Service & Maintenance Manual
Service & Maintenance Manual
Models
1930ES
2030ES
2630ES
2646ES
3246ES
3121166
November 27, 2013
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
C. MAINTENANCE
A. GENERAL
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.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY OR DEATH AND IS A SAFETY VIOLATION.
MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A
RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS
SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION.
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.
• 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.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL
OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN
THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT OFF
ALL POWER CONTROLS.
B. HYDRAULIC SYSTEM SAFETY
• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
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.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS
STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition
on, to direct any line pressure back into the reservoir.
Pressure feed lines to system components can then be
disconnected with minimal fluid loss.
3121166
– JLG Lift –
a
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
REVISION LOG
NOTE: All machines built before mid-year 2010 are equipped with the Sevcon-1600346 Power Module, in mid-year 2010 a new
design ZAPI-1001092456 Power Module was introduced for production. ES Scissors built in the USA and Belgium may be
equipped with either one of two different power modules after mid-2010. All China built machines were equipped the
ZAPI-1001092456 Power Module. If power module service is required, see Section-3 in order to locate and identify which
power module your machine is equipped with.
Original Issue - May 27, 2003
Revised - October 31, 2003
Revised - March 19, 2004
Revised - July 8, 2004
Revised - July 27, 2004
Revised - October 22, 2004
Revised - May 4, 2005
Revised - July 27, 2005
Revised - May 9, 2006
Revised - September 6, 2006
Revised - September 28, 2006
Revised - November 22, 2006
Revised - April 27, 2007
Revised - August 27, 2007
Revised - January 11, 2008
Revised - July 30, 2008
Revised - November 4, 2008
Revised - October 8, 2009
Revised - June 1, 2010
Revised - August 30, 2011
Revised - October 3, 2012
Revised - November 27, 2013
b
– JLG Lift –
3121166
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
1.8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Travel Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Lift Speed (No Load in Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Model Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
High Drive Speed Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Torque ChartS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION 2 - GENERAL
2.1
2.2
2.3
3121166
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 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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TABLE OF CONTENTS
2.4
2.5
2.6
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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
ii
Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MDI (Multifunction Digital Indicator) and brake release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Roll Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Oil Check/Fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Motor and Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hub Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Replacing Motor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Inspecting Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Replacing Motor Brushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Replacing the Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Reassembling the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Electric Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Drive Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Drive Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Drive Motor Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Drive Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Drive Motor Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Drive Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
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3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Power Module - Sevcon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Power Module Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Power Module - ZAPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
ZAPI Power Module Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Battery Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Battery Maintenance and Safety Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Battery Charger/Inverter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Battery Charger/Inverter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Drive Motor Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Pothole Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Rotary Angle Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Printed Circuit Board (PCB) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Tilt Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Arms and Platform Positioning and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
SECTION 4 - HYDRAULICS
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
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
Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cylinders Without Counterbalance Valves and Steer Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lift Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hydraulic Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Slide Block Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Pump/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pump Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Steer Cylinder Piston Removal - Cyl. p/n-1684456 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
SECTION 5 - JLG CONTROL SYSTEM
5.1
5.2
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Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
Ground Module Software Version 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Ground Module Software Version 1.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Failure Troubleshooting for The Field. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tilt Sensor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Elevation Angle Sensor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tilt vs. Allowed Height Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Elevation Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Machine Model Adjustment - SEVCON - 1600346 Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Machine Model Adjustment - ZAPI - 1001092456 Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Machine Configuration Programming Information - SEVCON - 1600346 . . . . . . . . . . . . . . . . . . . . 5-27
Machine Configuration Programming Information - ZAPI - 1001092456 . . . . . . . . . . . . . . . . . . . . 5-28
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.1
6.2
6.3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DTC Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-6 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.1
7.2
7.3
7.4
7.5
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
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TABLE OF CONTENTS
7.6
7.7
7.8
Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Automatic Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Circuit Boards: Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Electrical Schematics and Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
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.
3121166
TITLE
PAGE NO.
Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Torque Chart (METRIC Fasteners - Sheet 6 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Torque Chart (METRIC Fasteners - Sheet 7 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MDI Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Traction Control Circuit - Sevcon Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Traction Control Circuit - ZAPI Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Disengage Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Disengage Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Disengage Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Motor & Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Spindle DIsassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Motor & Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Motor Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Motor Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Bearing Pressure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Terminal Tightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Drive Motor Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Bearing Pressure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Wire Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Sevcon Power Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ZAPI Power Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Battery Charger/Inverter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Battery Charger/Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
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TABLE OF CONTENTS
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
3-45.
3-44.
3-45.
3-46.
3-47.
3-48.
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.
5-1.
5-2.
5-3.
5-4.
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.
7-21.
7-22.
7-23.
7-24.
7-25.
7-26.
7-27.
7-28.
7-29.
vi
Motor Cable Routing (1930ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Motor Cable Routing (2030ES/2630ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Limit Switch Locations - 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Limit Switch Locations - 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Pothole Switch Adjustment - 1930ES/2030ES/2630ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Pothole Switch Adjustment - 2630ES/3246ES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Tilt Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Tilt Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Arms and Platform Positioning and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Lift Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LIft Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Cylinder Rod Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Poly-Pak Piston Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Lift Cylinder/Pump/Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Analyzer Flow Chart - Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Analyzer Flow Chart - Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Analyzer Flow Chart - Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
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 - 1870164 G - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Electrical Schematic - 1870164 G - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Electrical Schematic - 187205 B - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Electrical Schematic - 187205 B - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Electrical Schematic - Sheet 1 of 2 (Machines with MDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Electrical Schematic - Sheet 2 of 2 (Machines with MDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Battery Inverter/Charger Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3 . . . . . . . . . . . 7-26
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3 . . . . . . . . . . . 7-27
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3 . . . . . . . . . . . 7-28
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3 . . . . . . . . . . . 7-29
Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 3 of 3 . . . . . . . . . . . 7-30
– JLG Lift –
3121166
TABLE OF CONTENTS
7-30.
7-31.
7-32.
7-33.
7-34.
7-35.
7-36.
7-37.
7-38.
7-39.
7-40.
3121166
Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Electrical Components - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Electrical Components - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Electrical Components - Sheet 1 of 2 (Machines with MDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Electrical Components - Sheet 2 of 2 (Machines with MDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Electrical Components - (Machines with 1001092456 Power Module) - Sheet 1 of 2 . . . . . . . . . 7-40
Electrical Components - (Machines with 1001092456 Power Module) - Sheet 2 of 2 . . . . . . . . . 7-41
Hydraulic Schematic - 2792599-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
– JLG Lift –
vii
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
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
5-5
5-6
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
viii
TITLE
PAGE NO.
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Oil Specifications (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
High Drive Speed Cutout Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cylinder Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Sevcon Power Module Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
ZAPI Power Module Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Battery Charger Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Battery Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Battery Charger/Inverter Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Tilt Sensor Harness Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Tilt Sensor Harness for 4000021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Tilt Sensor Harness for 1001114936 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Connector Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Lift Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Flash Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Machine Model Adjustment - (Machines with Sevcon - 1600346 Power Module Only) . . . . . . 5-25
Machine Model Adjustment - (Machines with ZAPI - 1001092456 Power Module Only) . . . . . 5-26
Machine Configuration Programming Information (Machines with Sevcon - 1600346 Power Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Machine Configuration Programming Information (Machines with ZAPI - 1001092456 Power Module Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Ground Board J1 (1600346 Power Module ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Ground Board J2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Ground Board J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Platform Board J1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Platform Board J3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Platform Board J4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Power Module (1600346 Power Module ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Power Module - J1 (1001092456 Power Module ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Power Module - J2 (1001092456 Power Module ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
– JLG Lift –
3121166
SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1
SPECIFICATIONS
Table 1-1. Operating Specifications
Description
Maximum Stowed Travel Grade
(Gradeability)
Maximum Stowed Travel Grade
(Sideslope)
Maximum Platform Height
Maximum Tire Load:
ANSI:
CE:
Ground Bearing Pressure (ANSI)
Ground Bearing Pressure (CE)
Maximum Drive Speed
Maximum Wind Speed
Maximum Horizontal Manual Side Force:
ANSI/CSA:
ANSI/CSA (Indoor):
ANSI/CSA (Outdoor):
ANSI/CSA (Zone A):
ANSI/CSA (Zone B):
CE (Indoor):
CE (Outdoor):
AUS (Indoor):
AUS (Indoor Zone A):
AUS (Indoor Zone B):
AUS (Outdoor):
AUS (Outdoor Zone A):
AUS (Outdoor Zone B):
Maximum Hydraulic Pressure
Inside Steer Angle
Outside Steer Angle
Electrical System Voltage (DC)
Approximate Gross Machine Weight ANSI/CSA
Approximate Gross Machine Weight CE/Australia
Ground Clearance with pot hole
protection system up
Ground Clearance with pot hole
protection system down
3121166
1930ES
2030ES
2630ES
2646ES
3246ES
25%
25%
25%
25%
25%
5°
5°
5°
5°
5°
18.75 ft.
5.7 m
20 ft.
6m
25.8 ft.
7.75 m
26 ft.
7.9 m
32 ft.
9.8 m
1365 lb (620 kg)
1540 lb (699 kg)
109 psi
(7.7 kg/cm2 )
8.7 kg/cm2
(123 psi)
3 mph
(4.8 kmh)
1660 (755)
1835 lb (832 kg)
81 psi
(5.7 kg/cm2 )
6.3 kg/cm2
(90 psi)
3 mph
(4.8 kmh)
100 lb force (445 N)
N/A
N/A
N/A
N/A
90 lb force (400 N)
45 lb force (200 N)
90 lb force (400 N)
N/A
N/A
45 lb force (200 N)
N/A
N/A
120 lb force (533 N)
N/A
N/A
N/A
N/A
90 lb force (400 N)
45 lb force (200 N)
90 lb force (400 N)
N/A
N/A
45 lb force (200 N)
N/A
N/A
1800psi
1800 psi
90°
69°
24V
90°
73°
24V
1850 psi (dual)
90°
73°
24V
2685 lbs
3830 lbs
1495 kg
2063.8 kg
1835 lb (832 kg)
2070 lb (939 kg)
2070 lb (939 kg)
1835 lb (832 kg)
2320 lb (1052 kg)
2320 lb (1052 kg)
90 psi
87 psi
87 psi
(6.3 kg/cm2 )
(6.1 kg/cm2 )
(6.1 kg/cm2 )
6.3 kg/cm2
6.9 kg/cm2
6.9 kg/cm2
(90 psi)
(98 psi)
(98 psi)
2.75 mph
2.5 mph
2.5 mph
(4.4 kmh)
(4 kmh)
(4 kmh)
28 mph (12.5 m/s)
(Depending on model, market, and indoor/outdoor selection, see Table 1-2, Platform Capacities)
150 lb force (667 N)
N/A
N/A
N/A
N/A
90 lb force (400 N)
90 lb force (400 N)
90 lb force (400 N)
N/A
N/A
90 lb force (400 N)
N/A
N/A
N/A
N/A
N/A
150 lb force (667 N)
105 lb force (467 N)
90 lb force (400 N)
45 lb force (200 N)
N/A
90 lb force (400 N)
90 lb force (400 N)
N/A
N/A
45 lb force (200 N)
2000 psi
2000 psi
90°
67°
24V
90°
67°
24V
4815 lbs
4945 lbs
4945 lbs
2197.7 kg
2705.7 kg
2871.2 kg
N/A
N/A
N/A
120 lb force (533 N)
100 lb force (445 N)
90 lb force (400 N)
N/A
N/A
90 lb force (400 N)
90 lb force (400 N)
N/A
N/A
N/A
1700 psi (single)
3.5 in (8.9 cm)
1 in (2.5 cm)
0.75 in (1.9 cm)
– JLG Lift –
1-1
SECTION 1 - SPECIFICATIONS
Capacities
Table 1-2. Platform Capacities
NOTE: All platform extension capacities are 250 lbs (120 kg)
Model
ANSI/CSA
CE INDOOR
CE OUTDOOR
AUSTRALIAN INDOOR
AUSTRALIAN
OUTDOOR
Max
Capacity
Max
Persons
Max
Capacity
Max
Persons
Max
Capacity
Max
Persons
Max
Capacity
Max
Persons
Max
Capacity
Max
Persons
1930ES
500 lbs
(227 kg)
2
230 kg
2
120 kg
1
230 kg
2
120 kg
1
2030ES
800 lbs
(363 kg)
2
360 kg
2
160 kg
1
360 kg
2
160 kg
1
2630ES
single cap
500 lbs
(227 kg)
2
230 kg
2
N/A
N/A
230 kg
2
N/A
N/A
2630ES
dual cap to 20 ft
800 lbs
(363 kg)
2
360 kg
2
N/A
N/A
360 kg
2
N/A
N/A
2630ES
dual cap to 26 ft
500 lbs
(227 kg)
2
230 kg
2
N/A
N/A
230 kg
2
N/A
N/A
2646ES
1000 lbs
(454 kg)
2
450 kg
2
230 kg
2
450 kg
2
230 kg
2
3246ES to 26 ft
1000 lbs
(454 kg)
Zone A
2
450kg
2
320 kg
1
450 kg
2
320 kg
1
3246ES to 32 ft
700 lbs
(317 kg)
Zone B
2
320kg
2
320 kg
1
320 kg
2
320 kg
1
Fluid Capacities
Table 1-3. Fluid Capacities
Description
1930ES
2030ES
2630ES
2646ES
3246ES
Hydraulic Tank
2 Gal
(7.6 L)
2 Gal
(7.6 L)
3 Gal
(11.3 L)
Hydraulic System (Including Tank)
2.2 Gal
(8.3 L)
2.8 Gal
(10.6 L)
5.3 Gal
(19.9 L)
1-2
– JLG Lift –
3121166
SECTION 1 - SPECIFICATIONS
Tires
Table 1-4. Tire Specifications
Description
1930ES
2030ES
2630ES
2646ES
Size
323mm x 100mm
406 mm x 125 mm
Max Tire Load
2500 lbs (1134 kg)
4000 lbs (1814 kg)
Wheel Bolt Torque
3246ES
105 - 120 ft lb (142-163 Nm)
Motors
Batteries
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 BATTER Y CHARGER TO OPTIMIZE BATTER Y 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.
