Prior to Present, RS Scissor(PN
Service & Maintenance Manual
Models
1932RS/6RS
3248RS/10RS
3121273
April 8, 2013
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A. GENERAL
C. MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE
MANUFACTURER.
The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual.
These precautions are, for the most part, those that apply
when servicing hydraulic and larger machine component
parts.
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
B. HYDRAULIC SYSTEM SAFETY
It should be noted that the machines hydraulic systems
operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system
pressure prior to disconnecting or removing any portion of
the system.
3121273
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
L I S T E D I N T H I S S E C T I O N C O U L D R E S U LT I N
MACHINE DAMAGE, PERSONNEL INJURY OR DEATH
AND IS A SAFETY VIOLATION.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL
PARTS OR COMPONENTS.
• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL
CAP IS CLOSED AND SECURE AT ALL OTHER
TIMES.
• REMOVE ALL RINGS, WATCHES AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE-FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.
• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.
• KEEP OIL, GREASE, WATER, ETC. WIPED FROM
STANDING SURFACES AND HAND HOLDS.
• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.
• NEVER WORK UNDER AN ELEVATED SCISSOR
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR SAFETY PROP HAS BEEN
ENGAGED.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
– JLG Lift –
a
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
REVISION LOG
Original Issue - January 30, 2012
Manual Revised - August 1, 2012
Manual Revised - January 29, 2013
Manual Revised - April 8, 2013
b
– JLG Lift –
3121273
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A
B
C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
SECTION 1 - SPECIFICATIONS
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
High Drive Speed Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SECTION 2 - GENERAL
2.1
2.2
2.3
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Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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TABLE OF CONTENTS
2.4
2.5
2.6
Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
SECTION 3 - CHASSIS & SCISSOR ARMS
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
ii
Machine Component Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Battery Removal/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DC to AC Inverter (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Inverter Location on Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Inverter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Inverter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removal (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Main Power Contactor Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Elevation Limit Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
LSS - Scissor Arm Angle Sensor - location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Tilt Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Tilt Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Tilt Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Tilt Sensor Switch - Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Traction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Power Control Module - ZAPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
ZAPI Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Drive Motor Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Drive Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Drive Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Brake - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Drive Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Drive Motor Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Torque Hub Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Roll Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Oil Check/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Main Gearbox Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
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TABLE OF CONTENTS
3.15
3.16
3.17
3.18
3.19
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Hub Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Steer Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Removing scissor arm assembly as a complete unit:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Removing/Installing scissor arms individually: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Installation/Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Control Station Harness Installation to Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Control Station Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Overview of Control Station Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
SECTION 4 - HYDRAULICS
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Valves - Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Manual Descent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pump/Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Pump Motor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Pump/Tank Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Pump Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lift Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Steer Cylinder Piston Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Lift Cylinder - LSS Pressure Sensor Location (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
SECTION 5 - JLG CONTROL SYSTEM
5.1
5.2
5.3
3121273
Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
To Connect the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Using the Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Changing the Access Level of the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Machine ConfiguRation Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
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TABLE OF CONTENTS
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.1
6.2
6.3
6.4
6.5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
System Fault/DTC Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
X-Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
DTC Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
iv
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Min/Max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Continuity Measurement Over Long Distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Applying Silicone Dielectric Compound To Amp Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Wedge Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
DT/DTP Series Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DT/DTP Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
HD30/HDP20 Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Circuit Boards: Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Electrical Schematics and Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
– JLG Lift –
3121273
TABLE OF CONTENTS
LIST OF FIGURES
FIGURE NO.
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3-19.
3-20.
3-21.
3-22.
3-23.
3-24.
3-25.
3-26.
3-27.
3-28.
3-29.
3-30.
3-31.
3-32.
3-33.
3-34.
3-35.
3-36.
3-37.
3-38.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3-45.
3-46.
3-47.
3121273
TITLE
PAGE NO.
Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Machine Frame Covers (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Battery Location and Hold Down Bar (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Charger Decal LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
DC to AC Inverter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Inverter On/Off Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Ground Control Station Component Location (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Ground Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Main Power Contactor Relay Location (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Elevation Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Elevation Limit Switch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
1932RS/6RS - Elevation Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3248RS/10RS - Elevation Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
LSS - Scissor Arm Angle Sensor - Location Rear of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Tilt Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Tilt Sensor Switch - Bubble Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Tilt Sensor Switch - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Traction Control Circuit - ZAPI Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
ZAPI Power Module Location and Orientation (All models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Main Electrical Power Connections - (1001129845 - ZAPI Power Module) . . . . . . . . . . . . . . . . . .3-17
Brakes - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Electric Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Drive Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Drive Motor Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Wire Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32
Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
1932RS/6RS - Steer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
3248RS/10RS - Steer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
1932RS/6RS - Scissor Arm Assembly - Ref. Figure 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
1932RS/6RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
3248RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
3248RS/10RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45
Platform Control Station Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
Platform Control Station Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46
– JLG Lift –
v
TABLE OF CONTENTS
3-48.
3-49.
3-50.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
4-14.
4-15.
4-16.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
7-10.
7-11.
7-12.
7-13.
7-14.
7-15.
7-16.
7-17.
7-18.
7-19.
7-20.
vi
Platform Control Station Components - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Platform Control Station Components - Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Hydraulic Oil Check Procedure - All Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Hydraulic Motor, Pump and Tank Assembly (All Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Wiper Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Rod Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
LSS Pressure Sensors Location - 1932RS/6RS - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
LSS Pressure Sensors Location - 3248RS/10RS - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . .4-12
1932RS/6RS - Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
3248RS/10RS - Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
1932RS/6RS - Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
3248RS/10RS - Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Diagnostic Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Analyzer Menu - Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Analyzer Menu - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Analyzer Menu - System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Analyzer Menu - Personalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Analyzer Menu - Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Analyzer Menu - Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Analyzer Menu - Emulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Voltage Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Current Measurement (DC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Connector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10
HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
HD/HDP Unlocking Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11
Electrical Schematic - (ANSI) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16
Electrical Components Layout - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
– JLG Lift –
3121273
TABLE OF CONTENTS
LIST OF TABLES
TABLE NO.
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
1-15
1-16
1-17
1-18
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
4-1
4-2
4-3
5-1
5-2
7-1
7-2
3121273
TITLE
PAGE NO.
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Electrical System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Lift Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
High Drive Cutout Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Battery Charger Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
ZAPI Power Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Module Terminal Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Connector Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Hydraulic System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Lift Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Pressure Fitting Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Power Module - J1 Connector Pin Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
Power Module - J2 Connector Pin Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
– JLG Lift –
vii
TABLE OF CONTENTS
NOTES:
viii
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1
SPECIFICATIONS
Table 1-1. Operating Specifications
DESCRIPTION
1932RS/6RS
3248RS/10RS
19 ft. (5.8 m)
32 ft. (9.75 m)
PLATFORM
Maximum Platform Height
DRIVING
Maximum Drive Speed
Stowed:
Elevated:
2.5 mph (4 kph)
0.3 mph (0.5 kph)
Maximum Stowed Travel Grade (Gradeability)
25% (14°)
Inside Turning Radius
23.6 in. (60 cm)
47.9 in. (121.7 cm)
Outside Turning Radius
87.9 in. (221.9 cm)
125.3 in. (318.1 cm)
CHASSIS
Approximate Gross Machine Weight
ANSI/CSA:
CE:
3,000 lb. (1,360 kg)
3,450 lb. (1,565 kg)
5,070 lb. (2,300 kg)
6,050 lb. (2,744 kg)
Maximum Tire Load (per wheel)
ANSI/CSA:
CE:
1,365 lb. (620 kg)
1,835 lb. (832 kg)
2,070 lb. (940 kg)
Ground Bearing Pressure
ANSI/CSA:
CE:
130 PSI (9.18 kg/cm2)
81 PSI (5.69 kg/cm2)
108 PSI (7.6 kg/cm2)
3.1 in. (7.8 cm)
4.1 in. (10.3 cm)
Ground Clearance
Platform Capacities
Table 1-2. Platform Capacities
MAXIMUM CAPACITY
ALLOWED ON
PLATFORM EXTENSION
MAXIMUM PERSONS
ALLOWED IN PLATFORM
500 Lb. (227 Kg)
250 Lb. (113 Kg)
2
100 Lb. (445 N)
28 mph
3248
705 Lb. (320 Kg)
250 Lb. (113 Kg)
2
100 Lb. (445 N)
28 mph
1932
480 Lb. (218 Kg)
240 Lb. (109 Kg)
2
100 Lb. (445 N)
28 mph
3248
683 Lb. (310 Kg)
236 Lb. (107 Kg)
2
100 Lb. (445 N)
28 mph
6RS
230 Kg
120 Kg
Indoor - 2 Persons + 70 Kg
400 N
0 m/s
Outdoor - 1 Person + 150 Kg
200 N
12.5 m/s
Indoor - 2 Persons + 160 Kg
400 N
0 m/s
Outdoor - 1 Person + 240 Kg
200 N
12.5 m/s
SPECIFICATION
MACHINE
MODEL
ANSI/CSA/JPN
1932
ANSI EXPORT
CE
10RS
MAXIMUM
PLATFORM
CAPACITY (1)
320 Kg
120 Kg
MAX. SIDE FORCE
MAXIMUM
(Platform Fully Extended OPERATING
@ Max. Capacity)
WIND SPEED
NOTE: (1) Maximum Platform Capacity includes platform and platform extension.
3121273
– JLG Lift –
1-1
SECTION 1 - SPECIFICATIONS
Dimensional Data
Batteries
Table 1-3. Machine Dimensions
DESCRIPTION
Platform Height Elevated
Platform Height Stowed
Platform Height Stowed (Rails Down)
Working Height
Rail Height
(From platform floor)
Rail Height
(Platform Floor to Top of
Rail)
Rail Height - Folded
(Ground to Mid Rail)
Overall Machine Width
Overall Machine Length
(w/ladder)
Platform Size - Length
Platform Size - Width
Wheelbase
Table 1-5. Battery Specifications
1932RS/6RS
3248RS/10RS
19 ft.
(5.8 m)
79.4 in.
(2.02 m)
25 ft.
(7.62 m)
40 in.
(101.6 cm)
32 ft.
(9.75 m)
95.8 in.
(2.43 m)
78.3 in.
(1.99 m)
38 ft.
(11.5 m)
40.5 in.
(102.9 cm)
40 in.
(101.6 cm)
41 in. (104.3 cm) - ANSI
43.6 in. (110.7 cm) - CE
N/A
DESCRIPTION
Voltage (24V-DC System - Series)
6 V per battery
Amp Hour (Standard Battery)
220 Amp Hour @ 20 HR. Rate
Reserve Capacity (Standard Battery)
447 Minutes
NOTICE
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
69.3 in. (176 cm) 78.3 in. (198.9 cm)- ANSI
CE ONLY
77.6 in. (197.1 cm) - CE
32 in.
48 in.
(81.28 cm)
(122 cm)
81.5 in.
90 in. (2.28 m) - ANSI
(207 cm)
94.8 in. (240.7 cm) - CE
71.7 in.
84.7 in.
(182 cm)
(215.1 cm)
26.9 in.
42.5 in.
(68.4 cm)
(107.9 cm)
55 in.
73 in.
(139.7 cm)
(185.4 cm)
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG’S AFTERMARKET PARTS DISTRIBUTION CENTERS
OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH
PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR
LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE
ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES
NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES
ARISING FROM THE USE OF NON APPROVED BATTERIES.
Battery Quick-Disconnect (If Equipped)
Tires
Table 1-4. Tire Specifications
DESCRIPTION
Size
Wheel Bolt Torque
1-2
ALL MACHINES
1706740A
1932RS/6RS
3248RS/10RS
12.71 in. x 3.94 in.
(323 mm x 100 mm)
16 in. x 5 in.
(406 mm x 127 mm)
120 ft lb. (163 Nm)
Machines equipped with the battery
quick-disconnect allow all machine
power to be easily disconnected at
the batteries without removing battery cables from the battery posts. To disconnect power,
locate the RED quick-disconnect connector on top of the
batteries inside the battery compartment and pull halves
apart.
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
Electrical System
Motors
• Drive Motor
Table 1-6. Electrical System Specifications
DESCRIPTION
Type: Shunt Wound, Sepex 24V DC
ALL MACHINES
Electrical System Voltage (DC)
Power: 0.65 Horsepower @ 3750 rpm
24V - DC
• Hydraulic Pump/Electric Motor Assembly
(All Models)
Battery Charger: (1001129847)
Input:
AC Input Voltage:
Nominal AC Input Voltage:
Input Frequency:
Max. AC Input Current:
Ingress Protection:
Operating Temperature:
Output:
Nominal DC Output Voltage:
Max. DC Output Voltage:
Max DC Output Current:
Max. Interlock Current:
Protection:
Output Reverse Polarity:
Output Short Circuit:
AC Overload:
DC Overload:
DC to AC Inverter - Output Rating:
(OPTION)
Type: Series Wound Permanent Magnet 24V DC
85-265V AC
120VAC / 230VAC RMS
45 - 65Hz
12A - RMS @ 108V AC
IP46 NEMA4 Type 4
-22°F (-30°C) to 122°F (+50°C)
Power: 3kW
24V
33.6V
25A
1A
Electronic Protection-Auto Reset
Electronic Protection-Auto Reset
Current Limited
Current Limited
120V-AC, 60Hz - 7.5 Amps - 900
Watts - Modified Sinewave
Travel Speed
Table 1-7. Travel Speed
ELEVATED SPEED
MAXIMUM SPEED (PLATFORM LOWERED)
UNIT OF MEASURE
MODEL
Mph
Sec/25 ft
(Sec/7.6 m)
Kph
Mph
Sec/25 ft
(Sec/7.6 m)
Kph
1932RS/6RS
0.3
59 - 65
0.5
2.5
6.85 - 8.5
4
3246RS/10RS
0.3
57 - 65
0.5
2.5
6.85 - 8.5
4
Lift Speed
NOTE: Maximum rated load in platform on measured lift speeds. Platform fully raised and lowered.
Table 1-8. Lift Speed
LIFT UP
(SECONDS)
LIFT DOWN
(SECONDS)
1932RS/6RS
22 - 29
21 - 31
3246RS/10RS
55 - 65
40 - 50
MODEL
3121273
– JLG Lift –
1-3
SECTION 1 - SPECIFICATIONS
1.2
CRITICAL STABILITY WEIGHTS
Table 1-11. Lubrication Specifications
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT
OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.
KEY
SPECIFICATIONS
MPG
Multipurpose Grease having a minimum dripping
point of 350°F. Excellent water resistance and adhesive qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL
Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105.
Table 1-9. Critical Stability Weights
COMPONENT
1932RS/6RS
3248RS/10RS
Wheel and Tire Assembly (each)
Front: 21.6 lb. (9.8 kg)
Rear: 21.6 lb. (9.8 kg)
43 lb. (19.5 kg)
40.5 lb. (18.4 kg)
Wheel/Tire and
Drive Assembly (each)
113 lb. (51.3 kg)
HO
Table 1-12. Hydraulic Oil Specifications
134 lb. (60.8 kg)
Batteries (each) Standard:
AGM:
62 lb. (28.1 kg)
65 lb. (29.5 kg)
Batteries (combined)
Standard :
AGM:
248 lb. (111.1 kg)
260 lb. (118 kg)
1.3
JLG Recommends - Mobil DTE 10, EXCEL 15 or
ATF - Automatic Transmission Fluid
Mobil EAL ENVIRONSYN H 32 (IN U.S.A.)
Mobil EAL HYDRAULIC OIL 32 (IN EUROPE)
LUBRICATION
Hydraulic Oil
SPECIFICATION
MOBIL
DTE 10
EXCEL 15
MOBIL EAL
ENVIRONSYN
H 32
MOBIL EAL
HYDRAULIC
OIL 32
ISO Viscosity
Grade
#15
#32
#32
Spec Gravity API
31.9
0.950
—
Pour Point, Max
-40°F
(-40°C)
-59°F
(-51°C)
-38.2°F
(-39°C)
Flash Point, Min.
330°F
(166°C)
514.4 °F
(268°C)
478°F (248°C)
15 cSt
33.1 cSt
32 cSt
at 100°C
4.1 cSt
6.36 cSt
7 cSt
at 100°F
80 SUS
—
—
at 210°F
43 SUS
—
—
cp at -30°F
3.2
—
—
Viscosity Index
Operating Temp
140
—
VISCOSITY SPECIFICATIONS
at 40°C
NOTE: Hydraulic oils must have anti-wear qualities at least
to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system service. JLG Industries recommends DTE 10 or Excel
15 hydraulic oil.
Aside from JLG recommendations, it is not advisable
to mix oils of different brands or types, as they may
not contain the same required additives or be of
comparable viscosities. If use of hydraulic oil other
than DTE 10 or Excel 15 is desired, contact JLG
Industries for proper recommendations.
.
1001102685_3
Pressure Settings
Table 1-13. Pressure Settings
Table 1-10. Hydraulic Oil
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
SAE VISCOSITY GRADE
0°F to +23°F (-18°C to -5°C)
10W
0°F to 210°F (-18°C to + 99°C)
10W-20, 10W-30
50°F to 210°F (+10°C to +210°C)
20W-20
1.4
LIMIT SWITCHES
147
189
-20°F (29°C) - 200°F (392°C)
MAIN RELIEF
LIFT RELIEF
STEER
RELIEF
1932RS/6RS
2300 psi
(158 bar)
2300 psi
(158 bar)
1000 psi
(69 bar)
3246RS/10RS
2500 psi
(172 bar)
2500 psi
(172 bar)
1000 psi
(69 bar)
MODEL
Illuminates a light on the platform control, sounds an alarm
and cuts out lift up and drive when the machine is out of
Tilt Alarm
1-4
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
level and above stowed depending on model and specifications.
1.6
MAJOR COMPONENT WEIGHTS
Table 1-17. Major Component Weights
Table 1-14. Tilt Activation Setting
MODEL
TILT
SETTING
(FRONT TO
BACK)
TILT
SETTING
(SIDE TO
SIDE)
PLATFORM
ELEVATION
@ TILT
ACTIVATION
(± 6 IN.)
3°
1.5°
69 in.
(1.75 m)
3°
2°
88.5 in.
(2.25 m)
3°
1.5°
88.5 in.
(2.25 m)
1932RS/6RS - ALL
3248RS/10RS ANSI/CSA/JPN
3248RS/10RS - CE
COMPONENT
1932RS/6RS
3246RS/10RS
Platform
240 lb.
(109 kg)
412 lb.
(187 kg)
Manual Platform Extension
115 lb.
(52 kg)
150 lb.
68 kg
Arm Assembly - (Includes
Lift Cylinder)
520 lb.
(236 kg)
1,806 lb.
(820 kg)
Chassis w/Wheel/Tire and
Drive Assembly
2,125 lb.
(964 kg)
2,702 lbs
(1226 kg)
1.7
High Drive Speed Cutout
High drive speed is cut out @ when the platform is raised
above the preset height per model as follows:
NOTE: These figures are given with a tolerance of ± 6 in.
(0.15 m).
TORQUE REQUIREMENTS
Self locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.
Table 1-18. Torque Requirements
Table 1-15. High Drive Cutout Height
HIGH DRIVE SPEED
CUTOUT HEIGHT
DRIVE SPEED
REDUCTION
1932RS/6RS
68.9 in. (1.75m)
3248RS/10RS
88.5 in. (2.25 m)
2.5 mph (4 kph) to
0.3 mph (0.5 kph)
MODEL
1.5
TORQUE VALUE
(DRY)
INTERVAL
HOURS
Front Wheel Spindle Nut
30-40 ft lb
(40-54 Nm)
50
105 -120 ft lb
(142-163 Nm)
50
Wheel Bolts
CYLINDER SPECIFICATIONS
NOTE: Anytime a wheel bolt is replaced, be sure one of the
same length is used. Use bolt shown below on
wheels that use the 1/4" (6.4mm) ring.
Table 1-16. Cylinder Specifications
DESCRIPTION
DESCRIPTION
1932RS/6RS
3246RS/10RS
2.48 in.
(63 mm)
3.93 in.
(100 mm)
43.3 in.
(1100 mm)
48.5 in.
(1232 mm)
1.77 in.
(45 mm)
2.48 in.
(63 mm)
22
Steer Cylinder Bore
1.5 in.
(38.1 mm)
1.57 in.
(40 mm)
M12 - 1.5 x 22
Steer Cylinder Stroke
4.92 in
(125 mm)
6.77 in.
(172 mm)
0.75m in.
(19.05 mm)
0.78 in.
(20 mm)
Lift Cylinder Bore
Lift Cylinder Stroke
Lift Cylinder Rod Diameter
Steer Cylinder Rod Diameter
NOTE: After tightening the spindle nut to the proper torque,
loosen completely until you can turn by hand. Finger
tighten nut by hand without rotating hub. Install cotter
pin by backing nut off, if necessary, in order to line up
slot.
When maintenance becomes necessary or a fastener has loosened, refer to the Torque Charts on
page 1-6 to determine proper torque value.
3121273
– JLG Lift –
1-5
SECTION 1 - SPECIFICATIONS
Torque Charts
Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
SAE GRADE 5 BOLTS & GRADE 2 NUTS
Torque
(Dry)
Tensile
Clamp Load
Stress Area
Torque
Lubricated
Torque
Torque
(Loctite® 242TM or 271TM
(Loctite® 262TM or VibraTM
OR Vibra-TITE 111 or
TITETM 131)
140)
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
IN-LB
[N.m]
4
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
380
420
580
610
900
940
1120
1285
2020
2320
8
9
16
18
30
31
43
49
96
120
0.9
1.0
1.8
2.0
3.4
3.5
4.8
5.5
10.8
13.5
6
7
12
13
22
23
32
36
75
86
0.7
0.8
1.4
1.5
2.5
2.6
3.5
4
9
10
105
135
12
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
3340
3700
4940
5600
6800
7550
9050
10700
11600
12950
14400
16300
21300
23800
29400
32400
38600
42200
42300
47500
53800
59600
64100
73000
78000
87700
FT-LB
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
800
880
1120
1240
1460
1680
1940
2200
[N.m]
23
26
41
47
68
75
102
122
149
163
203
230
353
407
583
637
868
949
1085
1193
1518
1681
1979
2278
2630
2983
FT-LB
13
14
23
25
35
40
55
65
80
90
110
130
200
220
320
350
480
530
600
660
840
920
1100
1260
1460
1640
[N.m]
18
19
31
34
47
54
75
88
108
122
149
176
271
298
434
475
651
719
813
895
1139
1247
1491
1708
1979
2224
FT-LB
19
21
35
40
55
60
85
100
120
135
165
190
285
330
475
520
675
735
840
925
1175
1300
1525
1750
2025
2300
[N.m]
26
29
48
54
75
82
116
136
163
184
224
258
388
449
646
707
918
1000
1142
1258
1598
1768
2074
2380
2754
3128
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
IN-LB
[N.m]
FT-LB
16
17
28
32
45
50
68
80
98
109
135
153
240
268
386
425
579
633
714
802
1009
1118
1322
1506
1755
1974
[N.m]
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
NO. 5000059
REV. J
REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N
Loctite® P/N
ND Industries P/N
0100011
0100019
0100071
242TM
271TM
262TM
Vibra-TITE TM 121
Vibra-TITE TM 140
Vibra-TITE TM 131
Description
Medium Strength (Blue)
High Strength (Red)
Medium - High Strength (Red)
Figure 1-1. Torque Chart (SAE Fasteners - Sheet 1 of 7)
1-6
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
Tensile
Clamp Load
Stress Area
Torque
(Dry or Loctite® 263)
K= 0.20
Torque
Torque
(Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or
TITETM 131)
140)
K=.18
K=0.15
Size
TPI
Bolt Dia
Sq In
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
In
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
LB
4
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059
REV. J
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7))
3121273
– JLG Lift –
1-7
SECTION 1 - SPECIFICATIONS
SOCKET HEAD CAP SCREWS
Magni Coating (Ref 4150701)*
Tensile
Stress Area
Clamp Load
See Note 4
Torque
(Dry) K = .17
Torque
(Loctite® 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85®
K=0.16
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
4
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
122
139
14
16
114
131
13
15
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
20
25
35
40
60
65
90
100
130
145
180
205
320
355
515
570
730
845
1095
1225
1545
1710
2025
2300
2690
3020
[N.m]
25
35
50
55
80
90
120
135
175
195
245
280
435
485
700
775
995
1150
1490
1665
2100
2325
2755
3130
3660
4105
FT-LB
20
20
35
40
55
60
85
95
125
135
170
190
300
335
485
535
685
795
1030
1155
1455
1610
1905
2165
2530
2845
[N.m]
25
25
50
55
75
80
115
130
170
185
230
260
410
455
660
730
930
1080
1400
1570
1980
2190
2590
2945
3440
3870
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite® 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059
REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7)
1-8
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
SOCKET HEAD CAP SCREWS
Zinc Yellow Chromate Fasteners (Ref 4150707)*
Tensile
Stress Area
Clamp Load
See Note 4
Torque
(Loctite® 242TM or 271TM
OR Vibra-TITE TM 111 or
140 OR Precoat 85®
K=0.18
Torque
(Dry)
K = .20
Size
TPI
Bolt Dia
In
Sq In
LB
IN-LB
[N.m]
IN-LB
[N.m]
4
40
48
32
40
32
36
24
32
20
28
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
2860
3280
143
164
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
775
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1055
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Torque
(Loctite® 262TM
TM
or Vibra-TITE 131)
K=0.15
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m]
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH
CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.
Figure 1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7)
3121273
– JLG Lift –
1-9
SECTION 1 - SPECIFICATIONS
CLASS 8.8 METRIC BOLTS
CLASS 8 METRIC NUTS
Size
PITCH
Tensile
Stress
Area
Sq mm
Clamp
Load
Torque
(Dry or Loctite®
263TM)
Torque
(Lub)
KN
[N.m]
[N.m]
Torque
Torque
(Loctite®
(Loctite® 262TM 242TM or 271TM
OR VibraOR VibraTITETM 131)
TITETM 111 or
140)
[N.m]
[N.m]
3
0.5
5.03
2.19
1.3
1.0
1.2
1.4
3.5
0.6
6.78
2.95
2.1
1.6
1.9
2.3
4
0.7
8.78
3.82
3.1
2.3
2.8
3.4
5
0.8
14.20
6.18
6.2
4.6
5.6
6.8
6
1
20.10
8.74
11
7.9
9.4
12
7
1
28.90
12.6
18
13
16
19
8
1.25
36.60
15.9
26
19
23
28
10
1.5
58.00
25.2
50
38
45
55
12
1.75
84.30
36.7
88
66
79
97
14
16
2
2
115
157
50.0
68.3
140
105
126
154
219
164
197
241
18
2.5
192
83.5
301
226
271
331
20
2.5
245
106.5
426
320
383
469
22
2.5
303
132.0
581
436
523
639
24
3
353
153.5
737
553
663
811
27
3
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530
33
3.5
694
302.0
1990
1490
1790
2090
36
4
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7))
1-10
– JLG Lift –
3121273
SECTION 1 - SPECIFICATIONS
CLASS 10.9 METRIC BOLTS
CLASS 10 METRIC NUTS
CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
Size
PITCH
Tensile
Stress
Area
Clamp
Load
Torque
(Dry or Loctite®
263TM)
K = 0.20
Sq mm
KN
[N.m]
Torque
(Lub OR Loctite®
242TM or 271TM OR
Vibra-TITE TM 111 or
140)
K= 0.18
Torque
(Loctite® 262TM OR
Vibra-TITE TM 131)
K=0.15
[N.m]
[N.m]
3
0.5
5.03
3.13
3.5
0.6
6.78
4.22
4
0.7
8.78
5.47
5
0.8
14.20
8.85
6
1
20.10
12.5
7
1
28.90
18.0
25.2
22.7
18.9
8
1.25
36.60
22.8
36.5
32.8
27.4
10
1.5
58.00
36.1
70
65
55
12
1.75
84.30
52.5
125
115
95
14
16
2
2
115
157
71.6
97.8
200
180
150
315
280
235
18
2.5
192
119.5
430
385
325
20
2.5
245
152.5
610
550
460
22
2.5
303
189.0
830
750
625
24
3
353
222.0
1065
960
800
27
3
459
286.0
1545
1390
1160
30
3.5
561
349.5
2095
1885
1575
33
3.5
694
432.5
2855
2570
2140
36
4
817
509.0
3665
3300
2750
42
4.5
1120
698.0
5865
5275
4395
NO. 5000059
REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7)
3121273
– JLG Lift –
1-11
SECTION 1 - SPECIFICATIONS
Magni Coating (Ref 4150701)*
CLASS 12.9 SOCKET HEAD CAP SCREWS
M6 AND ABOVE*
Size
PITCH
Tensile
Stress
Area
Sq mm
Torque
Torque
(Lub OR Loctite®
Torque
(Loctite® 262TM
Clamp Load (Dry or Loctite® 242TM or 271TM
OR Vibra-TITE TM
See Note 4
263TM)
OR Vibra-TITE TM
131)
K = .17
111 or 140)
K = .15
K = .16
kN
[N.m]
[N.m]
[N.m]
11
3
0.5
5.03
3.5
0.6
6.78
4
0.7
8.78
5
0.8
14.20
6
1
20.10
12.5
13
12
7
1
28.90
18.0
21
20
19
8
1.25
36.60
22.8
31
29
27
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
97.8
265
250
235
18
2.5
192
119.5
365
345
325
20
2.5
245
152.5
520
490
460
22
2.5
303
189.0
705
665
625
24
3
353
220.0
900
845
790
27
3
459
286.0
1315
1235
1160
30
3.5
561
349.5
1780
1680
1575
33
3.5
694
432.5
2425
2285
2140
36
4
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7)
1-12
– JLG Lift –
3121273
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1 MACHINE PREPARATION, INSPECTION,
AND MAINTENANCE
General
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness and maintain its safe
operating condition. For maximum service life and safe
operation, ensure that all the necessary inspections and
maintenance have been completed before placing the
machine into service.
