118
- CLEANING SLIP RINGS 118
- 3120895 – JLG Lift – 3-67 119
- 3.19 FORD EFI ENGINE 120
- Performing Diagnostics 120
- ECM and Sensors 121
- 3-70 – JLG Lift – 3120895 122
- 3120895 – JLG Lift – 3-71 123
- READ ONLY MEMORY (EEPROM) 123
- HEATED OXYGEN SENSOR 123
- 3-72 – JLG Lift – 3120895 124
- 3120895 – JLG Lift – 3-73 125
- ENGINE CONTROL MODULE (ECM) 125
- 3-74 – JLG Lift – 3120895 126
- ECM INPUTS/OUTPUTS 126
- ECM SERVICE PRECAUTIONS 126
- THROTTLE POSITION (TP) SENSOR 126
- USE OF CIRCUIT TESTING TOOLS 126
- Fuel System 127
- 3-76 – JLG Lift – 3120895 128
- FUEL METERING SYSTEM PURPOSE 128
- 3-78 – JLG Lift – 3120895 130
- ELECTRONIC IGNITION 130
- 3120895 – JLG Lift – 3-79 131
- IGNITION COIL 131
- Procedure 132
- Controller Status 132
- Failure Modes 132
- 3120895 – JLG Lift – 3-81 133
- 3-82 – JLG Lift – 3120895 134
- Manual Adjustment 135
- 3-84 – JLG Lift – 3120895 136
- 3120895 – JLG Lift – 3-85 137
- 3.22 HYDRAULIC WELDER (225-4) 138
- Replacement of Fine Control 138
- Rotor Replacement 139
- Replacement of Flow Regulator 139
- Replace Brushes on Sky Welder 140
- Replacing Range Switch 140
- Replacing Selector Switch 140
- Replacement of Couplings 141
- 3-90 – JLG Lift – 3120895 142
- 3120895 – JLG Lift – 3-91 143
- 3-92 – JLG Lift – 3120895 144
- 3120895 – JLG Lift – 3-93 145
- Receptacle Output OK 146
- Intermittent Welder Operation 146
- 3120895 – JLG Lift – 3-95 147
- 3-96 – JLG Lift – 3120895 148
- 3120895 – JLG Lift – 3-97 149
- 3-98 – JLG Lift – 3120895 150
- 3120895 – JLG Lift – 3-99 151
- 3-100 – JLG Lift – 3120895 152
- 3120895 – JLG Lift – 3-101 153
- 3-102 – JLG Lift – 3120895 154
- 3120895 – JLG Lift – 3-103 155
- 3-104 – JLG Lift – 3120895 156
- 3120895 – JLG Lift – 3-105 157
- 3-106 – JLG Lift – 3120895 158
- 3120895 – JLG Lift – 3-107 159
- Maintenance of the Drive Belt 160
- Changing The Engine Oil 161
- 3-110 – JLG Lift – 3120895 162
- Fuel Filter 163
- Electric Lock Off 163
- EPR Assembly 164
- Low Pressure Regulator (LPR) 164
- Air Fuel Mixer 165
- Engine Control Module 166
- 3120895 – JLG Lift – 3-115 167
- Propane Fuel System Leak Test 168
- Assembly Replacement 169
- (TMAP) Sensor 170
- 3120895 – JLG Lift – 3-119 171
- MIXER REPLACEMENT 172
- Coolant Hose Replacement 172
- Vapor Hose Replacement 172
- 3120895 – JLG Lift – 3-121 173
- Diagnostic Aids 174
- 3120895 – JLG Lift – 3-123 175
- 3-124 – JLG Lift – 3120895 176
- 3120895 – JLG Lift – 3-125 177
- 3-126 – JLG Lift – 3120895 178
- 3120895 – JLG Lift – 3-127 179
- 3-128 – JLG Lift – 3120895 180
- 3120895 – JLG Lift – 3-129 181
- 3-130 – JLG Lift – 3120895 182
- 3120895 – JLG Lift – 3-131 183
- 3-132 – JLG Lift – 3120895 184