Drive Motor
Type: Shunt Wound, Sepex 24V DC
Power: 0.65 Horsepower @ 3750 rpm
Hydraulic Pump/Electric Motor Assembly
(All Models)
Type: Series Wound Permanent Magnet 24V DC
Power: 3kW
Battery Charger
20 Amp SCR
110/250 Volts AC - 50/60 Hz input
24 Volts DC - 20 Amp output w/auto timer
Japanese Specification
100/200 Volts AC - 50/60 Hz input
24 Volts DC - 20 Amp output w/auto timer
3121166
– JLG Lift –
1-3
SECTION 1 - SPECIFICATIONS
Travel Speed
Table 1-5. Travel Speed
Model
Elevated Speed
Maximum Speed
Unit of Measure
Mph
Sec/25 ft
Kph
Sec/7.6 m
Mph
Sec/25 ft
Kph
Sec/7.6 m
1930ES
0.5
28-37
0.8
33 - 38
3
5.5 - 6.2
4.8
5.5 - 6.2
2030ES
0.5
28-37
0.8
33 - 38
2.75
6.18 - 6.6
4.4
6.18 - 6.6
2630ES
0.5
28-37
0.8
33 - 38
2.75
6.18 - 6.6
4.4
6.18 - 6.6
2646ES
0.5
28-37
0.8
33 - 38
2.5
7-8
4
7-8
3246ES
0.5
28-37
0.8
33 - 38
2.5
7-8
4
7-8
Lift Speed (No Load in Platform)
NOTE: No load in platform on measured lift speeds.
Table 1-6. Lift Speed
1-4
Model
Lift Up (Seconds)
Lift Down (Seconds)
1930ES
18 - 23
25 - 35
2030ES
25 - 32
35 - 45
2630ES
28 - 38
35 - 40
2646ES
38 - 45
45 - 55
3246ES
50 - 60
58 - 66
– JLG Lift –
3121166
SECTION 1 - SPECIFICATIONS
Model Dimensions
Table 1-7. Dimensions
Model
1930ES
2030ES
2630ES
2646ES
3246ES
Platform Height - Elevated
18.75 ft
(5.7 m)
20 ft
(6 m)
25.8 ft
(7.9 m)
26 ft
(7.9 m)
32 ft
(9.8 m)
Platform Height - Stowed
2.9 ft
(0.9 m)
3.6 ft
(1.1 m)
4 ft
(1.2 m)
4 ft
(1.2 m)
4 ft
(1.2 m)
Working Height
25 ft
(7.6 m)
26 ft
(7.9 m)
32 ft
(9.8 m)
32 ft
(9.8 m)
38 ft
(11.6 m)
Overall Stowed Machine Height - Rails Up
6.5 ft
(2 m)
7.2 ft
(2.2 m)
7.7 ft
(2.3 m)
7.7 ft
(2.3 m)
7.7 ft
(2.3 m)
N/A
6 ft
(1.8 m)
6.4 ft (
1.9 m)
6.4 ft
(1.9 m)
6.4 ft
(1.9 m)
Rail Height (From platform floor)
3.6 ft
(1.1 m)
3.6 ft
(1.1 m)
3.6 ft
(1.1 m)
3.6 ft
(1.1 m)
3.6 ft
(1.1 m)
Overall Machine Width
2.5 ft
(0.8 m)
2.5 ft
(0.8 m)
2.5 ft
(0.8 m)
3.7 ft
(1.2 m)
3.7 ft
(1.2 m)
Overall Machine Length - Deck Retracted
6 ft
(1.9 m)
7.5 ft
(2.3 m)
7.5 ft
(2.3 m)
8.2 ft
(2.5 m)
8.2 ft
(2.5 m)
Overall Machine Length - Deck Extended
9 ft
(2.8 m)
10.5 ft
(3.2 m)
10.5 ft
(3.2 m)
12.4 ft
(3.8 m)
12.4 ft
(3.8 m)
Platform Size - Length
6.1 ft
(1.9 m)
7.5 ft
(2.3 m)
7.5 ft
(2.3 m)
8.2 ft
(2.5 m)
8.2 ft
(2.5 m)
Platform Size - Width
2.5 ft
(0.8 m)
2.5 ft
(0.8 m)
2.5 ft
(0.8 m)
3.7 ft
(1.1 m)
3.7 ft
(1.1 m)
Platform Extension Length
3 ft
(0.9 m)
3 ft (
0.9 m)
3 ft
(0.9 m)
4.2 ft
(1.3 m)
4.2 ft
(1.3 m)
Wheelbase
5.3 ft
(1.6 m)
6.2 ft
(1.9 m)
6.2 ft
(1.9 m)
6.9 ft
(2.1 m)
6.9 ft
(2.1 m)
Overall Stowed Machine Height - Rails Collapsed
3121166
– JLG Lift –
1-5
SECTION 1 - SPECIFICATIONS
1.2
Table 1-9. Hydraulic Oil
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..
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
Table 1-8. Torque Requirements
Description
Rear Wheel Spindle Nut
Wheel Bolts
Torque Value (Dry)
Interval Hours
30-40 ft lb
(40-54 Nm)
50
105 -120 ft lb
(142-163 Nm)
50
Table 1-10. Lubrication Specifications
Key
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.
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.
HO
Hydraulic Oil. API service classification GL-3,e.g. DTE 11M.
Table 1-11. Hydraulic Oil Specifications (Standard)
MOBIL
DTE 10
EXCEL 15
MOBIL EAL
ENVIRONSYN 32
ISO Viscosity Grade
#15
#32
Gravity API
31.9
—
Pour Point, Max
-40°F (-40°C)
-59°F (-51°C)
Flash Point, Min.
330°F (166°C)
514°F (268°C)
at 40°C
15 cSt
33.1 cSt
at 100°C
4.1 cSt
6.36 cSt
at 100°F
80 SUS
—
at 210°F
43 SUS
—
cp at -30°F
3.200
—
Viscosity Index
140
147
Specification
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 Section 1.8, Torque ChartS to
determine proper torque value.
1.3
LUBRICATION
Hydraulic Oil
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 11M hydraulic
oil.
Viscosity Specifications
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 11M is desired, contact JLG Industries for
proper recommendations.
1-6
– JLG Lift –
3121166
SECTION 1 - SPECIFICATIONS
1.4
High Drive Speed Cutout
LIMIT SWITCHES
High drive speed is cut out when the platform is raised
above the preset height per model as follows:
Tilt Alarm
Illuminates a light on the platform, sounds an alarm and
cuts out lift up and drive when the machine is out of
level and above stowed depending on model and specifications.
NOTE: These figures are given with a tolerance of ± 6 in
(0.15 m).
Table 1-13. High Drive Speed Cutout Height
Table 1-12. Tilt Settings
Model
1930ES
2030ES
2630ES
High Drive Speed Cutout
Tilt Setting
(front to back)
Tilt Setting
(side to side)
Maximum Deck
Elevation
1930ES
54 in (1.4 m)
2030ES
66 in (1.7 m)
18.75 ft (5.7 m)
14 ft (4.3 m)
11 ft (3.4 m)
9 ft (2.7 m)
2630ES
76 in (1.9 m)
3°
1.5°
2°
2.5°
3°
2646ES
76 in (1.9 m)
3246ES
76 in (1.9 m)
3°
1.5°
2°
2.5°
3°
20 ft (6 m)
15 ft (4.5 m)
12 ft (3.7 m)
10 ft (3 m)
3°
1.5°
2°
2.5°
3°
25.4 ft (7.7 m)
20 ft (6 m)
16 ft (4.9 m)
13 ft (4 m)
Model
Lift Relief
Steer Relief
1930ES
1800 psi ± 50 psi
(124 bar ± 3.4 bar)
1500 psi
(103 bar)
2030ES
1800 psi ± 50 psi
(124 bar ± 3.4 bar)
1500 psi
(103 bar)
2630ES
1950 psi +/- 50 psi
(134 bar ± 3.4 bar)
1500 psi
(103 bar)
2646ES
2000 psi +/- 50 psi
(138 bar ± 3.4 bar)
1500 psi
(103 bar)
3246ES
2000 psi +/- 50 psi
(138 bar ± 3.4 bar)
1500 psi
(103 bar)
2646ES
3°
2°
2.5°
3°
26 ft (7.9 m)
22 ft (6.7 m)
20 ft (6 m)
3246ES
3°
2°
2.5°
3°
31.75 ft (9.7 m)
22 ft (6.7 m)
20 ft (6 m)
3121166
Model
Pressure Settings
Table 1-14. Pressure Settings
– JLG Lift –
1-7
SECTION 1 - SPECIFICATIONS
1.5
CYLINDER SPECIFICATIONS
Table 1-15. Cylinder Specifications
Description
1930ES
2030ES
2630ES
2646ES
3246ES
Lift Cylinder Bore
2.8 in
(7.1 cm)
3.1 in
(7.9 cm)
3.1 in
(7.9 cm)
3.9 in
(9.9 cm)
3.9 in
(9.9 cm)
Lift Cylinder Stroke
43.2 in
(108 cm)
48 in
(122 cm)
48 in
(122 cm)
44.9 in
(114 cm)
56.8 in
(144 cm)
Lift Cylinder Rod Diameter
1.8 in
(4.5 cm)
2.1 in
(5.5 cm)
2.1 in
(5.5 cm)
2.4 in
(6 cm)
2.4 in
(6 cm)
Steer Cylinder (Stroke)
6.3 in
(16 cm)
6.3 in
(16 cm)
6.3 in
(16 cm)
6.1 in
(15.6 cm)
6.1 in
(15.6 cm)
2646ES
3246ES
1.6
MAJOR COMPONENT WEIGHTS
Table 1-16. Major Component Weights
Component
1930ES
Platform
2030ES
100 lbs
(45 kg)
2630ES
133 lbs
(61 kg)
176 lbs
(80 kg)
Manual Platform Extension
45 lbs
(20 kg)
Arm Assembly - (Includes Lift Cylinder)
620 lbs
(281 kg)
Chassis w/Wheel/Tire and Drive Assembly
1,067 lbs
(484 kg)
1.7
939 lbs
(426 kg)
1,213 lbs
(550 kg)
1,645 lbs
(746 kg)
1,764 lbs
(800 kg)
1,554 lbs
(705 kg)
CRITICAL STABILITY WEIGHTS
DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENTWEIGHT OR
SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT
STABILITY.
