jlg fault codes list pdf
JLG Fault Codes List PDF: A Comprehensive Guide
Navigating JLG aerial lift diagnostics requires a detailed fault codes list PDF, essential for technicians and operators alike. These codes, stemming from systems like hydraulics and electronics, pinpoint potential issues.
Accessing these PDFs unlocks efficient troubleshooting, reducing downtime and ensuring safe operation of JLG equipment – including models like the 25RTS, 33RTS, and 40RTS.
JLG (Jerrard-Leach Glass) is a leading manufacturer of aerial work platforms, renowned for their durability and innovation in lifting solutions. These lifts, encompassing scissor lifts, boom lifts, and telehandlers, are vital across diverse industries – construction, maintenance, and warehousing, to name a few.
However, even the most robust machinery experiences occasional malfunctions. This is where JLG fault codes become indispensable. These alphanumeric codes are generated by the lift’s onboard diagnostic system, signaling specific issues within the hydraulic, electrical, or drive systems. Understanding these codes is paramount for efficient troubleshooting and minimizing downtime.
A comprehensive JLG fault codes list PDF serves as a technician’s primary reference, detailing each code’s meaning, potential causes, and recommended corrective actions. Accessing and interpreting these codes correctly ensures safe and effective repairs, maintaining the operational integrity of the aerial lift.
Why Understanding JLG Fault Codes is Crucial
Proficiently interpreting JLG fault codes is not merely a convenience; it’s fundamental to operational safety, cost-effectiveness, and regulatory compliance. Ignoring or misdiagnosing these codes can lead to escalating repair costs, prolonged equipment downtime, and, most critically, potential safety hazards for operators and ground personnel.
A JLG fault codes list PDF empowers technicians to pinpoint the root cause of a problem quickly, avoiding unnecessary component replacements and streamlining the repair process. This minimizes disruption and maximizes equipment availability. Furthermore, accurate diagnosis ensures that repairs meet JLG’s stringent safety standards.
Beyond repair, understanding fault codes facilitates preventative maintenance. Recurring codes can indicate underlying issues requiring attention before they escalate into major failures. Access to a detailed PDF is therefore a cornerstone of responsible fleet management and a proactive approach to equipment longevity.

Common JLG Fault Code Categories
JLG fault codes are systematically organized into key categories: hydraulic, electrical, drive, and platform control systems. A PDF list clarifies these classifications for efficient diagnosis.
Hydraulic System Fault Codes
Hydraulic system fault codes within a JLG fault codes list PDF often indicate issues with pressure, flow, or component malfunctions. Common examples relate to the lift and swing functions, potentially signaling a failing hydraulic pump, faulty valve, or cylinder leak.
These codes, such as those referencing set point sensors (like 201:2), are crucial for pinpointing the source of hydraulic inefficiencies. A PDF provides detailed descriptions, aiding technicians in understanding whether the problem stems from low pressure, overheating, or a more complex internal failure.
Troubleshooting involves checking fluid levels, inspecting hoses for damage, and verifying the proper operation of solenoids and control valves. Accurate interpretation of these codes, readily available in a comprehensive JLG PDF, minimizes diagnostic time and ensures effective repairs, restoring optimal lift performance.
Electrical System Fault Codes
Electrical system fault codes, detailed within a JLG fault codes list PDF, cover a broad range of issues, from low battery voltage to wiring harness problems and sensor failures. Codes related to the Battery Management System (BMS), like 4001 and 4002 (low charging temperature), are frequently encountered.
A comprehensive PDF will explain these codes, helping technicians diagnose problems with the charging circuit, control panel, or individual electrical components. Troubleshooting often involves checking connections, testing voltage levels, and inspecting wiring for shorts or open circuits.
Understanding these codes is vital for ensuring the safe and reliable operation of the aerial lift. The JLG documentation provides specific guidance on interpreting these electrical faults, enabling efficient repairs and preventing further damage to the machine’s sensitive electronic systems.
Drive System Fault Codes
A JLG fault codes list PDF is crucial for diagnosing issues within the drive system, encompassing motors, controllers, and associated sensors. These codes often indicate problems with wheel speed, drive enable circuits, or hydraulic drive components. Identifying these faults quickly minimizes downtime and ensures operational safety.
Common drive system faults may relate to motor overheating, controller errors, or issues with the joystick control. The PDF documentation details specific codes, guiding technicians through troubleshooting steps like inspecting wiring, testing motor functionality, and verifying controller settings.
Proper interpretation of these codes, found within the JLG service manuals, allows for targeted repairs, preventing more extensive and costly damage to the drive system. Accurate diagnosis is paramount for maintaining the lift’s mobility and overall performance.
Platform Control System Fault Codes
The JLG fault codes list PDF provides essential diagnostic information for the platform control system, covering issues with the joystick, emergency stop, and platform leveling functions. These codes pinpoint malfunctions within the control panel, wiring harnesses, or individual control components.
Faults often relate to joystick input errors, emergency stop circuit failures, or problems with the platform leveling sensors. A detailed PDF guide assists technicians in systematically troubleshooting these issues, starting with visual inspections and progressing to component testing.
Understanding these codes, as detailed in official JLG documentation, is vital for ensuring safe and precise platform operation. Correctly identifying and resolving platform control system faults prevents unintended movements and maintains operator safety during elevated work.

