Fault codes of 2011 engines equipped with EMR system in JLG Aerial Lifts

Fault Code Fault Code

using JLG using Deutz Fault
Analyzer SERDIA description Cause Results Troubleshooting Engine Troubleshooting Machine
Engine speed Sensor failure OR Gap Loss of engine speed signal will cause the engine
190:8 1 Speed Sensor Check distance from sensor to ringgear. Check for
from sensor tip to ringgear too large to shut down or not start. contamination on sensor end. Check wiring
OR Additional incorrect impulses
connection. Check sensor located at flywheel housing
received OR Wiring to sensor
190:8 2 Speed Sensor 2 and replace if required.
interrupted.

Speedometer failed. Cable Governor in emergency operation. (see chapter Check cable connection and Speedometer. Replace if
84:8 3 Speed Sensor
connection interrupted. 4.15 of the DEUTZ EMR manual) required.
Check parameter (21). Check speed settings. Check This error message should not occur on a JLG
Excess speed Engine Speed was/ is in excess of Engine stop. ( see chapter 4.3.3 of the DEUTZ rods. Check actuator and replace if required. Check machine due to engine configuration supplied
190:0 4
switch-off limit. EMR manual) cable to actuator. Check # of teeth. For vehicles check
possible thrust mode.

Set point sensor 1 Check ECU for proper CAN bus data flow and correct Check relevant wiring and connections between
91:2 5 Loss of CAN bus input. Engine will only run at constant speed of 1835 rpm
(accelerator pedal) programming. machine and ECU for open or short circuit.

Set point sensor 2

201:2 6
(Hand Throttle)

102:2 7 Charge air pressure

The engine will continue operating with the failure
100:2 8 Oil Pressure Fault at corresponding sensor OR Check relevant sensor replace if required. Check
of either Oil Pressure or Coolant Temperature
wiring connection has a short circuit relevant wiring and connections between sensor and
sensors. However with a failure of the sensor, the
110:2 9 Coolant temperature or open circuit. ECU.
associated monitoring function is de-activated
Charge Air
105:2 10
Temperature
174:2 11 Fuel Temperature

Check engine oil level. Check oil pressure sensor and

wiring. Check engine for other possible mechanical
Oil Pressure Engine Oil Pressure has fallen below Fault message occurs. Engine may also shutdown causes. The engine has a 12 second monitoring Depending on Machine Programming the engine
100:1 30
warning acceptable value. depending on JLG Machine programming delay on startup, so proceed carefully not to cause will either Shutdown OR only give a warning
further low oil pressure damage to engine on repeated
start attempts

Fault message occurs. Engine may also shutdown

Coolant Check engine oil level. Check Oil temperature sensor
Engine Oil Temperature has depending on JLG Machine programming. Fault Depending on Machine Programming the engine
110:0 31 Temperature and wiring. Check cooling system for leaks or
exceeded acceptable value. will disappear when Oil Temperature drops below will either Shutdown OR only give a warning
warning contamination, etc.
preset recovery temperature.
Fault message (disappears when charge air
Charge air Charge air temperature has Check charge air. Check charge air-temperature
105:0 32 temperature again drops below recovery level).
temperature warning exceeded warning level. sensor and cable. This error message should not occur on a JLG
After a delay time- fill limitation
machine due to engine configuration supplied
Coolant level Switch input "Low coolant level" is Check coolant level. Check coolant level sensor and
111:1 34 Fault message
warning active cable.
If engine exceeds maximum rpm set point (3300
OverSpeed warning Engine RPM was or is above If condition persists: Check fuel rack. Check actuator
rpm) the fuel rack is set to zero position until Check for external envrionmental conditions that
702:14 35 (with thrust mode maximum allowed rpm limit limit. and replace if required. Check wiring to actuator.
engine speed returns below acceptable recovery could cause engine overspeed condition
operation). "Thrust mode" function is active Check engine speed sensor, ringgear teeth, etc.
speed (2810 rpm).

Fuel temperature Fuel-temperature has exceeded Fault message (disappears when fuel temperature This error message should not occur on a JLG
174:0 36 Check fuel. Check fuel temperature sensor and cable.
warning warning level. again drops below recovery level). machine due to engine configuration supplied

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 Fault codes of 2011 engines equipped with EMR system in JLG Aerial Lifts

Fault Code Fault Code

using JLG using Deutz Fault
Analyzer SERDIA description Cause Results Troubleshooting Engine Troubleshooting Machine
Oil pressure switch-
100:1 40 Oil pressure below switch-off limit. See Oil Pressure Warning info
off
Normally this would cause an Emergency stop of
the engine. But EMR is not programmed to
Coolant temperature Oil temperature has exceeded switch-
110:0 41 directly shutdown the engine in JLG machines. See Coolant Temperature Warning info
switch-off off limit
Only if the JLG machine is programmed to
Charge air shutdown will this occur
Charge air temperature has Check charge air. Check charge air-temperature
105:0 42 temperature switch- This error message should not occur on a
exceeded switch-off limit sensor and cable. Check switch-off limit
off JLG machine due to engine configuration
Coolant level switch- Switch input "Low coolant level" is Check coolant level. Check coolant level sensor and supplied
111:1 44 Emergency stop. Start lock
off active cable.
Check wiring and connections at Actuator and to
536:12 50 Feedback
Actuator not connected. Fault in Emergency switch-off . Actuator cannot be Actuator. Check Acutator replace if required
actuator confirmation operated Check wiring and connections at Actuator and to
536:13 52 Reference feedback
Actuator. Check Acutator replace if required

Injection pump/actuator jammed or Fault message occurs and will disappear when
actuator wiring not connected. OR difference value is <10%. Engine will likely Check wiring and connectors at Actuator and between
Control travel
535:7 53 Difference between setpoint value shutdown when fault occurs. But engine will ECU and Actuator. Check actuator/ fuel rack/ injection
difference
compared to actual values of control normally restart immediately. If problem continues pumps for correct operation. Replace as required.
rack position is >10% . to persist begin troubleshooting process.