Table 1-17. Critical Stability Weights
Component
Counterweight(s) (CE, AUS)
1930 ES
582 lbs (264 kg)
Counterweight (ANSI, CSA, JPN)
N/A
Wheel and Tire Assembly (each)
22 lbs (9.8 kg)
Wheel/Tire and Drive Assembly (each)
117 lbs (53 kg)
Lift Cylinder
176 lbs(80 kg)
Batteries: (each)
220 Amp
220 Amp (used with Inverter/Charger)
245 Amp
60 lbs (27 kg)
66 lbs (30 kg)
N/A
1-8
2030ES
2630ES
721 lbs (327 kg)
N/A
2646ES
3246ES
1592 lbs (722 kg)
1956 lbs (887 kg)
721 lbs (327 kg)
589 lbs (267 kg)
42 lbs (19 kg)
162 lbs (73.4 kg)
205 lbs (93 kg)
263 lbs (119 kg)
283 lbs (128 kg)
60 lbs (27 kg)
66 lbs (30 kg)
70 lbs (32 kg)
– JLG Lift –
3121166
SECTION 1 - SPECIFICATIONS
1.8
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
0100011
0100019
0100071
Loctite® P/N
TM
242
271TM
262TM
ND Industries P/N
TM
Vibra-TITE 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)
3121166
– JLG Lift –
1-9
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
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
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))
1-10
– JLG Lift –
3121166
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)
3121166
– JLG Lift –
1-11
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)
1-12
– JLG Lift –
3121166
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)
TITE TM 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))
3121166
– JLG Lift –
1-13
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)
1-14
– JLG Lift –
3121166
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]
3
0.5
3.5
0.6
5.03
6.78
4
0.7
8.78
5
0.8
14.20
6
1
20.10
12.5
13
12
11
7
1
28.90
18.0
21
20
19
27
8
1.25
36.60
22.8
31
29
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)
3121166
– JLG Lift –
1-15
SECTION 1 - SPECIFICATIONS
This page intentionally left blank.
1-16
– JLG Lift –
3121166
SECTION 2 - GENERAL
SECTION 2. GENERAL
2.1
this inspection must be increased as environment,
severity and frequency of usage requires.
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
Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator 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
3121166
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
Type
Primary
Responsibility
Frequency
Service
Qualification
Reference
Pre-Start
Inspection
Prior to use each day; or
At each Operator change.
User or Operator
User or Operator
Operator 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.
Frequent
Inspection
In service for 3 months or 150 hours, whichever
comes first; or
Out of service for a period of more than 3
months; or
Purchased used.
Owner, Dealer, or User
Qualified JLG Mechanic
Service and Maintenance Manual and applicable JLG inspection form.
Annual Machine
Inspection
Annually, no later than 13 months from the
date of the prior inspection.
Owner, Dealer, or User
Factory Trained
Service Technician
(recommended)
Service and Maintenance Manual and applicable JLG inspection form.
Preventative
Maintenance
At intervals as specified in the Service and
Maintenance Manual.
Owner, Dealer, or User
Qualified JLG Mechanic
Service and Maintenance Manual
2.2
component is disconnected, cap or cover all openings to prevent entry of foreign matter.
SERVICE AND GUIDELINES
General
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.
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
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.
Components Removal and Installation
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.
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.
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or
2-2
– JLG Lift –
3121166
SECTION 2 - GENERAL
having the same specifications of the original, or
one which is equivalent.
Component Disassembly and Reassembly
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
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.
3. Unless specific torque requirements are given
within the text, standard torque values should be
used on heat-treated bolts, studs, and steel nuts, in
accordance with recommended shop practices.
(See Torque Chart Section 1.)
Hydraulic Lines and Electrical Wiring
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
Bearings
1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system,
drain and flush the entire system.
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.
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
2. Disassemble and reassemble parts on 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.
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.
Lubrication and Servicing
Components and assemblies requiring lubrication and
servicing are shown in the Lubrication Chart in Section
1.
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
3121166
– JLG Lift –
2-3
SECTION 2 - GENERAL
2.3
Changing Hydraulic Oil
LUBRICATION AND INFORMATION
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.
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.
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 in the Lubrication
Chart in Section 1. Always examine filters for evidence of metal particles.
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.
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
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 for an explanation
of the lubricant key designations appearing in the Lubrication Chart.
1. Refer to Section 1 for recommendations for viscosity ranges.
2. JLG recommends DTE11 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).
2-4
– JLG Lift –
3121166
SECTION 2 - GENERAL
2.4
CYLINDER DRIFT TEST
2.5
Maximum acceptable cylinder drift is to be measured
using the following methods.
Filament wound bearings.
1. Pinned joints should be disassembled and
inspected if the following occurs:
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.
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:
Cylinder Drift
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.
Table 2-2. Cylinder Drift
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
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.
b. Flaking, pealing, scoring, or scratches on the
pin surface.
c. Rusting of the pin in the bearing area.
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.
3121166
PINS AND COMPOSITE BEARING REPAIR
GUIDELINES
– JLG Lift –
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.
2-5
SECTION 2 - GENERAL
2.6
PREVENTIVE MAINTENANCE AND INSPECTION
SCHEDULE
The inspection and maintenance code numbers are as
follows:
1. Check for proper and secure installation.
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 JLG Dealer. Notify dealer if
inspection is overdue.
2. Check for visible damage and legibility.
3. Check for proper fluid level.
4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.
5. Check for leakage.
6. Check for presence of excessive dirt or foreign
material.
7. Check for proper operation and freedom of movement.
8. Check for excessive wear or damage.
9. Check for proper tightness and adjustment.
10. Drain, clean and refill.
11. Check for proper operation while pump/motor is
running.
12. Check for proper lubrication.
13. Check for evidence of scratches, nicks or rust and
for straightness of rod.
14. Check for condition of element; replace as necessary.
15. Check for proper inflation.
2-6
– JLG Lift –
3121166
SECTION 2 - GENERAL
Table 2-3. Preventive Maintenance and Safety Inspection
AREA
INTERVAL
Daily
Weekly
100 Hours
(3 Months)
200 Hours
(6 Months)
400 Hours
(1 year)
PLATFORM
Controller
1,11
Switches
1,11
Placards and Decals
1,2
Control Tags
1,2
Hoses and Cables
4,8
Wear Pads
8,12
Handrails and Chains
1,4
CHASSIS
Battery
3
5
Hydraulic Pump
1
5
Valves
1
5
Hydraulic Filter
Hydraulic Hoses and Tubing
ANNUAL
1
Hydraulic Oil Tank
Lift Cylinder
1,12
Limit Switch
1,7
5
5
3,4
5,6,13
4
Tilt Alarm Switch
1,7
Placards and Decals
1,2
Wheel and Tire Assemblies
1
Drive Motors
8,9
1,5,6
Drive Brakes
1,6
Drive Torque Hubs
8
1,3,5,6
Steer Cylinder
1
5,6,13
4
Steer Components
1
4,6
8
Wheel Bearings
8
Scissor Arms
1,4
Safety Props
1,4
Sliding Wear Pads
8,12
Pivot Pins/Bolts
1,4
Switches, Ground Control
1,11
Control Tags
1,2
3121166
12
7,8
– JLG Lift –
2-7
SECTION 2 - GENERAL
NOTES:
2-8
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
SECTION 3. CHASSIS & SCISSOR ARMS
3.1
Installation:
DIAGNOSTIC PORT
The diagnostic port is located behind the battery cover
at the near the ground control station as shown below.
The MDI (Multifunction Digital Indicator) and the JLG
Hand-Held Analyzer can be connected at this port..
NOTE: In order for the MDI to be functional the machine
must be equipped with either the Sevcon Power
Module with Ground Module Software Version P1.13
or higher, or the ZAPI Power Module. Use the JLG
Hand-held Analyzer to check the Sevcon software
version. Plug analyzer into diagnostic port. Scroll to
DIAGNOSTICS -> VERSIONS. Must be at least GM. SW
P1.13. Refer to Section 5.6, Updating Software, for
instructions on updating software.
NOTICE
ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE
PUSHED IN TO THE OFF POSITION BEFORE CONNECTING AND
MOUNTING THE MDI AND BRAKE RELEASE BRACKET.
1. Open the Battery Cover on the right side of the
machine (ground control station side). Lifting up
on the battery tray and pulling out will allow for
maximum extension.
2. Locate the Diagnostic Port (1) and Brake Release
Plugs (2).
Figure 3-1. Diagnostic Port
3.2
MDI (MULTIFUNCTION DIGITAL INDICATOR)
AND BRAKE RELEASE
1. Diagnostic Port
2. Brake Release Plugs
3. Apply di-electric grease to the two Brake Release
Plugs. Connect the Brake Release Plugs to the
Brake Release Button on the backside of the
mounting bracket.
MDI and Brake Release Bracket
NOTE: The brake release plugs have no polarity, therefore,
can be connected to either post on the button.
3121166
– JLG Lift –
3-1
SECTION 3 - CHASSIS & SCISSOR ARMS
5. Power machine and check to ensure LEDs on MDI
work. Check to ensure Brake Release Button works.
If the Software Version is not P1.13 or higher,
"Error" will display on the LCD. If a fault exists, the
trouble code will display on the LCD. (Refer to Section 6, Diagnostic Trouble Codes)
6. Using zip ties, tie back cables and wires to prevent
damage to the cables and wires.
4. Connect the MDI harness to the Diagnostic Port.
1. MDI Connected
2. Brake Release Connected
5. Using a 5/32" allen wrench, mount the MDI and
Brake Release Bracket onto the wall of the battery
compartment. (appropriate mounting holes are
pre-existing) Apply Loctite #242 to the screws and
torque to 3.6 ft-lb (5 Nm). (Refer to Figure 3-2.)
Removal:
NOTICE
ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE
PUSHED IN TO THE OFF POSITION BEFORE DISCONNECTING THE
MDI AND BRAKE RELEASE BRACKET.
1. Remove the two Screws (2) and Washers (3).
2. Disconnect Brake Release and MDI from the electrical harnesses.
3. Remove Bracket.
3
2
1
1. MDI & Brake Release Bracket
2. Screw, M5 x 16
3. Washer, 5mm
Figure 3-2. MDI Installation/Removal
3-2
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
3.3
TRACTION SYSTEM
Theory of Operation
The Armatures (rotating windings) of the separatelyexcited drive motors are wired in parallel to the Power
Module's M1 and M2 terminals (Sevcon) and -T and +B
terminals (ZAPI) . The M1/+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 M2/-T Terminal is pulled to Ground by the
Armature Switch MOSFET's (connected to -B Terminal).
To provide variable speed control, the Armature MOSFET transistors switch On and Off at high frequencies
(pulse-width 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).
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 force. On level terrain, the Power
Module will apply as little as 14A to the fields for higher
rotational speeds and better electrical efficiency.
3121166
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).
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.
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). Independent field control would require a
more complex Power Module, and parallel field windings would require impedance matching. For simplicity,
the vehicle uses 12V field windings wired in series to
ensure proper distribution of current.
Two electrically-released parking brakes are mounted to
the rear of the 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
– JLG Lift –
3-3
SECTION 3 - CHASSIS & SCISSOR ARMS
Line Contactor
Right Field Winding
Shunt
+B
1
M1
Left
Armature
Right
Armature
2
F1
Field
Switches
M2
24V
F2
3
4
-B
Armature
Switch
Power Module
Left Field Winding
Figure 3-3. Traction Control Circuit - Sevcon Power Module
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 3-4. Traction Control Circuit - ZAPI Power Module
3-4
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
3.4
Leak Test
TORQUE HUB
NOTICE
THE PROCEDURES WITHIN THIS SEC TION 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.
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.
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 (80W gear oil or 20W engine oil).
NOTE: The gearbox capacity is 10 oz of oil.
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.
CAUTION
RETURN BRAKE RELEASE CABLE BEFORE RETURNING TO NORMAL OPERATION.
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.
2. Allow the oil to settle than slowly remove the plug
at 3 o-clock.
3. If oil begins to come out the oil level is sufficient.
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.
3121166
– JLG Lift –
3-5
SECTION 3 - CHASSIS & SCISSOR ARMS
Manual Disengage Procedure
1. Brake Cover
2. Disengage Bolts
3. Brake Cover Bolts
Figure 3-5. Disengage Procedure
3. Locate the 2 disengage bolts that are stored in the
motor end-cap.
4. Remove these bolts and insert them into the two
holes in the brake housing.
5. Tighten down bolts and the brake will disengage.
6. Repeat this procedure for the other wheel drive.
NOTE: Applies only to:
USA machines built prior to S/N 0200118041,
Belgium machines built prior to S/N 1200001487.
In the event of a power loss to the Torque-Hub, the parking brake will engage as a safety precaution. Should the
unit need to be towed or pushed to an area where it can
be serviced or recharged the operator will need to manually disengage the parking brakes. The following procedure outlines how this is to be done.