- 3120895 – JLG Lift – 3-133 185
- 3-134 – JLG Lift – 3120895 186
- 3120895 – JLG Lift – 3-135 187
- 3-136 – JLG Lift – 3120895 188
- 3120895 – JLG Lift – 3-137 189
- 3.29 PERKINS ENGINE GENERAL 190
- MAINTENANCE 190
- Engine Oil Level - Check 190
- 3120895 – JLG Lift – 3-139 191
- Fuel Filter/Water Separator 192
- Setting the Actuator 193
- Speed Sensor Installation 194
- PERKINS & CATERPILLAR 194
- 3120895 – JLG Lift – 3-143 195
- 3-144 – JLG Lift – 3120895 196
- 3120895 – JLG Lift – 3-145 197
- Fault Code Broadcast 198
- Diagnostic Trouble Codes 198
- MIL Output 199
- Corrective Actions 199
- 3-148 – JLG Lift – 3120895 200
- 3120895 – JLG Lift – 3-149 201
- 3-150 – JLG Lift – 3120895 202
- 3120895 – JLG Lift – 3-151 203
- 3-152 – JLG Lift – 3120895 204
- DBW Diagnostic Test 205
- DESCRIPTIONS 206
- DTC 117- ECT/CHT Low Voltage 207
- 3-156 – JLG Lift – 3120895 208
- DTC 118- ECT/CHT High Voltage 209
- 3-158 – JLG Lift – 3120895 210
- 3120895 – JLG Lift – 3-159 211
- 3-160 – JLG Lift – 3120895 212
- 3120895 – JLG Lift – 3-161 213
- 3-162 – JLG Lift – 3120895 214
- 3120895 – JLG Lift – 3-163 215
- 3-166 – JLG Lift – 3120895 218
- 3120895 – JLG Lift – 3-167 219
- Pressure 221
- Normally Open Switch 222
- Normally Closed Switch 222
- Sensor/Transducer Type 223
- DTC 524- Oil Pressure Low 224
- 3-176 – JLG Lift – 3120895 228
- 3120895 – JLG Lift – 3-177 229
- 3-178 – JLG Lift – 3120895 230
- 3120895 – JLG Lift – 3-179 231
- 3-180 – JLG Lift – 3120895 232
- 3120895 – JLG Lift – 3-181 233
- 3-182 – JLG Lift – 3120895 234
- 3120895 – JLG Lift – 3-183 235
- 3-184 – JLG Lift – 3120895 236
- 3120895 – JLG Lift – 3-185 237
- 3-186 – JLG Lift – 3120895 238
- 3-188 – JLG Lift – 3120895 240
- 3-190 – JLG Lift – 3120895 242
- 3120895 – JLG Lift – 3-191 243
- SFC 555- RTI 2 Loss 244
- 3120895 – JLG Lift – 3-193 245
- SFC 556- RTI 3 Loss 246
- 3120895 – JLG Lift – 3-195 247
- SFC 513- A/D Loss 248
- 3120895 – JLG Lift – 3-197 249
- SFC 512- Invalid Interrupt 250
- 3-202 – JLG Lift – 3120895 254
- 3120895 – JLG Lift – 3-203 255
- 3-206 – JLG Lift – 3120895 258
- 3120895 – JLG Lift – 3-207 259
- 3-208 – JLG Lift – 3120895 260
- DTC to SPN/FMI Table 262
- 3120895 – JLG Lift – 3-211 263
- 3-212 – JLG Lift – 3120895 264
- 4.1 BOOM 265
- Inspection 267
- 4-6 – JLG Lift – 3120895 270
- 3120895 – JLG Lift – 4-7 271
- 4-8 – JLG Lift – 3120895 272
- 3120895 – JLG Lift – 4-9 273
- Test Notes 274
- Lift, Swing, and Drive Cards 275
- Flow Control Card 275
- 4-12 – JLG Lift – 3120895 276
- 4.5 HELAC ROTARY ACTUATOR 277
- Theory Of Operation 277
- 4-14 – JLG Lift – 3120895 278
- 3120895 – JLG Lift – 4-15 279
- 3120895 – JLG Lift – 4-17 281
- 4-18 – JLG Lift – 3120895 282