Auto calibration No automatic actuator equalization Engine stop/ start lock. Governor cannot be taken Check actuator and replaced if required. Check This error message should not occur on a
535:13 59 BOSCH-EDC pumps possible. Incorrect input of the into use. EDC actuator calibration required ( see feedback cable. Check voltage supply/cable. Check JLG machine due to engine configuration
faulty operation actuator reference values. Chapter 8.4). fault limits and reference values of the feedback. supplied

Digital output 3 (Switch-

563:2 60 off solenoid, pin M2)
Driver level is switch off. This error message should not occur on a
Fault (short circuit/ cable break) at Check cable of digital output (cable break or short
JLG machine due to engine configuration
digital output. circuit).
Digital output 6, pin supplied
572:2 62 Fault message
M7
This error message should not occur on a
Excess current at
563:6 63 JLG machine due to engine configuration
switch-off solenoid
supplied
91:11 67 Error Hand Setp1 Check CAN Connection and wiring connection
Loss of CAN bus input. Engine will only run at constant speed of 1835 rpm entering engine ECU from Machine. Check ECU for
898:2 68 Error CAN Setp1 proper CAN bus data flow and correct programming.

Controller for CAN-bus is faulty. Fault

Check relevant wiring and connections
743:12 70 CAN-Bus controller removal despite reinitializing
Check CAN connection and wiring connection entering between machine and ECU for open or
continuously not possible. Engine will shutdown or not restart OR Engine will
engine ECU from machine. Check ECU for proper short circuit. Check Terminating resistor in
only run at constant speed of 1835 rpm
Overflow in input buffer or a CAN bus data flow and correct programming. Machine wiring
CAN interface SAE
743:9 71 transmission cannot be placed on
J 1939
the bus.

Engine will shutdown or not restart OR Engine will Check CAN connection and wiring connection entering
743:14 74 CAN Passive error Open or Short circuit in wiring
only run at constant speed of 1835 rpm engine ECU from machine.

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 Fault codes of 2011 engines equipped with EMR system in JLG Aerial Lifts

Fault Code Fault Code

using JLG using Deutz Fault
Analyzer SERDIA description Cause Results Troubleshooting Engine Troubleshooting Machine
Parameter
Fault in parameter programming in
765:12 76 programming (write
the governor fixed value memory. Switch ignition off and on again. Check Fault code
EEPROM)
again to see if it remains active. If fault does not clear
Constant monitoring of program
inform DEUTZ Service.
752:12 77 Cyclic program test memory shows error (so called
"Flash-test" Engine will shutdown. Engine cannot be started.

Using SERDIA check RAM values of parameters 3895

Constant monitoring of working
766:2 78 Cyclic RAM test and 3896. Switch ignition off and on again. Check
memory shows error.
values again. Report values to DEUTZ Service.

Switch ignition off and on again. Check again. If fault

Power supply Power supply for actuator not in the Fault message occurs. Fault disappears when
766:2 80 returns check wiring from ECU to actuator. Then
(Actuator) permissible range power returns to the normal range.
inform DEUTZ Service.
766:2 83 Reference voltage 1 Reference voltage for engine
Fault message occurs. Fault disappears when
sensors not in the permissible range Switch ignition off and on again. Check again. Check
766:2 84 Reference voltage 2 reference voltage returns to normal range. Engine
voltage supply into ECU. Check Pin M22 for +5V. If
5 V Reference voltage for engine Oil will continue operation but Oil Pressure monitoring fault does not clear inform DEUTZ Service.
766:2 85 Reference voltage 4 Pressure sensor not in the is de-activated
permissible range

Internal temperature of EMR control Fault message occurs. Fault disappears when Switch ignition off and on again. Check again. If faulty Look for unusual source of high temperatures
171:12 86 Internal temperature
unit (ECU) not in permissible range temperature returns to normal range. does not clear inform DEUTZ Service. near engine ECU

Fault message (disappears when power again in

Atmospheric Atmospheric pressure not in Switch ignition off and on again. Check again. If faulty This error message should not occur on a JLG
108:12 87 normal range). Atmospheric pressure monitoring
pressure permissible range inform DEUTZ Service. machine due to engine configuration supplied
function de-activated.

Internal ECU fault. No data found or

Parameter Fault Check ECU program for correct settings. Save correct
checksum of data is faulty (note: fault
765:2 90 (EEPROM retrieval Engine cannot be started. parameters if necessary. Switch ignition off and on
only occurs during setting of
or checksum faulty). again. Check again. If faulty inform DEUTZ Service.
parameter/saving or reset).

Using SERDIA check RAM values of parameters 3897

Internal ECU fault. Calculation fault Engine will shutdown. Engine cannot be started
752:2 93 Stack overflow and 3898. Switch ignition off and on again. Check
(so-called "Stack overflow" fault). until fault is cleared
values again. Report values to DEUTZ Service.

Using SERDIA check RAM values of parameters

Internal ECU fault. Calculation fault Engine will shutdown. Engine cannot be started 3095, 3096, 3097, and 3098. Switch ignition off and on
766:2 94 Internal Fault
(so-called "Exception" fault). until fault is cleared again. Check values again. Report values to DEUTZ
Service.

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