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.
CAUTION
THE DISENGAGE BOLTS MUST BE REMOVED FROM THE BRAKE
HOUSING AFTER THE MACHINE IS TOWED OR PUSHED TO ITS
SERVICING LOCATION. THE BRAKES CAN NOT BE ENGAGED
WITH THE DISENGAGE BOLTS IN THE BRAKE HOUSING. THIS
WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN
INCLINE.
1. Remove the 3 brake cover bolts from the back end
of the motor.
2. Remove brake cover.
3-6
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Manual Disengage Procedure
1. Brake Cover Bolts
2. Brake Cover
3. Cover O-ring Seal
4. Disengage Holes
Figure 3-6. Disengage Procedure
NOTE: Applies only to:
USA machines built S/N 0200152825 to S/N
020170585,
Belgium machines built S/N 1200008481 to S/N
1200015159.
1. Chock wheels or secure machine with tow vehicle.
2. Power machine in ground mode.
3. Remove the two cover bolts, cover, and cover oring seal from the back of drive motor unit.
4. Insert the cover bolts into the two disengage holes
in the brake housing.
5. Tighten down the bolts and the brake on that
drive motor will disengage.
6. Repeat this procedure on opposite wheel drive.
With both drive motor brakes now disengaged,
the machine can be moved manually.
7. After towing is complete, chock wheels and
remove cover bolts from disengage holes.
3121166
8. Reinstall cover. Before installation, check the cover
o-ring seal for damage, replace if necessary.
CAUTION
AFTER THE MACHINE IS TOWED, THE DISENGAGE 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.
– JLG Lift –
3-7
SECTION 3 - CHASSIS & SCISSOR ARMS
Manual Disengage Procedure
1. Brake Cover
2. Cover Bolts
3. Disengage Holes
Figure 3-7. Disengage Procedure
NOTE: Applies only to:
USA machines built S/N 0200170585 to Present,
Belgium machines built S/N 1200015159 to Present.
1. Chock wheels or secure machine with tow vehicle.
2. Ensure battery disconnect switch is in to the "OFF"
position.
3. Remove the two Cover Bolts and Brake Cover.
4. Insert the Cover Bolts into the two Disengage
Holes in the brake housing.
5. Tighten down the Cover Bolts and the brake on
that drive motor will disengage.
6. Repeat this procedure on opposite wheel drive.
With both drive motor brakes now disengaged,
the machine can be moved manually.
7. After towing is complete, chock wheels and
remove Cover Bolts from Disengage Holes.
8. Reinstall Brake Cover.
3-8
CAUTION
AFTER THE MACHINE IS TOWED, THE DISENGAGE 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.
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor and Brake Disassembly
1.
2.
3.
4.
Brake Cover
Disengage Bolts
Socket Head Screws
Brake Housing
5.
6.
7.
8.
5. Disc Brake
Motor
Thru Bolts
Spacers
9. Retention Bolt
10. Washer
Figure 3-8. Motor & Brake Disassembly
6. Remove the retention bolt and washer from the
end of the motor shaft.
7. Remove the brake disc from the motor shaft.
NOTE: Applies only to:
USA machines built prior to S/N 0200118041,
Belgium machines built prior to S/N 1200001487.
1. Drain the oil out of the unit by removing pipe plug.
Note the condition of the oil.
2. Perform the manual disengage procedure outlined in a previous page.
3. Disconnect the brake connector (not shown).
4. Remove the 3 socket head screws in the brake
housing.
NOTE: Each screw goes through a spacer when assembled.
When the screw is removed the spacer will become
loose.
5. Remove the three spacers and the brake housing.
3121166
NOTICE
REINSTALL THE RETENTION BOLT AND WASHER INTO THE END
OF THE MOTOR SHAFT.
8. Remove the two thru bolts that bolt though the
motor housing.
9. Gently remove the motor.
NOTE: Care should be taken when removing the motor. A
good method is to use a pry bar between the strain
relief of the cable and the back of the spindle. While
applying gentle pressure to the pry bar, tap the bottom of the motor housing with a rubber mallet. The
motor should slip out.
– JLG Lift –
3-9
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Disassembly
1. Motor
2. Cable
3. Bolt
4. Washer
Figure 3-9. Motor Disassembly
NOTE: Applies only to:
USA machines built S/N 0200152825 to S/N
020170585,
Belgium machines built S/N 1200008481 to S/N
1200015159.
3. Drain the oil out of the unit by removing the pipe
plug, note the condition of the oil.
4. Remove the 2 motor mounting bolts and washers.
5. Gently remove the motor.
1. Make sure the E-stop button is pushed in.
2. Disconnect the cable from the power control module.
3-10
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Drive Motor Removal
1. Drive Motor
2. Motor Mounting Bolts
3. Washers
4. Motor Cable
Figure 3-10. Motor Removal
NOTE: Applies only to:
USA machines built S/N 0200170585 to Present,
Belgium machines built S/N 1200015159 to Present.
3. Remove the two motor mounting bolts and washers.
4. Gently remove the drive motor (1).
CAUTION
ENSURE THE BATTERY DISCONNECT SWITCH IS IN THE OFF
POSITION BEFORE REMOVING DRIVE MOTOR.
1. Disconnect the motor cable from the power control module.
2. Drain the oil out of the unit by removing the cover
plug. Note the condition of the oil, replace if necessary.
3121166
– JLG Lift –
3-11
SECTION 3 - CHASSIS & SCISSOR ARMS
Main Gearbox Disassembly
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
9. Pipe Plug
10. Input Carrier Sub-Assembly
11. Hub Sub-Assembly
Figure 3-11. Main Gearbox Disassembly
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.
4.
5.
6.
Remove input sun gear.
Remove input carrier sub-assembly.
Remove cover o-ring.
Remove input ring gear.
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 misaligned 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 subassembly.
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
3-12
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Disassembly
1. Planet Gears
2. Output Sun Gears
3. Input Carrier
4. Thrust washer
5. Input Planet Gear
6. Needle Bearings
7. Thrust Plate
8. Snap Ring
9. Retaining Ring
Figure 3-12. Input Carrier Disassembly
1. Remove retaining rings from each of the 3 planet
shafts.
NOTE: Do not overstress these retaining rings when removing them.
2.
3.
4.
5.
6.
7.
8.
9.
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.
Remove thrust plate.
Remove a thrust washer from each planet shaft.
Slide each input planet gear off the planet shaft.
Remove 22 needle bearings from the bore of each
planet gear.
Remove the thrust washer from each planet gear.
Remove retaining ring from output sun gear.
Slide output sun gear out from the center of the
input carrier.
Remove the three planet shafts from the input carrier.
3121166
– JLG Lift –
3-13
SECTION 3 - CHASSIS & SCISSOR ARMS
Hub Disassembly
1. Seal
2. Hub
3. Main Bearing
Figure 3-13. Hub Disassembly
2. Remove main lip seal.
1. Remove main wheel bearing.
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.
3-14
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 –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Spindle Disassembly
1.
2.
3.
4.
Spindle Sub-Assembly
Main Bushing
Shaft Ball Bearing
Tanged Washer
5.
6.
7.
8.
Thrust Washer
Output Planet Gear
Output Planet Pins
Main Bearing
9.
10.
11.
12.
O-Ring
Shaft Seal
Snap Ring
Needle Roller Bearings
Figure 3-14. Spindle DIsassembly
6. Press out the motor shaft seal from the center
bore.
7. Remove the main bearing from the outside diameter of the spindle.
1. Place unit on bench with planet gears facing up.
2. Remove 3 output planet shafts.
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.
3. Remove the output planet gear, thrust washer, and
tanged washer out of each gear “window” of the
spindle.
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.
NOTE: The output planet gears are a very similar size to the
input planet gears, tag or label the planet gears to
avoid confusion.
8. Press out the main bushings at the top of the spindle neck.
9. Remove the motor O’ring from the groove on side
opposite from the carrier side.
4. Using a screwdriver remove the shaft bearing snap
ring.
5. Remove the shaft ball bearing from the center
bore.
3121166
– JLG Lift –
3-15
SECTION 3 - CHASSIS & SCISSOR ARMS
Spindle Sub-Assembly
1. Using an appropriate pressing tool, press in the 2
main bushings in the upper bore of the spindle.
The lower bushing needs to be flush with the bottom of the bore and the upper bushing needs to
be flush with the bottom of the bore.
2. Using the clevis pin from the steering linkage or an
M12 bolt, drive the flanged steer link bushing into
the appropriate spindle ear hole. If the wheel drive
is for the left wheel then, with the carrier side up
and kingpin bore oriented to the top, put the steer
link bushing in the left ear.
3. Using the appropriate pressing tool, press on main
bearing until it is fully seated.
4. 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.
5. Retain the bearing with the spiral retaining ring.
6. Line the bore of the output planet gear with 22
needle rollers. Use grease to retain the needle rollers in the bore.
7. 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.
8. 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.
9. Slide the planet gear into the window with the
tanged washer until the bores line up.
10. 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.
11. Before pressing the planet pin into the spindle
make sure the gear spins freely.
12. 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.
13. Repeat Steps 6-12 for the other two output planet
gears.
14. Turn the spindle over so that the carrier is down.
15. 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.
16. 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.
3-16
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Hub Sub-Assembly
1. Seal
2. Hub
3. Main Bearing
Figure 3-15. Hub Disassembly
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.
3121166
– JLG Lift –
3-17
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Sub-Assembly
1. Planet Gears
2. Output Sun Gears
3. Input Carrier
4. Thrust washer
5. Input Planet Gear
6. Needle Bearings
7. Thrust Plate
8. Snap Ring
9. Retaining Ring
Figure 3-16. Input Carrier Disassembly
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.
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.
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
3-18
6.
7.
8.
9.
visually. Additional grease may help hold everything together.
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.
Repeat 5 & 6 for the other 2 planet gears.
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.
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 –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
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
9. Pipe Plug
10. Input Carrier Sub-Assembly
11. Hub Sub-Assembly
Figure 3-17. Main Gearbox Disassembly
1. Inspect seal surface of spindle. Remove any debris
that may be present.
2. Apply a coating of grease to the lip seal of the hub
sub-assembly.
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.
3121166
– JLG Lift –
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.
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.
5. Install retaining ring into the groove on the OD 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.
3-19
SECTION 3 - CHASSIS & SCISSOR ARMS
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.
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.
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.
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.
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.
NOTE: It may be helpful to stretch the o’ring out prior to
assembly to avoid pinching or shearing when the
cover is assembled.
3-20
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor and Brake Assembly
13.
14.
15.
16.
Brake Cover
Disengage Bolts
Socket Head Screws
Brake Housing
17.
18.
19.
20.
5. Disc Brake
Motor
Thru Bolts
Spacers
21. Retention Bolt
22. Washer
Figure 3-18. Motor & Brake Disassembly
NOTE: Applies only to:
USA machines built prior to S/N 0200118041,
Belgium machines built prior to S/N 1200001487.
1. Remove back sealing cover from motor if it is not
already removed.
2. Remove retention bolt and washer from the motor
shaft end. Do not let the armature shaft fall out
of the open end of the motor.
3. Open up Brake Kit. It should have a brake housing,
brake disc, and three spacers.
4. Install Brake disc onto splined end of motor shaft.
7.
8.
9.
10.
11.
NOTE: Keep the brake disc clear of any oil or grease.
5. Reinstall the retention bolt and washer into the
shaft end to keep the armature in the motor.
6. Install the brake housing onto motor end cap; use
the included spacers to space the brake housing
3121166
12.
– JLG Lift –
from the motor end. There may be motor wires in
the way. Push them aside to mount the brake.
Fasten with 3 Bolts to a torque of 4 - 5 ft.-lbs.
Remove the disengage bolts from the brake housing and install them into the tapped holes in the
motor end cap for storage.
Connect the connector (not shown) from the
brake housing to the connector from the motor.
If not already done, remove thru bolts from motor.
Grease the motor O’ring (31) and install in the
groove of the gearbox assembly. Also, apply
grease to the lip of the motor shaft seal (17) in the
gearbox.
Lift motor and line up the thru bolt holes with the
tapped holes of the gearbox so that the motor orients with the strain relief behind the neck of the
spindle.
3-21
SECTION 3 - CHASSIS & SCISSOR ARMS
13. Lower motor into the bore of the spindle. Motor
may need to be tapped with a rubber mallet to get
by the O’ring.
14. Install the thru bolts. Tighten to 9-11 ft.-lbs.
15. Reinstall the back sealing cover onto the motor
end.