Specific JLG Fault Codes & Their Meanings (Examples)
A JLG fault codes list PDF reveals codes like 201:2 (Set Point Sensor 2) and 102:2, offering technicians precise diagnostic clues for swift repairs.
201:2 Fault Code ─ Set Point Sensor 2
The JLG fault codes list PDF identifies 201:2 as relating to the Set Point Sensor 2. This indicates a problem with the sensor providing feedback to the control system, potentially impacting lift or swing functionality. Troubleshooting involves verifying the sensor’s wiring connections, checking for physical damage, and confirming proper voltage levels.
A faulty sensor can lead to inaccurate readings, causing erratic movements or preventing operation altogether. Technicians should consult the official JLG service manual for specific testing procedures and calibration instructions. Replacement of the sensor may be necessary if testing confirms a failure. Proper diagnosis, guided by the fault codes list PDF, is crucial for restoring safe and reliable operation of the aerial lift.
Ignoring this code could result in unpredictable behavior and potential safety hazards.
102:2 Fault Code ─ Details & Troubleshooting
According to the JLG fault codes list PDF, code 102:2 signifies an issue requiring careful attention. While specific details vary by model, it generally points to a problem within the control system, often related to joystick input or platform controls. Initial troubleshooting steps involve inspecting the joystick for obstructions or damage, and verifying the wiring harness connections.
Technicians should utilize an analyzer to read current and logged fault codes, providing a more comprehensive understanding of the problem. The JLG service manual offers detailed diagnostic procedures, including voltage checks and component testing. Resetting the code after repair is essential, but only after confirming the root cause has been addressed. Ignoring 102:2 can lead to unpredictable lift behavior and potential safety risks.
Referencing the PDF is vital for accurate diagnosis.
4001 Fault Code ─ Low Charging Temperature (Battery BMS)
The JLG fault codes list PDF identifies 4001 as a critical alert: “Low Charging Temperature” detected by the Battery Management System (BMS). This indicates the battery temperature is below the acceptable range for charging, potentially damaging the battery if charging continues. This is particularly relevant for lithium-ion batteries used in newer JLG lifts.
Troubleshooting involves verifying the BMS sensor functionality and checking the ambient temperature. Charging should be halted immediately. Referencing the JLG service manual is crucial for specific temperature thresholds and BMS calibration procedures. The PDF details that this fault limits lift and drive speed.
Ignoring this code can lead to reduced battery life and performance. Ensure proper ventilation and a suitable charging environment to prevent recurrence.
4002 Fault Code ─ Low Charging Temperature (Battery BMS) ⎼ Continued
Building upon fault code 4001, the JLG fault codes list PDF details that 4002 also signifies a “Low Charging Temperature” as reported by the Battery Management System (BMS). However, 4002 often indicates a persistent low-temperature condition, or a secondary confirmation of the issue. It’s crucial to not dismiss this as a duplicate error.
The PDF emphasizes a thorough inspection of the battery pack and charging system. Check for proper insulation and heating elements (if equipped). Verify the BMS is correctly communicating with the controller. This fault, like 4001, results in limited lift and drive speeds to protect the battery.
Continued occurrences of 4002 necessitate a deeper dive into the BMS calibration and potential battery cell degradation. Always consult the official JLG documentation for model-specific guidance.
Fault Codes Related to Lift/Swing Lock Functionality
The JLG fault codes list PDF highlights several codes concerning the lift and swing lock mechanisms, critical for safe operation. These often indicate issues with the sensors, solenoids, or control logic governing these functions. A common example, as noted in diagnostic resources, involves a “LIFT/SWING LOCKED ⎼ JOYSTICK MOVED” error.
This suggests the system incorrectly detects the locks as engaged while operator input attempts movement. The PDF advises checking the lock sensor wiring and functionality. Intermittent connections or faulty sensors are frequent culprits. Furthermore, the controller itself may require investigation.
Proper lock operation is paramount; therefore, any related fault code demands immediate attention. Referencing the JLG service manual, alongside the PDF, is essential for accurate diagnosis and repair, ensuring operational safety.