Preparation, Inspection, and Maintenance
It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The
following table outlines the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency
of inspections and maintenance must be increased as
environment, severity and frequency of usage requires.
Pre-Start Inspection
It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use
daily or at each change of operator. Reference the Operation and Safety Manual for completion procedures for the
Pre-Start Inspection. The Operation and Safety Manual
must be read in its entirety and understood prior to performing the Pre-Start Inspection.
Pre-Delivery Inspection and Frequent
Inspection
The Pre-Delivery Inspection and Frequent Inspection shall
be performed by a qualified JLG equipment mechanic.
JLG Industries, Inc. recognizes a qualified JLG equipment
mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or
experience, has successfully demonstrated the ability and
proficiency to service, repair, and maintain the subject
JLG product model.
The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed
prior to each sale, lease, or rental delivery. The Frequent
Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first);
out of service for a period of more than 3 months; or when
purchased used. The frequency of this inspection must be
increased as environment, severity and frequency of
usage requires.
3121273
Reference the JLG Pre-Delivery and Frequent Inspection
Form and the Inspection and Preventative Maintenance
Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate
areas of this manual for servicing and maintenance procedures.
Annual Machine Inspection
JLG recommends that the Annual Machine Inspection be
performed by a Factory-Trained Service Technician on an
annual basis, no later than thirteen (13) months from the
date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory-Trained Service Technician
as a person who has successfully completed the JLG Service Training School for the subject JLG product model.
Reference the machine Service and Maintenance Manual
and appropriate JLG inspection form for performance of
this inspection.
Reference the JLG Annual Machine Inspection Form and
the Inspection and Preventative Maintenance Schedule for
items requiring inspection during the performance of this
inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.
For the purpose of receiving safety-related bulletins, it is
important that JLG Industries, Inc. has updated ownership
information for each machine. When performing each
Annual Machine Inspection, notify JLG Industries, Inc. of
the current machine ownership.
Preventative Maintenance
In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment
mechanic. JLG Industries, Inc. recognizes a qualified JLG
equipment mechanic as a person who, by possession of a
recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the
ability and proficiency to service, repair, and maintain the
subject JLG product model.
Reference the Preventative Maintenance Schedule and
the appropriate areas of this manual for servicing and
maintenance procedures. The frequency of service and
maintenance must be increased as environment, severity
and frequency of usage requires.
– JLG Lift –
2-1
SECTION 2 - GENERAL
Table 2-1. Inspection and Maintenance Responsibilities
Type
Frequency
Primary
Responsibility
Service
Qualification
Reference
Pre-Start
Inspection
Prior to use each day; or
At each Operator change.
User or Operator
User or Operator
Operation and Safety Manual
Pre-Delivery
Inspection
Prior to each sale, lease, or
rental delivery.
Owner, Dealer, or
User
Qualified JLG
Mechanic
Service and Maintenance Manual and applicable JLG inspection form.
In service for 3 months or 150 hours, whichever comes
Owner, Dealer, or
first; or Out of service for a period of more than 3 months;
User
or Purchased used.
Qualified JLG
Mechanic
Service and Maintenance Manual and applicable JLG inspection form.
Factory-Trained
Service Technician
(recommended)
Service and Maintenance Manual and applicable JLG inspection form.
Qualified JLG
Mechanic
Service and Maintenance Manual
Frequent
Inspection
Annual Machine Annually, no later than 13 months from the date of the prior Owner, Dealer, or
Inspection
inspection.
User
Preventative
Maintenance
At intervals as specified in the Service and Maintenance
Manual.
Owner, Dealer, or
User
2.2 PREVENTIVE MAINTENANCE AND
INSPECTION SCHEDULE
4. Check for cracked or broken welds.
5. Operates properly.
6. Returns to neutral or "off" position when released.
The preventive maintenance and inspection checks are
listed and defined in the following table. This table is
divided into two basic parts, the “AREA” to be inspected
and the “INTERVAL” at which the inspection is to take
place. Under the “AREA” portion of the table, the various
systems along with the components that make up that
system are listed. The “INTERVAL” portion of the table is
divided into five columns representing the various inspection time periods. The numbers listed within the interval
column represent the applicable inspection code for
which that component is to be checked.
The checks and services listed in this schedule are not
intended to replace any local or regional regulations that
may pertain to this type of equipment nor should the lists
be considered as all inclusive. Variances in interval times
may occur due to climate and/or conditions and depending on the location and use of the machine.
NOTICE
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
"ANNUAL MACHINE INSPECTION REPORT" FORM.
NOTE: This machine requires periodic safety and maintenance inspections by a qualified JLG mechanic.
Notify JLG dealer if inspection is overdue.
Maintenance and Inspection Schedule Codes:
1. Check for proper and secure installation.
2. Visual inspection for damage, cracks, distortion, or
excessive wear.
3. Check for proper adjustment.
2-2
7. Clean and free of debris.
8. Interlocks function properly.
9. Check for signs of leakage.
10. Decals installed and legible.
11. Check for proper fluid level.
12. Check for chafing and proper routing.
13. Check for proper tolerances.
14. Properly lubricated.
15. Torqued to proper specification.
16. No gouges, excessive wear, or cords showing.
17. Properly inflated and seated around rim.
18. Proper and authorized components.
19. Fully charged.
20. No loose connections, corrosion, or abrasions.
21. Verify.
22. Perform.
23. Sealed properly.
24. Overrides Platform controls.
25. Remove pump motor cover and blow away any
brush wear dust from cover, brushes, and brush
holder assembly.
Footnotes:
(a) Prior to each sale, lease, or delivery
(b) In service for 3 months; or Out of service for 3 months
or more; or Purchased used
(c) Annually, no later than 13 months from the date of the
prior inspection
– JLG Lift –
3121273
SECTION 2 - GENERAL
Table 2-2. Preventive Maintenance & Inspection Schedule.
INTERVAL
PRE-DELIVERY (a)
OR FREQUENT (b)
INSPECTION
ANNUAL (c)
(YEARLY)
INSPECTION
Platform Controls
5, 6, 7
5, 6, 7
Ground Controls
AREA ON MACHINE
FUNCTIONS/CONTROLS
5, 6
5, 6, 14
Function Control Locks, Guards, or Detents
5
5
Function Enable System
5
5
Emergency Stop Switches (Ground & Platform)
5
5
Function Limit or Cutout Switch Systems
5
5
Manual Descent or Auxiliary Power
5
5
1
1
1, 2, 4
1, 2, 4
PLATFORM ASSEMBLY
Platform
Guard Rails
Gate
1, 5
1, 5
Floor
1, 2
1, 2
Lanyard Anchorage Point
1, 4
1, 4
1, 2, 4
1, 2, 4
1, 5
1, 5
Cylinder Pins, Pivot Pins & Attaching Hardware
1
1
Arm Pins, Wear Pads & Attaching Hardware
1
1
1, 7
1, 7
SCISSOR ARMS
Scissor Arms
Arm Safety Prop
CHASSIS ASSEMBLY
Covers Installation
Static Strap
1
1
Wheel and Tire Assemblies
2, 15
2, 15
Drive Motors
1, 7, 9
1, 7, 9
—
—
9
18
Drive Motor Brushes **
POWER SYSTEM
Batteries
Battery Charger
5
HYDRAULIC/ELECTRIC SYSTEM
3121273
Hydraulic Lift/Steer Pump
1, 2, 9
1, 2, 5, 9, 25
Hydraulic Cylinders (arms and steering)
2, 7, 9
2, 9
Steer Cylinder Attachment Pins and Pin Retainers
1, 2
1, 2
Hydraulic Hoses, Lines, and Fittings
1, 9
1, 9
Hydraulic Reservoir, Cap, and Breather
5, 7
5, 7
Hydraulic Fluid ***
11
11
Electrical Connections
20
20
Instruments, Gauges, Switches, Lights, Horn
5
5
– JLG Lift –
2-3
SECTION 2 - GENERAL
Table 2-2. Preventive Maintenance & Inspection Schedule. (Continued)
INTERVAL
PRE-DELIVERY (a)
OR FREQUENT (b)
INSPECTION
ANNUAL (c)
(YEARLY)
INSPECTION
Operation & Safety Manual in Storage Box
21
21
ANSI & EMI Handbooks in Storage Box (ANSI
ONLY)
21
21
Capacity Decals Installed, Secure, Legible
21
21
All Decals/Placards Installed, Secure, Legible
21
21
AREA ON MACHINE
GENERAL
Annual Machine Inspection Due
21
No Unauthorized Modifications or Additions
21
21
All Relevant Safety Publications Incorporated
21
21, 22
General Structural Condition and Welds
2, 4
2, 4
All Fasteners, Pins, Shields, and Covers
1, 2
Grease and Lubricate to Specifications
22
22
Function Test of All Systems
22
22
Paint and Appearance
7
Notify JLG of change in Machine Ownership
7
22
** Replace when system performance is degraded.
*** Every two years, drain and remove hydraulic oil reservoir , clean pick-up screen, refill with fresh hydraulic fluid.
2-4
– JLG Lift –
3121273
SECTION 2 - GENERAL
2.3 SERVICE AND GUIDELINES
Component Disassembly and Reassembly
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this book.
Safety and Workmanship
When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially
disassemble or assemble one part, then start on another.
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
those recommended, without obtaining proper approval.
Pressure-Fit Parts
Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of weight. Never attempt to move heavy
parts without the aid of a mechanical device. Do not allow
heavy objects to rest in an unstable position. When raising
a portion of the equipment, ensure that adequate support
is provided.
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.
Bearings
1. When a bearing is removed, cover it to keep out dirt
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed
air can be used but do not spin the bearing.
Cleanliness
1. The most important single item in preserving the
long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.
2. At any time when air, fuel, or oil lines are disconnected, clean adjacent areas as well as the openings and fittings themselves. As soon as a line or
component is disconnected, cap or cover all openings to prevent entry of foreign matter.
3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings
are unobstructed. Cover all parts to keep them
clean. Be sure all parts are clean before they are
installed. New parts should remain in their containers until they are ready to be used.
Components Removal and Installation
2. Discard bearings if the races and balls (or rollers)
are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light
coat of oil and wrap it in clean (waxed) paper. Do not
unwrap reusable or new bearings until they are
ready to install.
4. Lubricate new or used serviceable bearings before
installation. When pressing a bearing into a retainer
or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the
inner race.
Gaskets
Check that holes in gaskets align with openings in the
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material
and thickness. Be sure to cut holes in the right location, as
blank gaskets can cause serious system damage.
Bolt Usage and Torque Application
1. Use adjustable lifting devices, whenever possible, if
mechanical assistance is required. All slings (chains,
cables, etc.) should be parallel to each other and as
near perpendicular as possible to top of part being
lifted.
2. Should it be necessary to remove a component on
an angle, keep in mind that the capacity of an eyebolt or similar bracket lessens, as the angle between
the supporting structure and the component
becomes less than 90°.
3. If a part resists removal, check to see whether all
nuts, bolts, cables, brackets, wiring, etc., have been
removed and that no adjacent parts are interfering.
3121273
– JLG Lift –
1. Self locking fasteners, such as nylon insert and
thread deforming locknuts, are not intended to be
reinstalled after removal. Always use new replacement hardware when installing locking fasteners.
2. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
3. Unless specific torque requirements are given within
the text, standard torque values should be used on
2-5
SECTION 2 - GENERAL
heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See
Torque Chart Section 1.)
Hydraulic Lines and Electrical Wiring
2.4 LUBRICATION AND INFORMATION
Hydraulic System
1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various
means, e.g., using inadequate hydraulic oil, allowing
moisture, grease, filings, sealing components, sand,
etc., to enter when performing maintenance, or by
permitting the pump to cavitate due to insufficient
quantity of oil in supply tube.
Clearly mark or tag hydraulic lines and electrical wiring, as
well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
reinstalled.
Hydraulic System
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain
and flush the entire system.
2. The design and manufacturing tolerances of the
component working parts are very close, therefore,
even the smallest amount of dirt or foreign matter
entering a system can cause wear or damage to the
components and generally results in faulty operation. Every precaution must be taken to keep
hydraulic oil clean, including reserve oil in storage.
Hydraulic system filters should be checked,
cleaned, and/or replaced as necessary, at the specified intervals required. Always examine filters for evidence of metal particles.
2. Disassemble and reassemble parts on a clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
Lubrication
Service applicable components with the amount, type,
and grade of lubricant recommended in this manual, at
the specified intervals. When recommended lubricants are
not available, consult your local supplier for an equivalent
that meets or exceeds the specifications listed.
3. Cloudy oils indicate a high moisture content which
permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be
drained, flushed, and refilled with clean oil.
Battery
Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
cleaning, thoroughly dry battery and coat terminals with
an anti corrosion compound.
4. It is not advisable to mix oils of different brands or
types, as they may not contain the same required
additives or be of comparable viscosities. Good
grade mineral oils, with viscosities suited to the
ambient temperatures in which the machine is operating, are recommended for use.
NOTE: Metal particles may appear in the oil or filters of new
machines due to the wear-in of meshing components.
Hydraulic Oil
1. Refer to Section 1 for recommendations for viscosity
ranges.
2. JLG recommends DTE10 or Excel 15 hydraulic oil,
which has an SAE viscosity of 10W-30 and a viscosity index of 152.
NOTE: Start-up of hydraulic system with oil temperatures
below -15°F (-26°C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low
density, electrical heater to a minimum temperature
of -15°F (-26°C).
2-6
– JLG Lift –
3121273
SECTION 2 - GENERAL
Changing Hydraulic Oil
2.5 CYLINDER DRIFT TEST
1. Use of any of the recommended crankcase or
hydraulic oils eliminates the need for changing the
oil on a regular basis. However, filter elements must
be changed annually unless operating in extreme
conditions. If it is necessary to change the oil, use
only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain
the same type of oil supplied with the machine, consult local supplier for assistance in selecting the
proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.
Maximum acceptable cylinder drift is to be measured
using the following methods.
Platform Drift
Measure the drift of the platform to the ground. Fully elevate the platform. Maximum allowable drift is 2 inches (5
cm) in 10 minutes. If the machine does not pass this test,
proceed with the following.
Cylinder Drift
Table 2-3. Cylinder Drift
2. Use every precaution to keep the hydraulic oil clean.
If the oil must be poured from the original container
into another, be sure to clean all possible contaminants from the service container. Always replace the
filter and clean magnet any time the system oil is
changed.
3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection
of all hydraulic components, lines, fittings, etc., as
well as a functional check of each system, before
placing the machine back in service.
NOTE: Refer to section 4 for oil checking and oil changing
procedure.
Lubrication Specifications
Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however,
multi-purpose greases usually have the qualities which
meet a variety of single purpose grease requirements.
Should any question arise, regarding the use of greases in
maintenance stock, consult your local supplier for evaluation. Refer to Section 1, Table 1-11, Lubrication Specifications for an explanation of the lubricant key designations.
3121273
Cylinder Bore Diameter
Max. Acceptable Drift
in 10 Minutes
inches
mm
inches
mm
3
76.2
0.026
0.66
3.5
89
0.019
0.48
4
101.6
0.015
0.38
5
127
0.009
0.22
6
152.4
0.006
0.15
7
177.8
0.005
0.13
Drift is to be measured at the cylinder rod with a calibrated
dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.
The cylinder must have the normal load, which is the normal platform load applied.
If the cylinder passes this test, it is acceptable.
NOTE: This information is based on 6 drops per minute cylinder leakage.
– JLG Lift –
2-7
SECTION 2 - GENERAL
2.6 PINS AND COMPOSITE BEARING REPAIR
GUIDELINES
Filament wound bearings.
1. Pinned joints should be disassembled
inspected if the following occurs:
3. Pins should be replaced if any of the following is
observed (pin should be properly cleaned prior to
inspection):
a. Detectable wear in the bearing area.
and
b. Flaking, pealing, scoring, or scratches on the pin
surface.
c. Rusting of the pin in the bearing area.
a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any
of the following is observed:
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
c. Bearings that have moved or spun in their housing.
d. Debris embedded in liner surface.
4. Re-assembly of pinned joints using filament wound
bearings.
a. Housing should be blown out to remove all dirt
and debris, bearings and bearing housings must
be free of all contamination.
b. Bearing / pins should be cleaned with a solvent
to remove all grease and oil...filament wound
bearings are dry joints and should not be lubricated.
c. Pins should be inspected to ensure it is free of
burrs, nicks, and scratches which would damage the bearing during installation and operation.
2-8
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
SECTION 3. CHASSIS & SCISSOR ARMS
3.1 MACHINE COMPONENT COVERS
2
2
1
3
4
Figure 3-1. Machine Frame Covers (All Models)
1. Left Side (Hydraulic) Frame Cover
2. Side Cover Release Handles
3121273
3. Right Side (Batteries) Frame Cover
4. Rear (Drive Motor/Charger/Control Module) Cover
– JLG Lift –
3-1
SECTION 3 - CHASSIS & SCISSOR ARMS
3.2 BATTERY REMOVAL/MAINTENANCE
NOTICE
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE
THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE
WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT
YOUR LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE
DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND
MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE
ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES
NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES
ARISING FROM THE USE OF NON APPROVED BATTERIES.
3
2
1
3
Figure 3-2. Battery Location and Hold Down Bar
(All Models)
Battery Quick-Disconnect (If Equipped)
Machines equipped with the battery
quick-disconnect allow all machine
power to be easily disconnected at
the batteries without removing battery cables from the battery posts. To disconnect power,
locate the RED quick-disconnect connector on top of the
batteries inside the battery compartment and pull halves
apart.
1706740A
CAUTION
BEFORE BATTERY REMOVAL CAN BEGIN, ENSURE THAT THE (+)
AND (—) BATTERY CABLES HAVE BEEN PROPERLY DISCONNECTED.
1. The machine batteries are located inside the
machine right side cover, remove the cover.
2. Once the battery door is removed from the machine,
battery replacement/maintenance can begin.
3. To remove one or more batteries from the machine,
the battery hold down bar will need to be removed.
(See Figure 3-2.)
4. Remove the (2) nuts and washers from each holddown anchor at the ends of the hold-down bar.
Remove the bar and lay aside.
5. After battery removal and installation re-install the
battery hold down bar.
6. After any maintenance on the batteries or replacement of the batteries is complete, reconnect the batteries and check for proper operation.
7. Re-install the machine right side cover.
3-2
1. Batteries (4 - 6V)
2. Hold-Down Bar
3. Hold-Down Bar Fasteners
Battery Maintenance and Safety Practices
CAUTION
ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT
WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND
EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY
BATTERY ACID SPILLS WITH BAKING SODA AND WATER.
BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO OPEN FLAMES, SPARKS OR LIGHTED TOBACCO
PRODUCTS IN THE AREA WHILE CHARGING BATTERIES.
CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA.
ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING
WATER TO THE BATTERIES, A NON-METALLIC CONTAINER AND/
OR FUNNEL MUST BE USED.
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS
BATTERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Check the electrolyte level of the batteries often, adding
only distilled water when required. When fully charged,
battery fluid level should be 1/8" below vent tubes. (See
Figure 3-3.).
• DO NOT fill to bottom of vent tubes.
• DO NOT allow fluid level to go below the top of the
plates when charging or operating.
• Clean terminal connections if they become corroded.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
BATTERY
FILLER CAP
1
FLUID LEVEL OF FULLY
CHARGED BATTERY
VENT TUBE
1/8 "
PLATES
2
Figure 3-3. Battery Fluid Level
3
1. AC Voltage - Input Cable
2. Charger Interlock Cable
3.3 BATTERY CHARGER
3. DC Power Cable to Batteries
Figure 3-4. Battery Charger
The Battery Charger is located at the rear of the machine
under the rear access cover, remove the cover to gain
access to the charger.
Table 3-1. Battery Charger Specs
BATTERY CHARGER
OUTPUT
Nominal DC Output Voltage
Maximum DC Output Voltage
Maximum DC Output Current
Maximum Interlock Current
INPUT
AC Input Voltage
Nominal AC Input Voltage
AC Input Frequency
Maximum AC Input Current
OPERATION
Charging Indicator
Battery Fault Indicator
100% Charge Indicator
Charger Fault Indicator
PROTECTION
Output Reverse Polarity
Battery Charger Location
Output Short Circuit
AC Overload
DC Overload
MECHANICAL
Operating Temperature
Housing
3121273
– JLG Lift –
SPECIFICATION
24V
33.6V
25A
1A
85-265VAC
120VAC - 230VAC RMS
45-65 HZ
12A [email protected]
Yellow LED
Flashing Yellow LED
Green LED
Red LED
Electronic Protection - Automatic
Reset
Electronic Protection - Automatic
Reset
Current Limited
Current Limited
–22° F to +122°F
(–30°C to +50°C)
Shock and Water Resistant Aluminum
3-3
SECTION 3 - CHASSIS & SCISSOR ARMS
3.4 BATTERY CHARGING
NOTE:
NOTE:
Be sure that machine is parked in a well ventilated
area before charging begins.
If the charger is left plugged in, the charger will
automatically restart a complete charge cycle if the
batteries voltage drops below a minimum voltage or
30 days has elapsed.
CAUTION
ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND
GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR
MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF
OUTPUT CONNECTOR OR NON-INSULATED BATTERY TERMINAL.
DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW,
BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY.
ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE
MAKING OR BREAKING THE (POS/NEG) CONNECTIONS TO THE
BATTERY.
DO NOT OPEN OR DISASSEMBLE CHARGER.
GREEN
3. When powered up the charger will go through a short
LED indicator self-test. The battery charger LED indicators on the charger (Figure 3-5.), will flash in sequence
for two seconds. These LED indicators can be viewed
through the opening on the rear panel where the charger AC cord is accessed.
AMBER (ON) Battery Charging
AMBER
AMBER (FLASHING) Battery/System
Problem
RED
RED (FLASHING) Charger Problem
Figure 3-5. Charger Decal LED Indicators
1. The battery charger AC input plug is located in an
opening on the panel at the lower rear of the machine.
2. Connect the charger AC input plug to a grounded outlet using a 3 wire heavy duty extension cord. (See
Table 3-1, Battery Charger Specs, for battery charger
AC input specifications.)
GREEN (ON) Battery Fully Charged
LEDS
Battery Charger Fault (LED Flash)
If a fault has occurred during battery charging, the (AMBER
or RED) LED on the charger LED indicator will flash corresponding to the fault which occurred. Refer to Table 3-2 following for the flash codes and their meaning.
If required, further general and troubleshooting information
about the battery charger can be found in the charger manufacturers Owner’s Guide.
4. The batteries are fully charged when the green light on
the battery charger status panel is illuminated.
Table 3-2. Battery Charger Fault (LED Flash)
FLASHING LED
FAULT
REMEDY
AMBER
Battery High Voltage
Upon battery voltage >2.5V per cell @ startup, charger shall flash amber LED and not allow
charging - Battery or System problem.
AMBER
Battery Low Voltage
Upon battery voltage <0.17V per cell @ startup, charger shall flash amber LED and not
allow charging - Battery or System problem.
AMBER
Failed Trickle to min V
Should battery fail to reach 1.75V per cell charge shall flash an amber LED until charger is
power cycled - Battery or System problem.
RED
Charger Internal Fault
Signals a hardware fault of the charger and shall indicate flashing red LED.
3-4
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Battery Charger Maintenance
Battery Charger Troubleshooting
No Lights at all
USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC
BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY
AND DAMAGE.
LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION. KEEP SPARKS,
FLAMES, AND SMOKING MATERIALS AWAY FROM BATTERIES.
PROVIDE ADEQUATE VENTILATION DURING CHARGING. NEVER
CHARGE A FROZEN BATTERY.
STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND
REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.
CAUTION
ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND
GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR
MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF
OUTPUT CONNECTOR OR NON-INSULATED BATTERY TERMINAL.
DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW,
BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY.
ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE
MAKING OR BREAKING THE (POS/NEG) CONNECTIONS TO THE
BATTERY.
DO NOT OPEN OR DISASSEMBLE CHARGER.
No Lights at all indicate that AC power to the charger is
not connected or that the AC voltage is too low. It could
also indicate an internal failure in the charger.
1. Check the connections to AC power. Check for AC
voltage between 90 and 260 VAC at the charger.
2. If the AC voltage is verified to be correct at the connection to the charger, and the charger still displays
no lights at all, return the charger for service.
FAULT LED Flashing
The Fault LED flashes to indicate the micro-controller
inside the battery charger has detected a fault. The fault
detected is indicated by the number of flashes. Count the
number of flashes to determine the fault.
With any battery system, the most common problem will
be a faulty battery connection. Because of the high likelihood of a battery connection problem, it is always worthwhile to confirm that all connections are good before
checking for any other problems.
[1 Flash] - High Battery Voltage
1. Indicates a high battery voltage. Check that the battery charger voltage is consistent with the battery
pack voltage. The first two digits of the four digit
model name indicate the battery voltage the charger
supports.
2. Check for wiring errors.
3. This fault will automatically clear and the charger will
restart charging when this problem is removed.
1. For flooded lead-acid batteries, regularly check
water levels of each battery cell after charging and
add distilled water as required to level specified by
battery manufacturer. Follow the safety instructions
recommended by the battery manufacturer.
4. High battery voltage could also occur if there is
another source charging the battery. Disconnect any
other sources during charging.
2. Make sure charger connections to battery terminals
are tight and clean.
3. Do not expose charger to oil or to direct heavy water
spraying when cleaning vehicle.
5. If this problem does not clear after the battery voltage is confirmed to be less than 2.4V per cell, return
the charger for service.
[2 Flashes] - Low Battery Voltage
1. Indicates either a battery failure, no battery connected, or a lower than expected battery voltage.
Check the battery and battery connections.
2. Check the nominal battery voltage. The first two digits of the four digit model name indicate the battery
voltage the charger supports. Confirm that a nominal battery voltage is the same as the charger voltage.
3. This fault will clear automatically when the low battery voltage problem is rectified.
3121273
– JLG Lift –
3-5
SECTION 3 - CHASSIS & SCISSOR ARMS
4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and
all connections are good, return the charger for service.
[5 Flashes] - Over Temperature
This fault indicates the charger has become too hot during
operation. Though not damaging to the charger, charge
time will be extended significantly.
[3 Flashes] - Charge Time-out
1. This fault indication will not clear automatically, but
the charger will restart charging automatically when
the temperature drops. The fault indication must be
cleared manually by unplugging the AC, waiting 30
seconds and reconnecting the AC power.
Indicates the battery failed to charge within the allowed
time. This could occur if the battery is of larger capacity
than the algorithm is intended for. In unusual cases it
could mean charger output is reduced due to high ambient temperature. It can also occur if the battery is damaged, old, or in poor condition.
2. If possible, move the machine to a cooler location.
3. Confirm that dirt or mud is not blocking the cooling
fins of the charger. Clean the charger. Rinse the
charger with a low pressure hose if required. Do no
use high pressure. Do not us a pressure washer.
1. Check the battery for damage such as shorted cells
and insufficient water. Try the charger on a good battery.
2. If the same fault occurs on a good battery, check the
connections on the battery and connection to AC,
and the AC voltage itself.
3. Confirm that the nominal battery pack voltage is the
same as the battery charger voltage.
4. This fault must be cleared manually by unplugging
the AC, waiting 30 seconds and reconnecting the
AC power.
[6 Flashes] - Over Load/Over Temperature
This fault indicates that the batteries will not accept charge
current, or an internal fault has been detected in the charger. This fault will nearly always be set within the first 30
seconds of operation. If it occurs after the charger has
started charging normally, complete the following steps.
5. If a charger displays this fault on a battery pack, and
the pack is of questionable status, reset the charger
by disconnecting AC for 30 seconds, and then
reconnect the AC to start a new charge cycle. After a
few charge cycles, this problem could stop occurring as the pack "recovers."
[4 Flashes] - Check Battery
This fault indicates the battery pack could not be trickle
charged up to the minimum level required for the normal
charge cycle to be started.
1. Check that none of the battery pack connections
between modules are reversed or incorrectly connected.
2. Check that one or more cells in the battery are not
shorted.
3. Confirm that the nominal battery pack voltage is the
same as the battery charger voltage.
1. Try to clear the fault by unplugging the AC, waiting
30 seconds and reconnecting the ac power.
2. Check all battery connections. Look for a high resistance connection.The most likely reason for this fault
is a fault in the battery such as a bad battery connection, an open cell, or insufficient water.
3. This fault will occur if an internal fuse inside the charger blows. If the green wire is shorted to ground
even momentarily, this fuse will blow. To check the
fuse, measure with an ohmmeter between the green
and red wires with the AC disconnected. If a short
circuit is not measured, the fuse has blown. Return
unit to a service depot to have this fuse replaced.
4. If this fault occurs after battery charging has started,
confirm that AC power was not interrupted and that
all battery connections are good.
5. If all battery connections are good, an internal fault
has been detected and the charger must be brought
to a qualified service depot.
4. Try the charger on a good battery.
5. If this fault occurs, the battery is likely in poor condition. Try to recover the pack with a charger that can
charge the individual cells - such as an automotive
charger. Be sure to set this charger to the appropriate voltage - 6V per 6V battery, 12V per 12V string/
battery.
3-6
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Excessive Battery Watering Requirements or
Strong Sulphur (Rotten Egg) Smell
These symptoms indicate over-charging or high battery
temperature. These symptoms are unlikely to be caused
by too high a charge current since the maximum charge
current of the charger will be small compared to even a
moderately sized battery pack. The most likely cause for
this problem is incorrect charge algorithm setting and/or
high ambient temperatures.