16. Fill the gearbox with ISO grade 68 oil or oil of a
similar viscosity (80W gear oil or 20W engine oil).
NOTE: This is a blind assembly, make sure the specified
torque is attained. If the torque is not attainable,
then the thru bolt is not in the tapped hole. The
motor will need to be aligned properly.
3-22
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Assembly
1. Motor
2. Cable
3. Bolt
4. Washer
Figure 3-19. Motor Assembly
NOTE: Applies only to:
USA machines built S/N 0200152825 to S/N
020170585,
Belgium machines built S/N 1200008481 to S/N
1200015159.
1. Insert motor into back of gearbox. 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.
2. Install the two motor mounting bolts. Torque to 9 11 ft-lbs (12 - 15 Nm).
3. Connect the end of the cable to the power control
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.
NOTE: The motor may need to be rotated to line up the sun
gear splines with the motor shaft splines.
3121166
– JLG Lift –
3-23
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Assembly
1. Drive Motor
3. Washers
2. Motor Mounting Bolts
4. Motor Cable
Figure 3-20. Drive Motor Assembly
NOTE: Applies only to:
USA machines built S/N 0200170585 to Present,
Belgium machines built S/N 1200015159 to Present.
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.
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.
NOTE: The motor may need to be rotated to line up the sun
gear splines with the motor shaft splines.
2. Install the two motor mounting bolts and washers.
Torque to 9 - 11 ft-lbs (12 - 15 Nm).
3-24
– JLG Lift –
3121166
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 3-22. Assembly Tool 2
BOLT B
Assembly Tools
Figure 3-23. Assembly Tool 3
Figure 3-21. Assembly Tool 1
3121166
– JLG Lift –
3-25
SECTION 3 - CHASSIS & SCISSOR ARMS
3.5
Replacing Motor Brushes
ELECTRIC DRIVE MOTOR
NOTE: The information contained within this section
applies to the following machines:
USA machines built S/N 0200152825 to S/N
020170585,
Belgium machines built S/N 1200008481 to S/N
1200015159.
1. When installing new brushes, the motor commutator must be cleaned to allow for good brush contact. To do this, mount the armature in a lathe and
take a skin cut on the commutator diameter.
2. Remove any copper chips that may have settled
between the commutator bars.
3. Measure the diameter of the commutator. If the
diameter is less than 2.8 in. (70.5 mm) the commutator can no longer be used.
4. Measure the depth of the commutator mica (commutator bar insulation). Verify that the depth of
the mica is at least.016 in. (0.4 mm). If the depth is
too shallow, undercut the mica to a maximum
depth of 0.048 in. (1.2 mm). After undercut, clean
the armature of any loose mica.
5. Install the new brushes into the brush holders.
Make sure the brush is in the correct orientation to
make smooth contact on the commutator.
6. Connect the brush wires to the terminal on the
brush holder using the bolts that were removed
earlier.
7. Pull each brush spring so that it is contacting the
side of the brush. Push the brush springs towards
the outside of each brush box so that the armature
can be reassembled.
DISCONNECT THE BATTERY AND ALLOW THE MOTOR TO COOL
DOWN BEFORE PERFORMING ANY MAINTENANCE. THE SURFACE TEMPERATURE OF THE MOTOR FRAME MAY CAUSE INJURY
TO PERSONNEL.
Disassembly
1. Disassemble the motor from the gearbox.
2. Mark the position of the motor end cap to the
motor shell.
3. Remove the end cap retaining bolt.
4. Remove the retention bolt and washer from the
end of the armature and remove armature from
the motor shell.
NOTE: The load spring that is behind the motor bearing will
be loose when the armature is removed. Take care
not to lose it.
Replacing the Motor Cable
Replacing Motor Bearing
1. Carefully remove the bearing from the armature
by using a bearing puller.
2. Support the armature securely, Using a sleeve
pressing tool or a large socket press the bearing
onto the end of the shaft until it bottoms out on
the shoulder. The pressing tool must touch the
bearing on the inner raceway.
Inspecting Motor Brushes
1. Using a knife, remove the shrink tubing from the
cable butt splices that stick through a cast hole in
the motor cap end.
2. Mark the brush leads at each splice according to
the color of the cable lead that it is connected to.
3. Cut the leads going into each butt splice.
NOTE: Be sure to cut the leads just below the splice to leave
as much cable as possible.
4. Cut off the motor connector that connects to the
brake.
5. Remove the motor end cap from the motor shell.
6. Using a knife, remove the shrink tubing that is on
the field lead butt splices. There should be 2
splices.
7. Mark the field leads going into each splice according to the color of the cable lead.
8. Cut the leads going into each butt splice.
NOTE: Motor brushes should be inspected every 1000 hours.
1. Loosen the strain relief of the cable and push
approximately 1 in. (25 mm) of cable into the
motor.
2. Separate the end piece from the motor shell by
approximately 1 in. (25 mm).
3. Using compressed air, clean the brush housing
area of any accumulated carbon dust.
4. Remove the screw in each of the brush holders
that connects the brush wires.
5. Remove each of the four brushes from the brush
holder.
6. Inspect each brush, if the brush is equal to or less
than 3/8 in. (9.5 mm), the brush will need replaced.
3-26
NOTE: Be sure cut the leads just below the splice to leave as
much cable as possible.
9. Remove the old cable from the motor shell.
10. Install the new motor cable into the motor shell
through the strain relief such that the end of the
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
11.
12.
13.
14.
15.
16.
cable with the terminals is outside of the motor
shell. Turn the cable so that the orange and blue
wires are facing the field coils.
Push the cable in so that the outer jacket is flush
with the bottom of the strain relief. Reassemble
the strain relief to clamp the cable in place.
Using small butt splices and small shrink tubing,
connect the field wires (orange and blue) with the
appropriate marked wires coming from the field
coils.
Connect the armature wires (2 red and 2 black) to
the appropriately marked brush leads using the
large butt splices and shrink tubing.
Pull each of the 4 armature slices through the
access holes in the motor end cap.
Pull the brake leads (yellow and brown) through
the access hole in the motor end cap.
Install the connector for the brake onto the yellow
and brown leads. The leads can go with either of
the connector pins.
3121166
Reassembling the Motor
1. Install the armature through the motor shell and
into the separated end cap. Retain the armature in
the end cap with the retention bolt.
2. Using a small brush hook or similar tool, pull each
of the brush springs so that they are contacting
the back of the brushes and are pushing the brush
down on the commutator.
3. Push the end cap back into the motor shell. Line
up the marks made in the disassembly instructions. Install the end cap retaining bolt to hold the
parts together.
NOTE: Take care not to pinch any wires in the interface of
the end cap and motor shell. Cable access may need
to be pulled out of the strain relief to get the parts
assembled.
– JLG Lift –
4. Reassemble the strain relief onto the cable.
5. Reassemble the motor to the gearbox per assembly instructions shown in the motor and brake disassembly in this section.
6. After both motors are serviced, jack up the drive
wheels of the scissor lift and drive the wheels
under no load for approximately 10 minutes to
seat the brushes, if the brushes have been
replaced.
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SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Maintenance
1.
2.
3.
4.
5.
6.
7.
8.
Frame and Field Assembly
Armature Assembly
Brush and Terminal Assembly
Brush Spring
Brush Box Assembly
Retaining Ring
Bearing
Wire Harness
9.
10.
11.
12.
13.
14.
15.
Commutator End Head
Friction Disc
Brake Assembly
Cover Plate
O-Ring
Strain Relief Bushing
Cover
Figure 3-24. Drive Motor
3-28
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SECTION 3 - CHASSIS & SCISSOR ARMS
NOTE: A well-planned maintenance program will save
many hours of future down time and expense on a
piece of equipment. Periodic maintenance consisting
of inspections of motors, batteries and wiring circuitry is recommend.
CAUTION
EYE PROTECTION SHOULD BE WORN DURING ANY MAINTENANCE OPERATION.
3. Discard the O-ring (13) located inside the cover.
WIRE HARNESS
FIELD CONNECTION
BRAKE CONNECTOR
BLACK WIRES
RED WIRES
BRAKE ASSEMBLY
MOUNTING SCREWS
COVER PLATE
MOUNTING SCREWS
COVER MOUNTING
SCREWS
THREADED HOLES IN
BRAKE ASSEMBLY
Figure 3-26. Motor Front
Figure 3-25. Motor Side
Disassembly
1. Remove the 2 (#8-32UNC x.50 in long) screws
holding the cover plate in place and remove the
cover plate from the motor.
2. Remove the 2 (M5 x 0.8 x 20mm long) screws holding the cover (15) in place and set aside. These
screws are needed later to manually release the
brake. Slide the strain relief bushing (14) and wire
harness out of the cover and remove the cover
from the motor. Remove strain relief bushing from
wire harness and set aside.
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4. Remove the wire harness (8) from the motor by
disconnecting the field connection and brake connection. Install the 2 cover mounting screws into
the threaded holes in the brake assembly and
tighten to manually release the brake. See Figure 2
below or image in the “Manual Disengage Procedure” on page 8 of the gearbox section of this
manual.
5. Remove the 3 screws holding the brake assembly
(11) to the motor. Carefully remove the brake
assembly and friction disk (10) from the motor by
sliding it off of the shaft.
6. Remove the screws holding the commutator end
head (9) in place and remove the commutator end
head from the frame and field assembly (1). The
armature (2) will be attached to the commutator
end head.
7. 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.
8. Use an arbor press or a bearing puller to remove
the armature from the commutator end head
assembly.
9. Remove the snap ring (6) and bearing (7) from the
commutator end head. Discard the bearing.
3-29
SECTION 3 - CHASSIS & SCISSOR ARMS
Inspection and Service
Reassembly
1. Carefully blow out any accumulated carbon dust
and dirt from the end head and the frame assembly using clean, oil free, compressed air.
2. Replace brushes (3) that are worn below their
usable length (0600 in.), 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 or
eight. 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 failure and excessive brush
wear.
3. Make sure the brush box assembly (5) 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 (1)
for overheating or other signs of damage. Check
all wiring to insure that the insulation is in good
condition. Verify that pole screws are torqued to
250-300 in-lb [28.2-33.9 N-m]. 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 (2) assembly 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.
6. Visually inspect the brake surfaces for excessive
wear. Remove any RTV Silicone sealant that may
be present on the friction disc, cover, or commutator end head. Replace brake assembly (11) if necessary.
7. Visually inspect the wire harness (8) for frayed
insulation, loose terminals, or other damage.
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 4. 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. Replace the snap ring (6) in
the snap ring groove.
1.
Press Fixture must press against Outer Race
2.
Bearing
3.
End Head (held stationary)
4.
Armature Assembly
5.
Assembled End Head, Bearing, and Retaining Ring
6.
Press Fixture must press against Inner Race (held stationary)
Figure 3-27. Bearing Pressure Guidelines
3. Press the armature (2) commutator end into the
commutator end head and bearing assembly,
carefully supporting the inner-race of the bearing.
See Figure 3.
4. Carefully release the brush springs (4) allowing the
brushes to contact the commutator. Make sure
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3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
brush shunts do not interfere with spring movement.
5. Assemble the commutator end head to the frame
and field assembly (1) and tighten the screws to
120-140 in-lb. [13.6-15.8 N-m]. 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 a small amount of RTV
Silicone Sealant.
6. Align wires from brake assembly (11) into notch in
friction disc (10). Install both items onto shaft of
motor aligning wires with groove in commutator
end head. Secure brake assembly to commutator
end head using 3 bolts and apply small bead of
RTV Silicone sealant around wires between friction
disc and commutator end head and in notch in
friction disc.
MOTOR CABLE
SECURING NUT
7. Install wire harness (8) to motor by connecting the
field and brake connectors and securing the armature terminals to the terminal studs. Refer to Figure
2 for proper connections. Motor terminals must be
assembled as shown in the figure above. Always
secure the bottom nut with a wrench as you
tighten the top nut. Torque top nut to 90-110 inlb. [10.2-12.4 N-m].
8. Remove manual release screws from brake assembly. Apply new o-ring (13) and affix cover (15) to
motor using the 2 manual release screws. A small
dab of RTV Silicone sealant may be used to secure
the o-ring into the o-ring groove in the cover to
aid in assembly.
9. Assemble strain relief bushing (14) around jacket
of wire harness and slide into slot in cover.
10. Align cover plate (12) with groove in frame and
field and affix using 2 screws.