Accessing JLG Fault Codes
JLG fault codes are typically accessed via an analyzer tool, revealing both current and logged errors. PDF lists are also available online and through official JLG documentation.
Using an Analyzer to Read Fault Codes
Employing an analyzer is the primary method for retrieving JLG fault codes directly from the aerial lift’s control system. These diagnostic tools connect to the machine’s interface, allowing technicians to view a comprehensive list of both active and historical error codes.
The analyzer differentiates between current faults – issues actively impacting operation – and logged faults, which represent past occurrences that may or may not be presently affecting performance; Understanding this distinction is crucial for accurate diagnosis.
Modern analyzers often display not only the fault code itself (e.g., 201:2, 102:2, 4001) but also a descriptive explanation of the potential problem, streamlining the troubleshooting process. Accessing a corresponding JLG fault codes list PDF alongside the analyzer’s output provides further detail and repair guidance.
Proper analyzer usage, combined with a reliable PDF resource, significantly reduces diagnostic time and ensures effective repairs.
Interpreting Current vs. Logged Fault Codes
Distinguishing between current and logged fault codes is vital when diagnosing JLG aerial lifts. Current faults indicate ongoing issues actively affecting the machine’s operation, demanding immediate attention. These codes typically illuminate warning lights or restrict functionality.
Logged faults, conversely, represent problems that occurred previously but aren’t necessarily present now. They serve as valuable historical data, potentially revealing intermittent issues or recurring problems. A JLG fault codes list PDF will detail if a code requires immediate action or further investigation.
Technicians should prioritize resolving current faults first, then analyze logged codes to prevent future breakdowns. Clearing logged codes without addressing the root cause can lead to repeated occurrences. Utilizing a PDF guide alongside the analyzer ensures accurate interpretation and effective repair strategies.
Remember, a logged code doesn’t always mean a current malfunction, but ignoring it could invite future complications.
Locating JLG Fault Code Lists (PDF Format)
Finding reliable JLG fault code lists in PDF format is crucial for efficient troubleshooting. Official documentation is the primary source; the JLG website offers service manuals and technical publications, often including comprehensive code lists. These resources typically require registration or a subscription.
Alternatively, authorized JLG service dealers can provide the latest PDF versions. Online forums and communities dedicated to aerial lift maintenance sometimes host user-shared documents, but verify their accuracy against official sources.
Beware of outdated or incomplete lists, as JLG frequently updates its diagnostic codes. Ensure the PDF corresponds to the specific model and year of your lift (e.g., 25RTS, 33RTS, 40RTS). A current JLG fault codes list PDF is an indispensable tool for any technician working on these machines.
Always prioritize official sources for the most accurate and up-to-date information.

Troubleshooting JLG Fault Codes
Effective troubleshooting, guided by a JLG fault codes list PDF, involves systematic diagnosis, repair verification, and code resetting—crucial for restoring optimal lift functionality.
General Troubleshooting Steps
Initiating troubleshooting with a JLG fault codes list PDF demands a methodical approach. First, accurately record the fault code and its description. Then, visually inspect the related components – hydraulic lines, electrical connections, and sensors – for obvious damage or loose fittings.
Utilize a JLG analyzer to differentiate between current and logged codes, understanding that logged codes represent past issues. Consult the PDF to pinpoint potential causes, starting with the simplest solutions like checking fluid levels or battery charge.
If the issue persists, systematically test components using a multimeter or other diagnostic tools. Always prioritize safety, disconnecting power before working on electrical systems. Document each step taken and the results obtained, aiding in a focused and efficient repair process. Remember to refer to the official JLG documentation for specific procedures.
Resetting Fault Codes After Repair
Successfully repairing the issue identified using a JLG fault codes list PDF isn’t complete until the fault code is cleared. Typically, this is achieved through the JLG analyzer. After confirming the repair, navigate to the fault code clearing function within the analyzer’s menu.