1. Confirm that the battery pack is not too small - usually > 50Ah.
3.5 DC TO AC INVERTER (IF EQUIPPED)
Inverter Location on Machine
The inverter is located to the right rear of the machine in
the battery side compartment on all RS Scissor models.
11
9
1
2. Confirm that the nominal battery voltage matches
the charger output voltage.
3. If the output voltage of the charger seems excessive,
return the charger for service. Contact JLG to get the
expected battery voltage settings for the charger in
question. Be sure to have the charger’s serial number and charge algorithm setting available when
calling.
2
3
10
8
4
6
5
7
1. DC to AC Inverter
2. Overload LED Indicator
3. Inverter Internal ON/OFF
Switch - Set to ON from
factory
4. Inverter VAC Output Cord
5. To Inverter ON/OFF Switch
at Ground Control Panel
6. Inverter Power Relay
7. From VDC Battery POS (+)
8. To VDC Inverter POS (+)
Input
9. External DC 15A Fuse(s)*
10. From VDC Battery NEG (–)*
11. Inverter Cooling Fan*
Figure 3-6. DC to AC Inverter Components
* Items located under shield.
1
100114
3010A
OFF
INVE
ON
RTE
R
2
1. Inverter On/Off Switch
2. Ground Control Panel
Figure 3-7. Inverter On/Off Switch Location
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3-7
SECTION 3 - CHASSIS & SCISSOR ARMS
Inverter Operation
Poor or week battery condition.
DANGER
DANGER OF SHOCK OR ELECTROCUTION - TREAT INVERTER
OUTPUT THE SAME AS COMMERCIAL AC POWER.
If servicing remove any frame covers required to gain
access to the inverter unit.
1. Turn ON the inverter at the ground control station
inverter ON/OFF switch. (Make certain the overload
LED is not lit on the inverter.)
Recharge or replace battery(s).
Inadequate power being delivered Use lower gauge (heavier) cable.
to the inverter or excessive voltKeep cable length as short as posage drop.
sible.
Inverter Specifications
Name
Description
Input
24V (20-30V) DC
Output
110V AC
Output Waveform
Modified Sine Wave (MSW)
Continuous Power
900 Watt
Surge Power
1800 Watt
Efficiency
Aprox. 90%
4. Turn ON the inverter.
Power Switch
ON/OFF Control
5. Turn on the appliance (tool).
Power Switch OFF
<0.5 ADC
6. Plug in any additional appliances (tools).
Battery Low Alarm
21 ± 0.5 V DC
Battery Low Shutdown
20 ± 0.5 V DC
AC Output Sockets
(2) North American Standard 15 Amps
External Fuses
3 x 15 Amp (Automotive Spade Type)
Dimensions
5 in. (W) x 2.75 in. (H) x 10.5 in. (D)
(12,7cm x 7cm x 26,67cm)
Net Weight
6 lbs. (2,72 Kg)
2. Turn OFF the inverter. The overload LED may briefly
"blink" and the audible alarm may also sound a short
"chirp". This is normal.
3. When you have confirmed that the appliance (tool)
to be operated is turned off, plug the appliance cord
into the inverter AC output cord.
NOTE: The audible alarm may make a momentary "chirp"
when the inverter is turned OFF. This same alarm
may also sound when the inverter is being connected to or disconnected from the 24 volt battery
bank.
Inverter Troubleshooting
Problem: No Input Voltage
Poor contact with battery terminals.
Shut down the inverter and disconnect battery power. Clean terminals thoroughly and reconnect.
Blown DC battery fuse(s).
Turn off inverter. Replace fuse(s)
with the same type and rating.
NOTE: All specifications are typical at nominal line, half
load, and 77° F (25° C) unless otherwise specified. Specifications are subject to change without
notice.
Problem: Inverter Is In Shut Down
Battery voltage is below 20 volts.
Charge or replace battery.
Inverter is too hot (thermal shut
down mode). Overload LED indicator on inverter is lit ORANGE/
RED.
Allow inverter to cool. Check for
adequate ventilation. Reduce the
load on the inverter to rated continuous power.
Unit may be defective.
See warranty and call customer
service.
Problem: Low Battery Alarm On All The Time
Input voltage below 21 volts buzzing sound.
3-8
Keep input voltage above 21 volts
to maintain regulation.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
3.6 GROUND CONTROL STATION
1
NOTICE
DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE
ATTEMPTING TO REMOVE THE GROUND CONTROL PANEL OR
SERVICING THE ELECTRICAL SYSTEM. FAILURE TO DO SO
COULD CAUSE DAMAGE TO THE MACHINES ELECTRICAL COMPONENTS.
2
3
Components Location
1
2
3
1001132360A
1
5
4
Figure 3-9. Ground Control Station Removal
1. Attach Screws and
Washers
1001146979A
2. Brake Release Switch
3. Power Relay
Installation
1. Check that all components are installed into the
panel and connected to the wiring harness.
Figure 3-8. Ground Control Station Component Location
(All Models)
1. Platform Lift/Lower Switch
2. Key Selector Switch
3. Ground Emergency StopButton
2. Insert the panel into position on the machine and
align the mounting holes in the panel with the
mounting holes in the frame.
3. Attach using the (4) mounting screws and washers.
4. MDI - Indicator
5. Overload Indicator (If
Equipped)
4. Reconnect the main power at the batteries, power
machine up and check machine operation.
5. Install machine side cover.
Removal (All Models)
1. Disconnect main power at the batteries.
2. Remove the machine side cover on the left side of
the machine (ground control station/pump side).
3. Remove the (4) screws and washers attaching the
ground control panel to the frame.
4. When panel is released, rotate and position to
unplug or disconnect the desired connectors and
components on the back of the panel.
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3-9
SECTION 3 - CHASSIS & SCISSOR ARMS
3.7 MAIN POWER CONTACTOR RELAY
3.8 ELEVATION LIMIT SWITCH ASSEMBLY
The main power relay is located under the rear cover next
to the battery charger.
Location
NOTICE
DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE
ATTEMPTING TO REMOVE THE MAIN POWER CONTACTOR
RELAY OR SERVICING THE ELECTRICAL SYSTEM. FAILURE TO
DO SO COULD CAUSE DAMAGE TO THE MACHINES ELECTRICAL COMPONENTS.
1
1932RS/6RS
3
2
4
1
1
3248RS/10RS
Figure 3-11. Elevation Limit Switch Location
1. Limit Switch
Figure 3-10. Main Power Contactor Relay Location (All
Models)
1. Main Power Contactor Relay
2. To X14 Harness Connector ( Power Relay and Control Module)
Installation
3. To Battery (BT03+)
4. To Control Module (X09 B+F1)
4
3
2
1
4
1932RS/6RS
Figure 3-12. Elevation Limit Switch Mounting
1. Switch Assembly
2. Scissor Arm Cam
3-10
– JLG Lift –
3. Switch Lever Arm
4. Mounting Hardware
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Models - 3248RS/10RS
(See Figure 3-12. and Figure 3-14.)
1. With the roller lever arm set at 30° from vertical,
attach switch to frame mount using the mounting
hardware as shown.
4
2
3
2. With the scissor arms in the stowed position, adjust
the switch up or down in the vertical mounting slots
in the frame, so that the roller contacts both surfaces
of the scissor arm cam, then tighten.
Switch Notes (All Models):
•
•
•
•
The lever arm angle is to be pre-set to 30° from vertical.
Switch Reset = 13°
Switch Trip = 25°
Drive speed to be reduced before:
1932RS/6RS - 5 ft. 9 in. (1.75 m) platform height
3248RS/10Rs - 7 ft. 4 in. (2.25 m) platform height.
• The switch is to be in the trip position (25° - 70°) when
the machine platform height is above:
1932RS/6RS - 5 ft. 9 in. (1.75 m) platform height
3248RS/10Rs - 7 ft. 4 in. (2.25 m) platform height.
• The switch is to be in the reset position (0° - 13°) when
the machine is stowed.
1
4
3248RS/10RS
Figure 3-12. Elevation Limit Switch Mounting
1. Switch Assembly
2. Scissor Arm Cam
3. Switch Lever Arm
4. Mounting Hardware
Switch Adjustment
Models - 1932RS/6RS (See Figure 3-12. and Figure 3-13.)
1. With the roller lever arm set at 30° from vertical,
attach switch to frame mount using the mounting
hardware as shown.
2. With the scissor arms in the stowed position, adjust
the switch fore or aft in the horizontal mounting slots
in the frame, so that the roller contacts both surfaces
of the scissor arm cam, then tighten.
0°
(30°)
7 ft. 4 in. 31 ft. 11 in. -
18 ft. 11 in. -
(30•‹)
0•‹
5 ft. 9 in. -
Figure 3-14. 3248RS/10RS - Elevation Limit Switch
Adjustment
Figure 3-13. 1932RS/6RS - Elevation Limit Switch
Adjustment
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3-11
SECTION 3 - CHASSIS & SCISSOR ARMS
1932RS/6RS
3248RS/10RS
1. Platform Gate
2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway)
3. Platform Entry Ladder
1. Elevation Limit Switch Location
2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway)
3. Platform Entry Ladder
Figure 3-15. LSS - Scissor Arm Angle Sensor - Location Rear of Machine
3.9 LSS - SCISSOR ARM ANGLE SENSOR LOCATION
RS Scissor machines equipped with the Load Sensing
System (LSS) are equipped with a separate scissor arm
angle sensor switch besides the standard elevation limit
switch. This switch communicates with the power control
module in tandem with the lift cylinder pressure switches
to accurately determine platform load for any given platform height.
3.10 TILT SENSOR REPLACEMENT
The tilt sensor is located inside the left side machine cover
(ground control station side).
There is no adjustment to the angle sensor switch and
arm assembly, just install in the proper orientation.
3
See the LSS Service Manual (3124288) for complete service information for the RS Scissors - LSS system.
1
2
3
Figure 3-16. Tilt Sensor Installation
1. Tilt Sensor
2. Locating Hole
3-12
– JLG Lift –
3. Mounting Hardware
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Tilt Sensor Removal
1. Disconnect power at the batteries.
2. Remove the machine left side cover (ground control
station side).
3. Unplug the tilt sensor 3-wire harness connector.
4. Remove the two (2) mounting nuts, bolts and washers attaching the sensor to the base frame.
Tilt Sensor Installation
1. Before mounting the tilt sensor to the base frame,
check the mating surfaces of the sensor and the
mounting plate, be certain there is no debris or burrs
to prevent a flush mount.
1
2
2. When mounting the tilt sensor back into the base
frame, align the mounting pin on the bottom of the
sensor with the hole in the mounting plate on the
base frame (item 2 - Figure 3-16.).
3. Secure to the base frame with the mounting hardware.
4. Adjust per instructions following.
Figure 3-17. Tilt Sensor Switch - Bubble Level
1. Level
2. Not Level
Tilt Sensor Switch - Adjustment Procedure
NOTICE
2
PERFORM TILT SWITCH LEVELING PROCEDURE A MINIMUM OF
EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND
ADJUSTMENT OF SWITCH.
1. Park the machine on a smooth, firm, and level surface. Be sure it is as level as possible.
NOTE: Ensure switch mounting is level and securely
attached.
1
1
2. Tighten the three flange nuts with a socket wrench.
Each nut should be tightened approximately onequarter of its spring’s travel.
3. Using bubble level on top of indicator, Tighten or
loosen the three flange nuts until indicator is level.
4. Individually push down on one corner at a time.
There should be enough travel to cause the indicator to trip. If the indicator does not trip in all three
tests, the flange nuts have been tightened too far.
1
Figure 3-18. Tilt Sensor Switch - Adjustment
1. Flange Adjusting Nuts
2. Bubble Level
3121273
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3-13
SECTION 3 - CHASSIS & SCISSOR ARMS
3.11 TRACTION SYSTEM
force. On level terrain, the Power Module will apply as little
as 14A to the fields for higher rotational speeds and better
electrical efficiency.
Theory of Operation
The Field Windings also provide direction reversal for traction. When driving forward, MOSFET switches 1 and 4
turn On to apply positive potential to F2 and ground
potential to F1. In reverse, MOSFET switches 2 and 3 turn
On to apply positive potential to F1 and ground potential
to F2. Theses switches are pulse-width modulated by the
Power Module to maintain a fixed relationship between
Field and Armature Current (also called the Field Map).
The armatures (rotating windings) of the separatelyexcited drive motors are wired in parallel to the Power
Module's -T and +B terminals (ZAPI) . The +B Terminal is
always at the same voltage as the +B (Battery Voltage
when the Line Contactor is closed) and allows the module
to measure current with the internal shunt (extremely low
impedance). The -T Terminal is pulled to Ground by the
Armature Switch MOSFET's (connected to -B Terminal).
Since the two 24V Armatures are wired in parallel, the
drive motors will attempt to rotate at the same speed
under all conditions. If one wheel slips, the wheel with
traction will demand more current as it slows slightly
(under load). In this manner, the system provides effective
traction control with no added complexity.
To provide variable speed control, the Armature MOSFET
transistors switch On and Off at high frequencies (pulsewidth modulation; 16kHz). The Duty Cycle (On & Off time)
is varied to control the voltage applied to the Armatures.
When the MOSFET's spend 50% of the period On and
50% Off, approximately ½ of the available Battery Voltage
will be applied to the Armatures. Similarly, the MOSFET
are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the Armatures (as in Driving at Full
Speed).
It is essential that the same amount of field current is supplied to both drive motors, or one wheel will pull the vehicle (motor overheating and excessive tire wear would
result). The vehicle uses 12V field windings wired in series
to ensure proper distribution of current.
Instead of permanent magnets, the separately-excited
drive motors use electro-magnets (called Field Windings)
located in the stator (non-rotating) portion of the motor.
Field windings are preferable to permanent magnets
because the Power Module can adjust the stator's magnetism for optimum motor performance. When climbing a
grade a low speeds, the Power Module may apply as
much as 40A to the field windings for more electro-motive
Two electrically-released parking brakes are mounted to
the rear drive motors. The Ground Module energizes the
two 24V electro-magnets when appropriate to allow vehicle motion. The parking brakes can be released electrically for emergency vehicle towing.
24V
Line Contactor
+
+
+
Left
Armature
+
Right
Armature
BF1
BF2
T
+B
+
+
Right Field Winding
B
F2
F1
Armature
MOSFET
Field
MOSFETS
Shunt
Left Field Winding
Power Module
Figure 3-19. Traction Control Circuit - ZAPI Power Module
3-14
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3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Common Traction System Difficulties
1. Ground Module Interlocks
There are a variety of interlocks that prevent Drive
due to system events. Before investigating Traction
System issues, examine the JLG Analyzer's HELP
Menu while attempting to Drive from Platform Mode.
Refer to the Section 5 for explanation of the JLG
Analyzer Help Messages.
2. Power Module Diagnostic Issues
5. Open-Circuit Motor Field
The Power Module executes a self-test during every
power-up to ensure proper functionality. If a Diagnostic Issue is detected, the Power Module will not
energize the Main Power Contactor. Instead, it will
flash the Green LED, please refer to ZAPI Power
Module Electrical Evaluation - page 3-18.
3. Open-Circuit Motor Armature
This issue will allow the vehicle to drive, but one
motor will handle the entire traction load. Motor
overheating and excessive tire wear will result, along
with a lack of traction control.
This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform
stowed). Under DIAGNOSTICS - TRACTION, the
JLG Analyzer's ARM CUR display (Armature Current
Reading) should be less than 50A. One wheel will
rotate at full speed, while the other will not rotate at
all. The Power Module's self-diagnostics cannot
detect this fault unless both armatures are open-circuit.
To find the source of the difficulty, disconnect main
power at the batteries and investigate the wiring
pathways from the Power Controller's M1 and M2
terminals to the armature on the motor that does not
rotate. Investigate for issues like improper crimps,
loose terminals, and corrosion.
4. Short-Circuit Motor Armature
This issue will allow the vehicle to drive very slowly
or not at all. Rapid motor overheating (one motor)
will result.
This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform
stowed). Under DIAGNOSTICS - TRACTION, the
JLG Analyzer's ARM CUR display (Armature Current
Reading) will hover around 350A. The FLD CUR display (Field Current Reading) will hover around 40A.
Neither wheel will rotate at normal speed, but it will
be possible to rotate the drive wheel by hand. The
Power Module's self-diagnostics cannot detect this
fault since the situation appears identical to climbing
a steep grade.
3121273
To find the source of the difficulty, disconnect main
power at the batteries and disconnect the Armature
Wiring (heavy red and black conductors) from the
suspected drive motor leading to the Power Module's M1 and M2 Terminals. Re-test the traction function. If the remaining drive motor is able to reach full
speed (and Armature Current is less than 50A), the
drive motor that has been disconnected is fault.
Investigate for crushed and burned cables. Check if
the drive motor smells burned.
– JLG Lift –
This issue will allow the vehicle to drive very slowly
or not at all. Rapid motor overheating (both motors)
will result.
This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform
stowed). Under DIAGNOSTICS - TRACTION, the
JLG Analyzer's ARM CUR display (Armature Current
Reading) will hover around 350A. The FLD CUR display (Field Current Reading) will be erratic or low
(less than 10A). Neither wheel will rotate at normal
speed, but it will be possible to rotate the drive
wheel by hand.
To find the source of the difficulty, pull the Main Battery Disconnect and disconnect the Field Wiring
(two blue wires leading to F1 and F2 Terminals) from
the Power Module. Using a voltmeter set for resistance scale (Ohms), investigate if there is a short-circuit (less than 5 Ohms) between the two blue wires
(this is normal). If not, investigate for improper
crimps, burned cables, damaged cables, or damaged field windings.
6. Short-Circuit Brake Release
This issue will not allow the vehicle to drive. Rapid
motor overheating (both motors) will result. Continued attempts to drive the vehicle may result in armature damage.
This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform
stowed). Under DIAGNOSTICS - TRACTION, the
JLG Analyzer's ARM CUR display (Armature Current
Reading) will hover around 350A. The FLD CUR display (Field Current Reading) will hover around 40A.
Neither wheel will rotate, and it will be impossible to
rotate either drive wheel by hand. The Ground Module cannot detect this fault during power-up or selftest since energizing the brakes could pose a hazard. However, it may detect this issue during Drive
(investigate using JLG Analyzer).
3-15
SECTION 3 - CHASSIS & SCISSOR ARMS
3.12 POWER CONTROL MODULE - ZAPI
NOTE: The power module for the RS Scissors is installed on
the machine in the upside down position. This is the
correct mounting position.
Table 3-3. ZAPI Power Module Specifications
Operating Voltage ( B+)
14.5 to 40 VDC
Maximum Current Limits:
Armature
Field
Pump
Integral Main Fuse
5. When installing the power module, be sure that the
terminals are oriented as shown in Figure 3-20.
300 A
40 A
180 A
250 A
6. After installing the new power module, begin connecting the wire connectors/cables to the module.
(See Table 3-4 and Figure 3-21.)
150 mA
Temperature Range:
Operating
Storage
Thermal Limit
7. Torque all terminal bolts to torque specifications as
shown on the front of the module. Overtightening
could damage the module.
-40°C to 75°C
-40°C to 125°C
75°C to 90°C
8. After all connections to the power module are made,
the batteries can be reconnected.
Switching Frequency
16 kHz
9. Power up machine and check for normal machine
operation.
Standby Current
The power module is located inside rear machine cover
at the left rear of the machine, as shown in Figure 3-20.,
ZAPI Power Module Location and Orientation (All models).
Use the following instructions when replacing the power
module.
10. Re-install the rear machine cover.
1. Turn machine power off and disconnect the batteries.
Table 3-4. Module Terminal Functions
+ BF1
Controller to Main Power Contactor
+ BF2
Left and Right Positive Armature
+B
Positive Pump Connection
2. Locate and remove the rear cover from the machine.
–B
Controller to Battery Negative
3. Tag and note the wire terminal locations before
removing the power module, also see Figure 3-21.
–T
Left and Right Negative Armature
–P
Negative Pump Connection
F1
To Motor Fields Wired in Series
F2
To Motor Fields Wired in Series
4. Disconnect all wire connectors and cables from the
power module and remove it from the machine.
Figure 3-20. ZAPI Power Module Location and Orientation (All models)
3-16
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3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
4
5
6
A2
A1
A1
A2
9
8
3
2
7
1
10
Figure 3-21. Main Electrical Power Connections - (1001129845 - ZAPI Power Module)
1.
2.
3.
4.
5.
3121273
Batteries
Power Module
Main Power Contactor Relay
Hydraulic Pump Motor
Drive Motor Stator Field Wires
6.
7.
8.
9.
10.
– JLG Lift –
Drive Motor Armature (Brush) Cables
To Battery Charger (+)
To Battery Charger (–)
To Pin 13 and Pin 32 - J1 Connector on Power Module
Battery Quick-Disconnect (OPTION)
3-17
SECTION 3 - CHASSIS & SCISSOR ARMS
ZAPI Power Module Electrical Evaluation
INTEGRATED HEALTH INDICATOR
The ZAPI Power Module provides a green STATUS LED
that shines through the cover to indicate module "health"
status. The LED shall be illuminated when the device is
powered on. The LED blinks (2Hz) when an internal issue
is detected that cannot be repaired by a technician. It
should be noted that this will require replacement of the
device.
P/N - 1001139845
ZAPI Power Module - "HEALTH" (Status LED)
3-18
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
3.13 DRIVE MOTOR SERVICING
The drive motors are located at the rear of the machine,
inside the machine rear cover, remove the machine rear
cover, see Figure 3-1.
Drive Motor Troubleshooting
1. Turn off power to unit, remove side cover and disconnect main battery power.
2. Disconnect drive motor connections from the Power
Module inside rear cover.
3. Verify field continuity between the blue and orange
wires. If available, use a 4-wire ohmmeter to verify
the field resistance per the applicable motor specification below.
4. Verify armature continuity between the red and black
wires. If available, use a 4-wire ohmmeter to verify
the field resistance per the applicable motor specification below.
Model
Field Resistance
@ 75°F (24°C)
Armature Resistance
@ 75°F (24°C)
1932RS/6RS
0.21 Ohms
0.037 Ohms
3248RS/10RS
0.127 Ohms
0.051 Ohms
5. Using a dielectric tester, verify that there are no
shorts between the following items:
a. Field connector pins and the case of the motor.
b. Armature terminals and the case of the motor.
c. Field connector pins to the armature terminals.
6. Verify continuity in 2 pin brake connector (yellow
and brown wires). Measure the brake resistance and
verify that it is between 18 and 22 Ohms.
Drive Motor Electrical Evaluation
Several basic electrical tests can be performed on the
Drive Motors. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.
Refer to Figure 7-2., Resistance Measurement. Disconnect
the Main Battery Disconnect and all drive motor cables
during this analysis.
• Resistance < 2 Ohms Red to Black Armature Wires.
The heavy red and black conductors are connected to
the motor's armature winding. The winding is a very low
impedance and should appear to be a short-circuit for
an ordinary voltmeter. High resistance can signal corrosion, improper crimps, damaged cabling, worn
brushes, a faulty commutator, or an open armature
winding.
3121273
• Resistance < 2 Ohms Blue to Orange Field Wires.
The blue and orange conductors are connected to the
motor's field winding. In order to make this measurement, it will be necessary to disconnect the butt-splice
on the two orange wires or use a piercing meter probe.
As with the armature, the field is a very low impedance
and should appear to be a short-circuit for an ordinary
voltmeter. High resistance can signal corrosion,
improper crimps, damaged connectors, damaged
cabling, or an open field winding.
• Resistance 15-25 Ohms Yellow to Brown Brake
Wires. The yellow and brown wires are connected to
the integral brake. Improper resistance can signal corrosion, improper crimps, damaged cabling, or a faulty
solenoid.
• Resistance > 1 Mega-Ohms Red Armature Wire to
Motor Housing. The armature winding should be electrically isolated from the motor housing. Low resistance
may be an indication of a crushed cable, a burned
cable, or a burned armature winding. Investigate by disconnecting the drive motor cable from the motor and
re-measure resistance (isolation).
• Resistance > 1 Mega-Ohms Blue Field Wire to
Motor Housing. The field winding should also be electrically isolated from the motor housing. Low resistance
may be an indication of a crushed cable, a burned
cable, or a burned field winding. Investigate by disconnecting the drive motor cable from the motor and remeasure resistance (isolation).
• Resistance > 1 Mega-Ohms Red Armature Wire to
Blue Field Wire. The armature and field windings
should also be electrically isolated from one another.
Low resistance may be an indication of a crushed
cable, a burned cable, damaged windings. Investigate
by disconnecting the drive motor cable from the motor
and re-measure resistance (isolation).
Servicing Guidelines
Since the operating environment of industrial equipment
varies widely, the following are suggested for periodic
maintenance inspection intervals.
• Normal Service – Perform routine inspection (outlined
in the Inspection and Service portion of this section)
every 1,000 hours of drive time.
• Severe Service – Perform routine inspection every 500
hours of drive time. Severe service environments are
listed below:
a. Dusty or dirty locations like cement plants, lumber and flour mills, coal mining, stone quarries,
etc.
– JLG Lift –
b. High temperature areas like steel mills, foundries, etc.
c. Environments with sudden temperature change,
such as in refrigeration plant, etc.
3-19
SECTION 3 - CHASSIS & SCISSOR ARMS
Brake - Manual Disengage Procedure
4
3
2
1
Figure 3-22. Brakes - Manual Disengage Procedure
1. Cover Bolts
2. Brake Cover
3. Cover Gasket
4. Disengage Holes
5. Repeat this procedure on opposite wheel drive. With
both drive motor brakes now disengaged, the
machine can be moved manually.
NOTE: The brakes may also be disengaged electrically
using the brake release switch, see procedure in
Operation Manual.
6. After towing is complete, chock wheels and remove
cover bolts from disengage holes.
CAUTION
7. Reinstall brake cover, replace cover gasket if damaged.
CHOCK WHEELS OR SECURE MACHINE WITH TOW VEHICLE.
1. Ensure battery disconnect switch is in to the "OFF"
position.
2. Start with either of the drive motors and remove the
two cover bolts and brake cover.
3. Thread the cover bolts into the two disengage holes
in the brake housing.
CAUTION
AFTER THE MACHINE IS TOWED, THE COVER BOLTS MUST BE
REMOVED FROM THE BRAKE DISENGAGE HOLES. THE BRAKES
CANNOT BE ENGAGED WITH THE DISENGAGE BOLTS IN THE
BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE
TO ROLL WHEN PARKED ON AN INCLINE.
4. Tighten down the cover bolts so the brake on that
drive motor will disengage.
3-20
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Drive Motor Removal
3
1
2
3
Figure 3-23. Electric Drive Motor Removal
1. Electric Drive Motor
2. Motor Mounting Bolts
3. Washers
3. Remove the two motor mounting bolts and washers.
NOTICE
DISCONNECT ALL POWER BY REMOVING THE POSITIVE (+) BATTERY CABLE AT THE BATTERIES BEFORE REMOVING DRIVE
MOTOR.
1. Disconnect the power cables, brake and field power
connectors from the drive motor.
2. Drain the oil out of the unit by removing the cover
plug. Note the condition of the oil, replace if necessary.
4. Gently remove the drive motor (1).
NOTE: Reference Figure 3-24., Drive Motor Components for
part names and locations when servicing the Drive
Motor.
Periodic maintenance consisting of inspections of motors,
batteries and wiring circuitry is recommended, see Section 2, Table 2-2, Preventive Maintenance & Inspection
Schedule..
CAUTION
ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE
OPERATION.
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3-21
SECTION 3 - CHASSIS & SCISSOR ARMS
Drive Motor Disassembly
2
5
6
1
11
3
4
12
7
13
14
8
9
10
Figure 3-24. Drive Motor Components
1.
2.
3.
4.
5.
6.
7.
Shaft Pilot Bearing
Frame & Field Assembly
Armature Assembly
Brush Spring (4)
Brush & Terminal Assembly (Qty.-2)
Brush Box Assembly
Retaining Ring
NOTE: Refer to Figure 3-24.
1. Remove the two Cover Plate Mounting Screws (14)
holding the Cover Plate (13) in place and remove the
cover plate from the motor.
8.
9.
10.
11.
12.
13.
14.
Bearing
Commutator End Head
Motor to Hub Mounting Screws (Qty.-2)
Brake Assembly
Cover Gasket
Brake Cover
Brake Cover Mounting Screws (Qty.-2)
5. Remove the wire harness from the motor by disconnecting the brake connection and armature connections. Cut the field connection close to the crimp
connection on the motor side.
2. Remove the Brake Cover Mounting Screws (15)
holding the Brake (11) in place and set aside. These
screws are used to manually release the brakes.
6. Install the two Brake Cover Mounting Screws (15)
into the threaded holes in the brake assembly and
tighten to manually release the brake (see Figure 323.).
3. Remove the two Terminal Cover Mounting Screws
(16). Slide the strain relief of the Wire Harness (1)
out of the cover and remove the cover from the
motor.
7. Remove the three screws holding the brake assembly to the motor. Carefully remove the brake assembly, brake disc and reaction disc from the motor by
sliding off of the shaft.
4. Discard the Gasket (12) that was located under the
brake and terminal covers.
8. Remove the screws holding the Commutator End
Head (9) in place and remove the commutator end
head from the frame and field assembly. The Arma-
3-22
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
ture (2) will be attached to the commutator end
head.
9. Pull back the Brush Springs (4) in the commutator
end head, pull the brush back and rest the springs
on the side of the brush. The brushes should move
freely within the holders.
7. Visually inspect the Wire Harness (1) for frayed insulation, loose terminals, or other damage. Replace as
necessary.
Drive Motor Reassembly
NOTE: Refer to Figure 3-24.