STUD TERMINAL
SECURING NUT
CABLE LUG
TERMINAL
FLAT WASHER
SECURE NUT WHILE
APPLYING TORQUE
INSULATING WASHER
MOTOR HOUSING
Figure 3-28. Terminal Tightening
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3-31
SECTION 3 - CHASSIS & SCISSOR ARMS
3.6
ELECTRIC DRIVE MOTOR
NOTE: Applies only to:
USA machines built S/N 0200170585 to Present, Belgium machines built S/N 1200015159 to Present.
1. Wire Harness
7. Retaining Ring
13. Cover Plate Kit
2. Frame & Field Assembly
8. Bearing
14. Cover Plate Mounting Screws
3. Armature Assembly
9. Commutator End Head
15. Brake Cover Mounting Screws
4. Brush Spring
10. Grommet
16. Terminal Cover Mounting Screws
5. Brush & Terminal Assembly
11. Brake Assembly
6. Brush Box Assembly
12. Gasket Seal Kit
Figure 3-29. Drive Motor Components
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SECTION 3 - CHASSIS & SCISSOR ARMS
NOTE: Reference Figure 3-29., 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.
CAUTION
ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE
OPERATION.
Drive Motor Troubleshooting
1. Turn off power to unit and disconnect main battery power. Disconnect drive motor connections
from the Power Module.
2. 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.
3. 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)
1930ES
0.21 Ohms
0.037 Ohms
2030ES/2630ES/2646ES/
3246ES
0.127 Ohms
0.051 Ohms
4. Discard the Gasket (12) that was located under the
brake and terminal covers.
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.
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
3-10.).
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.
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
Armature (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.
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 3-29.
4. 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.
5. 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 Disassembly
NOTE: Refer to Figure 3-29.
1. Remove the two Cover Plate Mounting Screws (14)
holding the Cover Plate (13) in place and remove
the cover plate from the motor.
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.
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.
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– JLG Lift –
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 con-
3-33
SECTION 3 - CHASSIS & SCISSOR ARMS
dition. 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.
6. Visually inspect the brake surfaces for excessive
wear. Replace Brake Assembly (11) if necessary.
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 3-29.
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 3-31. 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 3-27.. 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 3-27.
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.
3-34
– JLG Lift –
1.
2.
3.
4.
5.
Press Fixture must press against Outer Race
Bearing
End Head (held stationary)
Armature Assembly
Assembled End Head, Bearing, and Retaining
Ring
6. Press Fixture must press against Inner Race (held
stationary)
Figure 3-30. Bearing Pressure Guidelines
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).
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SECTION 3 - CHASSIS & SCISSOR ARMS
Figure 3-31. Wire Harness Connections
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.
Drive Motor Servicing Guidelines
Because 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 Drive Motor 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.
b. High temperature areas like steel mills, foundries, etc.
c. Environments with sudden temperature
change, such as in refrigeration plant, etc.
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3-35
SECTION 3 - CHASSIS & SCISSOR ARMS
3.7
• Resistance > 1 MegaOhms 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 re-measure resistance (isolation).
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.
• 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 buttsplice 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 > 1 MegaOhms 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.
• 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.
• 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.
b. High temperature areas like steel mills, foundries, etc.
c. Environments with sudden temperature
change, such as in refrigeration plant, etc.
• Resistance > 1 MegaOhms 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).
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3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Common Traction System Difficulties
1. 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 exceed 120A. 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.
To find the source of the difficulty, pull the Main
Battery Disconnect 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.
Note if the drive motor smells burned.
2. 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 exceed 120A. 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 self-test since energizing the
brakes could pose a hazard. However, it may
detect this issue during Drive (investigate using
JLG Analyzer).
investigate using resistance measurement (refer to
Drive Motor Electrical Evaluation). Suspect damaged cabling, burned cabling, or faulty brake
release solenoids. Trace the brake release cabling
from the Power Module Compartment to the
Ground Module Connector J1-24.
3. Open-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 exceed 120A. The FLD CUR
display (Field Current Reading) will hover around
40A. It is possible that one wheel may rotate, or
neither may rotate (depending on the location of
the open-circuit). Listen for the brake release solenoid when activating drive. 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).
If one wheel rotates, the open-circuit is located in
the wiring for that specific drive motor (Power
Module compartment or Drive Motor Cable).
Investigate for improper crimps, unlatched connectors, damaged cables, or open brake release
solenoids (refer to Drive Motor Electrical Evaluation).
If neither wheel rotates, the open-circuit is located
in the wiring between the Power Module compartment and Ground Module. Using a voltmeter, measure the brake release voltage on either brake
connector in the Power Module compartment during drive (should be approximately 24V). Investigate for improper crimps, unlatched connectors,
damaged harnessing, or a faulty Ground Module.
As an alternative, insert a short piece of wire with a
Deutsch Female Crimp directly into Ground Module's J1-24 and measure voltage as a diagnostic
measure (eject vehicle harness from that pin).
To find the source of the difficulty, remove the rear
cover from either drive motor. Insert voltmeter
leads into the white connector leading to the
brake solenoid (yellow and brown wires) and
attempt to drive (Platform Mode). The Ground
Module will apply approximately 24V to the brake
release solenoids (wired in parallel) during drive,
but will reduce this voltage in the event of a shortcircuit. If this voltage is improper (less than 8V),
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.8
POWER MODULE - SEVCON
F1
P
M2
M1
B+
B-
F2
MACHINE FRONT
SEVCON POWER MODULE
Figure 3-32. Sevcon Power Module Location
The Sevcon Power Module, P/N-1600346 was replaced
by the ZAPI Power Module (See Figure 3-33.) on
machines built starting in mid year 2010.
The Power Module is located at the front of the machine
as shown in Figure 3-32., Sevcon Power Module Location. Use the following instructions when replacing the
Power Module.
Table 3-1. Sevcon Power Module Specs
Operating Voltage
(Pin 1 and B+)
Maximum Current Limits:
Armature
Field
Pump
Standby Current
14.5 to 40 VDC
350 A
40 A
150 A
150 mA
Temperature Range:
Operating
Storage
Thermal Limit
-30°C to 40°C
-40°C to 70°C
75°C to 90°C
Switching Frequency
16 kHz
3-38
1. Make sure power to the machine is turned off and
the batteries are disconnected.
NOTE: Note the wire terminal locations when removing the
old Power Module.
2. Disconnect all wires from the old Power Module
and remove from the machine.
3. Before bolting the Power Module on, using a Vnotch trowel, apply a layer of heat transfer grease
to the back of the new Power Module.
4. Be sure that the terminals are oriented as shown.
5. After installing the new Power Module, begin connecting the wires back to the controller.
6. Torque the M6 terminal bolts to 5 ft-lb. (7 Nm).
Torque the M8 terminal bolts to 7 ft-lb. (10Nm).
7. After all connections to the Power Module are
made, the battery can be reconnected.
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SECTION 3 - CHASSIS & SCISSOR ARMS
Power Module Electrical Evaluation
Several basic electrical tests can be performed on the
Power Module. Failure of one of these evaluations is significant and may indicate that the device is physically
damaged. If a Power Module is suspected to be faulty,
thoroughly examine the rest of the system for possible
damage.
Refer to Figure 7-2., Resistance Measurement. Disconnect the Main Battery Disconnect and all cables from
the Power Module during this analysis. Wait 60 seconds
after power is disconnected to allow internal charge to
dissipate (risk of hazard, improper readings otherwise).
• Resistance >100kOhms all Terminals to Housing.
Ensure that there is an open-circuit between all terminals of the Power Module and the module's aluminum housing. The device is fully potted and all
electronics are insulted from the housing. Place the
Black meter lead on the housing and use the Red
meter lead to probe all terminals.
• Resistance < 2 Ohms between +B and M1. Ensure
that there is a short-circuit between the +B and M1
Terminals. Internally, there is a low-impedance current measurement shunt for the Armature portion of
Traction. Place the Red meter lead on +B, and the
Black meter lead on M1.
• Resistance >100kOhms between P and -B. Ensure
that there is an open-circuit between the P and the B Terminals. Internally, there are MOSFET transistors
between these terminals that should be high-impedance when the module is un-powered. Place the
Black meter lead on -B, and the Red meter lead on P.
Note that a measurement of increasing resistance
(capacitor charge) is normal, but a persistently low
impedance is not.
• Resistance >1kOhms between M2 and -B. Ensure
that there is an open-circuit between the M2 and -B
Terminals. Internally, there are MOSFET transistors
between these terminals that should be high-impedance when the module is un-powered. Place the
Black meter lead on -B, and the Red meter lead on
M2. Note that a measurement of increasing resistance (capacitor charge) is normal, but a persistently
low impedance is not.
• Resistance 120 Ohms between Pins 10 & 11.
Ensure that the resistor that terminates the CANbus
is within tolerance between pins 10 and 11 on the 12
position Mini-Fit Jr (Connector "B"). Place the Red
meter lead on pin 10, and the Black meter lead on pin
11. The resistance should measure between 110 - 130
Ohms.
• Resistance >1 MegaOhms between F1 and -B; F2
and -B. Ensure that there is an open-circuit between
the two Field Terminals (F1 & F2) and -B. Internally,
there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on -B
and the Red meter lead on F1 / F1.
• Resistance >1 MegaOhms between F1 and +B; F2
and +B. Ensure that there is an open-circuit
between the two Field Terminals (F1 & F2) and +B.
Internally, there are MOSFET transistors between
these terminals that should be high-impedance
when the module is un-powered. Place the Black
meter lead on +B and the Red meter lead on F1 / F1.
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.9
POWER MODULE - ZAPI
MACHINE FRONT
ZAPI POWER MODULE
Figure 3-33. ZAPI Power Module Location
ES Scissors built starting in mid year 2010 replaced the
Sevcon Power Module with the ZAPI Power Module (P/
N-1001092456).
Table 3-2. ZAPI Power Module Specs
Operating Voltage ( B+)
14.5 to 40 VDC
Maximum Current Limits:
Armature
Field
Pump
300 A
40 A
180 A
Standby Current
150 mA
Temperature Range:
Operating
Storage
Thermal Limit
-40°C to 75°C
-40°C to 125°C
75°C to 90°C
Switching Frequency
16 kHz
The power module is located behind a protective cover
at the front of the machine as shown in Figure 3-33.,
ZAPI Power Module Location. Use the following instructions when replacing the power module.
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– JLG Lift –
1. Turn machine power off and disconnect the batteries.
2. Locate and remove the power module protective
cover from the machine.
3. Note the wire terminal locations when removing
the old power module.
4. Disconnect all wire connectors and cables from
the old power module and remove it from the
machine.
5. When installing the new power module, be sure
that the terminals are oriented as shown in Figure
3-33.
6. After installing the new power module, begin connecting the wire connectors/cables to the module.
7. Torque all terminal bolts to torque specifications
shown on the front of the module.
8. After all connections to the power module are
made, the batteries can be reconnected.
9. Reinstall the power module cover, then check for
normal machine operation.
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ZAPI Power Module Electrical Evaluation
"HEALTH"
(STATUS LED)
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 trigger
replacement of the device.
P/N - 1001092456
ZAPI Power Module - "HEALTH" (Status LED)
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.10 BATTERY REMOVAL
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.
4. Adjust the lifting device to take the weight of the
battery door and remove door from under the
machine.
5. Once the battery door is removed from the
machine, battery replacement/maintenance can
begin.
6. After any maintenance on the batteries or replacement of the batteries is complete lift the battery
door back onto the machine.
7. Make sure the rollers are replaced and tight.
8. Reconnect batteries and check for proper operation.
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.
BEFORE BATTERY REMOVAL CAN BEGIN, ENSURE THAT THE
BATTERIES HAVE BEEN PROPERLY DISCONNECTED TO AVOID
SERIOUS INJURY OR POSSIBLE DEATH.
1. Pull the battery door completely out and disconnect the batteries.
2. Rest the battery door onto the forks of a fork truck,
or suitable lifting device. Be sure the forks or lifting
device are properly centered over the weight of
the battery door.
3. Using a phillips screwdriver, remove the battery
door rollers located at the rear corners of the battery door.
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3.11 BATTERY CHARGER
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.
The Battery Charger is located on the top of the chassis
at the rear of the machine. Raise and secure scissor arms
with arm prop to gain access to the charger.
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 3-34.).
• 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.