Select the specific fault code(s) to be reset. The analyzer may require a key switch activation or a specific sequence to confirm the reset. It’s crucial to verify that the code is no longer present after the reset attempt.
Some codes may automatically clear upon power cycle if the underlying issue is resolved. However, manual clearing is often necessary. Always document the reset process and re-test the lift to ensure proper functionality before returning it to service. Failure to properly reset can lead to continued error indications.
When to Consult a JLG Service Manual

While a JLG fault codes list PDF provides initial diagnostic direction, complex issues demand the comprehensive detail found within the official JLG service manual. Consult the manual when encountering codes with ambiguous descriptions, or when troubleshooting requires detailed component testing procedures.
The service manual offers exploded views, wiring diagrams, and precise repair instructions beyond the scope of a simple fault code list. It’s essential for tasks like hydraulic system diagnostics, electrical circuit tracing, and component replacement.
Furthermore, the manual details specific safety precautions related to each repair procedure. Always refer to the service manual for any repair exceeding basic troubleshooting, ensuring accurate diagnosis and safe, effective repairs, especially for critical systems.

Resources for JLG Fault Code Information
Locating JLG fault code information involves utilizing official documentation, online forums, and parts catalogs (like those for the 25RTS, 33RTS, 40RTS) for comprehensive support.
Official JLG Documentation
JLG provides extensive official documentation, often in PDF format, as the primary resource for accurate fault code information. These documents, including service manuals and diagnostic guides, detail specific fault codes, their meanings, and recommended troubleshooting procedures for various JLG aerial lift models.
Accessing these resources directly from JLG’s website or through authorized dealers ensures you have the most up-to-date and reliable data. These manuals often contain detailed schematics and wiring diagrams, crucial for pinpointing the root cause of issues indicated by the fault codes; They cover everything from hydraulic system errors to electrical and drive system malfunctions.
Furthermore, JLG documentation frequently includes information on resetting fault codes after repairs and provides critical safety precautions to observe during the diagnostic process. Utilizing these official resources is paramount for maintaining the safety and operational integrity of JLG equipment.
Online Forums and Communities
JLG aerial lift operators and technicians frequently utilize online forums and communities as supplementary resources for deciphering fault codes and sharing troubleshooting experiences. While not official documentation, these platforms can offer valuable insights and practical solutions from peers facing similar issues.
These forums often host discussions regarding specific fault codes – like 201:2 or 4001 – with users detailing their diagnostic steps and repair outcomes. Searching these communities can reveal real-world applications of JLG fault code list PDF information and uncover undocumented fixes.

However, it’s crucial to exercise caution and verify information obtained from online sources against official JLG documentation. User-generated content may not always be accurate or safe. These forums are best used as a complement to, not a replacement for, professional guidance and official resources.
JLG Parts Manuals & Catalogs (25RTS, 33RTS, 40RTS)
While not directly a JLG fault codes list PDF, parts manuals for popular models like the 25RTS, 33RTS, and 40RTS scissor lifts are invaluable when addressing issues identified through fault code diagnostics. Understanding component locations and part numbers streamlines the repair process, ensuring the correct replacements are ordered.
These manuals often include detailed diagrams illustrating system layouts – hydraulic, electrical, and drive – which can aid in tracing the root cause of a fault code. Identifying the specific component related to a code (e.g., a sensor or solenoid) is significantly easier with a visual reference.
Accessing these catalogs, often available online or through JLG distributors, complements the fault code list PDF by providing the practical information needed to execute repairs efficiently and accurately. They are essential for maintaining these specific lift models.

Safety Precautions During Fault Code Diagnosis
Prioritize safety when using a JLG fault codes list PDF; de-energize the lift before inspection, wear appropriate PPE, and follow general maintenance guidelines.
General Maintenance Safety
Maintaining JLG aerial lifts demands strict adherence to safety protocols, even when referencing a JLG fault codes list PDF. Always de-energize the machine and disconnect the battery before commencing any inspection or repair work. Ensure the lift is positioned on a level surface and properly stabilized, utilizing wheel chocks as necessary.
Personnel should wear appropriate Personal Protective Equipment (PPE), including safety glasses, gloves, and steel-toe boots. Never work under a suspended platform without proper fall protection. Familiarize yourself with the machine’s operation manual and heed all warning labels. Regularly inspect hydraulic hoses for leaks and electrical wiring for damage.
Avoid modifications to the lift without JLG’s approval. Proper training is crucial; only qualified technicians should perform complex repairs. Remember, a fault codes list PDF aids diagnosis, but safe practices are paramount during all maintenance procedures.


























































