10. Use an arbor press or a bearing puller to remove the
armature from the commutator end head assembly.
11. Remove the Snap Ring (7) and Bearing (8) from the
commutator end head. Discard the bearing.
Drive Motor Inspection and Service
NOTE: Refer to Figure 3-24.
1. Carefully blow out any accumulated carbon dust
and dirt from the Commutator End Head (9) and the
Frame & Field Assembly (2) using clean, oil free,
compressed air.
2. Replace Brushes (5) that are worn below their
usable length of 0.6 in (1.5 cm), show signs of
uneven wear or signs of overheating, such as discolored brush shunts and brush springs. Brushes
should always be replaced in complete sets of four.
Use identical replacement parts; do not substitute
brush grades as the brushes are matched to the
motor type and application to provide the best service. Substituting brushes of the wrong grade can
cause premature commutator failure and excessive
brush wear.
3. Make sure the Brush Box Assembly (6) is tight on
the commutator end head. Replace brush box
assemblies in the commutator end head if they are
physically damaged or brush holders are loose on
the brush plate.
4. Visually inspect the frame and field assembly for
overheating or other signs of damage. Check all wiring to ensure that the insulation is in good condition.
Verify that pole screws are torqued to 250 - 300 in-lb
(28.2 - 33.9 Nm). Verify field resistance using a suitable ohmmeter per the appropriate motor specification. Verify that the field is electrically isolated from
the frame using a dielectric tester. Replace as necessary.
5. Visually inspect the Armature Assembly (3) for signs
of overheating or physical damage. Visually inspect
the seal surface of the shaft for excessive wear.
Check for grounded circuits using a dielectric tester
by applying voltage between the commutator and
the shaft. Visually inspect the commutator for excessive wear and overheating. Replace as necessary.
1. After inspection and servicing, reassemble the wiring in the Commutator End Head (9) as originally
found. Ensure the wiring does not contact metal
parts and that it allows the brushes to move unrestricted in the holders. Motor terminals must be
assembled as shown Figure 3-26. Torque bottom
terminal nut to 110 - 140 in-lb (12.4 - 15.8 Nm).
2. After the motor has been disassembled, it is recommended that new bearings be installed because
bearings may have been damaged during removal.
Although the bearings may appear and feel good,
the bearing races could be “brinelled” (races or balls
deformed) and may exhibit noise and vibration problems or fail within a relatively short period of service.
Press a new bearing into the commutator end head,
pressing on the outer race only. See Figure 3-25..
Replace the Retaining Ring (7) in the retaining ring
groove.
3. Press the Armature (3) commutator end into the
commutator end head and bearing assembly, carefully supporting the inner-race of the bearing. See
Figure 3-25.
4. Carefully release the Brush Springs (4) allowing the
Brushes (5) to contact the commutator. Make sure
brush shunts do not interfere with spring movement.
5. Assemble the commutator end head to the Frame &
Field Assembly (2) and tighten the screws to 120 140 in-lb (13.6 - 15.8 Nm). Make sure to align the
field connection with the notch in the commutator
end head. Seal wires where they exit from commutator end head with the Grommet (10).
6. Place the Gasket Seal (12) in the bottom of the
notch in the commutator end head. Align wires from
the Brake Assembly (11) into the notch in the commutator end head. Secure brake assembly to commutator end head using three bolts.
7. Install Wire Harness (1) to motor by connecting the
brake connectors and securing the armature terminals to the terminal studs. Crimp the field connection
(red/orange to orange and blue to blue) together
and heat shrink. Motor terminals must be assembled
as shown in Always secure the bottom nut with a
wrench as you tighten the top nut. Torque top nut
to 90 - 110 in-lb (10.2 - 12.4 Nm).
6. Visually inspect the brake surfaces for excessive
wear. Replace Brake Assembly (11) if necessary.
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3-23
SECTION 3 - CHASSIS & SCISSOR ARMS
8. Remove manual release screws from brake assembly. Apply new Gasket (12) and affix brake cover to
motor using the 2 manual release screws.
9. Attach terminal cover to the commutator end head
using two terminal cover screws.
10. Slide the strain relief of the wire harness into the slot
of the terminal cover. Align cover plate with groove in
frame and field and affix using two cover plate
screws.
Figure 3-25. Drive Motor Shaft Bearing
1.
2.
3.
4.
5.
6.
Press Fixture must press against Outer Race
Bearing
End Head (held stationary)
Armature Assembly
Assembled End Head, Bearing, and Retaining Ring
Press Fixture must press against Inner Race (held stationary)
Figure 3-26. Wire Harness Connections
3-24
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Drive Motor Installation
3
1
2
3
Figure 3-27. Drive Motor Assembly
1. Drive Motor
2. Motor Mounting Bolts
3. Washers
1. Insert the drive motor into the back of the gearbox.
The drive motor will pilot on the four bosses in the
gearbox. Try to keep the end of the motor shaft from
causing damage to the lip seal in the gearbox.
NOTE: The motor may need to be rotated to line up the sun
gear splines with the motor shaft splines.
3. Connect the end of the Motor Cable to the Power
Module.
4. Fill the gearbox with oil ISO grade 68 oil or oil of a
similar viscosity (80W gear oil or 20W engine oil).
The gearbox will need to be filled with 10 oz of oil.
2. Install the two motor mounting bolts and washers.
Torque to 9 - 11 ft-lbs (12 - 15 Nm).
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– JLG Lift –
3-25
SECTION 3 - CHASSIS & SCISSOR ARMS
3.14 TORQUE HUB SERVICING
Leak Test
NOTICE
THE PROCEDURES WITHIN THIS SECTION APPLY TO ALL
MACHINES AND TORQUE HUBS. PROCEDURES THAT APPLY TO
SPECIFIC MACHINES AND TORQUE HUBS WILL BE SO NOTED
BY PROPER SERIAL NUMBERS.
NOTE: These instructions will cover how to completely
assemble and disassemble the Torque-Hub unit.
However, if the unit is under warranty you should
contact JLG Industries, Inc. for a replacement unit.
The warranty will no longer be valid if the unit is disassembled by non-JLG personnel.
NOTICE
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK
TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO
MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE
WORKING PROPERLY.
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure that
the unit's gears, bearings and seals are working properly.
The following information briefly outlines what to look for
when performing these tests.
The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to fall
after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings are located. The exact location of
a leak can usually be detected by brushing a soap and
water solution around the main seal and where the o-rings
or gaskets meet on the exterior of the unit, then checking
for air bubbles. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked.
Leak test at 10 psi for 20 minutes.
NOTE: Due to the small air volume inside this Torque-Hub, it
will pressurize to 10 psi very quickly. If the pressure
becomes excessive in the unit the seals will be
destroyed.
Oil Check/Fill Procedure
The torque hub unit is shipped with ISO 68 viscosity oil
(hydraulic fluid). It is designed to utilize the same oil
throughout its service life. However, should it need to be
checked/serviced use the following procedure.
In the event of servicing, fill the unit with ISO grade 68
hydraulic oil.
NOTE: The gearbox capacity is 10 oz of oil.
IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE
ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING
THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR
EVEN DEATH.
1. To check the oil level, rotate the wheel so that the
plugs in the cover are at 12 o-clock and 3 o-clock.
NOTE: The brake must be released before performing the
roll test. This can be accomplished by connecting the
brake release cable and depressing button. The
brake can also be released by following the manual
disengage procedures outlined in this section.
3. If oil begins to come out the oil level is sufficient.
CAUTION
RE-ENGAGE BRAKES BEFORE RETURNING TO NORMAL OPERATION.
2. Allow the oil to settle than slowly remove the plug at
3 o-clock.
4. If no oil is noticed at the 3 o-clock plug remove both
plugs.
5. Slowly add oil at the 12 o-clock plug location until oil
begins to seep out at the 3 o-clock plug location.
6. Apply pipe dope or teflon tape to the cover plugs
and reinstall into the cover.
7. TIghten to 6 ft lbs - 8 ft lbs (8.4 Nm to 11.2 Nm).
Roll Test
The purpose of the roll test is to determine if the unit's
gears are rotating freely and properly. You should be able
to rotate the wheel or hub of the gearbox by hand. If you
feel more drag in the gears only at certain points, then the
gears are not rolling freely and should be examined for
improper installation or defects. Some gear packages roll
with more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
3-26
– JLG Lift –
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SECTION 3 - CHASSIS & SCISSOR ARMS
Main Gearbox Disassembly
Figure 3-28. Main Gearbox Disassembly
1.
2.
3.
4.
5.
6.
Spindle Sub-Assembly
Spiral Snap Ring
Input ring Gear
Input Sun Gear
Cover O-Ring
Cover Thrust Washer
7.
8.
9.
10.
11.
1. Using a screwdriver, pry off the cover snap ring.
2. Remove cover. Cover Thrust washer should be in
the inner counter bore of the cover.
NOTE: To grip the cover for removal a pipe may need to be
inserted into the pipe plug holes.
3. Remove input sun gear.
Cover
Cover Snap Ring
Pipe Plug
Input Carrier Sub-Assembly
Hub Sub-Assembly
aligned in the bore. The screws will push against the
outer race of the main bearing. This bearing will
have to be replaced afterwards.
7. Using a screwdriver remove spiral snap ring.
8. Pull hub sub-assembly off of the spindle sub-assembly.
4. Remove input carrier sub-assembly.
5. Remove cover o-ring.
6. Remove input ring gear.
NOTE: The input ring gear is held in with a press fit on its
outside diameter. Insert jacking screws (1/4-20UNC
grade 8) with at least 1.5 inches of thread length into
each of the three tapped holes to force the ring gear
out. Be sure and alternate between the jacking
screws to keep the ring gear from becoming mis-
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3-27
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Disassembly
Figure 3-29. Input Carrier Disassembly
1.
2.
3.
4.
5.
Planet Gears
Output Sun Gears
Input Carrier
Thrust washer
Input Planet Gear
6.
7.
8.
9.
1. Remove retaining rings from each of the 3 planet
shafts.
NOTE: Do not overstress these retaining rings when removing them.
Needle Bearings
Thrust Plate
Snap Ring
Retaining Ring
NOTE: The planet pins are held in with a press fit. To avoid
damage to the parts, use an arbor or hydraulic press
to remove the planet pins.
2. Remove thrust plate.
3. Remove a thrust washer from each planet shaft.
4. Slide each input planet gear off the planet shaft.
5. Remove 22 needle bearings from the bore of each
planet gear.
6. Remove the thrust washer from each planet gear.
7. Remove retaining ring from output sun gear.
8. Slide output sun gear out from the center of the
input carrier.
9. Remove the three planet shafts from the input carrier.
3-28
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Hub Disassembly
Figure 3-30. Hub Disassembly
1. Seal
2. Hub
3. Main Bearing
1. Remove main wheel bearing.
2. Remove main lip seal.
NOTE: This part is held in the hub with a press. To remove
have the hub sitting seal side up. Use a plate or rod
with a large enough diameter push in the inner race
of the bearing. Apply force to the push the bearing
out. This bearing will need to be replaced upon reassembly.
3121273
NOTE: This lip seal is also held in with a press fit. Remove
the lip seal only if the hub or seal needs to be
replaced. The lip seal will most likely become damaged during removal. Try not to damage the hub
bore.
– JLG Lift –
3-29
SECTION 3 - CHASSIS & SCISSOR ARMS
Spindle Disassembly
Figure 3-31. Spindle Disassembly
1.
2.
3.
4.
5.
6.
Spindle Sub-Assembly
Shaft Ball Bearing
Tanged Washer
Thrust Washer
Output Planet Gear
Output Planet Pins
7.
8.
9.
10.
11.
Main Bearing
O-Ring
Shaft Seal
Snap Ring
Needle Roller Bearings
1. Place unit on bench with planet gears facing up.
6. Press out the motor shaft seal from the center bore.
2. Remove 3 output planet shafts.
7. Remove the main bearing from the outside diameter
of the spindle.
NOTE: These planet shafts are held in with a press fit. Use
the tapped hole in the end of the pin in conjunction
with a slide hammer or similar tool to remove them.
NOTE: This bearing is held in with a press fit. You will need
to pry against the spindle to remove it. The bearing
will need to be replaced when this is done.
3. Remove the output planet gear, thrust washer, and
tanged washer out of each gear “window” of the
spindle.
8. Remove the motor o-ring from the groove on side
opposite from the carrier side.
NOTE: The output planet gears are a very similar size to the
input planet gears, tag or label the planet gears to
avoid confusion.
4. Using a screwdriver remove the shaft bearing snap
ring.
5. Remove the shaft ball bearing from the center bore.
3-30
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3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Tightening and Torquing Bolts
If an air impact wrench is used to tighten bolts, extreme
care should be taken to ensure that the bolts are not tightened beyond their specified torque.
The following steps describe how to tighten and torque
bolts or socket head cap screws in a bolt circle.
1. Tighten (but do not torque) bolt "A" until snug.
2. Go to the opposite side of the bolt circle and tighten
bolt "B" until equally snug.
3. Crisscross around the bolt circle and tighten remaining bolts.
4. Now use a torque wrench to apply the specified
torque to bolt "A".
5. Using the same sequence, crisscross around the
bolt circle and apply an equal torque to the remaining bolts.
BOLT A
Figure 3-33. Assembly Tool 2
BOLT B
Assembly Tools
Figure 3-34. Assembly Tool 3
Figure 3-32. Assembly Tool 1
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3-31
SECTION 3 - CHASSIS & SCISSOR ARMS
Spindle Assembly
Figure 3-35. Spindle Assembly
1.
2.
3.
4.
Spindle Sub-Assembly
Shaft Ball Bearing
Tanged Washer
Thrust Washer
5.
6.
7.
8.
Output Planet Gear
Output Planet Pins
Main Bearing
O-Ring
8. Insert an output planet pin into the planet pin hole of
the spindle and through the bores of the thrust
washers and the planet gear.
1. Using the appropriate pressing tool, press on main
bearing until it is fully seated.
2. Insert the motor shaft bearing into the center bore of
the spindle. The bearing is a slight slip fit, but it may
require some press to assemble if the bearing
becomes misaligned.
3. Retain the bearing with the spiral retaining ring.
4. Line the bore of the output planet gear with 22 needle rollers. Use grease to retain the needle rollers in
the bore.
5. Place tanged thrust washer into each planet “window” of the spindle. Make sure the tang sits in the
cast groove on the inside of the window.
6. Place a thrust washer onto the plane gear. Line up
the bores as best as you can. Use grease to hold the
thrust washer in place.
7. Slide the planet gear into the window with the
tanged washer until the bores line up.
3-32
9. Shaft Seal
10. Snap Ring
11. Needle Roller Bearings
9. Before pressing the planet pin into the spindle make
sure the gear spins freely.
10. Press the planet pin into the spindle until it bottoms
out. Make sure the planet gear turns freely after the
planet pin is pressed in.
11. Repeat Steps 6-12 for the other two output planet
gears.
12. Turn the spindle over so that the carrier is down.
13. Using a flat plate or rod, press the motor shaft seal
into the center bore so that it is flush with the face of
the spindle.
14. Grease and install the motor o-ring into the groove.
CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING
CONTACT WITH THE BRAKE DISCS. IF THIS OCCURS IT WILL
DEGRADE THE BRAKES PERFORMANCE.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Hub Assembly
Figure 3-36. Hub Assembly
1. Seal
2. Hub
3. Main Bearing
1. Put hub on a table with the tapped holes facing
down.
2. Using a flat plate in conjunction with a pressing tool,
press in the seal so it is flush with the edge of the
hub.
3. Flip the hub over.
4. Using an appropriate pressing tool, press the main
bearing into the bore until it bottoms out.
NOTE: The seal has a thin outer shell that can be easily
damaged if not installed with care. It is a good idea
to start the seal into the bore with a rubber mallet
before pressing.
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3-33
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Assembly
Figure 3-37. Input Carrier Assembly
1.
2.
3.
4.
5.
Planet Gears
Output Sun Gears
Input Carrier
Thrust washer
Input Planet Gear
6.
7.
8.
9.
1. Press 3 input planet shafts into the 3 holes of the
input carrier. The head of the input planet shaft
needs to sit flush in the counter bore of the input carrier hole.
visually. Additional grease may help hold everything
together.
6. Place the input planet gear and thrust washers onto
the input planet shaft sticking out from the carrier.
When you slide the input planet shafts into the
bores, the needle bearings will try to push out. If you
have the thrust washers lined up properly they will
contain the needle bearings within the input planet
gear.
2. Insert output sun gear into the splined bore of the
input carrier. The gear tooth end of the output sun
gear should protrude in the opposite direction of the
input planet shaft.
3. Using retaining ring pliers, install the retaining ring
into the groove of the output sun gear. Make sure
that the ring is correctly seated in the groove and
that the output sun gear cannot be pulled out of the
input carrier.
7. Repeat 5 & 6 for the other 2 planet gears.
8. Put the thrust plate onto the three input planet
shafts. Use the 3 holes on the innermost bolt circle.
The other 3 holes are for a different gear ratio.
4. Load 22 needle rollers into the bore of each input
planet gear. Retain the needle bearings in the bore
with a coating of grease.
5. Place a thrust washer on each side of the input
planet gear. Line up the bores as well as you can
3-34
Needle Bearings
Thrust Plate
Snap Ring
Retaining Ring
9. Using the appropriate retaining ring pliers put a
retaining ring into the groove of each planet shaft.
NOTE: Do not overstress the snap ring.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Main Gearbox Assembly
Figure 3-38. Main Gearbox Assembly
1.
2.
3.
4.
Spindle Sub-Assembly
Spiral Snap Ring
Input ring Gear
Input Sun Gear
5.
6.
7.
8.
Cover O-Ring
Cover Thrust Washer
Cover
Cover Snap Ring
1. Inspect seal surface of spindle. Remove any debris
that may be present.
c. Stage 3: Once all the planet gears are in mesh
apply pressure to the hub, it should go on the
rest of the way.
2. Apply a coating of grease to the lip seal of the hub
sub-assembly.
5. Install retaining ring into the groove on the outside
diameter of the spindle carrier. This is a spiral retaining ring so it will not require pliers. You will need to
pull the retaining ring apart and work it into the
groove.
3. Place Spindle Sub-Assembly on table with carrier
side up.
4. Carefully install the hub sub-assembly (seal side
down) onto the spindle. This installation should be a
slip fit and takes place in 3 stages.
a. Stage 1: The hub slides together until the gear
teeth of the hub hit the gear teeth of the 3 output
planets.
b. Stage 2: Find the planet gear that is tight and
turn it until you feel it go into mesh with the hub
gear teeth, apply slight downward pressure to
the hub and then find the next gear that is tight
and do the same.
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9. Pipe Plug
10. Input Carrier Sub-Assembly
11. Hub Sub-Assembly
6. Using an appropriate pressing tool, press the Input
Ring gear (recessed side down) into the hub subassembly.
NOTE: Do not use excessive pressing force because it will
be reacted by the main wheel bearings.
– JLG Lift –
7. Install the input carrier sub-assembly into mesh. The
output sun portion of the sub-assembly will mesh
with the output planet gears and the planet gears
mounted on the sub assembly will mesh with the
input ring gear.
3-35
SECTION 3 - CHASSIS & SCISSOR ARMS
8. Install the input sun gear into the area between the 3
input planet gears.
9. Apply a coating of grease to the cover o’ring and
install it into the o’ring groove of the hub.
NOTE: It may be helpful to stretch the o’ring out prior to
assembly to avoid pinching or shearing when the
cover is assembled.
10. Apply a heavy coating of grease to the cover thrust
washer and place it in the center counter bore of the
cover. The grease will help keep it in the bore during
assembly.
11. Center the cover in the hub bore so that the “JLG”
logo is up. Push it into the bore.
3-36
NOTE: Do not hit the cover with a hammer or mallet, shocks
may cause the cover thrust washer to dislodge and
drop into the gear cavity prior to the cover getting
positioned properly. If all the parts are to size and
assembled properly, the cover should not need
excessive force to assemble.
12. Install the cover retaining ring into the hub groove.
13. Re-install drive motor to torque hub per instructions
Drive Motor Installation - page 3-25, install on
machine.
14. Test per instructions in Section 3.14, Torque Hub
Servicing, for proper operation and to check for any
oil leaks.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
NOTES:
3121273
– JLG Lift –
3-37
SECTION 3 - CHASSIS & SCISSOR ARMS
3.15 STEER ASSEMBLY COMPONENTS
2
2
1
3
1
Figure 3-39. 1932RS/6RS - Steer Assembly
NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-purpose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking.
1. Install the bearing with the flange surface on top of the spindle arm.
2. Assemble the spindle kingpin attach, banjo pin hardware, in the frame hole towards the front of the machine.
3. Install cylinder to frame attach pin with cotter pin hole on top.
3-38
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
1
1
Figure 3-40. 3248RS/10RS - Steer Assembly
NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-purpose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking.
1. Install the bearing with the flange surface on top of the spindle arm.
3121273
– JLG Lift –
3-39
SECTION 3 - CHASSIS & SCISSOR ARMS
3.16 ARMS AND PLATFORM POSITIONING
AND SUPPORT
3.18 SCISSOR ARMS REMOVAL
1. Remove platform (refer to Section 3.17, Platform
Removal).
2. Disconnect all wiring and cables attached to scissor
arm assembly.
NEVER WORK UNDER N ELEVATED PLATFORM UNTIL IT HAS
BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS,
BLOCKING OR OVERHEAD SLING.
The arm stack can be supported by using an overhead
crane,(See Figure 3-41.). If an overhead crane is not available the stack may also be lifted by using a fork-truck
using the following instructions:
3. The scissor arms can be removed as a complete
unit or individually.
Removing scissor arm assembly as a
complete unit:
1. Remove the pin attaching the bottom scissor arms
to the rear of the frame by removing the bolt.
1. With the forks on the fork-truck slid close together,
enter from the front of the machine and place the
forks on the cross tube of the second arm assembly
below the platform.
2. Place two straps around each end of the the entire
scissor arm assembly. Using an overhead crane,
slowly and carefully move the arm stack forwards so
that slide blocks at front of machine slide out the
front of the slide channel on the frame.
2. Slowly lift the arm stack with the fork-truck while the
manual descent valve is being engaged (this allows
the oil to drain back into the tank).
3. Place machine on safety prop and leave the fork
truck in place.
NOTE: Overhead crane and straps must be capable of lifting
at least 2000 lbs (907 kg).
3. Once slide blocks are clear of machine, the scissor
stack can be moved to a more desirable location for
further arm disassembly.
4. At this point the lift cylinder removal may begin.
(Refer to Section 4.6, Lift Cylinder Removal)
If removal of the platform becomes necessary use the
above procedure to stabilize the platform for pin and platform removal.
Removing/Installing scissor arms
individually:
See Figure 3-42., Figure 3-43., Figure 3-44. and Figure 345.
3.17 PLATFORM REMOVAL
1. Support the platform using an overhead crane with
straps capable of lifting at least 500 lbs (227 kg)
(See Figure 3-41.). Refer to Section 3.16, Arms and
Platform Positioning and Support.
1. With the platform removed, start with the top arms
(closest to platform).
2. Secure each arm section being removed using an
overhead crane with suitable lifting straps.
2. Disconnect and remove the platform control station
and wiring harness at the platform. Disconnect AC
receptacle cable if applicable. Route the cables out
through the hole at the right-rear of the platform to
free platform of any constraints when lifting.
3. Remove the bolts attaching the pins and slide
blocks at each corner to the arm stack. Carefully
remove the four pins attaching the platform to the
arm stack.
4. Lift the platform from the arm stack and set aside.
NOTE: When attaching platform back onto scissor arm
assembly, follow removal procedures in reverse
order.
3-40
3. Remove the bolts securing the connecting pins in
place.
4. Remove the pins from the arms.
5. Remove the arm section from the machine using the
overhead crane.
6. Repeat previous steps for remaining arm sections.
NOTE: When attaching scissor arm assembly back onto
frame, follow removal procedures in reverse order.
Self locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Figure 3-41. Arms and Platform Positioning and Support
3121273
– JLG Lift –
3-41
SECTION 3 - CHASSIS & SCISSOR ARMS
E
C
H
F
I
C
D
G
A
C
E
B
Figure 3-42. 1932RS/6RS - Scissor Arm Assembly - Ref. Figure 3-43.
3-42
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
H
G
F
D
E
A
B
C
I
Figure 3-43. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration
3121273
– JLG Lift –
3-43
SECTION 3 - CHASSIS & SCISSOR ARMS
C
K
E
C
K
E
E
F
E
J
E
F
E
E
H
E
D
L
C
E
G
E
A
C
E
B
B
Figure 3-44. 3248RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45.
3-44
– JLG Lift –
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
F
E
H
G
J
L
A
Figure 3-45. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration
3121273
– JLG Lift –
3-45
SECTION 3 - CHASSIS & SCISSOR ARMS
3.19 PLATFORM CONTROL STATION
Control Station Harness Installation to
Scissor Arms
NOTICE
POWER MACHINE DOWN AT THE GROUND CONTROL STATION
BEFORE DISCONNECTING THE PLATFORM CONTROL STATION.
Installation/Removal
1. Disconnect the platform control station harness at
the connector below the control station mount.
2. Remove the pin securing the control station to the
platform station mount, swing and lift to remove control station from the machine.
Below are a few notes for positioning and securing the
platform control station harness to the scissor arms when
installing or removing the harness on the machine.
• Orange and yellow marker tape strips are located on
the platform harness to assist in installation.
• At every yellow marker tape, secure the harness to the
nuts welded on the arms using wire ties.
• At every orange marker tape, secure the harness to the
cable carrier using wire ties.
• If necessary, additional wire ties should be used to
firmly attach the harness to the machine.
Control Station Disassembly
1. Place the platform control station assembly on a
suitable work bench.
2. Remove the main body from the mount, by removing the long through bolt, cap-nut and washers (item
1) and the two (2) bolts and nuts (item 2) along the
rear edge.
3
2
1
1
1
Figure 3-46. Platform Control Station Installation
1. Harness Connector
2. Mounting Pin
3. Lift and Remove
3. To install, reverse steps 1 and 2 above.
2
Figure 3-47. Platform Control Station Disassembly
1. Through Bolt, Cap-nut
and Washers
3-46
– JLG Lift –
2. Rear Edge Bolts and Nuts
3121273
SECTION 3 - CHASSIS & SCISSOR ARMS
Overview of Control Station Components
1
1
NT
O
FR
2
3
2
9
4
11
2
1
5
62
23
13
01
10
6
B
8
7
7
8
10
3
5
Figure 3-48. Platform Control Station Components External
1.
2.
3.
4.
Steer Control Switch
7. Machine Tilt Indicator
Drive and Lift Joystick Control
8. Emergency Stop Switch
Trigger Switch
9. Horn Button
Forward/Reverse/Lift/Lower
10. Drive and Lift Select
Direction Decal
Switch
5. Alarm
11. Low Battery Charge/Sys6. Overload Indicator (If Equipped)
tem Fault Indicator
3121273
6
4
9
Figure 3-49. Platform Control Station Components Internal
1. Drive and Lift Joystick Control
2. Low Battery Charge/System
Fault Indicator
3. Drive and Lift Select Switch
4. Emergency Stop Switch
5.
6.
7.
8.
Horn Button
Harness Splice Connector(1)
Machine Tilt Indicator
Overload Indicator
(If Equipped)
9. Alarm
NOTE: (1) Zip-tie item-6 - Harness Splice Connector - to
item- 5 - Horn Switch, to prevent any possible interference with the joystick path.
– JLG Lift –
3-47
SECTION 3 - CHASSIS & SCISSOR ARMS
Joystick Controller
Figure 3-50. Joystick
Table 3-5. Joystick Specifications
Table 3-6. Connector Chart
Input Voltage
+5 (±0.1) VDC
Current Consumption
10 mA @ 12 VDC
Term
Color
Function
2.5 (±0.1) VDC
1
RED
HANDLE COM
4 (±0.1) VDC
2
VIOLET
TRIGGER N.O.
3
--
SPARE
4
YELLOW
ROCKER RT
5
GREEN
ROCKER LT
Output: Handle Centered
Output: Full Positive (Reverse) Deflection
Output: Full Negative (Forward) Deflection
CONNECTOR PINOUT
1 (±0.1) VDC
NOTE: For joystick calibration procedure see Joystick Calibration - page 5-5.
3-48
– JLG Lift –
6
--
SPARE
7
WHITE/RED
+5VDC
8
WHITE/BLACK
GROUND
9
BROWN
SIG OUTPUT
3121273
SECTION 4 - HYDRAULICS
SECTION 4. HYDRAULICS
4.1 CYLINDERS - THEORY OF OPERATION
Relief Valves
Cylinders are of the double acting type. The Lift and Steer
systems incorporate double acting cylinders. A double
acting cylinder is one that requires oil flow to operate the
cylinder rod in both directions. Directing oil (by actuating
the corresponding control valve to the piston side of the
cylinder) forces the piston to travel toward the rod end of
the barrel, extending the cylinder rod (piston attached to
rod). When the oil flow is stopped, movement of the rod
will stop. By directing oil to the rod side of the cylinder, the
piston will be forced in the opposite direction and the cylinder rod will retract.
NOTE:
The lift cylinder is a single acting cylinder which takes
hydraulic pressure to extend and gravity to retract.
A holding valve is used in the hydraulic lift circuit to prevent motion unintended by the operator in the event of a
hydraulic line failure.