BATTERY
FILLER CAP
VENT TUBE
Figure 3-35. Battery Charger Location
FLUID LEVEL OF FULLY
CHARGED BATTERY
1
1/8 "
PLATES
2
4
3
Figure 3-34. Battery Fluid Level
1. AC Voltage - Input Cable
2. Charger Interlock Cable
3. DC Power Cable to Batteries
4. LED Indicator Cable
Figure 3-36. Battery Charger
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SECTION 3 - CHASSIS & SCISSOR ARMS
Table 3-3. Battery Charger Specs
BATTERY CHARGER
SPECIFICATION
OUTPUT
Nominal DC Output Voltage
Battery Charger Maintenance
24V
Maximum DC Output Voltage
33.6V
Maximum DC Output Current
25A
Maximum Interlock Current
20A
INPUT
AC Input Voltage
85-265VAC
Nominal AC Input Voltage
120VAC - 230VAC RMS
AC Input Frequency
45-65 HZ
Maximum AC Input Current
12A [email protected]
OPERATION
Charging Indicator
Yellow LED
100% Charge Indicator
Green LED
Fault Indicator
Red LED
PROTECTION
Output Reverse Polarity
Electronic Protection - Automatic Reset
Output Short Circuit
Electronic Protection - Automatic Reset
AC Overload
Current Limited
DC Overload
Current Limited
MECHANICAL
Operating Temperature
–22°F to +122°F
(–30°C to +50°C)
Housing
Shock and Water Resistant Aluminum
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.
DANGER
RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO
AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND
GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES. A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK
OF ELECTRIC SHOCK - DO NOT USE GROUND ADAPTERS OR MODIFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF OUTPUT
CONNECTOR OR UNINSULATED BATTERY TERMINAL. DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY WHILE CHARGING. DO NOT OPEN
OR DISASSEMBLE CHARGER. 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 - REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL. NOT FOR USE BY CHILDREN.
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.
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.
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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.
Battery Charger Troubleshooting
No Lights at all
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.
[3 Flashes] - Charge Time-out
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.
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.
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."
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.
4. High battery voltage could also occur if there is
another source charging the battery. Disconnect
any other sources during charging.
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.
[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.
[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.
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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 no
shorted.
3. Confirm that the nominal battery pack voltage is
the same as the battery charger voltage.
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.
3-45
SECTION 3 - CHASSIS & SCISSOR ARMS
[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.
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.
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.
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.
[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, be sure to make
a note of it.
1. Remove excessive AC loads from inverter if
installed.
2. Try to clear the fault by unplugging the AC, waiting 30 seconds and reconnecting the ac power.
3. 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.
4. 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.
5. If this fault occurs after battery charging has
started, confirm that AC power was not interrupted and that all battery connections are good.
6. If all battery connections are good, an internal
fault has been detected and the charger must be
brought to a qualified service depot.
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– JLG Lift –
1. Confirm that the battery pack is not too small usually > 50Ah.
2. Confirm that the nominal battery voltage matches
the charger output voltage.
3. Confirm the correct battery charge algorithm. If
the battery pack is new, the algorithm will need to
be changed if the pack is not the same as the old
one. for instructions on how to determine and
change the battery charge algorithm see the following sub-section.
4. 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.
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SECTION 3 - CHASSIS & SCISSOR ARMS
Checking/Changing the Battery Charge Algorithm
The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-4,
Battery Algorithms. Contact JLG if your specific battery
model is not listed.
Each time AC power is applied with the battery pack not
connected, the charger enters an algorithm select/display mode for approximately 11 seconds. During this
time, the current Algorithm # is indicated on the Yellow
Charging LED. A single digit Algorithm # is indicated by
the number of blinks separated by a pause. A two digit
Algorithm # is indicated by the number of blinks for the
first digit followed by a short pause, then the number of
blinks for the second digit followed by a longer pause.
3. Remove the AC power from the charger and
reconnect the charger’s positive connector to the
battery. It is recommended to check a newly
changed algorithm by repeating the above steps 1
and 3.
Table 3-4. Battery Algorithms
Algorithm #
Battery Type
43
Harris Battery Discover EVGC6A-A (AGM)
35
JLG P/N 0400242
23
Douglas Flooded (JLG default)
GES Battery A1055
Trojan T105
East Penn GC-110-WNL
Trojan T105 PLUS
Champion CHGC2 GC2
US BATT EV-145-WNL
US BATT 2200 XC
8
Concorde 10xAh AGM
7
J305 DV/DT CP
6
DEKA 8G31 Gel
5
Trojan 30/31XHS
4
US Battery USB2200
3
T105 DV/DT CP
2
Trojan T105 tapped
1
Trojan T105
To check/change the charging algorithm:
1. Disconnect the charger positive connector from
the battery pack. Apply AC power and after the
LED test, the Algorithm # will display for 11 seconds.
2. To change the algorithm, touch the connector to
the battery’s positive terminal for 3 seconds during
the 11 second display period and then remove.
The Algorithm # will advance after 3 seconds.
Repeat this procedure until the desired Algorithm
# is displayed. A 30 second time-out is extended
for every increment. Incrementing beyond the last
Algorithm will recycle back to the first Algorithm.
When the desired Algorithm is displayed, touch
the charger connector to the battery positive terminal until the output relay makes a clicking noise
(approx. 10 seconds). The algorithm is now in the
permanent memory.
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.12 BATTERY CHARGER/INVERTER (OPTION)
Table 3-5. Battery Charger/Inverter Specs
The Battery Charger/Inverter is located on the top of
the chassis at the rear of the machine. Raise and secure
scissor arms with arm prop to gain access to the charger.
Battery Charger/
AC Inverter
Specification
AC Inverter - Specs
Output Power (Continuous)
1000 W
Output Power (Surge)
3000 W
AC Output Current
36 A
AC Output Voltage
115 to 125 VAC
Output Frequency
60 Hz
DC Input Voltage
21.2 to 29 VDC
Remote ON/OFF
Yes
Charger - Specs
Nominal DC Output Voltage
28 VDC
Maximum DC Output Voltage
33 VDC
Maximum DC Output Current
23 to 27 ADC
Required Interlock Current
1A
Input Voltage (AC)
100 to 130 VAC
Nominal Input Voltage (AC)
120 VAC
Input Frequency
54 to 66 Hz
Operation
Figure 3-37. Battery Charger/Inverter Location
Charging Indicator
Yellow LED
100% Charge Indicator
Green LED
Fault Indicator
Red LED
Protection
4
5
6
1
2
125 A Replaceable Fuse
Output AC Short Circuit
Electronic Protection - Automatic Reset
AC Overload
20 A Internal Slow Blow Charger Fuse
DC Overload
Voltage Limited - Internally Controlled
Mechanical
3
1. AC Output Connector
2. AC Input Connector
3. Remote On/Off Switch Cable
Output Reverse DC Polarity
Operating Temperature
–40°F to +185°F
(–40°C to +85°C)
Housing
Shock and Water Resistant Aluminum
4. External DC Fuse Location
5. DC (+) Connection
6. DC (-) Connection
Figure 3-38. Battery Charger/Inverter
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Battery Charger/Inverter Troubleshooting
The Fault LED Flash Codes are the same as the Battery
Charger (see Battery Charger Troubleshooting on pages
3-29 and 3-30).
For further specification and troubleshooting information refer to the manufacturers’ Charger/Inverter
Owner’s Guide shipped with the machine. Publication RM1024-JLG - Part # 3128406.
Use the information below to supplement the information in the Inverter/Charger manual. First, go through
the troubleshooting in the Owner’s Guide (JLG part
number 3128406), then use the procedures below. For
control of the Inverter/Charger there is an 8 position
connector on a cable entering the case of the Inverter/
Charger. Looking at the pins of the connector, terminals
are numbered clockwise starting with number 1 nearest
the notch. Terminal 8 is in the center.
No charge voltage:
1. Disconnect control cable from Inverter/charger.
2. Turn on machine.
3. Inverter/charger control cable 8 position connector socket 1 should have Vbatt present. If it is not,
check charger interlock connector, 2 position,
socket 1. If voltage is present there replace the
Inverter/Charger data interface harness. If Vbatt is
not present at the 2 position connector socket 1,
check the circuit through the chassis harness back
to Ground Module terminal J1-19.
Loads will not start when there is no external AC/
Inverter will not produce AC power:
2. Disconnect Inverter/Charger control cable at the 6
position connector and the chassis harness at the
4 position connector at the Ground Box. There
should be continuity between the following:
a. 6 pos. terminal 3 to 4 pos. terminal 1
b. 6 pos. terminal 4 to 4 pos. terminal 3
c. 6 pos. terminal 5 to 4 pos. terminal 2
d. 6 pos. terminal 6 to 4 pos. terminal 4
3. If wiring is found to be good, the LED printed circuit card is likely to be bad.
Interlock Cable suspected to be bad or vehicle thinks
charging is in progress, but it is not:
1. Disconnect Interlock (2 position) connector on the
Inverter/Charger control cable.
2. Turn on machine.
3. There should be Vbatt present on the Interlock
connector socket 1.
4. Turn off machine.
5. Disconnect Inverter/Charger control cable at the
charger.
6. Inverter/Charger connector (8 position) pin 6
should have continuity to Interlock connector pin
2 and then to ground module socket J1-29.
Ground Module powered while key is off or similar
behavior:
This condition can be caused by various ground module
outputs getting shorted to battery. If not done already,
cycle power and check for fault codes. If no fault codes,
perform the following:
1. Check that Inverter/Charger switch is in ON position.
2. Disconnect control cable from the Inverter/Charger.
3. Turn on machine.
4. Inverter/Charger control cable socket 2 should
have Vbatt present when the switch is ON. If not
check that there is Vbatt on the switch Yellow/Red
wire. Vbatt signal originates from Ground module
pin J1-19 then goes to harness Interlock connector
terminal 1 (Yellow/Red wire), then to switch.
LED(s) suspected to be bad:
1. Disconnect the Inverter/Charger control cable at
the 8 position connector and the 2 position Interlock connector.
2. Set digital multimeter to diode check or continuity
check to check diode in Inverter/Charger control
harness. If the meter does not have these features
a low range Ohm scale (20 Ohms for example) will
work.
3. Place red lead on 8 position connector pin 1. Place
black lead on Interlock connector pin 1.
4. Meter should read an open. Swap leads. Meter
should read a short. If either condition is not
good, replace Inverter/Charger control cable.
1. Disconnect Inverter/Charger control cable from
the charger (8 position connector) and the 6 position connector at the chassis harness. There
should be continuity between the following:
a. 8 pos. terminal 3 to 6 pos. terminal 3
b. 8 pos. terminal 4 to 6 pos. terminal 5
c. 8 pos. terminal 5 to 6 pos. terminal 4
d. 8 pos. terminal 6 to 6 pos. terminal 6
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.13 DRIVE MOTOR CABLE ROUTING
USA Built Machines Prior to S/N 0200170585 &
Belgium Built Machines Prior to S/N 1200015159:
CAUTION
BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS
BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR
CABLING.
Figure 3-39. Motor Cable Routing (1930ES)
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Figure 3-40. Motor Cable Routing (2030ES/
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USA Built Machines S/N 0200170585 to Present &
Belgium Built Machines S/N 1200015159 to Present:
15. Place the Green Clamp on the clamping rings as
shown below.
NOTE: The below procedures (1 - 19) apply to 1930ES only.
CAUTION
BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS
BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR
CABLING.
1. Orient the drive cables going back towards the
rear of the machine as shown below.
16. Bolt the clamp onto the underside of the frame.
a. The Spacer goes between the frame and the
Clamp.
b. Place the Larger Washer against the clamp.
17. Connect the drive motor cables to the power module.
18. Tuck all wires into the power module compartment and install cover.
1
2. Loop the cables forward towards the front of the
machine then up and back so that the clamping
rings on the cables are aligned together.
3. Obtain the Cable Clamp and hardware.
1. Cable Clamp
2. Spacer Plate
3
2
1
1. Drive Cables
2. Cable Clamp
3. Spacer Plate
3. Capscrew, Washers, and
Nut
19. Reconnect battery cable plug. Power up machine
and operate the drive function to ensure drive
motors operate properly.
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SECTION 3 - CHASSIS & SCISSOR ARMS
3. Bolt the Green Clamp onto the backside of the
frame using the the back hole drilled in step #4.
The roll pins inserted in the front-most holes act as
a stop to prevent the clamp from turning.
USA Built Machines S/N 0200170585 to Present &
Belgium Built Machines S/N 1200015159 to Present:
NOTE: The below procedures apply to 2030ES/2630ES/
2646ES/3246ES only.