- 3120895 – JLG Lift – 4-19 283
- 3120895 – JLG Lift – 4-21 285
- 4-22 – JLG Lift – 3120895 286
- 3120895 – JLG Lift – 4-23 287
- 4-24 – JLG Lift – 3120895 288
- SECTION 5. HYDRAULICS 289
- Cleaning and Inspection 291
- SECTION 5 - HYDRAULICS 293
- Solenoid Control Valve 302
- Reassembly Shaft End 308
- Gerotor End 310
- Timing Procedure 311
- Standard Rotation 311
- Reverse Rotation 311
- PROCEDURES AND 315
- RECOMMENDATIONS 315
- 6.1 INTRODUCTION 317
- 6-2 – JLG Lift – 3120895 318
- SYSTEM ANALYZER 319
- 6.3 USING THE ANALYZER 319
- 6-4 – JLG Lift – 3120895 320
- HAND HELD ANALYZER 321
- 6-6 – JLG Lift – 3120895 322
- 6.6 MACHINE SETUP 324
- 6.7 LEVEL VEHICLE DESCRIPTION 324
- 3120895 – JLG Lift – 6-9 325
- 6-10 – JLG Lift – 3120895 326
- 3120895 – JLG Lift – 6-11 327
- 6-12 – JLG Lift – 3120895 328
- 3120895 – JLG Lift – 6-13 329
- 6-14 – JLG Lift – 3120895 330
- 3120895 – JLG Lift – 6-15 331
- 6-16 – JLG Lift – 3120895 332
- 3120895 – JLG Lift – 6-17 333
- 6-18 – JLG Lift – 3120895 334
- 4150365-3 335
- 6-20 – JLG Lift – 3120895 336
- 3120895 – JLG Lift – 6-21 337
- 6-22 – JLG Lift – 3120895 338
- 3120895 – JLG Lift – 6-23 339
- 6-24 – JLG Lift – 3120895 340
- 3120895 – JLG Lift – 6-25 341
- 6-26 – JLG Lift – 3120895 342
- 3120895 – JLG Lift – 6-27 343
- 6-28 – JLG Lift – 3120895 344
- 3120895 – JLG Lift – 6-29 345
- 6-30 – JLG Lift – 3120895 346
- 3120895 – JLG Lift – 6-31 347
- 6-32 – JLG Lift – 3120895 348
- 3120895 – JLG Lift – 6-33 349
- 6-34 – JLG Lift – 3120895 350
- 3120895 – JLG Lift – 6-35 351
- 6-36 – JLG Lift – 3120895 352
- 3120895 – JLG Lift – 6-37 353
- 6-38 – JLG Lift – 3120895 354
- 3120895 – JLG Lift – 6-39 355
- 6-40 – JLG Lift – 3120895 356
- 3120895 – JLG Lift – 6-41 357
- 6-42 – JLG Lift – 3120895 358
- 3120895 – JLG Lift – 6-43 359
- 6-44 – JLG Lift – 3120895 360
- 3120895 – JLG Lift – 6-45 361
- 6-46 – JLG Lift – 3120895 362
- 3120895 – JLG Lift – 6-47 363
- 6-48 – JLG Lift – 3120895 364
- 3120895 – JLG Lift – 6-49 365
- 6-50 – JLG Lift – 3120895 366
- 3120895 – JLG Lift – 6-51 367
- 6-52 – JLG Lift – 3120895 368
- 4150364-18 369
- 6-54 – JLG Lift – 3120895 370
- 3120895 – JLG Lift – 6-55 371
- 6-56 – JLG Lift – 3120895 372
- 3120895 – JLG Lift – 6-57 373
- 6-58 – JLG Lift – 3120895 374
- 4150364-19 375
- 6.9 SYSTEM TEST 378
- Test from the Platform 378
- 3120895 – JLG Lift – 6-63 379
- Test from the Ground Station 380
- 3120895 – JLG Lift – 6-65 381
- 6-66 – JLG Lift – 3120895 382
- 3120895 – JLG Lift – 6-67 383
- 6-68 – JLG Lift – 3120895 384
- 3120895 – JLG Lift – 6-69 385
- 6-70 – JLG Lift – 3120895 386
- 3120895 – JLG Lift – 6-71 387
- 6-72 – JLG Lift – 3120895 388
- 3120895 – JLG Lift – 6-73 389