4.2 VALVES - THEORY OF OPERATION
Solenoid Control Valves (Bang-Bang)
Control valves used are four-way, three-position solenoid
valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool
is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with
the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve
spool returns to neutral (center) and oil flow is then
directed through the valve body and returns to reservoir. A
typical control valve consists of the valve body, sliding
spool, and two solenoid assemblies. The spool is
machine fitted in the bore of the valve body. Lands on the
spool divide the bore into various chambers, which, when
the spool is shifted, align with corresponding ports in the
valve body open to common flow. At the same time other
ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is
released, the spool automatically returns to neutral, prohibiting any flow through the circuit.
3121273
Main relief valves are installed at various points within the
hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure
can be developed when a cylinder reaches its limit of
travel and the flow of pressurized fluid continues from the
system control. The relief valve provides an alternate path
for the continuing flow from the pump, thus preventing
rupture of the cylinder, hydraulic line or fitting. Complete
failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit
between the pump outlet (pressure line) and the cylinder
of the circuit, generally as an integral part of the system
valve bank. Relief pressures are set slightly higher than
the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pressure of the component is reached.
Crossover Relief Valves
Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the
required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral relief’s are provided for each side of the
circuit.
Proportional Valve
Flow is proportional to the amount of voltage supplied to
the valve coil. Voltage is gained by the machine controller
and determined by the position of the joystick.
Manual Descent Valve
The manual descent valve is located on the top of the
holding valve on the lift cylinder. The holding valve is a
normally closed solenoid valve, and holds the platform in
place when raised. When activated, the valve opens to
permit lift down. The holding valve is connected to the
manual descent valve, which is connected to a cable
which, when pulled, manually opens the lift down port of
the valve and allows the platform to be lowered in the
event hydraulic and/or electric power is lost.
– JLG Lift –
4-1
SECTION 4 - HYDRAULICS
4.3 PUMP/MOTOR
post of the left battery in the left-side batter compartment.
The vehicle should be placed on a smooth, firm, and level
surface for all analysis.
Theory of Operation
The Power Module (see Section 3.12, Power Control Module - ZAPI) is essentially a "low-side" switch for the pump
motor. The positive terminal of the pump is tied to Battery
Positive after the Line Contactor. The negative terminal of
the pump connects to the P Terminal of the Power Module, which switches current through MOSFET transistors
to the Battery Negative.
For variable speed pump operation, the MOSFET transistors switch On and Off at high frequencies (16kHz). The
Duty Cycle is varied to control the voltage applied to the
pump motor. When the MOSFET's spend 50% of the
period On and 50% Off, approximately ½ of the available
Battery Voltage will be applied to the pump motor. Similarly, the MOSFET are On continuously (100% Duty Cycle)
to apply all available Battery Voltage to the pump motor
(as in Lift Up at full speed).
When the Control System is energized, the voltage at the
P Terminal will be approximately +24V (referenced to -B)
when the pump is static. The P Terminal will be approximately at +1V (referenced to -B) when the pump is running at full speed (Lift Up from Ground Mode).
Pump Motor Electrical Evaluation
Several basic electrical tests can be performed on the
Pump Motor. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.
Refer to Figure 7-2., Resistance Measurement. Make all
measurements with a voltmeter set to resistance scale
(Ohms). Disconnect main power at the batteries and all
pump motor cables during this analysis.
• Resistance < 5 Ohms between Motor Terminals.
The internal windings are very low impedance and
should appear to be a short-circuit for an ordinary voltmeter (other tests can determine if the windings are
truly shorted). High resistance can signal worn
brushes, a faulty commutator, or open windings.
• Resistance > 1 Mega-Ohms between Motor Terminals and Motor Housing. The internal windings
should be electrically isolated from the motor housing.
Low resistance may be an indication of a broken motor
terminal, damaged brush, faulty commutator, or
burned winding.
COMMON DIFFICULTIES
The following difficulties can be examined using the JLG
Analyzer, a voltmeter, and simple hand tools. Unless otherwise noted, the Control System shall be energized in
Ground Mode during testing. For a convenient Ground
Reference, place the black meter lead on the negative
4-2
– JLG Lift –
1. Open-Circuit between +B Terminal and Pump
Motor Positive Terminal
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump
Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show PUMP PWM 100%
and PUMP CUR 0.0A when Lift Up is operated from
Ground Mode.
As shown in the diagram, the voltage measured
between the Pump Motor Positive Terminal and
Ground Reference should be 24V. If it is not, examine the cable between the terminal and the Power
Module compartment. Inspect crimps for corrosion
and ensure that bolted connections are tight.
Ensure that the cable is not crushed where it passes
between the frame side sheets and the cylinder
assembly.
2. Open-Circuit between Pump Motor Negative Terminal and P Terminal
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump
Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show PUMP PWM 100%
and PUMP CUR 0.0A when Lift Up is operated from
Ground Mode.
After ensuring there is not an Open-Circuit between
the +B Terminal and Pump Motor Positive Terminal,
check that the voltage measured between the Pump
Motor Negative Terminal and Ground Reference is
24V. If not, examine the issues within Open-Circuit
Pump Motor. This voltage should ramp to approximately 0V when Lift Up is operated from Ground
Mode. If not, examine the cable between the terminal and the Power Module compartment (P Terminal). Inspect crimps for corrosion and ensure that
bolted connections are tight. Ensure that the cable is
not crushed where it passes between the frame side
sheets and the cylinder assembly.
3. Open-Circuit Pump Motor
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump
Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show PUMP PWM 100%
and PUMP CUR 0.0A when Lift Up is operated from
Ground Mode.
Disconnect main power at the batteries to completely de-energize the Control System. Next,
detach the cable from Pump Motor Positive Terminal. Using a voltmeter set for resistance measurement (Ohms), ensure that the resistance between
3121273
SECTION 4 - HYDRAULICS
Line Contactor
+B
24V
P
Series DC
Pump Motor
-B
Power Module
the Pump Motor Positive and Negative Terminals is
less than 2 Ohms. If not, examine the pump motor
for worn brushes or broken terminals. After examination, re-connect the Pump Motor Positive Terminal
and main power at the batteries.
Hydraulic Oil Check Procedure
Lube Point(s) - Hydraulic Reservoir
Lube - Hydraulic Oil
Interval - Check Daily
4. Short-Circuit between Pump Motor Positive and
Negative Terminals
This issue will allow the vehicle to drive, but Lift Up
and Steer Functionality will be lost and the Pump
Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show an erratic reading
for PUMP PWM % and PUMP CUR will hover around
150A when Lift Up is operated from Ground Mode.
Table 4-1. Hydraulic System Capacities
COMPONENT
3121273
3248RS/10RS
Hydraulic Tank
1.32 Gal. (5 L)
2.38 Gal. (9 L)
Hydraulic System
1.85 Gal. (7 L)
3.96 Gal. (15 L)
NOTE:
Disconnect main power at the batteries to completely de-energize the Control System. Next,
detach both Pump Motor Terminals and insulate
them independently. Re-connect main power at the
batteries and re-try Lift Up. If the same symptoms
persist (erratic PUMP PWM%, PUMP CUR around
150A), examine the cabling between the Pump
Motor and Power Module compartment for a shortcircuit (most likely near area where cylinder retracts
between frame side sheets or near pot-hole mechanism, if equipped). If the symptoms change, suspect
a short-circuited (or mechanically frozen) pump
motor.
A clamp-on ammeter (set for 200A DC) can be
placed on either Pump Motor Cable for verification.
During Lift Up, the ammeter will read approximately
150A.
1932RS/6RS
Check the hydraulic oil level with the platform in the
stowed position ONLY. Be certain the hydraulic oil
has warmed to operating temperature before
checking the oil level in the reservoir.
1. On the left side of the machine, remove the side
access door on the base frame. Locate the
hydraulic oil reservoir (1) on the pump unit (2).
Check the oil level in the hydraulic reservoir by looking at the markings on the side of the tank. The reservoir is marked with a MAX (maximum) marking
(3). The oil level must be kept at or within one (1)
inch of this marking to operate properly.
2. If additional oil is required, wipe all dirt and debris
from the filler/breather cap (4) area, add proper
grade of oil. Fill until oil level is close to the MAX
marking (3), but not over the MAX marking.
NOTE: Care should be taken not to introduce any impurities
(dirt, water, etc.) while cap is removed.
– JLG Lift –
4-3
SECTION 4 - HYDRAULICS
c. Replace the tank. Torque mounting bolts to 6-7
ft-lb. (8.5-10 Nm).
4
d. If only replacing the oil filter and maintenance is
complete, reinstall tank assembly on machine,
remove fill cap and refill tank with proper grade
of oil by using a funnel. Fill until oil is up to the
MAX level indicator on the side of the tank.
3
4. To remove the oil pickup line, squeeze retainer and
slide outward.
NOTE:
1
2
5. Replace the o-rings if necessary.
Figure 4-1. Hydraulic Oil Check Procedure - All
Machines
NOTE:
6. Remove allen nut on the return/filter line and rotate
large retainer ring to remove return/filter line.
Recommended lubricating intervals are based on
machine operations under normal conditions. For
machines used in multi-shift operations and/or
exposed to hostile environments or conditions,
lubrication frequencies must be increased accordingly.
7. With the return line and the pickup tube removed,
the pump can be removed.
8. Loosen and remove the two hexhead nuts from the
pump and block.
NOTE:
Pump/Tank Disassembly
1. Place the pump/motor assembly on a clean workbench.
Drain the hydraulic oil by carefully removing the oil fill plug
located on the hydraulic reservoir and tilting the assembly up
allowing oil to drain into a clean container.
NOTICE
NOTE TORQUE VALUES IN FIGURE 4-2. FOR THE VARIOUS FASTENERS AND VALVES INSTALLED ON THE VALVE BODY. DO NOT
OVERTIGHTEN OR DAMAGE COULD OCCUR.
Pump Motor Removal
2. Remove the oil tank from the pump as follows:
a. Slowly loosen and remove the four bolts that
hold the tank to valve body attachment ring on
to the valve body.
b. Carefully remove the tank from the valve taking
care not to damage internal pickup tube or oring gasket on tank.
c. Place tank on a suitable work bench or work
area.
NOTE:
Be sure to remove and discard the plastic plug at the oil inlet
on the new pump before installing.
9. Check o-ring on valve block and replace if necessary before installing the new pump.
(See Figure 4-2.)
NOTE:
There are two o-rings located in the valve for the pump outlet.
1. Remove the four bolts attaching the motor to the
valve adapter assembly.
2. Pull motor from valve.
3. Once all maintenance is performed, reinstall tank
assembly on machine, remove fill cap and refill tank
with proper grade of oil by using a funnel. Fill until oil
is up to the MAX level indicator on the side of the
tank.
The filter and bypass are located on the pickup tube inside
the tank. The filter should be changed once a year.
3. If replacing filter, pull old filter off the end of the tube
and push new filter onto the end of tube.
a. Thoroughly clean the tank and clean any debris
from the magnet.
b. Wipe out tank with clean, lint free rag, taking
care not to introduce debris or dirt.
4-4
– JLG Lift –
3121273
SECTION 4 - HYDRAULICS
32 - 40 Nm
Torque: 24 - 29 ft.lb.
14
19
Torque: 37 - 44 ft. lb.
50 - 60 Nm
10
13
18
Torque: 15 - 18 ft. lb.
20 - 25 Nm
23
44
1
2
12
Torque: 3.5 - 4.5 ft.lb.
5 - 6 Nm
6
3
Torque: 15 - 18 ft. lb.
20 - 25 Nm
21
Torque: 15 - 18 ft. lb.
20 - 25 Nm
17
16
11
22
Torque: 18 - 22 ft. lb.
25 - 30 Nm
7
Torque: 29 - 37 ft. lb.
15
40 - 50 Nm
8
9
8.5-10 Nm
Torque: 6 - 7 ft. lb.
20
5
4
Figure 4-2. Hydraulic Motor, Pump and Tank Assembly (All Machines)
1.
2.
3.
4.
5.
6.
7.
8.
Main Valve Body
Pump Electric Motor
Motor to Valve Body Adapter
Hydraulic Oil Tank
Tank to Valve Body Attachment Ring
Tank to Valve Body - O-Ring
Auxiliary Pressure (M) Port
Suction Pipe
3121273
9.
10.
11.
12.
13.
14.
15.
16.
Suction Filter
Modular to Main Valve Body Screw
Solenoid Valve
Lift Relief Valve
Steer Relief Valves
Valve Coil for Steer Cylinder
Gear Pump
Return Filter w/Bypass
– JLG Lift –
17.
18.
19.
20.
21.
22.
23.
Return Filter Pipe
1/4" JIC/BSPP Adapter
3/8" JIC/BSPP - 90° Adapter
Product ID Plate
Valve Coil for Lift Up/Down
M Port - 1/4" BSPP
P1 Port - 3/8" BSPP
4-5
SECTION 4 - HYDRAULICS
4.4 LIFT PRESSURE SETTING PROCEDURE
1. Place 120% of the rated load of the machine on the
platform.
4.5 CYLINDER CHECKING PROCEDURE
NOTE:
2. Increase lift pressure to raise the platform to full
height.
1. Using all applicable safety precautions, activate
pump motor and fully extend cylinder to be
checked.
3. Adjust the pressure setting screw on lift relief valve
to reach the proper lift pressure per model as listed
in Table 4-2.
2. Carefully disconnect hydraulic hoses from retract
port of cylinder. There will be some initial weeping of
hydraulic fluid which can be caught in a suitable
container. After the initial discharge, there should be
no further drainage from the retract port.
Table 4-2. Lift Pressure Settings
Model
Lift Relief
Steer Relief
1932RS/6RS
2300 psi ± 50 psi
(159 bar ± 3.5 bar)
1000 psi
(69 bar)
3248RS/10RS
2500 psi ± 50 psi
(172 bar ± 3.5 bar)
1000 psi
(69 bar)
3. Activate pump motor and extend cylinder.
4. If cylinder retract port leakage is less than 6-8 drops
per minute, carefully reconnect hose to port and
retract cylinder. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repair must be
made.
Alternate Lift Pressure Setting Procedure (if 120% load or high ceiling is not available):
NOTE:
1. Install adapter from table into M-port or P1-port on
pump (see Figure 4-2.) and attach pressure gauge.
Table 4-3. Pressure Fitting Adapter
PORT
JLG PART #
P1
300057 - JIC
M
Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected.
Steps 5 through 7 for Steer Cylinder Only.
5. With cylinder fully retracted, shut down machine
power and carefully disconnect hydraulic hose from
cylinder extend port.
6. Activate pump motor and retract cylinder. Check
extend port for leakage.
300017 - JIC
2221222 - Quick Disconnect
2. Remove the solenoid from the lift valve.
3. Activate the lift function from the ground or platform
and adjust the pressure setting screw on lift relief
valve to reach the proper lift pressure per model as
listed in Table 4-2.
7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, than
activate cylinder through one complete cycle and
check for leaks. If leakage continues at a rate of 6-8
drops per minute or more, cylinder repairs must be
made.
4. Remove the pressure gauge from port M or P1 and
replace plug.
5. Replace the solenoid on the lift valve.
4-6
– JLG Lift –
3121273
SECTION 4 - HYDRAULICS
4.6 LIFT CYLINDER REMOVAL
NOTE:
3. Remove the valve connector, the two hoses and the
manual decent cable from the cylinder.
If there is a pump failure, a crane or a forktruck can be used
to raise the platform. Refer to Figure 3.15, Scissor Arms
Removal.
NOTE:
Self locking fasteners, such as nylon insert and thread
deforming locknuts, are not intended to be reinstalled
after removal. Always use new replacement hardware
when installing locking fasteners.
1. Raise the platform and use an overhead crane or
fork truck to secure the platform and scissor arms
before lift cylinder removal begins. (See Figure 341.)
2. Cut any wire ties that attach any cables or hoses to
the lift cylinder.
To avoid having to readjust the manual descent, remove the
large nut located behind the manual descent bracket as
shown.
Also see Figures 3-42., 3-43., 3-44., for lift cylinder mounting hardware configurations.
4. Ensuring that the deck and scissor arms are properly secure, remove the top lift cylinder pin and rest
the top of the cylinder on the arm cross tube directly
below the cylinder.
5. Remove the bolt from the lower cylinder pin and
have someone assist you in lifting the cylinder from
the scissor arms.
6. Place the cylinder on a clean workbench.
NOTICE
DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE
REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER
ASSEMBLY.
3121273
– JLG Lift –
4-7
SECTION 4 - HYDRAULICS
4.7 CYLINDER REPAIR
NOTE:
removing again. If still no release, tap barrel with
hammer in threaded area, and try again. Repeat if
necessary, until head is completely removed.
The following are general procedures that apply to the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.
7. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
Disassembly
NOTICE
NOTICE
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
1. Connect a suitable auxiliary hydraulic power source
to the port block fitting in the manifold located on the
cylinder.
8. With the barrel clamped securely, apply pressure to
the rod pulling device and carefully withdraw the
complete rod assembly from the cylinder barrel.
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
2. Operate the hydraulic power source and extend the
cylinder. Shut down and disconnect the power
source. Adequately support the cylinder rod, if applicable.
3. If applicable, remove the cartridge-type holding
valve and fittings from the cylinder port block. Discard o-rings.
4. Place the cylinder barrel into a suitable holding fixture.
Figure 4-4. Cylinder Rod Support
9. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to the piston
as possible.
NOTE:
For steer cylinder piston removal, see Steer Cylinder Piston
Removal on page 4-9 following.
10. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.
11. Insert the cap screw(s) in the threaded holes in the
outer piece of the tapered bushing. Progressively
tighten the cap screw(s) until the bushing is loose
on the piston.
Figure 4-3. Cylinder Barrel Support
12. Remove the bushing from the piston.
5. Mark cylinder head and barrel with a center punch
for easy realignment. Loosen the cylinder head setscrew.
6. Using the proper wrench, loosen the cylinder head
and remove head from cylinder barrel.
When removing cylinder head do not force if binding
occurs. Reverse rotation a couple times and try
4-8
13. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.
14. Remove and discard the piston o-rings, seal rings,
and backup rings.
15. If applicable, remove the piston spacer from the rod.
16. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applica-
– JLG Lift –
3121273
SECTION 4 - HYDRAULICS
ble. Discard the o-rings, back-up rings, rod seals,
and wiper seals.
Steer Cylinder Piston Removal
1. Using the spanner holes, rotate the piston until the
end of the retaining ring can be seen through the
cross-drilled retaining ring hole.
2. Insert a flathead screwdriver (or similar tool) into the
cross-drilled retaining ring hole.
3. Using the screwdriver, guide the retaining ring into
the cross-drilled retaining ring hole while turning the
piston.
10. Inspect threaded portion of head for damage. Dress
threads as necessary.
11. Inspect seal and o-ring grooves in head for burrs
and sharp edges. Dress applicable surfaces as necessary.
12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
a. Thoroughly clean hole, (steel bushing) of burrs,
dirt etc. to facilitate bearing installation.
4. Continue turning the piston approximately one (1)
full turn until the start of the retaining ring is again
aligned with the cross-drilled retaining ring hole.
b. Inspect steel bushing for wear or other damage.
If steel bushing is worn or damaged, rod/barrel
must be replaced.
5. Lift up on the retaining ring so that the hook on the
start of the retaining ring releases from the hole in
the rod.
c. Lubricate inside of steel bushing with WD40
prior to bearing installation.
d. Using an arbor of the correct size, carefully
press the bearing into steel bushing.
6. Pull the retraining ring all the way out of the crossdrilled retraining ring hole.
7. Slide the piston over the rod in the direction of the
spanner holes to remove.
NOTE:
Install pin into the Gar-Max bearing dry. Lubrication is not
required with nickel plated pins and bearings.
Cleaning and Inspection
1. Clean all parts thoroughly in an approved cleaning
solvent.
STEEL
BUSHING
2. Inspect the cylinder rod for scoring, tapering, ovality,
or other damage. If necessary, dress rod with
Scotch Brite or equivalent. Replace rod if necessary.
3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.
ARBOR
4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for
tapering or ovality. Replace if necessary.
5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.
6. Inspect piston surface for damage and scoring and
for distortion. Dress piston surface or replace piston
as necessary.
GAR-MAX
BUSHING
Figure 4-5. Gar-Max Bearing Installation
14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter
surface with Scotch Brite or equivalent.
15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
16. Inspect the oil ports for blockage or the presence of
dirt or other foreign material. Repair as necessary.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.
3121273
– JLG Lift –
4-9
SECTION 4 - HYDRAULICS
Assembly
NOTE:
Prior to cylinder assembly, ensure that the proper cylinder
seal kit is used. See your JLG Parts Manual for these
machine models.
Apply a light film of hydraulic oil to all components prior to
assembly.
1. A special tool is used to install a new rod seal into
the applicable cylinder head gland groove.
Figure 4-8. Wiper Seal Installation
3. Place a new “O-ring and back-up seal in the applicable outside diameter groove of the cylinder head.
Figure 4-6. Rod Seal Installation
NOTICE
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
Figure 4-9. Installation of Head Seal Kit
4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod
seals are not damaged or dislodged. Push the head
along the rod to the rod end, as applicable.
2. Use a soft mallet to tap a new wiper seal into the
applicable cylinder head gland groove. Install a new
wear ring into the applicable cylinder head glandgroove.
5. If applicable, correctly place new o-ring in the inner
piston diameter groove. (The backup ring side facing the O-ring is grooved.)
6. If applicable, correctly place new seals and guide
lock rings in the outer piston diameter groove. (A
tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal.)
NOTE:
Figure 4-7. Poly-Pak Piston Seal Installation
The backup rings for the solid seal have a radius on one side.
This side faces the solid seal.(See magnified insert in Figure
4-9. The split of seals and backup rings are to be positioned
so as not to be in alignment with each other.
7. Using suitable protection, clamp the cylinder rod in
a vise or similar holding fixture as close to piston as
possible.
4-10
– JLG Lift –
3121273
SECTION 4 - HYDRAULICS
8. Carefully thread the piston on the cylinder rod hand
tight, ensuring that the o-ring and back-up rings are
not damaged or dislodged.
19. Secure the cylinder head gland using the washer
ring and socket head bolts.
9. Thread the piston onto the rod until it abuts the
spacer end and install the tapered bushing.
Barrel Asssembly
NOTE:
When installing the tapered bushing, piston and mating end
of rod must be free of oil.
Piston Asssembly
10. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and
into the tapped holes in the piston.
Cylinder Rod
11. Tighten the capscrews evenly and progressively in
rotation to the specified torque value.
12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass
shaft (approximately 3/4" in diameter) as follows;
a. Place the shaft against the cylinder rod and in
contact with the bushing in the spaces between
the capscrews.
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.
Head Gland
Figure 4-10. Rod Assembly Installation
20. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
14. Remove the cylinder rod from the holding fixture.
21. If applicable, install the cartridge-type holding valve
and fittings in the rod port block, using new o-rings
as applicable. (See Figure 4-13., 1932RS/6RS - Lift
Cylinder or Figure 4-14., 3248RS/10RS - Lift Cylinder).
15. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
22. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut.
13. Retorque the capscrews evenly and progressively in
rotation to the specified torque value.
16. Position the cylinder barrel in a suitable holding fixture.
NOTICE
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
17. With the barrel clamped securely, and while adequately supporting the rod, insert the piston end into
the barrel cylinder. Ensure that the piston loading oring and seal ring are not damaged or dislodged.
18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
3121273
WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #262 TO
THE PISTON NUT, THEN TORQUE PISTON NUT. REFER TO APPLICABLE CYLINDER ILLUSTRATION FOR TORQUE REQUIREMENT.
NOTE:
Reverse the procedure Steer Cylinder Piston Removal on
page 4-9 for installing the steer cylinder piston.
23. Remove the cylinder rod from the holding fixture.
24. Position the cylinder barrel in a suitable holding fixture.
NOTICE
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND
CYLINDER BARREL SURFACES.
– JLG Lift –
4-11
SECTION 4 - HYDRAULICS
25. With barrel clamped securely, and while adequately
supporting the rod, insert the piston end into the
barrel cylinder. Ensure that the piston loading o-ring
and seal ring are not damaged or dislodged.
26. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.
1
27. If applicable, secure the cylinder head retainer using
a suitable chain wrench.
28. After the cylinder has been reassembled, the rod
should be pushed all the way in (fully retracted) prior
to the reinstallation of any holding valve or valves.
29. If applicable, install the cartridge-type holding valve
and fittings in the port block using new o-rings as
applicable. Refer to Figure 4-13., 1932RS/6RS - Lift
Cylinder on page 4-13. or Figure 4-14., 3248RS/
10RS - Lift Cylinder on page 4-14
Lift Cylinder - LSS Pressure Sensor Location
(If Equipped)
Lift cylinders on machines with the Load Sensing System
(LSS) are equipped with two pressure sensing transducers installed. These sensors, two are used in case one
should fail, are wired in parallel directly to the machine
control module as part of the LSS system.
2
3
Figure 4-12. LSS Pressure Sensors Location 3248RS/10RS - (If Equipped)
1. Ports On Bottom of Cylinder
2. Pressure Sensors
3. Harness Connectors
3
2
1
Figure 4-11. LSS Pressure Sensors Location 1932RS/6RS - (If Equipped)
1. Ports On Barrel of Cylinder
2. Pressure Sensors
4-12
3. Harness Connectors
– JLG Lift –
3121273
SECTION 4 - HYDRAULICS
Torque: 29 - 38 ft. lb.
39 - 51 Nm
4
6
5
Torque: 25 - 30 ft. lb.
33 - 40 Nm
1
(Apply Loctite #262 to threads
before assembly.)
Torque: 240 - 294 ft. lb.
325 - 398 Nm
15
14
16
17
13
12
11
9
10
8
7
2
Torque: 358 - 438 ft. lb.
485 - 593 Nm
3
Figure 4-13. 1932RS/6RS - Lift Cylinder
1.
2.
3.
4.
Cylinder Barrel
Cylinder Rod
Bushing
Proportional Valve w/Manual
Release
5. Check Valve
3121273
6.
7.
8.
9.
10.
11.
Extend/Retract - Block Fittings
Head
Seal
Seal w/Backing Ring
O-Rings
Wear Ring
– JLG Lift –
12.
13.
14.
15.
16.
17.
Rod Piston
D-Ring
Seal
Wear Ring
O-Ring
Piston Nut
4-13
SECTION 4 - HYDRAULICS
Torque: 29 - 38 ft. lb.
39 - 51 Nm
4
6
5
Torque: 25 - 30 ft. lb.
33 - 40 Nm
1
(Apply Loctite #262 to threads
before assembly.)
Torque: 406 - 448 ft. lb.
634 - 700 Nm
15
14
16
13
17
12
11
9
10
8
7
2
Torque: 577 - 637 ft. lb.
782 - 863 Nm
3
Figure 4-14. 3248RS/10RS - Lift Cylinder
1.
2.
3.
4.
Cylinder Barrel
Cylinder Rod
Bushing
Proportional Valve and Coil, w/
Manual Release
5. Check Valve
4-14
6.
7.
8.
9.
10.
11.
Pressure/Tank - Block Fittings
Head
Seal
Seal w/Backing Ring
O-Rings
Wear Ring
– JLG Lift –
12.
13.
14.
15.
16.
17.
Rod Piston
D-Ring
Seal
Wear Ring
O-Ring
Piston Nut
3121273
SECTION 4 - HYDRAULICS
Torque: 13 ft. lb.
17.6 Nm
14
15
(Apply Loctite #262 to threads
before assembly.)
1
131 - 161 Nm
Torque: 97 - 119 ft. lb.
15
12
11
10
13
8
3
7
9
6
5
4
2
Torque: 306 - 374 ft. lb.
415 - 507 Nm
Figure 4-15. 1932RS/6RS - Steer Cylinder
1.
2.
3.
4.
5.
3121273
Cylinder Barrel
Cylinder Rod
Head
Wiper Seal
Rod Seal
6.
7.
8.
9.
10.
Wear Ring
O-Ring
O-Ring
Piston
Rod O-Ring
– JLG Lift –
11.
12.
13.
14.
15.
Piston Seal
Wear Ring
Nut
Hose Fittings
O-Ring
4-15
SECTION 4 - HYDRAULICS
Torque: 13 ft. lb.
17.6 Nm
15
14
1
(Apply Loctite #262 to threads
before assembly.)
131 - 161 Nm
Torque: 97 - 119 ft. lb.
12
15
11
10
13
8
7
5
9
6
4
3
2
Torque: 306 - 374 ft. lb.
415 - 507 Nm
Figure 4-16. 3248RS/10RS - Steer Cylinder
1.
2.
3.
4.
5.
4-16
Cylinder Barrel
Cylinder Rod
Head
Wiper Seal
Rod Seal
6.
7.
8.
9.
10.
O-Ring
Wear Ring
O-Ring
Piston
Piston O-Ring
– JLG Lift –
11.
12.
13.
14.
15.
Piston Seal
Wear Ring
Nut
Hose Fittings
O-Ring
3121273
SECTION 5 - JLG CONTROL SYSTEM
SECTION 5. JLG CONTROL SYSTEM
5.1 HAND HELD ANALYZER
men u:
HELP:PRESS ENTER
Analyzer Display
Escape Key
Enter Key
To return home or access
previous menu
Stores and selects Top Level, Sub
Level, and item menus
Left & Right Arrow Keys
Up & Down Arrow Keys
Used to move between Top Level,
Sub Level, and item menus
Value Selector
Figure 5-1. Hand Held Analyzer
Diagnostic Port
The diagnostic port to connect the Hand Held Analyzer is
located behind the hydraulic cover (machine left side) at
or near the ground control station as shown in Figure 5-2.
To Connect the Hand Held Analyzer:
1. Connect the four pin end of the cable supplied with
the analyzer, to the diagnostic port and connect the
remaining end of the cable to the analyzer.
NOTE: The cable has a four pin connector at each end of
the cable; the cable cannot be connected backwards.
2. Power up the Control System by turning the lower
key to the platform position and pulling both emergency stop buttons on.
Figure 5-2. Diagnostic Port Location
3121273
– JLG Lift –
5-1
SECTION 5 - JLG CONTROL SYSTEM
Using the Analyzer:
With the machine power on and the analyzer connected
properly, the analyzer will display the following:
In platform mode,
HELP: (001)
EVERYTHING OK,
In ground mode,
HELP: (002)
GROUND MODE OK
If ENTER is pressed again, the display moves to the following display:
MENU:
HELP:PRESS ENTER
l og:
HELP:
PRESS ENTER
At this point, using the RIGHT and LEFT arrow keys, you
can move between the top level menu items. To select a
displayed menu item, press ENTER. To cancel a selected
menu item, press ESC; then you will be able to scroll
using the right and left arrow keys to select a different
menu item.
The top level menus are as follows:
HELP
DIAGNOSTICS
SYSTEM TEST
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
CALIBRATION
EMULATION MODE
LOG: (211)
1: Power Cycle (Or last recorded fault)
At this point, the analyzer will display the highest priority
active fault, if any are present. You may scroll through the
fault logs to view what the last fifteen faults were. Use the
right and left arrow keys to scroll through the fault logs.
The active faults, are listed before the first POWER
CYCLE. To return to the top menu, press ESC two times.
When a top level menu is selected, a new set of menu
items may be offered; If for example you choose Personalities:
DRIVE
LIFT
STEER
GROUND
If you press ENTER, at the HELP:PRESS ENTER display,
and a fault is present, the analyzer display will scroll the
fault across the screen. If more than one fault is present
only the highest priority fault will show. The other active
faults are viewable in Logged Help. If there was no fault
detected, the display will read:
5-2
( 211)
Pressing ENTER with any of the above displayed menus,
will display additional sub-menus within the selected
menu. In some cases the next level is the parameter or
information to be changed. Refer to the flow chart for what
menus are available within the top level menus. You may
only view the personality settings for selected menus
while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key.
– JLG Lift–
3121273
SECTION 5 - JLG CONTROL SYSTEM
Changing the Access Level of the Hand Held
Analyzer:
When the analyzer is first connected, you will be in access
level 2 which enables you to only view most configuration
settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access
level, the correct password must be entered. To enter the
password, scroll to the ACCESS LEVEL menu.
MENU:
ACCESS LEVEL 1
For example:
MENU:
ACCESS LEVEL 2
MENU:
ACCESS LEVEL 1
Repeat the above steps if the correct access level is not
displayed or you can not adjust the personality settings:
MENU:
ACCESS LEVEL 2
Press ENTER to select the ACCESS LEVEL menu.
Using the UP or DOWN arrow keys, enter the first digit of
the password, 3.
Then using the RIGHT arrow key, position the cursor to
the right one space to enter the second digit of the password.
Use the UP or DOWN arrow key to enter the second digit
of the password which is 3.
Repeat this process until you have entered all five digits of
the password which is 33271.
Once the correct password is displayed, press ENTER.
The access level should display the following, if the password was entered correctly:
3121273
– JLG Lift –
5-3
SECTION 5 - JLG CONTROL SYSTEM
Adjusting Parameters Using the Hand Held
Analyzer
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
Machine Setup
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION.
PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
1=DESCENT
PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
There will be a minimum and maximum for the value to
ensure efficient operation. The Value will not increase if
the UP arrow is pressed when at the maximum value nor
will the value decrease if the DOWN arrow is pressed and
the value is at the minimum value for any particular personality. If the value does not change when pressing the
up and down arrows, check the access level to ensure
you are at access level 1.
1=DESCENT
The effect of the machine digit value is displayed along
with its value. The above display would be selected if the
machine was equipped with a ground alarm and you
wanted it to sound when driving. There are certain settings allowed to install optional features or select the
machine model.
When selecting the machine model to match the size of
the machine, the personality settings will return to default
settings.
NOTE: Refer to Table 5-1, Machine Model Adjustment and
Figure 5-2, Machine Configuration Programming
Information for the default settings.
Password 33271 will give you access to level 1,
which will permit you to change all machine personality and/or machine setup settings.
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE
PERFORMANCE OF YOUR MACHINE.
5-4
– JLG Lift–
3121273
SECTION 5 - JLG CONTROL SYSTEM
Joystick Calibration
Updating Software
The joystick calibration should be completed if the joystick
is replaced. To perform the joystick calibration both emergency stop switches must be pulled out (reset) and the
ground control keyswitch set on platform mode.
1. Plug the analyzer into the machine, "Help Press
Enter" should be displayed on the analyzer display.
2. Press the right arrow key to "Access Level 2".
3. Press Enter once. At this screen, you are asked to
enter a password: Enter "33271" by doing the following:
Updating the power control module software requires a
laptop computer, connecting cable, and software update
cd. Contact JLG Industries to acquire the software cd.
Before updating the software, use the Hand-held Analyzer
to view the machine’s settings (MACHINE SETUP and
PERSONALITIES) (refer to Figure 5-3. thru Figure 5-9. for
Analyzer Flow Chart). It is important to write down the settings to verify they are the same after software update is
complete.
NOTE: Software update must be done with the machine
powered in Ground Mode.
a. Using the up and down key enter the first number.
1. Disconnect analyzer from diagnostic port.
b. Right arrow key once and enter the next number.
2. Using the laptop connector cable, connect the laptop to the diagnostic port.
c. Repeat steps A and B until you have entered
"33271" and press Enter.
d. Access level 1 should be on the display.
4. Press right arrow key to "Calibrations" and press
Enter once.
5. "Calibration: Joystick" should appear, press Enter
once.
6. "Cal Joystick: Yes: Enter, No: Esc" should appear,
press Enter once.
7. "Cal Joystick: Fwd to Max" will appear. Move joystick
completely forward and hold, then press Enter.
8. "Cal Joystick: Center" will appear. Release joystick to
the neutral position and press Enter.
3. Run the software update cd.
a. When the JLG Reprogramming Tool dialogue
box appears, click on the Program button.
b. Another dialogue box will appear asking if you
want to overwrite the current software version.
Click YES.
4. After software update is complete, disconnect computer from diagnostic port.
5. Reconnect the hand-held analyzer to the diagnostic
port.
a. Enter Access Level 1 password; 33271
9. "Cal Joystick: Rev to Max" will appear. move joystick
completely in the reverse position and hold, then
press Enter.
b. Scroll to MACHINE SETUP. Change MODEL
NUMBER to a different model, but immediately
change it back to the proper setting. Do the
same for MARKET. This will ensure the settings
are carried over to all parameters.
10. "Cal Joystick: Complete" will appear. Power down
the machine.
c. Scroll through the settings to verify they are the
same as before the software update.
6. Disconnect Analyzer.
7. Software update is complete.
3121273
– JLG Lift –
5-5
HELP: PRESS
ENTER
DIAGNOSTICS
5-6
– JLG Lift–
CODE XXXXX
ACCESS
LEVEL
PERSONALITIES
MACHINE
SETUP
Figure 5-3. Analyzer Menu - Access Level
SYSTEM
TEST
JLG Analyzer
Diagnos c
Interface
CALIBRATIONS
EMULATION
MODE
SECTION 5 - JLG CONTROL SYSTEM
3121273
3121273
LIFT UP OPEN/
CLOSED
LIFT DN OPEN/
CLOSED
DRIVE SEL
OPEN/CLOSED
LIFT SEL
OPEN/CLOSED
– JLG Lift –
FOOTSWITCH OPEN/
CLOSED (Displayed
when FOOTSWITCH is
1=YES)
JOYSTICK
100% to -100%
TRIGGER
OPEN/CLOSED
HORN OPEN/
CLOSED
STEER RT
OPEN/CLOSED
STEER LT
OPEN/CLOSED
GROUND
PLATFORM
HELP: PRESS
ENTER
HORN OFF/
ON
FLD CUR
XXX.XA
TEMP XX.XC
BRAKES OFF/
ON
FLD PWM
0.0-100.0%
AC
CONNECTED/
NOT
CONNECTED
CHARGER
LOAD:TOCLEAROVLD
PRES XXXXPSI
LOAD:PRES DIFF
OVLD-P1 XXXXPSI
LOAD:PRES DIFF
P1-P2 XXXXPSI
LOAD:
PRES2 XXXXPSI
LOAD:
PRES1 XXXXPSI
LOAD:
OVERLOADED?
YES/NO
LOAD (Display
when LOAD is
1=CUTOUT PLT,
2=CUTOUT ALL)
ANGLE:
ANGLE XXX
ANGLE:
ANGLERANGE
XXX
ANGLE:
MAXANGLE
XXX
ANGLE:
MINANGLE
XXX
ANGLE
Figure 5-4. Analyzer Menu - Diagnostics
LIFT DOWN
0-100%
LIFT UP
OFF / ON
PLATFORM
STOWED/
ELEVATED
HIGH SPEED
STEER RIGHT
OFF / ON
ELEV SW2:
OPEN/
CLOSED
BATTERY
XX.XV
STEER LEFT
OFF / ON
ELEV SW1:
OPEN/
CLOSED
MODE:
GROUND/
PLATFORM
VALVES
ELEV SENSOR
SYSTEM
TILT: TILTED/
NOT TILTED
PUMP CUR
XXX.XA
PUMP PWM
0-100%
PUMP
ARM CUR
XXXA
ARM PWM
0.0-100.0&
SPEED 0-100%
TRACTION
DIAGNOSTICS
JLG Analyzer
Diagnos c
Interface
DRIVE XXH
YYM
LIFT XXH
YYM
RENTAL XXH
YYM
DATALOG
TOTAL XXH
YYM
SYSTEM
TEST
MACHINE
SETUP
ANALYZER
SYS HW REV
PWR SW PX.Y
SYS SW PX.Y
VERSIONS
PERSONALITIES
ERASE
RENTAL?(Display
for Access Level 0
&1)
ACCESS
LEVEL
SECTION 5 - JLG CONTROL SYSTEM
5-7
: PRESS
NTER
5-8
RUN SYSTEM TEST:
YES:ENTER, NO:ESC
DIAGNOSTICS
– JLG Lift–
LIFT DOWN OPEN/
CLOSED
STEER RT OPEN/
SHORT
DRIVE
LIFT
HORN
TRIGGER
RIGHT
LEFT
TEST PLT SW?
(Pla orm Mode Only)
ALARM
HORN
OVERLD
TEST OVLD&ALRM?
(Ground Mode Only)
PLAT ALARM
OVERLD
TILT LAMP
SYS DISTRESS
TEST LEDS&ALRM?
Pla orm Mode Only)
Figure 5-5. Analyzer Menu - System Test
LIFT UP OPEN/
CLOSED
STEER LT OPEN/
SHORT
LIFT UP OPEN/
SHORT
TEST GND SW?
(Ground Mode Only)
TEST VALVES?
SYSTEM
TEST
JLG Analyzer
Diagnos c
Interface
REV TO MAX
CENTER
FWD TO MAX
TEST PROP CNTRL?
(Pla orm Mode Only)
TEST COMPLETE
ACCESS
LEVEL
PERSON
SECTION 5 - JLG CONTROL SYSTEM
3121273
NOSTICS
SYSTEM TEST
ACCESS LEVEL
3121273
– JLG Lift –
UP ACCEL
0.1 – 5.0S
UP DECEL
0.1 – 1.0S
DN ACCEL
0.1 – 5.0S
DN DECEL
0.1 – 5.0S
UP MIN
0-100%
ACCEL
0.1 – 5.0S
DECEL
0.1 – 1.0S
MINIMUM
0-100%
MAXIMUM
0-100%
ELEV. MAX
0-25%
DN MAX
1-100%
DRIVE 0100%
STATIC 0100%
STEER
REV MAX
3.50 – 4.00V
REV MIN
2.60 – 2.80V
FWD MAX
1.00 – 1.50V
FWD MIN
2.20 – 2.40V
ACCELERATOR
ALARM 5100%
HORN 5100%
GROUND
PERSONALITIES
OVR HOLD
0.0 – 5.0S
OVR DBNCE
0.0 – 5.0S
LOAD
Figure 5-6. Analyzer Menu - Personalities
DN MIN 160%
UP MAX
0-100%
LIFT
DRIVE
JLG Analyzer
Diagnos c
Interface
FLD MIN
1- 100%
WEAK DROP
0 – 100%
NOM ARMA
0 – 100%
FLD MAX
ARM 0-100%
MAX CUR
0 – 100%
TRACTION
MAX CUR
0 – 100%
PUMP
MACHINE
SETUP
CALIBRATIONS
EM
M
SECTION 5 - JLG CONTROL SYSTEM
5-9
ACCESS LEVEL
5-10
– JLG Lift–
BATTERY:
(0=FLOODED)/
1=AGM
BATTERY:
(0=FLOODED)/
1=AGM
GROUND ALARM:
0=HORN ONLY/
1=DESCENT/
2=MOTION
CHARGER INTERLOCK
(0=DRIVE ONLY)/
1=DRV & LIFT UP
2=CSA
TILT CUTOUT
(0=NO)/1=YES
3=CE
4=AUSTRALIA
5=JAPAN
CALIBRATIONS
ARMGUARD:
0=NO/(1=YES)
BATTERY:
(0=FLOODED)/
1=AGM
LOAD:0=NOT
INSTALLED/
(1=CUTOUT PLT)/
2=CUTOUT ALL
GROUND ALARM:
0=HORN ONLY/
1=DESCENT/
2=MOTION
BATTERY:
(0=FLOODED)/
1=AGM
LOAD:0=NOT
INSTALLED/
(1=CUTOUT PLT)/
2=CUTOUT ALL
FOOTSWITCH:
0=NO/(1=YES)
BATTERY:
(0=FLOODED)/
1=AGM
LOAD:0=NOT
INSTALLED/
(1=CUTOUT PLT)/
2=CUTOUT ALL
GROUND ALARM:
0=HORN ONLY/
1=DESCENT/
2=MOTION
CHARGER INTERLOCK CHARGER INTERLOCK CHARGER INTERLOCK
(0=DRIVE ONLY)/
(0=DRIVE ONLY)/
(0=DRIVE ONLY)/
1=DRV & LIFT UP
1=DRV & LIFT UP
1=DRV & LIFT UP
MARKET:
MACHINE SETUP
Figure 5-7. Analyzer Menu - Machine Setup
BATTERY:
(0=FLOODED)/
1=AGM
LOAD:0=(NOT
INSTALLED)/
1=CUTOUT PLT/
2=CUTOUT ALL
GROUND ALARM:
0=HORN ONLY/
1=DESCENT/
2=MOTION
GROUND ALARM:
0=HORN ONLY/
1=DESCENT/
2=MOTION
1=ANSI EXPORT
CHARGER INTERLOCK
(0=DRIVE ONLY)/
1=DRV & LIFT UP
0=ANSI USA
MODEL
NUMBER:
6M/8M/10M
CHARGER INTERLOCK
(0=DRIVE ONLY)/
1=DRV & LIFT UP
PERSONALITIES
JLG Analyzer
Diagnos c
Interface
EMULATION
MODE
SECTION 5 - JLG CONTROL SYSTEM
3121273
3121273
– JLG Lift –
CAL ANGLE:
LIFT TO MAX
CAL ANGLE:
LOWER TO STOWED
CAL ANGLE:
COMPLETE/CAL FAIL
CAL JOYSTICK:
FWD TO MAX
CAL JOYSTICK:
CENTER
CAL JOYSTICK:
REV TO MAX
CAL JOYSTICK:
COMPLETE/CAL FAIL
CAL ANGLE:
YES:ENTER, NO:ESC
CAL JOYSTICK:
YES:ENTER, NO:ESC
MACHINE
SETUP
ANGLE
PERSONALITIES
JOYSTICK
ACCESS LEVEL
NOM FIELD
FIELD ADJ
ARMATURE ADJ
NOM FIELD CURR
MAX ARMA CURR
TRACTION
PUMP
PUMP ADJ
MAX PUMP CUR
CALIBRATIONS
Figure 5-8. Analyzer Menu - Calibrations
CAL LOAD:
COMPLETE/FAIL
CAL LOAD:
LOWER TO STOWED
CAL LOAD:
LIFT TO MAX
CAL LOAD:
110%LOAD,CENTER?
CAL LOAD:
YES:ENTER, NO:ESC
LOAD
JLG Analyzer
Diagnos c
Interface
TEMPERATURE
BATTERY
SYSTEM
CLEAR EEPROM:
YES:ENTER, NO ESC
LOGGED HELP CLEAR
CLEAR EEPROM:
YES:ENTER, NO ESC
CLEAR EEPROM
EMULATION
MODE
SECTION 5 - JLG CONTROL SYSTEM
5-11
HELP: PRESS
ENTER
DIAGNOSTICS
5-12
ACCESS
LEVEL
PERSONALITIES
MACHINE
CALIBRATIONS
SETUP
Figure 5-9. Analyzer Menu - Emulation Mode
SYSTEM
TEST
JLG Analyzer
Diagnos c
Interface
EMULATION
MODE OFF/ON
EMULATION
MODE
SECTION 5 - JLG CONTROL SYSTEM
– JLG Lift–
3121273
SECTION 5 - JLG CONTROL SYSTEM
5.2 MACHINE MODEL ADJUSTMENT
Table 5-1. Machine Model Adjustment
Adjustment
Adjustment Range
6RS
10RS
1932RS 3248RS
DRIVE
ACCEL
0.1 - 5.0 (Sec)
0.7
0.7
0.7
0.7
DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
MINIMUM
0 - 25%
0
0
0
0
MAXIMUM
0 -100%
100
100
100
100
ELEV. MAX.
0 - 30%
13
15
13
15
LIFT
UP ACCEL
0.1 - 5.0 (Sec)
0.5
0.5
0.5
0.5
UP DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
DN ACCEL
0.1 - 5.0 (Sec)
0.1
0.1
0.1
0.1
DN DECEL
0.1 - 5.0 (Sec)
0.1
0.1
0.1
0.1
UP MIN
0 - 50%
20
20
20
20
UP MAX
0 - 100%
100
100
100
100
DN MIN
1 - 60%
45
45
45
45
DN MAX
1 - 100%
85
85
85
85
STATIC
0 - 100%
40
50
40
50
DRIVE
0 - 100%
20
25
20
25
STEER
ACCELERATOR
FWD MIN
2.20 - 2.40 V
2.23
2.23
2.23
2.23
FWD MAX
1.00 - 1.50 V
1.19
1.19
1.19
1.19
REV MIN
2.60 - 2.80 V
2.74
2.74
2.74
2.74
REV MAX
3.50 - 4.00 V
3.78
3.78
3.78
3.78
GROUND
HORN
5 - 100%
100
100
100
100
ALARM
5 - 100%
15
15
15
15
OVR DBNCE
0.0 - 5.0 (Sec)
0.3
0.3
0.3
0.3
OVR HOLD
0.0 - 5.0 (Sec)
3.0
3.0
3.0
LOAD
3.0
1001135850-B
NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.
3121273
– JLG Lift –
5-13
SECTION 5 - JLG CONTROL SYSTEM
5.3 MACHINE CONFIGURATION PROGRAMMING INFORMATION
NOTE: 1. When configuring an RS scissors machine, the machine configuration must be completed before any personality
settings can be changed. Changing the personality settings first and then changing the model number of the machine
configuration will cause the personality settings to return to default.
2. Shaded entries are not available for the selected Market.
Table 5-2. Machine Configuration Programming Information
Market Default Setting
Configuration
Digit
Setting
Description
1
(MODEL1)
0
1
2
3
4
5
6RS
8RS
10RS
1932RS
2632RS
3248RS
0
2
(MARKET 1)
0
1
2
3
5
ANSI USA
ANSI EXPORT
CSA
CE
JAPAN
0
3
(TILT CUTOUT)
0
1
NO - Drive and Lift Up NOT prevented while Tilted (Ground and Platform Mode).
YES - Drive and Lift Up prevented while Tilted (Ground and Platform Mode).
4
(CHARGER
INTERLOCK)
0
1
DRIVE ONLY - Drive motion prevented while vehicle is charging.
DRIVE AND LIFT UP - Drive and lift up motions are prevented while vehicle is charging. Required for CE.
0
NOT INSTALLED - Vehicle alarm will function for Arm Guard (if enabled), Overload (if
LSS enabled), and as a Horn.
DESCENT - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled), as a Horn, and during Lift Down motion.
MOTION - Vehicle alarm will function for Arm Guard (if enabled), Overload (if LSS
enabled), as a Horn, and during Drive and Lift motions.
0
0
NOT INSTALLED - Load Sensing System (LSS) is not fitted to the vehicle.
CUTOUT PLT - Load Sensing System (LSS) is fitted, and Platform Controls are prevented in the event of an Overload. Ground Controls remain functional. This is the
default setting for CE machines.
CUTOUT ALL - Load Sensing System (LSS) is fitted. Platform and Ground Controls
are prevented in the event of an Overload.
0
0
5
(GROUND
ALARM)
1
2
0
1
6
(LOAD)
2
7
(BATTERY)
0
1
FLOODED - Batteries are conventional lead-acid type.
AGM - Batteries are absorbed glass mat type.
8
(FOOT-SWITCH
0
1
NO - Vehicle is not fitted with a footswitch.
YES - Vehicle is fitted with a footswitch.
0
1
1
1
2
3
5
0
1
0
1
1
0
1
1
0
1
1
0
0
0
0
0
1001135849-B
5-14
– JLG Lift–
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
SECTION 6. DIAGNOSTIC TROUBLE CODES
6.1
INTRODUCTION
This section provides a reference for Diagnostic Trouble Codes (DTC) read from the Multifunction Digital Indicator (MDI) or a
handheld analyzer. For more information on any sensors or indicators, refer to the appropriate manual section. Many of the
checks below require configuring and using a multimeter. Refer to Section 7: General Electrical Information & Schematics for
multimeter basics. To troubleshoot multiple DTCs, start with the DTC with the higher first two digits. The machine is powered
by four 6 Volt batteries in series, providing a nominal 24 Volts to the control system. Some procedures below refer to this
nominal voltage (VMN) as 24V. Actual voltage measurements may differ based on the charge of the batteries. If a correction
is made during a check, conclude the check by cycling the machine power, using the emergency stop switch. It may
also be helpful to run a system test, ANALYZER -> SYSTEM TEST for intermittent or difficult problems.
System Fault/DTC Indication
In addition to the DTC codes being displayed on the MDI and handheld analyzer, DTC codes are indicated by the number of
flashes and pauses of the Low Battery Charge/System Fault indicator on the face of the platform control box as shown below:
2
1
6.2
DIAGNOSTIC TROUBLE CODES (DTC)
The DTC tables following are sorted in groups by the first two digits, these digits represent the number of flashes the system
distress indicator lamp will flash on the platform indicator panel when a fault occurs.
For example: a “2-1 Power-Up” on page 6-5 would be indicated by 2 flashes, a pause, then 1 flash, a pause, then would
keep repeating until the fault is cleared.
The more detailed three digit code numbers in the DTC column of the following tables are only indicated on a JLG handheld
diagnostic analyzer.
To troubleshoot multiple DTCs, start with the DTC with the higher first two digits. If a correction is made during a check,
conclude the check by cycling the machine power off then back on, using the emergency stop switch.
NOTE: Reference to the Health (Status LED) indicator is the LED indicator on the system power module itself. (See “ZAPI
Power Module Electrical Evaluation” on page 3-18.)
6.3
X-CONNECTOR REFERENCES
Throughout the following DTC troubleshooting procedures, electrical connectors are given a three digit identifier number
preceded with an “X” for identifying and locating the specific connector on the machine.
See Section 9.8, X-CONNECTOR ID INDEX for description of "X" connectors and Figure 9-12. on page 9-20, and Figure 9-13.
on page 9-21 for location of "X" connectors on the machine.
Example of "X" connector usage nomenclature:
[X006.21] refers to terminal 21 (pin and socket) of connector X006.
[X006.21.soc] refers to the socket side of terminal 21, connector X006.
[X006.21.pin] refers to the pin side of terminal 21, connector X006.
3121273
– JLG Lift –
6-1
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.4
DTC INDEX
0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
001
002
003
004
005
008
EVERYTHING OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GROUND MODE OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM SOUNDING - TILTED & ABOVE ELEVATION (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVING AT CUTBACK - ABOVE ELEVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTIONS LOCKED OUT - SYSTEM POWERED DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5
6-5
6-5
6-5
6-5
6-5
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
211
POWER CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
221
223
224
225
226
227
228
229
2210
2232
FUNCTION PROBLEM - HORN PERMANENTLY SELECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION PROBLEM - DRIVE & LIFT ACTIVE TOGETHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED . . . . . . . . . . . . . . . . . . . . . . . .
ACCELERATOR FAULTY - WIPER OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEER SWITCHES FAULTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION LOCKED OUT - ACCELERATOR NOT CENTERED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION PROBLEM - DRIVE & LIFT BOTH OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-6
6-6
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
231
232
233
FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
GROUND LIFT UP / DOWN ACTIVE TOGETHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
FUNCTION PROBLEM - BRAKE RELEASE PERMANENTLY SELECTED . . . . . . . . . . . . . . . . . . . . . 6-7
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
253
254
255
258
259
2510
DRIVE PREVENTED - CHARGER CONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM OVERLOADED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE & LIFT PREVENTED - BRAKES ELECTRICALLY RELEASED FOR TOWING. . . . . . . . . . . . . .
MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS. . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE PREVENTED - BRAKES NOT RELEASING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7
6-7
6-8
6-8
6-8
6-8
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
311
314
OPEN CIRCUIT LINE CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
AUXILIARY RELAY - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
321
326
LINE CONTACTOR MISWIRED ON OR WELDED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
AUXILIARY RELAY - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
333
334
6-2
LIFT UP VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
LIFT UP VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
335
336
337
338
339
3310
3312
3313
3314
3315
3349
33297
33298
33299
33302
33303
33304
33305
33406
33407
LIFT DOWN VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
LIFT DOWN VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
STEER LEFT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
STEER LEFT VALVE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
STEER RIGHT VALVE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
STEER RIGHT VALVE - OPEN CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
LEFT BRAKE - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
RIGHT BRAKE SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
LEFT BRAKE - OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
RIGHT BRAKE OPEN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
LINE CONTACTOR COIL - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
LEFT BRAKE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
STEER LEFT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
LINE CONTACTOR COIL - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
NEGATIVE SUPPLY - SHORT TO BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
NEGATIVE SUPPLY - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
RIGHT BRAKE - SHORT TO GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
STEER RIGHT VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
LiFT UP VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
LIFT DN VALVE - SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
421
422
423
POWER MODULE TOO HOT - PLEASE WAIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
DRIVING AT CUTBACK - POWER MODULE CURRENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
LIFT UP AT CUTBACK - POWER MODULE CURRENT LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
441
442
446
4421
4422
BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
LOGIC SUPPLY VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
LOGIC SUPPLY VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
LOGIC SUPPLY VOLTAGE OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
661
6643
CANBUS FAILURE - POWER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
CANBUS FAILURE - LSS ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
772
773
774
775
776
777
778
779
7710
7711
7741
7742
3121273
STALLED TRACTION MOTOR OR POWER WIRING ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
CAPACITOR BANK FAULT - CHECK POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
SHORT CIRCUIT - FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
OPEN CIRCUIT - FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
STALLED PUMP MOTOR OR POWER WIRING ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
OPEN CIRCUIT PUMP MOTOR WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
TRACTION T HIGH - CHECK POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13
TRACTION T LOW - CHECK POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
PUMP P HIGH - CHECK POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
PUMP P LOW - CHECK POWER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
ARMATURE BRAKING CURRENT TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
FIELD VOLTAGE IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
– JLG Lift –
6-3
SECTION 6 - DIAGNOSTIC TROUBLE CODES
8-2 LSS - Load Sensing System (See 3124288 - LSS Manual) . . . . . . . . . . . . . . . . . 6-14
8212
8213
8214
8215
8216
825
LSS PRESSURE SENSOR - DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSS ANGLE SENSOR - DIRECTION DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSS ANGLE SENSOR - OUT OF RANGE HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSS ANGLE SENSOR - OUT OF RANGE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSS ANGLE SENSOR - OUT OF CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSS HAS NOT BEEN CALIBRATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14
6-14
6-14
6-14
6-15
6-15
8-4 Elevation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
84109
ELEVATION SWITCH CONTACTS DISAGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
995
996
998
999
9950
9951
9952
9953
9954
9955
9956
9957
9958
9960
9962
9963
9964
9969
9970
9971
99143
99144
99145
99146
99147
99148
99149
6-4
POWER MODULE FAILURE - PERSONALITY RANGE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EEPROM FAILURE - CHECK ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNCTION LOCKED OUT - POWER MODULE SOFTWARE VERSION IMPROPER . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER MODULE FAILURE - INTERNAL ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– JLG Lift –
6-15
6-15
6-15
6-15
6-15
6-15
6-15
6-15
6-15
6-15
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
6-16
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.5
DTC CHECK TABLES
0-0 Help Comments
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
001
EVERYTHING OK
The normal help message in platform
mode. Displays on the analyzer only.
• HEALTH (Status LED) - ON
002
GROUND MODE OK
The normal help message in ground
mode. Displays on the analyzer only.
• HEALTH (Status LED) - ON
003
ALARM SOUNDING - TILTED Control system senses that the platform • Check that the machine is tilted. If so, lower the platform and
& ABOVE ELEVATION
is elevated and the vehicle is tilted.
reposition the machine to a level surface.
(CE ONLY)
• Fully stow the platform.
• The tilt sensor is mounted inside the left side chassis cover.
Check that the tilt sensor is secured to the machine.