- 6-74 – JLG Lift – 3120895 390
- 3120895 – JLG Lift – 6-75 391
- 6-76 – JLG Lift – 3120895 392
- 3120895 – JLG Lift – 6-77 393
- 6-78 – JLG Lift – 3120895 394
- 3120895 – JLG Lift – 6-79 395
- 6-80 – JLG Lift – 3120895 396
- STRUCTURE 397
- 6-82 – JLG Lift – 3120895 398
- 3120895 – JLG Lift – 6-83 399
- 6-84 – JLG Lift – 3120895 400
- 3120895 – JLG Lift – 6-85 401
- 6-86 – JLG Lift – 3120895 402
- 3120895 – JLG Lift – 7-1 403
- Resistance Measurement 404
- Continuity Measurement 404
- Current Measurement 405
- 7.3 CHECKING SWITCHES 405
- Basic Check 405
- Limit Switches 405
- Automatic Switches 406
- COMPOUND TO ELECTRICAL 406
- CONNECTIONS 406
- AMP Seal 407
- AMP Mate-N-Lok 408
- DIN Connectors 408
- Exclusions 408
- 3120895 – JLG Lift – 7-7 409
- AMP JUNIOR TIMER 409
- SEALED ENCLOSURES 409
- MIL-C-5015 SPEC CONNECTORS 409
- 7.5 AMP CONNECTOR 410
- AMP Connectors 410
- 3120895 – JLG Lift – 7-9 411
- Wedge Lock 412
- Service - Voltage Reading 412
- 3120895 – JLG Lift – 7-11 413
- 7.6 DEUTSCH CONNECTORS 414
- DT/DTP Series Assembly 414
- DT/DTP Series Disassembly 414
- HD30/HDP20 Series Assembly 415
- HD30/HDP20 Series Disassembly 415
- 7-14 – JLG Lift – 3120895 416
- 3120895 – JLG Lift – 7-15 417
- 7-16 – JLG Lift – 3120895 418
- 3120895 – JLG Lift – 7-17 419
- 7-18 – JLG Lift – 3120895 420
- 3120895 – JLG Lift – 7-19 421
- 7-20 – JLG Lift – 3120895 422
- 3120895 – JLG Lift – 7-21 423
- 7-22 – JLG Lift – 3120895 424
- 3120895 – JLG Lift – 7-23 425
- 7-24 – JLG Lift – 3120895 426
- 3120895 – JLG Lift – 7-25 427
- 7-26 – JLG Lift – 3120895 428
- 3120895 – JLG Lift – 7-27 429
- 7-28 – JLG Lift – 3120895 430
- 3120895 – JLG Lift – 7-29 431
- 7-30 – JLG Lift – 3120895 432
- 3120895 – JLG Lift – 7-31 433
- 7-32 – JLG Lift – 3120895 434
- 3120895 – JLG Lift – 7-33 435
- 7-34 – JLG Lift – 3120895 436
- 3120895 – JLG Lift – 7-35 437
- 7-36 – JLG Lift – 3120895 438
- 3120895 – JLG Lift – 7-37 439
- 7-38 – JLG Lift – 3120895 440
- 3120895 – JLG Lift – 7-39 441
- 7-40 – JLG Lift – 3120895 442
- 3120895 – JLG Lift – 7-41 443
- 7-42 – JLG Lift – 3120895 444
- 3120895 – JLG Lift – 7-43 445
- 7-44 – JLG Lift – 3120895 446
- 3120895 – JLG Lift – 7-45 447
- 7-46 – JLG Lift – 3120895 448
- 3120895 – JLG Lift – 7-47 449
- 7-48 – JLG Lift – 3120895 450
- 3120895 – JLG Lift – 7-49 451
- 7-50 – JLG Lift – 3120895 452
- 3120895 – JLG Lift – 7-51 453
- 7-52 – JLG Lift – 3120895 454
- 3120895 – JLG Lift – 7-53 455
- 7-54 – JLG Lift – 3120895 456
- 3120895 – JLG Lift – 7-55 457
- 7-56 – JLG Lift – 3120895 458
- 3120895 – JLG Lift – 7-57 459
- 7-58 – JLG Lift – 3120895 460
- JLG Worldwide Locations 462
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