• Check that the elevation angle sensor is securely mounted.
• Backprobing ground board J1-18 should show about 0 volts.
• Backprobing ground board J1-10 should show about 0 volts.
• Adjust the tilt sensor, see Section 5.2.
• HEALTH (Status LED) - ON
004
DRIVING AT CUTBACK ABOVE ELEVATION
005
DRIVE & LIFT UP PREVENTED Driving is not possible since the plat- TILTED & ELEVATED
form is elevated and the chassis is not
level.
008
FUNCTIONS LOCKED OUT SYSTEM POWERED DOWN
The platform is elevated and the
machine is driving in creep speed.
•
•
•
•
•
•
Fully stow the platform.
Check that the elevation angle sensor is securely mounted.
Check the lift/drive switch.
Backprobing ground board J1-18 should show about 24 volts.
Backprobing ground board J1-19 should show about 0 volts.
HEALTH (Status LED) - ON
• Check that the machine is tilted. If so, lower the platform and
reposition the machine to a level surface.
• Fully stow the platform.
• The tilt sensor is mounted inside the left side chassis cover.
Check that the tilt sensor is secured to the machine.
• Check that the elevation angle sensor is securely mounted.
• Backprobing ground board J1-18 should show about 24 volts.
• Backprobing ground board J1-19 should show about 0 volts.
• Adjust the tilt sensor, see Section 5.2.
• HEALTH (Status LED) - ON
A period of time elapsed without activity • Cycle the Ground EMS in Ground Mode or the Platform EMS in
and the Control System entered a lowPlatform Mode to re-enable the vehicle.
power state to preserve battery charge • HEALTH (Status LED) - ON
(2 hours).
2-1 Power-Up
DTC
211
FAULT MESSAGE
POWER CYCLE
DESCRIPTION
CHECK
This help message is issued at each
power cycle. Displays on the analyzer
only.
• Normal operation. No check necessary.
• HEALTH (Status LED) - ON
2-2 Platform Controls
DTC
221
FAULT MESSAGE
FUNCTION PROBLEM HORN PERMANENTLY
SELECTED
3121273
DESCRIPTION
CHECK
The horn switch was closed during
power-up in platform mode.
• Check if the horn switch is damaged, obstructed or jammed.
• HEALTH (Status LED) - ON
– JLG Lift –
6-5
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-2 Platform Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
223
FUNCTION PROBLEM DRIVE & LIFT ACTIVE
TOGETHER
The Drive - Lift Selector Switch indicates that both functions are selected
simultaneously
• Check drive/lift switch for visible damage.
• Check switch continuity. There should only be continuity from the
center post to one of the outer posts at a time. Otherwise, replace
the switch.
• Check drive/lift switch signal and wiring to the ground module.
"Lift" selection output (24V when selected) is terminal J2-3.
"Drive" selection output (24V when closed) is terminal J2-13.
• Replace platform board.
• HEALTH (Status LED) - ON
224
FUNCTION PROBLEM The steer left switch was closed during • Check if the steer left switch is obstructed or jammed.
STEER LEFT PERMANENTLY power-up in platform mode.
• Check steer left switch and its wiring, its output (24V when
SELECTED
closed) is to terminal J2-4.
• Replace platform board.
• HEALTH (Status LED) - ON
225
FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED
The steer right switch was closed during power-up in platform mode.
226
ACCELERATOR FAULTY WIPER OUT OF RANGE
The joystick (accelerator) wiper signal • Center joystick and check to see if a power cycle will clear DTC.
input is outside the acceptable voltage • The wiper wire may be off, shorted to +B, or shorted to -B
range.
(ground) to cause this difficulty.
• Check voltage on MS35 connector pins - A - 5V, B - 0.5 to 4.5V,
and C - 0V.
• HEALTH (Status LED) - ON
227
STEER SWITCHES FAULTY
Both the Steer Left and Steer Right
Inputs are closed as the same time.
228
FUNCTION LOCKED OUT ACCELERATOR NOT CENTERED
Selected function (Drive or Lift) is not • Release joystick and allow to center.
allowed because the joystick (accelera- • Check if the joystick is obstructed or jammed.
tor) was not centered at power-up.
• Check the joystick signal and its wiring.
• Check voltage at MS35.
• HEALTH (Status LED) - ON
229
FUNCTION PROBLEM - TRIG- Trigger Switch in the Platform Control
GER PERMANENTLY
Box was closed at power-up.
CLOSED
• Check if the steer right switch is obstructed or jammed.
• Check steer right switch and its wiring, its output (24V when
closed) is to terminal J2-12.
• HEALTH (Status LED) - ON
• Check if the steer switches are damaged, obstructed or jammed.
• A short in the Steer Switch wiring or a failed Steer Switch can
cause this difficulty.
• Check the steer switch signals and wiring outputs (24V when
closed) to terminals J2-4 and J2-12 (left and right).
• HEALTH (Status LED) - ON
• Check if the trigger switch is obstructed or jammed.
• Release switch or repair the switch / wiring to clear the difficulty.
• Check the trigger switch signal and wiring. The trigger input (24V
when closed) is to terminal J2-10.
• HEALTH (Status LED) - ON
2210 TRIGGER CLOSED TOO LONG Trigger Switch in the Platform Control • Release switch or repair the switch / wiring to clear the difficulty.
WHILE IN NEUTRAL
Box was closed for more than five sec- • Check if the trigger switch is obstructed or jammed.
onds while the Joystick (accelerator) • Check the trigger switch signal and wiring. The trigger input (24V
was in the neutral position (centered)
when closed) is to terminal J2-10.
• HEALTH (Status LED) - ON
2232 FUNCTION PROBLEM DRIVE & LIFT BOTH OPEN
6-6
In Platform Mode, the Drive - Lift Selec- • Repair the wiring or switch to clear the message.
tor Switch indicates that neither func- • Check if either function is active, if Yes;
tion is selected.
• HEALTH (Status LED) - ON
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-3 Ground Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
231
FUNCTION PROBLEM - LIFT
PERMANENTLY SELECTED
Lift Switch (Up or Down) in the Ground • Release or repair the switch to clear the message.
Control Box was closed during power- • Check if the lift switch is obstructed or jammed.
up.
• Check the lift switch signal and wiring. The lift switch outputs
(24V when closed) are to ground board terminals J1-27, J1-10
(up and down).
• Replace ground board.
• HEALTH (Status LED) - ON
232
GROUND LIFT UP / DOWN
ACTIVE TOGETHER
In Ground Mode, the control system has • Check the Lift Switch and associated wiring in the Ground Control
detected the Lift Up and Down are active
Box.
simultaneously
• Check if the lift switch is obstructed or jammed.
• Check the lift switch signal and wiring to the ground board. The lift
switch outputs (24V when closed) to ground board terminals J127 (up), J1-10 (down).
• Replace ground board.
• HEALTH (Status LED) - ON
233
FUNCTION PROBLEM BRAKE RELEASE PERMANENTLY SELECTED
The manual brake release switch was
closed during power-up.
• Release or repair the switch to clear the message
• Check if the brake release switch is obstructed or jammed.
• Check the brake release switch signal and wiring to the ground
board. The brake release switch input (24V) is from ground board
terminal J1-31, and its output (24V when closed) is to ground
board terminal J1-25.
• If the brakes are released, the machine can be pushed or moved
without drive motor power.
• Replace ground board.
• HEALTH (Status LED) - ON
2-5 Function Prevented
DTC
FAULT MESSAGE
253
DRIVE PREVENTED - CHARGER CONNECTED
254
DRIVE & LIFT UP PREVENTED Drive or lift is not possible while the
• Check if the charger is connected to off board power source and
- CHARGER CONNECTED
vehicle is charging and is configured to
disconnect if desired.
prevent all motion.
• Check ANALYZER -> MACHINE SETUP -> CHARGER INTERLOC is set as desired. (Must be in ACCESS LEVEL 1 to change.)
• Check that charger's red (positive) battery wire connector terminal is receiving power (24V) from batteries.
• Check signal from charger interlock connector terminal 2 to
ground board terminal J1-26, where 0VDC indicates charging in
process.
• HEALTH (Status LED) - ON
3121273
DESCRIPTION
CHECK
Driving is not possible while the vehicle • Check if the charger is connected to off board power source and
is charging and it is configured to only
disconnect if desired.
allow lifting.
• Check ANALYZER -> MACHINE SETUP -> CHARGER INTERLOC is set as desired.
• Check that charger's red (positive) battery wire connector terminal is receiving power (24V) from batteries.
• Check signal from charger interlock connector terminal 2 to
ground board terminal J1-26, where 0VDC indicates charging in
process.
• HEALTH (Status LED) - ON
– JLG Lift –
6-7
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-5 Function Prevented
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
255
PLATFORM OVERLOADED
The load sensing system measured
platform load is excessive.
• Remove excess weight from the platform.
• Check that the platform is not caught on something, preventing
up or down movement.
• If any CAN bus faults are active, troubleshoot those first.
• Refer to Troubleshooting in the LSS manual, 3124288.
258
DRIVE & LIFT PREVENTED BRAKES ELECTRICALLY
RELEASED FOR TOWING
Manual brake release mode is activated • Push manual brake release switch again or cycle power to clear
with the switch under the left side chasmanual brake release mode.
sis cover near the ground control box. • Check if the brake release switch is obstructed or jammed.
Drive or lift is not possible.
• Check the brake release switch signal and wiring to the ground
board. The switch input (24V) is from ground board terminal J131, and its output (24V when closed) is to ground board terminal
J1-25.
• Replace ground board.
• HEALTH (Status LED) - ON
259
MODEL CHANGED The user changed the Model Selection
HYDRAULICS SUSPENDED - using the JLG Analyzer.
CYCLE EMS
•
•
•
•
Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER.
Cycle Emergency Stop Switch.
Replace ground board.
HEALTH (Status LED) - ON
2510 DRIVE PREVENTED - BRAKES While driving on a level surface, arma- • Ensure vehicle is not stuck on something preventing movement.
NOT RELEASING
ture current was > 150A for five sec- • Examine both drive motor brakes for electrical (open- and shortonds. Brakes assumed to not be
circuits) and mechanical (rust, corrosion, contamination) issues
releasing properly.
that prevent them from releasing.
• HEALTH (Status LED) - ON
3-1 Line Contactor Open Circuit
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
311
OPEN CIRCUIT LINE CONTACTOR
The System Module's Line Contactor
did not close when energized.
• Check contactor main contact wiring to battery (+) terminal and
power controller terminal B+.
• Contactor solenoid resistance should measure about 52 Ohms.
• Check contactor solenoid wiring to terminals J1-13 and J1-32.
• Replace the line contactor.
• HEALTH (Status LED) - ON
314
AUXILIARY RELAY - OPEN
CIRCUIT
The auxiliary relay did not close when
energized.
• Check the auxiliary relay coil and associated wiring to J1-13 and
J1-32.
• No voltage on J1-28.
• HEALTH (Status LED) - ON
6-8
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-2 Line Contactor Short Circuit
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
321
LINE CONTACTOR
MISWIRED ON OR WELDED
The Line contactor is off, but the System • Check wiring of contactor.
Module is being energized.
• Check resistance between the studs of the contactor while disconnected from the machine.
• Check contactor main contact wiring to battery (+) terminal and
power module terminal B+.
• Check continuity between contactor connector pin 1 and ground
board socket J1-13.
• Check continuity between contactor connector pin 2 and ground
module J1-32.
• Measure voltage between power model B+ and B- terminals. If
24V is present, replace line contactor.
• Replace power module.
• HEALTH (Status LED) - ON
326
AUXILIARY RELAY - SHORT
TO BATTERY
The Auxiliary Relay has not been ener- • The Auxiliary Relay's contacts or coil may be mis-wired
gized by the System Module, but J1-28 • There is a wire harness issue that allows +B to reach J1-28.
is energized.
This situation will cause the batteries to discharge while the vehicle is turned off.
• Alternately, the Auxiliary Relay is faulty, replace Auxiliary Relay.
• HEALTH (Status LED) - ON
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
333
LIFT UP VALVE - SHORT TO
BATTERY
Voltage from an external source was
• Check for continuity through this circuit. The lift up solenoid resisdetected on the Lift Up Solenoid (J2-17
tance should measure about 30 Ohms. The lift up solenoid is
NUV).
powered with 24V from ground board J2-1, and its ground is to
ground board J2-17.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
334
LIFT UP VALVE - OPEN CIRCUIT
Current flow to the Lift Up Solenoid was • Check for continuity through this circuit. The lift up solenoid resisnot detected (J2-17 NUV).
tance should measure about 30 Ohms. The lift up solenoid is
powered with 24V from ground board, and its ground is to ground
board.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
335
LIFT DOWN VALVE - SHORT
TO BATTERY
The power module detected voltage
while the lift down solenoid was commanded off. (J2-2 PDV or J2-16 NDV)
3121273
• Check ANALYZER -> MACHINE SETUP -> ELEV PROX is set to
NOT INSTALLED
• Check for continuity through this circuit. The lift down solenoid
resistance should measure about 20 Ohms. The lift down solenoid is powered (PWM) by ground board J2-2, and its ground is
to ground board J2-16.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
– JLG Lift –
6-9
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
336
LIFT DOWN VALVE - OPEN
CIRCUIT
The power module did not detect cur- • Check for continuity through this circuit. The lift down solenoid
rent flow to the lift down solenoid during
resistance should measure about 20 Ohms. The lift down solenormal operation. (J2-16 NDV)
noid is powered (PWM) by ground board, and its ground is to
ground board.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
337
STEER LEFT VALVE - SHORT Voltage from an external source was
• Check for continuity through this circuit. Steer left solenoid resisTO BATTERY
detected on the Steer Left Solenoid (J2tance should measure about 30 Ohms. The steer left solenoid is
9 NLV).
powered with 24V from ground board J2-1, and its ground is to
ground board J2-9.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
338
STEER LEFT VALVE - OPEN
CIRCUIT
Current flow to the Steer Left Solenoid
was not detected (J2-9 NLV).
339
STEER RIGHT VALVE SHORT TO BATTERY
Voltage from an external source was
• Check for continuity through this circuit. Steer right solenoid
detected on the Steer Left Solenoid (J2resistance should measure about 30 Ohms. The steer right sole18 NRV).
noid is powered with 24V from ground board J2-1, and its ground
is to ground board J2-18.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
• Check for continuity through this circuit. Steer left solenoid resistance should measure about 30 Ohms. The steer left solenoid is
powered with 24V from ground board, and its ground is to ground
board.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
3310 STEER RIGHT VALVE - OPEN Current flow to the Steer Right Solenoid • Check for continuity through this circuit. Steer right solenoid
CIRCUIT
was not detected (J2-18 NRV).
resistance should measure about 30 Ohms. The steer right solenoid is powered with 24V from ground board, and its ground is to
ground board.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
3312 LEFT BRAKE - SHORT TO
BATTERY
Voltage from an external source was
• Check for continuity through this circuit. The left brake is powered
detected on the Left Brake Solenoid (J1with 24V from ground board J1-29, and its ground is to ground
34 NLB).
board J1-34. Brake solenoid resistance should measure about 20
Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
3313 RIGHT BRAKE SHORT TO
BATTERY
Voltage from an external source was
detected on the Right Brake Solenoid
(J1-33 NRB).
6-10
• Check for continuity through this circuit. Brake solenoid resistance should measure about 20 Ohms. The right brake is powered
with 24V from ground board J1-30, and its ground is to ground
board J1-33.
• Inspect the wiring for physical damage.
• Replace ground board.
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
3314 LEFT BRAKE - OPEN CIRCUIT Current flow to the Left Brake Solenoid • Check for continuity through this circuit. The left brake is powered
was not detected (J1-34 NLB).
with 24V from ground board, and its ground is to ground board.
Brake solenoid resistance should measure about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
3315 RIGHT BRAKE OPEN CIRCUIT Current flow to the Right Brake Solenoid • Check for continuity through this circuit. Brake solenoid resiswas not detected (J1-33 NRB).
tance should measure about 20 Ohms. The right brake is powered
with 24V from ground board, and its ground is to ground board.
• Inspect the wiring for physical damage.
• Replace ground board.
• HEALTH (Status LED) - ON
3349 LINE CONTACTOR COIL SHORT TO GROUND
An external short to ground was
detected on the Negative Main Line
Contactor (J1-32 NMC).
• HEALTH (Status LED) - ON
33297 LEFT BRAKE - SHORT TO
GROUND
Excessive current flow to the Left Brake • HEALTH (Status LED) - ON
Solenoid was detected (J1-34 NLB).
33298 STEER LEFT VALVE - SHORT Excessive current flow to the steer left
TO GROUND
solenoid detected (J2-9 NLV).
• HEALTH (Status LED) - ON
33299 LINE CONTACTOR COIL SHORT TO BATTERY
• HEALTH (Status LED) - ON
Voltage from an external source was
detected on the Negative Main Line
Contactor.
33302 NEGATIVE SUPPLY - SHORT At power-up, the system module
• HEALTH (Status LED) - ON
TO BATTERY
detected an external short on J1-12, J117, J1-23, J2-14 or J2-15 when in platform mode. Normally these pins are
grounded by the System Module. All
functions are prevented to protect the
control system.
33303 NEGATIVE SUPPLY - SHORT At power-up, the System Module
• HEALTH (Status LED) - ON
TO GROUND
detected an external short on J1-12, J117, J2-14 or J2-15 when in platform
mode. Normally these pins are
grounded by the System Module. Since
the external ground may compromise
integrity, all functions will be prevented.
33304 RIGHT BRAKE - SHORT TO
GROUND
Excessive current flow to the Right
Brake solenoid was detected (J1-33
NRB).
• HEALTH (Status LED) - ON
33305 STEER RIGHT VALVE SHORT TO GROUND
Excessive current flow to the Steer
Right Solenoid was detected (J2-18
NRV).
• HEALTH (Status LED) - ON
33406 LiFT UP VALVE - SHORT TO
GROUND
Excessive current flow to the Lift Up
Solenoid was detected (J2-17 NUV).
• HEALTH (Status LED) - ON
33407 LIFT DN VALVE - SHORT TO
GROUND
Excessive current flow to the Lift Down • HEALTH (Status LED) - ON
Solenoid was detected (J2-16 NDV).
3121273
– JLG Lift –
6-11
SECTION 6 - DIAGNOSTIC TROUBLE CODES
4-2 Thermal Limit (SOA)
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
421
POWER MODULE TOO HOT - The System Module's internal tempera- • Power down and allow to cool.
PLEASE WAIT
ture is excessive (>+75° C). Allow to • Do not operate in ambients over 140° F (60° C).
cool by powering down.
• Check for jammed or obstructed drive motors.
• Check for excessively high current consumption in the pump,
ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP CUR over 130
Amps with an empty deck.
• Check for excessively high traction current consumption, ANALYZER -> DIAGNOSTICS -> TRACTION -> ARM CUR over 120
Amps while driving on the level.
• HEALTH (Status LED) - ON
422
DRIVING AT CUTBACK Armature current was greater than
• Check for jammed or obstructed drive motors.
POWER MODULE CURRENT 250A for at least 60 seconds. To avoid • Check for excessively high traction current consumption, ANALIMIT
damage to the vehicle, the System
LYZER -> DIAGNOSTICS -> TRACTION -> ARM CUR over 120
Amps while driving on the level.
Module has reduced the current limit to
• HEALTH (Status LED) - ON
120A.
423
LIFT UP AT CUTBACK Pump current was greater than 150A for • Check for jammed or obstructed arm stack or pivot bushing.
POWER MODULE CURRENT at least 60 seconds. To avoid damage • Check for excessively high current consumption in the pump,
LIMIT
to the vehicle, the System Module has
ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP CUR over 130
reduced the current limit to 80A
Amps with an empty deck.
• Refer to Section 4.3, Pump/Motor.
• HEALTH (Status LED) - ON
4-4 Battery Supply
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
441
BATTERY VOLTAGE TOO
Battery Voltage momentarily dropped • Recharge batteries or check for damaged batteries.
LOW - SYSTEM SHUTDOWN below 14.5V when using flooded lead- • Check battery charger function.
acid batteries, or 16.0V when using
• HEALTH (Status LED) - ON
AGM batteries. With a low battery
charge, this can occur during heavy
current demand due to Drive, Steer, or
Lift Up.
442
BATTERY VOLTAGE TOO
The System Module momentarily mea- • May be due to improper battery charging or incorrect voltage batHIGH - SYSTEM SHUTDOWN sured excessively high battery voltage
teries being used.
(>36.0V) and de-energized the Main • HEALTH (Status LED) - ON
Line Contactor and Battery Relay to protect system devices.
446
LOGIC SUPPLY VOLTAGE
OUT OF RANGE
4421 LOGIC SUPPLY VOLTAGE
OUT OF RANGE
6-12
The system module logic supply voltage was measured to be out of normal
operating range by the interface PCB
(<11V).
• This may be caused by a loose battery terminal, severely discharged batteries, damaged battery, or an improper wire harness
connection.
• Drive, Steer, and Lift Prevented
• HEALTH (Status LED) - ON
The system module logic supply volt- • This may be caused by a loose battery terminal, severely disage was measured by the power PCB to
charged batteries, damaged battery, or an improper wire harness
be more than 34V for 10uS.
connection.
• Drive, Steer, and Lift Prevented
• HEALTH (Status LED) - ON
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
4-4 Battery Supply
DTC
FAULT MESSAGE
4422 LOGIC SUPPLY VOLTAGE
OUT OF RANGE
DESCRIPTION
CHECK
The system module logic supply volt- • This may be caused by a loose battery terminal, severely disage was measured by the power PCB to
charged batteries, damaged battery, or an improper wire harness
be less than 11V for 10uS.
connection.
• Drive, Steer, and Lift Prevented
• HEALTH (Status LED) - ON
6-6 Communication
DTC
661
FAULT MESSAGE
CANBUS FAILURE - POWER
MODULE
6643 CANBUS FAILURE - LSS
ANGLE SENSOR
DESCRIPTION
CHECK
The control system failed to receive
messages from the power microprocessor.
• This may occur if re-programming was interrupted.
• Alternately, this may be an internal fault.
• HEALTH (Status LED) - ON
The control system failed to receive
messages from the angle sensor.
• Check wiring to the Angle Sensor.
• HEALTH (Status LED) - ON
7-7 Electric Motor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
772
STALLED TRACTION MOTOR The System Module detected armature • This is mostly likely caused by a stalled traction motor or power
OR POWER WIRING ERROR current feedback > 4.5V or < 0.5V.
wiring issue. Alternately, it could be an internal fault.
• HEALTH (Status LED) - ON
773
CAPACITOR BANK FAULT CHECK POWER CIRCUITS
There is an internal or external fault that • The System Module detected that the VMN of the pump and tracprevents the System Module’s capacition has not increased more than 1.3V in 1000mS. Alternately,
tor bank from charging.
the VMN of the pump or traction is less than 20% of battery voltage.
• If this message persists after disconnecting the drive and pump
wiring, there is an internal fault.
• HEALTH (Status LED) - ON
774
SHORT CIRCUIT - FIELD
WIRING
The field wiring passed System Module • This situation is caused by improper field wiring or a damaged
power-up diagnostics. However, an
motor.
external short circuit was detected
• HEALTH (Status LED) - ON
when current was applied to F1 / F2.
775
OPEN CIRCUIT - FIELD WIR- The System Module applied field cur- • The situation is caused by improper field wiring or a damaged
ING
rent, but could regulate the desired curmotor.
rent.
• HEALTH (Status LED) - ON
776
STALLED PUMP MOTOR OR The System Module measured
POWER WIRING ERROR
improper pump current feedback
(>4.5V or <0.5V) for 240mS.
• This is caused by a stalled pump motor, a power wiring issue, or
a System Module malfunction.
• HEALTH (Status LED) - ON
777
OPEN CIRCUIT PUMP
MOTOR WIRING
This indicates there is an open-circuit
between the System Module’s –P terminal and the pump motor.
• The System Module measured pump current less than 8A while
the motor voltage was greater than 7V for 1200mS.
• HEALTH (Status LED) - ON
778
TRACTION T HIGH - CHECK
POWER CIRCUITS
While driving, the voltage measured at • This issue may be caused by a power wiring error or an internal
the System Module’s T-terminal did not
fault.
agree with the predicted value.
• HEALTH (Status LED) - ON
3121273
– JLG Lift –
6-13
SECTION 6 - DIAGNOSTIC TROUBLE CODES
7-7 Electric Motor
DTC
779
FAULT MESSAGE
TRACTION T LOW - CHECK
POWER CIRCUITS
DESCRIPTION
CHECK
While driving, the voltage measured at • This issue may be caused by an opencircuit of the armature wirthe System Module’s T terminal did not
ing (+B and –T terminals) or an internal fault.
agree with the predicted value.
• VMN does not increase more than 1.3V
• VMN is less than 20% Battery Voltage
• Battery Voltage . VMN is greater than 4V
• HEALTH (Status LED) - ON
7710 PUMP P HIGH - CHECK
POWER CIRCUITS
While steering or lifting up, the voltage • This issue may be caused by a power wiring error or an internal
measured at the System Module’s P
fault.
terminal did not agree with the predicted • Pump Feedback . Predicted >7V
value.
• HEALTH (Status LED) - ON
PUMP P LOW - CHECK
POWER CIRCUITS
While steering or lifting up, the voltage • This issue may be caused by an open-circuit of the pump wiring
measured at the System Module’s P
(+BF2 and –P terminals) or an internal fault.
terminal did not agree with the predicted • Pump feedback does not increase more than 1.3V
value.
• Pump feedback is less than 20% Battery Voltage
• Battery Voltage - pump feedback is greater than 4V
• HEALTH (Status LED) - ON
7711
7741 ARMATURE BRAKING CUR- The System Module detected excessive • This can be caused by transporting an excessive load on a steep
RENT TOO HIGH
braking current.
grade. Alternately, this may indicate an internal fault.
• HEALTH (Status LED) - ON
7742 FIELD VOLTAGE IMPROPER
The System Module voltage at the F1
and F2 terminals was improper at
power-up (expected to be ½ Battery
Voltage).
• This is caused by an open- or short-circuit in the field wiring or
motor. Disconnect the field and motor wiring from the System
Module and connect F1 / F2 with a short wire. If the situation persists after a power cycle, it may be an internal issue.
• HEALTH (Status LED) - ON
8-2 LSS - Load Sensing System (See 3124288 - LSS Manual)
DTC
FAULT MESSAGE
8212 LSS PRESSURE SENSOR DISAGREEMENT
DESCRIPTION
CHECK
Pressure Sensor 1 and Pressure Sensor • Using the Analyzer LOAD submenu under DIAGNOSTICS check
2 do not agree. The system shall
PRES1 and PRES2 readings. They must agree within 75 PSI.
assume the machine is overloaded until
With the safety prop engaged check to ensure that the approprithe sensors agree.
ate voltage is being supplied to both sensors and that the wiring
and connections are intact. The voltage between pins A and B
should read +5V +/- 0.5V with the machine turned on. If the
voltage supplied is correct, replace both transducers.
• HEALTH (Status LED) - ON
8213 LSS ANGLE SENSOR - DIREC- The angle sensor’s change in reading • This indicates a wiring error or Angle Sensor malfunction.
TION DISAGREEMENT
does not agree with the direction of the- • HEALTH (Status LED) - ON
machine motion (lift up).
8214 LSS ANGLE SENSOR - OUT OF The Angle Sensor's reading when the • The Angle Sensors reading must be less than or equal to 245
RANGE HIGH
machine is at maximum elevation does
counts at maximum elevation.
not fall within the high end acceptable
Ensure that the Angle Sensor is mounted properly.
range
• HEALTH (Status LED) - ON
8215 LSS ANGLE SENSOR - OUT OF The angle sensor’s reading when the
RANGE LOW
machine is stowed does not fall within
the low end acceptable range.
8216 LSS ANGLE SENSOR HAS
NOT BEEN CALIBRATED
6-14
• The Angle Sensors reading must be greater than or equal to 5
counts with the platform stowed.
Ensure that the Angle Sensor is mounted properly.
• HEALTH (Status LED) - ON
The Angle Sensor has never been cali- • Calibrate the Angle Sensor using the CALIBRATION: ANGLE subbrated and the control system assumes
menu to clear the message.
that the platform is overloaded.
• HEALTH (Status LED) - ON
– JLG Lift –
3121273
SECTION 6 - DIAGNOSTIC TROUBLE CODES
8-2 LSS - Load Sensing System (See 3124288 - LSS Manual)
DTC
825
FAULT MESSAGE
LSS HAS NOT BEEN CALIBRATED
DESCRIPTION
CHECK
The Load Sensing System has never
• Empty Platform and Calibrate the Load Sensing System using
been calibrated and the control system
the calibration procedure in the LSS Manual.
assumes that the platform is over• HEALTH (Status LED) - ON
loaded.
8-4 Elevation Switch
DTC
FAULT MESSAGE
84109 ELEVATION SWITCH CONTACTS DISAGREEMENT
DESCRIPTION
CHECK
The Elevation Switch contacts are the • Check the wiring and the switch or replace the switch to clear the
same (high or low). Since the contacts
fault.
should always be complimentary, the • Health (Status LED) - ON
system assumes the platform is Elevated.
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
995
POWER MODULE FAILURE - The power module detected an out-of- • Record all personality settings in ANALYZER -> PERSONALITIES
PERSONALITY RANGE
range or corrupt personality setting
and ANALYZER -> MACHINE SETUP. Reset control system perERROR
sonalities to default settings by selecting a different model than
indicated, cycle power then select proper model. Then, enter personality settings recorded above.
• Health (Status LED) - ON
996
POWER MODULE FAILURE INTERNAL ERROR
998
EEPROM FAILURE - CHECK
ALL SETTINGS
999
FUNCTION LOCKED OUT The power module software version is • Re-program or replace with a Version 1.xx module
POWER MODULE SOFTnot compatible with the rest of the sys- • Health (Status LED) - ON
WARE VERSION IMPROPER tem.
• This is an internal failure.
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
The control system detected an
EEPROM failure.
• Personalities and Machine Setup settings may be reset to default
values. Check/Correct all settings and re-cycle power to clear difficulty.
• Health (Status LED) - ON
9950 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9951 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9952 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9953 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9954 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9955 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9956 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9957 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
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– JLG Lift –
6-15
SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
9958 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9960 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9962 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9963 POWER MODULE FAILURE - The System Module detected a misINTERNAL ERROR
match in the redundant RAM information stored in the power PCB.
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - ON
9964 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9969 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
9970 POWER MODULE FAILURE - The System Module detected a misINTERNAL ERROR
match in the redundant RAM information stored in the interface PCB.
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - ON
9971 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99143 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99144 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99145 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99146 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99147 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99148 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
99149 POWER MODULE FAILURE INTERNAL ERROR
• Cycle machine, if error still exists, replace System Module.
• HEALTH (Status LED) - FLASHING
6-16
– JLG Lift –
3121273
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.1 GENERAL
This section contains schematics to be used for locating and correcting most of the operating problems which may develop.
If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE
UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM
PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/
ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY
SATURATION.
7.2 MULTIMETER BASICS
A wide variety of multimeters or Volt Ohm Meters (VOM) can be used for troubleshooting your equipment. A digital meter
with reasonable accuracy (within 7%) is recommended for the measurements in these procedures. This section shows diagrams of a common, digital VOM configured for several different circuit measurements. Instructions for your VOM may vary.
Please consult the meter operator’s manual for more information.
Grounding
"Grounding the meter" means to take the black lead (which is connected to the COM (common) or negative port) and touch
it to a good path to the negative side of the voltage source.
Backprobing
To "backprobe" means to take the measurement by accessing a connector’s contact on the same side as the wires, the back
of the connector. Readings can be done while maintaining circuit continuity this way. If the connector is the sealed type,
great care must be taken to avoid damaging the seal around the wire. It is best to use probes or probe tips specifically
designed for this technique, especially on sealed connectors. Whenever possible insert probes into the side of the connector such that the test also checks both terminals of the connection. It is possible to inspect a connection within a closed connector by backprobing both sides of a connector terminal and measuring resistance. Do this after giving each wire a gentle
pull to ensure the wires are still attached to the contact and contacts are seated in the connector.
Min/Max
Use of the "Min/Max" recording feature of some meters can help when taking measurements of intermittent conditions while
alone. For example, you can read the voltage applied to a solenoid when it is only operational while a switch, far from the
solenoid and meter, is held down.
Polarity
Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed.
Check what reading is expected, the location of the signal and that the leads are connected to the device under test correctly. Also check that the lead on the "COM" port goes to the ground or negative side of the signal and the lead on the other
port goes to the positive side of the signal.
Scale
M = Mega = 1,000,000 * (Displayed Number)
k = kilo = 1,000 * (Displayed Number)
m = milli = (Displayed Number) / 1,000
μ = micro = (Displayed Number) / 1,000,000
Example: 1.2 kΩ = 1200 Ω
Example: 50 mA = 0.05 A
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Voltage Measurement
Resistance Measurement
Figure 7-1. Voltage Measurement (DC)
Figure 7-2. Resistance Measurement
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance)
• Use firm contact with meter leads
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Continuity Measurement
Current Measurement
Figure 7-3. Continuity Measurement
Figure 7-4. Current Measurement (DC)
• Some meters require a separate button press to
enable audible continuity testing
• Circuit power must be turned OFF before testing continuity
• Set up the meter for the expected current range
• Be sure to connect the meter leads to the correct
jacks for the current range you have selected
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multi meter’s operation manual)
• Use firm contact with meter leads
• Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Continuity Measurement Over Long Distances
When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.
Requirements:
• Harness with at least three separate wires including the wire under test.
• These wires must be able to be isolated from other wires, etc.
• Jumper or method to connect contacts on one side of harness.
• Meter that can measure resistance or continuity.
Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate measurement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach
of the jumper.
1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
3. On one side, jumper from contact of wire #1 and wire #2.
4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this
test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no continuity, repair wires or consult schematic for other wires to use for test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.
7-4
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS
Silicone Dielectric Compound must be used on the AMP connections for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and
female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by
using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside
the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus
preventing the housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
Figure 7-5. AMP Connector
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-6. Connector Assembly (1 of 4)). Proceed as follows:
Figure 7-6. Connector Assembly (1 of 4)
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7. Connector
Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lb. to be sure the retention fingers are holding the contact (See Figure 7-7. Connector Assembly (2 of 4)).
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8. Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9. Connector Assembly (4 of 4)).
Figure 7-7. Connector Assembly (2 of 4)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-8. Connector Assembly (3 of 4)
Figure 7-9. Connector Assembly (4 of 4)
Disassembly
5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs.
6. Pry open the wedge lock to the open position.
7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is
removed.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-10. Connector Disassembly
NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
Wedge Lock
The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by
using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Service - Voltage Reading
CAUTION
DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS.
It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This
practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system. The
resulting pinholes in the insulation will allow moisture to invade the system by traveling along the wire strands. This nullifies
the effectiveness of the connector seals and could result in system failure.
Figure 7-11. Connector Installation
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.4 WORKING WITH DEUTSCH CONNECTORS
DT/DTP Series Assembly
Figure 7-12. DT/DTP Contact Installation
1. Grasp crimped contact about 25mm behind the contact barrel.
2. Hold connector with rear grommet facing you.
3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in
place.
4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism. The wedgelock will snap into place. Rectangular wedges are not oriented. Thy may go in either way.
NOTE: The receptacle is shown - use the same procedure for plug.
DT/DTP Series Disassembly
Figure 7-13. DT/DTP Contact Removal
5. Remove wedgelock using needlenose pliers or a hook shaped wire to pull wedge straight out.
6. To remove the contacts, gently pull wire backwards, while at the same time releasing the locking finger by moving it
away from the contact with a screwdriver.
7. Hold the rear seal in place, as removing the contact may displace the seal.
HD30/HDP20 Series Assembly
Figure 7-14. HD/HDP Contact Installation
8. Grasp contact about 25mm behind the contact crimp barrel.
9. Hold connector with rear grommet facing you.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly
locked in place.
Figure 7-15. HD/HDP Locking Contacts Into Position
NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing
HD30/HDP20 Series Disassembly
Figure 7-16. HD/HDP Contact Removal
11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
12. Slide tool along into the insert cavity until it engages contact and resistance is felt.
13. Pull contact-wire assembly out of connector.
Figure 7-17. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.5 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. De-energize the circuit.
2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an
open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will
be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two
terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.
Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually operated switches except that the moving object operates the switch. These switches can be tested the same way as a standard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive
proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do
not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform
position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find
the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch
as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the
switch and object sensed.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Automatic Switches
If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch
to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate.
1. Connect instrumentation to monitor and/or control the parameter the switch is measuring.
2. Observe switch state in control system with the Analyzer. See vehicle or control system documentation on how to do
this.
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for example. The state indicated in the control system should change.
Switch Wiring - Low Side, High Side
When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can measure the voltage at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.6 CIRCUIT BOARDS: INPUTS AND OUTPUTS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
7-14
Table 7-1. Power Module - J1 Connector Pin Function
Function
Type
Spare - Analog Input - EAME - LSS Pressure Switch - 1
Spare - Analog Input - EAME - LSS Pressure Switch - 2
Control for Ground Alarm (PWM)
Positive for Analyzer (+12V)
Ground Select (Logic Supply for Ground Mode)
Positive for Tilt Sensor (Connect to +BATT)
Positive for Ground Alarm (Connect to +BATT)
Tilt Sig
Elevation Switch - SW1
Ground Lift Down Switch (High-Sensing)
Elevation Switch - SW2
Spare Negative Reference
Positive Main Line Contactor (Connect to GNDS diode OR’d with EMS)
Spare Digital Input (High-Sensing)
Spare Digital Input (High-Sensing)
Spare (+5V)
Spare (Negative)
Elevation Switch - SW2 (Connect to +BATT)
Elevation Switch - SW1 (Connect to +BATT)
RS-232 Receive
RS-232 Transmit
Negative for Analyzer (Connect to -B )
Spare Negative Reference (Connect to -B)
Spare Digital Input (High-Sensing)
Brake Release
Charger Interlock (High-Sensing)
Lift UP Switch
Battery Supply from External Relay
Positive Left Brake Release (Connect to +BATT)
Positive Right Brake Release (Connect to +BATT)
Positive Manual Brake Release (Connect to +BATT)
Negative Main Line Contactor (Low-Side Driver)
Negative Right Brake Solenoid (Low-Side Driver)
Negative Left Brake Solenoid (Low-Side Driver)
Spare Digital Output (Low-Side Driver) / Digital Input (High-Sensing)
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Analog
Analog
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Power
Power
Digital
Digital
Power
Power
Power
Power
Serial
Serial
Power
Power
Digital
Digital
Digital
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Input
Input
Output
Output
Input
Output
Output
Input
Input
Input
Input
Output
Output
Input
Input
Output
Output
Output
Output
Input
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
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Table 7-2. Power Module - J2 Connector Pin Function
Function
Type
Positive Lift/Steer Relays - (Connect to +BATT)
Positive Lift Down Valve (High-Side Driver)
Lift Select - Platform Switch
Steer Left - Joystick Controller
CANbus Low
CANbus High
Joystick Positive Analog Reference (+5V )
Platform EMS (Logic Supply for Platform Mode)
Negative Steer Left Solenoid Valve (Low-Side Driver)
Joystick Trigger - Pin 2
Platform Horn Switch
Joystick - Steer Right
Drive Select - Platform Switch
Joystick (Connect to -B)
CANbus Shield (Connect to -B)
Negative Lift Down Valve (Low-Side Driver)
Negative Lift Up Solenoid Valve (Low-Side Driver)
Negative Steer Right Solenoid Valve (Low-Side Driver)
Joystick Analog Input (0-5V)
Alarm - Platform Box
Yellow Lamp - Platform Box
Spare
Red Lamp - Platform Box
– JLG Lift –
Power
Power
Digital
Digital
Serial
Serial
Power
Power
Digital
Digital
Digital
Digital
Digital
Power
Power
Power
Digital
Digital
Analog
Digital
Digital
Digital
Digital
Output
Output
Input
Input
I/O
I/O
Output
Input
Output
Input
Input
Input
Input
Output
Output
Output
Output
Output
Input
Output
Output
Output
Output
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.7 ELECTRICAL SCHEMATICS AND LAYOUTS
Electrical Schematic - 1870164G - Sheet 1 of 2
1
2
4
X45
1
BLK 1 GND
X26
10A
JLG P/N 2400060
D
3
B1
B+
WHT 14 GND ALARM
WHT 21 12V IGN
YEL 2-3 GND MODE
YEL 3-1-6 TILT IGN
YEL 3-1-7 GND ALARM IGN
WHT 13 TILT SIG
WHT 11 ELEV SW1
WHT 4 LIFT DN SW
S18
WHT 12 ELEV SW2
WHT 6 P MAIN CON
SYSTEM MO
CO09-J1
3
4
5
6
7
8
9
10
11
12
13
14
YEL 3-1-5 ELEV SW2 IGN
YEL 3-1-4 ELEV SW1 IGN
WHT 24 TX
WHT 22 ANL GND
YEL 2-1 GND EMS
2
YEL 2-2 GND EMS
SW19-2
YEL 2-2 GND EMS
YEL 3-1-1 L BRK IGN
S36
KEYSWITCH
YEL 3-1 IGN
YEL 3-1-2 R BRK IGN
YEL 3-1-3 IGN
YEL 2-3 GND MODE
WHT 7 N MAIN CON
WHT 9 R BRAKE
1
SW20-2
WHT 8 L BRAKE
1
SW20-B1
WHT 58 PRES 1
1
SW20-4
WHT 60 5V SEN
WHT 59 PRES 2
LIFT SWITCH
S34
5
4
21
22
24
25
26
27
28
29
30
31
32
33
34
35
1
2
16
250A
17
WHT 4 LIFT DN SW
3
YEL 2-4 GND MODE
2
WHT 5 LIFT UP SW
1
BRAKE RELEASE
20
CO09-B+F1
1
WHT 61 GND
SW21
6
1
SW22-2
1
SW22-1
YEL 3-1-3 IGN
WHT 10 BRAKE RELEASE
3
MDI/HOURMETER
WHT 21 12V IGN
WHT 23 RX
6
4
2
WHT 24 TX
WHT 22 ANL GND
X30
5
1
1
2
2
3
3
4
4
X29
WHT 21 12V IGN
WHT 23 RX
WHT 24 TX
WHT 22 ANL GND
1
GD23
WHT 42-1 OVLD LAMP
1001129844_D - Sht. 2
POWER RELAY
3
YEL 3-2 IGN
YEL 3-16 IGN
4
5
6
YEL 3 IGN
YEL 3-3 IGN
7
8
BLK 1-2 GND
YEL 3-2 IGN
1
LB44
2
WHT 13 TILT SIG
YEL 3-1-6 TILT IGN
BLK 1-1 GND
3
SN31
2
1
B+ RED
GND BLK
GROUND ALARM
SIG WHT
WHT 11 ELEV SW1
WHT 12 ELEV SW2
1
2
3
YEL 3-1-4 ELEV SW1 IGN
YEL 3-1-5 ELEV SW2 IGN
SN37
4
YEL 3 IGN
4
30
87
WHT 7-2 N BATT RELAY
YEL 2-1 GND EMS
1
87a
3
2
86
CONNECT TO CONTACTOR
RL14 ON SHEET 3 A3
RL27
5
BLK 1-3 GND
WHT 14 GND ALARM
B
AH43
C
X14
1
A
2
EAME MACHINE ONLY
WHT 7-1 N MAIN CON
WHT 6-1 P MAIN CON
LB24+
WHT 6-2 IGN RELAY
YEL 3-16 IGN
85
1
YEL 3-1-7 GND ALARM IGN
LB241
A
(OPT) OVERLOAD LIGHT
S33
B
WHT 5 LIFT UP SW
YEL 2-5 PLAT MODE
1
YEL 2-4 GND MODE
SW20-3
C
19
CO09-B+
WHT 18 CHARGING STAT
1
SW20-B
18
23
WHT 10 BRAKE RELEASE
1
SW20-1
15
CO09-B+F2
1
1
SW19-1
ESTOP
WHT 23 RX
YEL 2 PWR
ATTACH SPLICE
ELEVATION
BEACON
TILT SENSOR
1
2
3
4
Figure 7-18. Electrical Schematic - (Global)
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Electrical Schematic - 1870164G - Sheet 2 of 2
5
6
7
8
C
WHT 40 5V JOY
WHT 39 JOYSTICK
WHT 41 GND JOY
GND MODE
6 TILT IGN
ALARM IGN
3 TILT SIG
ELEV SW1
FT DN SW
ELEV SW2
MAIN CON
4
5
6
CANL
7
8
9
CANH
10
11
12
13
14
V SW2 IGN
V SW1 IGN
WHT 23 RX
WHT 24 TX
2 ANL GND
15
18
19
CANS
20
21
22
23
EL 3-1 IGN
L BRK IGN
R BRK IGN
L 3-1-3 IGN
MAIN CON
9 R BRAKE
8 L BRAKE
58 PRES 1
59 PRES 2
60 5V SEN
27
C
WHT 41 GND JOY
WHT 39 JOYSTICK
B
A
MS35-2
WHT 40 5V JOY
WHT 31 LIFT SELECT
X28
1
WHT 38 STEER LEFT
2
WHT 40 5V JOY
3
WHT 2-6 PLAT MODE
D
4
5
6
7
WHT 32 TRIGGER
CONNECTS
8
WHT 33 HORN SW
9
WHT 37 STEER RIGHT
TO X11
10
WHT 30 DRIVE SELECT
11
WHT 41 GND JOY
SHEET 3 D1
12
YEL 2-5 PLAT MODE
13
WHT 6-3 PLAT PMC
14
WHT 34 RED LAMP
15
WHT 39 JOYSTICK
16
WHT 35 PLAT ALARM
17
WHT 36 YEL LAMP
18
WHT 42-2 OVLD LAMP
19
20
21
28
29
BLK 1-6 GND
30
32
SHIELD CANS CABLE
1
CO09-F2
33
34
35
BLK CANL CABLE
RED CANH CABLE
1
CO09-T-
1
2
16
17
1
2
3
4
5
6
C
EAME MACHINE ONLY
CONNECTS TO X90
1
CO09-P-
250A
X86
YEL 3-3 IGN
1
CO09-F1
31
CO09-B+F1
1
HT 61 GND
26
C
CO09-J2
YEL 3-1-8 IGN
1
WHT 20 P LIFT DN
2
WHT 31 LIFT SELECT
3
WHT 38 STEER LEFT
4
BLK CANL CABLE
5
RED CANH CABLE
6
WHT 40 5V JOY
7
WHT 2-6 PLAT MODE
8
WHT 16 ST LEFT VLV
9
WHT 32 TRIGGER
10
WHT 33 HORN SW
11
WHT 37 STEER RIGHT
12
WHT 30 DRIVE SELECT
13
WHT 41 GND JOY
14
SHIELD CANS CABLE
15
WHT 19 N LIFT DN
16
WHT 17 LIFT UP VLV
17
WHT 15 ST RIGHT VLV
18
WHT 39 JOYSTICK
19
WHT 35 PLAT ALARM
20
WHT 36 YEL LAMP
21
WHT 42 OVLD LAMP
22
WHT 34 RED LAMP
23
CO09-B1
IFT UP SW
CO09-B+
1
GING STAT
25
CO09-B+F2
1
RELEASE
24
A
MS35-3
S50
21 12V IGN
SYSTEM MODULE
CO09-J1
3
FOR DIAGNOSTICS
B
S84
ND ALARM
B
MS35-1
A
SEE MOTORS ON PAGE 3 B1
YEL 3-1-2 R BRK IGN
WHT 9 R BRAKE
YEL 3-1-1 L BRK IGN
WHT 8 L BRAKE
X02-B
1
2
X01-B
1
2
WHT 18 CHARGING STAT
2
1
R BRAKE (MS02-B)
L BRAKE (MS01-B)
CHARGER INTERLOCK
X08
YEL 3-4 IGN
WHT 15 ST RIGHT VLV
B
1
HV42
2
WHT 16 ST LEFT VLV
YEL 3-5 IGN
1
HV41
2
1
YEL 3-6 IGN
WHT 17 LIFT UP VLV
HV39
2
WHT 19 N LIFT DN
WHT 60 5V SEN
WHT 58 PRES 1
WHT 59 PRES 2
WHT 20 P LIFT DN
1
X53
2
3
4
5
6
ANSI MACHINE HAS
PINS 1 & 2 ONLY
CONNECTS TO X55
WHT 61 GND
SEE CHARGER ON PAGE 3 A3
1
2
3
4
5
X55
STEER LEFT
STEER RIGHT
YEL
GRN
RED
BLK
BLU
ORN
YEL 3-1 IGN
LIFT UP
A
1
X55A
2
3
4
5
6
1
X25
2
3
YEL 3-2 IGN
YEL 3-16 IGN
4
5
6
YEL 3-3 IGN
7
8
YEL 3 IGN
6
EAME MACHINE HAS
ADDITIONAL CABLE
ATTACH SPLICE BLOCK
THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES,INC.
AND CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION OF JLG. IT MAY NOT BE COPIED OR
DISCLOSED TO ANY THIRD PARTY WITHOUT JLG'S
WRITTEN CONSENT AND IS PROVIDED FOR THE
LIMITED PURPOSE OF REVIEW AND EVALUATION.
ON
5
6
1001129844_D - Sht. 2
Note: Sheet 1 of this Schematic was a table of contents and is not shown.
7
8
Figure 7-18. Electrical Schematic - (Global)
3121273
– JLG Lift –
7-17
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870205B - Sheet 1 of 2
2
X11
1
BLK/RED
2
3
BRN/BLK
BLU/RED
YEL
PLATFORM CABLE
6
7
BLU/BLK
8
9
7
8
9
14
14
15
15
16
16
17
17
18
18
19
19
20
20
20
21
21
21
RED
RED
BLK
BLK
ORN/BLK
ORN/BLK
RED/BLK
RED/BLK
BLU
BLU
ORN
ORN
ORN/RED
ORN/RED
YEL/RED
YEL/RED
GRN
GRN
4
5
6
X55
WHT 20 P LIFT DN
WHT 60-1 5V SEN
WHT 19 N LIFT DN
WHT 61-1 GND
WHT 60 5V SEN
WHT 58 PRES 1
S03
WHT 58 PRES 1
S04
WHT 60-2 5V SEN
WHT 59 PRES 2
WHT 61 GND
WHT 61-2 GND
WHT 59 PRES 2
3
4
6
5
2
1
X90
MS02-F
1
2
SHIELD
SHIELD
YEL
YEL
GRN
GRN
RED
RED
BLK
BLK
EAME MACHINE ONLY
BLK 4AWG
BLK 4AWG
SIG
PWR
B
GND
C
SIG
1
MS01-A1
2
1
MS01-F
4
5
2
1
SN91
CAN-H
CAN-L
B+
GND
WHT 28 F1 12AWG
1
X09-F1
X09-T1
BLK 4AWG
BLK 4AWG
BLK 2/0AWG
1
X09-B-
BLK 4AWG
BLK 4AWG
BLK 4AWG
BLK 4AWG
WHT 28-1 FIELD 12AWG
WHT 29 F2 12AWG
1
X09-B+F2
WHT 29 F2 12AWG
1
X09-F2
BLK 4AWG
1
X09-P-
BLK 4AWG
1
MS07-
M
1
MS07+
1
X09-B+
BLK 4AWG
BLK 4AWG
BLK 4AWG
1
X09-B+F1
SEE PAGE 2(A2)
EAME MACHINE ONLY
OPTIONAL
BLK 2/0AWG
BLK 2/0AWG
BLK 4AWG
BT82+
BLK 4AWG
1
BLK 2/0AWG
BT82BLK 4AWG
1
BLK 2/0AWG
BT83BLK 4AWG
1
BT83+
1
A
BLK 4AWG
BT801
1
X05
BT80+
1
2
1
ANSI MACHINE ONLY
BT81+
BLK 4AWG
1
BLK 2/0AWG
BT81BLK 4AWG
1
2
X06
YEL/BLK 18AWG TFFN
RED 18AWG TFFN
BLK 18AWG TFFN
ORN/BLK 18AWG TFFN
RED/BLK 18AWG TFFN
BLU 18AWG TFFN
ORN 18AWG TFFN
ORN/RED 18AWG TFFN
YEL/RED 18AWG TFFN
GRN 18AWG TFFN
X11
8
2
BLU/BLK
S97
G
PLATFORM CABLE MO
FOR JAPAN MARKET MA
CONTACTOR
1
MS01-A2
BRN 18AWG TFFN
3
6
1
A
BLU/BLK 18AWG TFFN
EAME MACHINE ONLY
SN88
A
SEE PAGE 2 ZONE B8
MS01-B
2
GND
C
YEL 18AWG TFFN
GREEN WIRE ON EAME MACHINE ONLY
WHT 28-1 FIELD 12AWG
MS02-A2
1
1
PWR
B
WHT 28 F1 12AWG
MS02-A1
1
2
MS02-B
SN87
A
BLU/RED 18AWG TFFN
X09 CONNECTIONS ON SYSTEM MODULE ON PAGE 2
3
1
2
HV40
BRN/BLK 18AWG TFFN
ANGLE SENSOR
2
WHT 19 N LIFT DN
LIFT DN
WHT 20 P LIFT DN
ANSI MACHINE HAS
PINS 1 & 2 ONLY
CONNECTS TO X53 1
BLK/RED 18AWG TFFN
PRES 1
19
RIGHT DRIVE MOTOR
7
9
YEL/BLK
13
18
LEFT DRIVE MOTOR
6
12
17
PUMP MOTOR
6
13
16
B
5
12
14
BRAKE
4
5
11
13
BRAKE
4
11
12
A
3
10
11
CONNECTS TO X86
2
3
10
15
C
2
8
BRN
YEL/BLK
10
SHEET 2 D8
BLU/BLK
BRN
1
X10
1
PRES 2
D
X12
BLK/RED
BLU/RED
5
TO X28
4
BRN/BLK
YEL
4
CONNECTS
3
WHT 43 2 FT SW
1
1
RL14
1
RL14-2
1
RL14-1
CONNECT TO X08 SHEET 2 B8
INTERLOCK
DC
AC
AC PLUG
BATTERY CHARGER
1001129844_D - Sht. 3
6V BATTERY 6V BATTERY 6V BATTERY 6V BATTERY
1
2
3
4
Figure 7-18. Electrical Schematic - (Global)
7-18
– JLG Lift –
3121273
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870205B - Sheet 2 of 2
6
7
WG TFFN
8
BLK/RED 18AWG TFFN
WG TFFN
YEL 3-9 IGN
AWG TFFN
RED 18AWG TFFN
6
DRIVE LIFT
5
5
4
TFFN
3
2
1
SW16
WG TFFN
TFFN
TFFN
JS47
1
YEL 3-10 IGN
BLU/BLK 18AWG TFFN
2
WG TFFN
3
YEL/BLK 18AWG TFFN
G TFFN
4
BRN/BLK 18AWG TFFN
STRAIN RELIEF
Y
5
6
BLU/RED 18AWG TFFN
7
BLK 18AWG TFFN
8
ORN 18AWG TFFN
X12
BLU/BLK
OUTPUT
9
YEL 3-11 IGN
SW17-1
1
BRN 18AWG TFFN
SW17-2
1
LB15+
RED LAMP
YEL 3-12 IGN
BLU 18AWG TFFN
1
1
LB15AH32+
1
ORN/RED 18AWG TFFN
AH321
YEL 3-14 IGN
GENERIC
YEL/RED 18AWG TFFN
PLATFORM CABLE MODIFICATION
FOR JAPAN MARKET MACHINES ONLY
C
ALARM
YEL 3-13 IGN
LSS LAMP (RED) YELLOW LAMP
WHT 43-2 FT SW
WHT 43-1 FT SW
8
2
S97
1
SW95
X11
8
LB13+
1
1
YEL 3-15 IGN
1
1
LB89-
YEL 3-14 IGN
YEL 3-13 IGN
YEL 3-12 IGN
YEL 3-11 IGN
YEL 3-10 IGN
YEL 3-9 IGN
YEL 3-15 IGN
LB89+
EAME MACHINE ONLY
1
X48
2
3
4
5
6
7
8
RED/BLK 18AWG TFFN
LB13-
GRN 18AWG TFFN
D
T
TFFN
AWG TFFN
EMS
1
SW38-2
JOYSTICK
WG TFFN
1
SW38-1
HORN SWITCH
YEL 18AWG TFFN
AWG TFFN
R
TFFN
TFFN
L
ORN/BLK 18AWG TFFN
WG TFFN
B
ATTACH SPLICE BLOCK
A
THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES,INC.
AND CONTAINS PROPRIETARY AND CONFIDENTIAL
INFORMATION OF JLG. IT MAY NOT BE COPIED OR
DISCLOSED TO ANY THIRD PARTY WITHOUT JLG'S
WRITTEN CONSENT AND IS PROVIDED FOR THE
LIMITED PURPOSE OF REVIEW AND EVALUATION.
5
6
1001129844_D - Sht. 3
Note: Sheet 1 of this Schematic was a table of contents and is not shown.
7
8
Figure 7-18. Electrical Schematic - (Global)
3121273
– JLG Lift –
7-19
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
PLATFORM
RECEPTACLE
LSS LIFT CYLINDER
TRANSDUCERS
LIFT
CYLINDER
VALVE
BLOCK
PLATFORM
CONTROL BOX
LSS
ARM
ANGLE
SENSOR
(CE SPEC)
BRAKE
RELEASE
RELAY
ELEVATION
SENSOR
LIMIT SWITCH
GROUND
CONTROL
PANEL
TILT
SENSOR
Figure 7-19. Electrical Components Layout - Sheet 1 of 2
7-20
– JLG Lift –
3121273
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
BATTERIES
ALARM
OR
BATTERY
CHARGER
BATTERY
QUICKDISCONNECT
(OPTION)
CONTACTOR
RELAY
J1
+BF1
DRIVE
MODULE
–T
PUMP/
MOTOR/
RESERVOIR
+B
+BF2
J2
–B
–P
F1 F2
BEACON
LIGHT
(REAR)
LEFT DRIVE
MOTOR
RIGHT DRIVE
MOTOR
BEACON
LIGHT
(FRONT)
Figure 7-19. Electrical Layout - Sheet 2 of 2
3121273
– JLG Lift –
7-21
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.8 HYDRAULIC SCHEMATIC
Hydraulic Schematic - 2792599C
1001131095_E
Figure 7-20. Hydraulic Schematic
7-22
– JLG Lift –
3121273
CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of Califormia
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
3121273
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
+61 2 65 811111
+55 19 3295 1025
+61 2 65 810122
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0)161 654 1000
+34 93 772 4700
+34 93 771 1762
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
+44 (0)161 654 1001
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
(852) 2639 5783
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
+39 029 359 5210
+39 029 359 5845
(852) 2639 5797
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534
www.jlg.com
Oshkosh-JLG Singapore
Technology Equipment Pte Ltd.
29 Tuas Ave 4
Jurong Industrial Estate
639379 - Singapore
+65-6591-9030
+65-6591-9031
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