CAUTION
BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS
BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR
CABLING.
1. Orient the drive cables going back towards the
rear of the machine. Loop the cables forward
towards the front of the machine then up and
back. Place the Green Clamp on the clamping ring
as shown below.
1. Drive Cable
2. Roll Pin
2. Obtain the Cable Clamp and hardware.
3. Cable Clamp
NOTE: When bolting the green clamp onto the frame, place
the larger washer against the clamp on the outside
of the clamp.
4. Connect the drive motor cables to the power module..
5. Tuck all wires into the power module compartment and install cover.
6. Reconnect battery cable plug. Power up machine
and operate the drive function to ensure drive
motors operate properly.
1. Bolt, Washers, and Nut
2. Cable Clamp
3-52
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
.
NOTE: Item 1 shows configuration for machines prior to S/N’s:
1930ES - USA built - S/N 0200150266
- Belgium built - S/N 1200007882
2030ES/2630ES - USA built - S/N 0200152825
- Belgium built - S/N 1200008481
2630ES/3246ES - USA built - S/N 0200151610
- Belgium built - S/N 1200008265
3
2
1
NOTE: Item 2 shows configuration for machines prior to S/N’s:
1930ES - USA built - S/N 0200150266
- Belgium built - S/N 1200007882
2030ES/2630ES - USA built - S/N 0200152825
- Belgium built - S/N 1200008481
2646ES/3246ES - USA built - S/N 0200151606
- Belgium built - S/N 1200008265
1. Pothole Switch (Typical on opposite side of machine)
2. Proximity Switch
3. Rotary Angle Switch
Figure 3-41. Limit Switch Locations - 1 of 2
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– JLG Lift –
3-53
SECTION 3 - CHASSIS & SCISSOR ARMS
2
1
NOTE: Item 1 shows configuration for machine from S/N to present:
1930ES - USA built - S/N 0200151266
- Belgium built - S/N 1200007882
2030ES/2630ES - USA built - S/N 0200152825
- Belgium built - S/N 1200008481
2630ES/3246ES - USA built - S/N 0200151610
- Belgium built - S/N 1200008265
1. Pothole Switch (Typical on opposite side of machine)
2. Rotary Angle Switch
Figure 3-42. Limit Switch Locations - 2 of 2
3-54
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
3.14 POTHOLE SWITCH REPLACEMENT
Pothole
Switch
Pothole
Switch
Link
Link
Machines from S/N’s to present:
1930ES - USA built - S/N 0200151266
- Belgium built - S/N 1200007882
2030ES/2630ES - USA built - S/N 0200152825
- Belgium built - S/N 1200008481
Machines prior to S/N’s:
1930ES - USA built - S/N 0200150266
- Belgium built - S/N 1200007882
2030ES/2630ES - USA built - S/N 0200152825
- Belgium built - S/N 1200008481
Figure 3-43. Pothole Switch Adjustment - 1930ES/2030ES/2630ES
1. With the machine in the stowed position and the
battery door open, remove the old pothole switch.
2. Mount the new limit switch and harness to crank
with the washer placed behind the switch.
3. Adjust the switch by inserting an 1/8" shim
between the link and the switch plunger.
4. Push the switch to fully depress the plunger and
tighten the switch screws.
5. Repeat this procedure on the opposite side.
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6. Raise and lower the machine from the ground control several times to ensure that the switch is functioning properly.
NOTE: From the platform, raise and lower the machine and
check that the switch is operating properly by cutting
back to elevated speed when the pothole is deployed.
Drive will be cutout if pothole is not set.
– JLG Lift –
3-55
SECTION 3 - CHASSIS & SCISSOR ARMS
Pothole
Switch
Link
Pothole
Switch
Link
Machines from S/N’s to present:
2630ES/3246ES - USA built - S/N 0200151610
- Belgium built - S/N 1200008265
Machines prior to S/N’s:
2630ES/3246ES - USA built - S/N 0200151610
- Belgium built - S/N 1200008265
Figure 3-44. Pothole Switch Adjustment - 2630ES/3246ES
1. With the machine in the stowed position, and the
battery door open remove the old pothole switch.
2. Mount the new limit switch and harness to crank
with the washer placed behind the switch.
3. Adjust the switch by inserting an 1/8" shim
between the link and the switch plunger.
4. Push the switch to fully depress the plunger and
tighten the switch screws.
5. Repeat this procedure on the opposite side.
6. Raise and lower the machine from the ground control several times to ensure that the switch is functioning properly.
back to elevated speed when the pothole is deployed.
Drive will be cutout if pothole is not set.
NOTE: From the platform, raise and lower the machine and
check that the switch is operating properly by cutting
3-56
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Pothole Switch Replacement
(Service Kit - 1001109345)
3. Remove the wedge lock (orange) from the front
end of the new connector, then load the socket
terminals into the back of the connector.
NOTE: Omit step 1 following if switches are the outboard of
frame rails design.
NOTE: Reference the chart below for proper pin loading.
1. Mount the new switches to the new mounting
plates using the supplied screws, nuts and washers. Tighten switch securely to the mounting plate.
Note there is a right side and left side mounting
plate, the plate mounting holes will mount
towards the center of the machine on both
sides.
PIN-3
PIN-4
PIN-2
PIN-1
4. With the socket terminals properly installed, reinsert the wedge lock (orange) back into the
socket to lock the socket terminals in place.
2. Strip approximately 1/4" of insulation off of the
wires of the existing wire harness. Using a crimping tool install a new socket terminal onto each of
the stripped ends of the existing wiring harness
wires.
EXISTING SWITCH
IF EXISTING SWITCH IS WIRED TO
PINS:
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NEW SWITCH
TELEMECHANIQUE
HONEYWELL
13 & 14
3&4
21 & 22
1&2
– JLG Lift –
TELEMECHANIQUE
NEW CONNECTOR SHOULD BE
LOADED TO PINS:
1&4
2&3
3-57
SECTION 3 - CHASSIS & SCISSOR ARMS
7. Adjust the switch assembly.
5. Before connecting the wire harness to the new
switch/mount assembly, apply the supplied
dielectric grease to both the connector end and
the switch socket pin areas.
SWITCHES INBOARD (SHOWN BELOW)
When pothole bar is in the deployed position,
adjust the switch/bracket assembly down until the
plunger "clicks". Tighten the switch/bracket
mounting screws until secure.
NOTE: There is a right side and left side mounting plate, the
plate mounting holes will mount towards the center
of the machine on both sides.
SWITCHES OUTBOARD
When pothole bar is in the deployed position,
depress the plunger fully and release just past the
"click". Tighten the switch mounting screws until
secure.
NOTE: Do not push the switch body down in contact with
the pothole crank link.
6. Mount the new switch assembly to the machine
using the supplied (10mm) bolts, nuts and washers.
8. Repeat this procedure on the opposite side pothole switch.
9. Power up machine and operate lift and drive to
ensure proper function.
3-58
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Rotary Angle Sensor Replacement
3.15 GROUND CONTROL STATION
Removal:
1. Lower platform to the stowed position.
2. Disable the machine and disconnect the batteries.
3. Remove the screws securing the sensor cover to
the frame and remove the sensor cover.
4. Disconnect the wiring harness from old/existing
rotary angle sensor. Disconnect the sensor from
the arm pin and remove the sensor.
Installation:
1. Connect the wiring harness to the new rotary
angle sensor.
2. Position and connect rotary angle sensor to the
arm pin as shown below.
NOTE: The Ground Control Station supplied with the ZAPI
Power Module (production start mid-year 2010) does
not require use of the printed circuit board inside the
ground contol box.
However box installation and removal instructions
shown are exactly the same as the ground control
box which does contain a printed circuit board and is
used with previous machines supplied with the SEVCON Power Module.
NOTE: Anytime the ground control box is removed, the tilt
sensor must be re-calibrated. Refer to Section 5, JLG
Control System to re calibrate the tilt.
Printed Circuit Board (PCB) Replacement
3. Rotate the sensor as described in the image above.
NOTE: The sensor is spring loaded. DO NOT rotate past its
internal stops.
1. Disconnect the batteries.
2. Remove the three bolts at the bottom of the
ground control station.
4. Install the rotary angle sensor cover and secure to
the frame with the two screws.
5. Reconnect the batteries.
3. Remove the four bolts where the control cable
enters into the control box.
4. Remove plug and place control box face down on
a suitable work bench.
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– JLG Lift –
3-59
SECTION 3 - CHASSIS & SCISSOR ARMS
Tilt Sensor Replacement
.
Tilt Sensor, JLG P/N 4000006:
5. Remove the six bolts at the back of the ground
control and separate.
6. Pull the pin connectors from the printed circuit
board.
2
1
1. Ground Control Station
2. Tilt Sensor (JLG PN 4000006)
Figure 3-45. Tilt Sensor Location
Tilt Sensor Removal:
NOTE: Refer to Figure 3-44., Tilt Sensor Removal for numbers in parenthesis.
7. Remove the two bolts inside the control box that
affix the printed circuit board to the control box.
8. Replace the printed circuit board and reassemble
the ground control box.
3-60
1. Disconnect the batteries.
2. Open the Ground Control Station to gain access to
the Tilt Sensor Assembly. (refer to prior mentioned
procedures)
3. Remove the four Screws (2) to remove the Tilt Sensor (1) from the Ground Control Box.
NOTE: Follow the above procedures in reverse order when
installing the tilt sensor assembly. After installing, be
sure to calibrate the tilt sensor (refer to Section 5.2,
Tilt Sensor Calibration).
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Tilt Sensor, JLG P/N 4000021 and 1001114936:
2 1
1
2
1. Ground Control Station
2. Tilt Sensor (JLG P/N 4000021 or
1001114936)
1. Tilt Sensor (JLG P/N 4000006)
2. Screw, 3.5 x 0.6 x 16 LG
Figure 3-45. Tilt Sensor Location
Figure 3-44. Tilt Sensor Removal
Tilt Sensor Removal:
Table 3-6. Tilt Sensor Harness Chart
Wire Color
Function
Connector Pin
Red
VCC
1
Black
Ground
4
Blue
PWMX
2
Yellow
PWMY
3
NOTE: Refer to Figure 3-46., Tilt Sensor Removal for numbers in parenthesis.
1. Disconnect the batteries.
2. Open the Ground Control Station to gain access to
the Tilt Sensor Assembly. (refer to prior mentioned
procedures)
3. Remove the four Screws (3), to remove the Tilt
Sensor (1) and Sensor Mount (2) from the Ground
Control Box.
4. The Tilt Sensor (1) can be removed from the Sensor
Mount (2) by removing the three Screws (4).
NOTE: Follow the above procedures in reverse order when
installing the tilt sensor assembly. After installing, be
sure to calibrate the tilt sensor (refer to Section 5.2,
Tilt Sensor Calibration).
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– JLG Lift –
3-61
SECTION 3 - CHASSIS & SCISSOR ARMS
4
Table 3-7. Tilt Sensor Harness for 4000021
1
3
2
Wire Color
Function
Connector Pin
Red
VCC
1
Green
PWMX
2
White
PWMY
3
Black
Ground
4
Table 3-8. Tilt Sensor Harness for 1001114936
Wire Color
Function
Connector Pin
Red
VCC
1
White
CANH
2
Green
CANL
3
Black
Ground
4
3.16 ARMS AND PLATFORM POSITIONING AND
SUPPORT
1. Tilt Sensor (JLG P/N 4000021 or
1001114936)
2. Sensor Mount
3. Screw, 3.5 x 0.6 x 16 LG
4. Screw, 3.5 x 0.6 x 10 LG
Figure 3-46. Tilt Sensor Removal
CAUTION
PLATFORM IS HEAVY AND PRESENTS A CRUSHING HAZARD.
TAKE GREAT CARE WHEN REMOVING PLATFORM OR SCISSOR
ARM ASSEMBLY
The arm stack can be supported by using an overhead
crane,(See Figure 3-47.). If an overhead crane is not
available the stack may also be lifted by using a forktruck using the following instructions:
1. With the forks on the forktruck slid close together,
enter from the front of the machine and place the
forks on the cross tube of the second arm weldment below the platform.
2. Slowly lift the arm stack with the forktruck 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 forktruck in place.
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.
3-62
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
3.17 PLATFORM REMOVAL
3.18 SCISSOR ARMS REMOVAL
1. Support the platform using an overhead crane
with straps capable of lifting at least 250 lbs (114
kg) (See Figure 3-47.). Refer to Section 3.16, Arms
and Platform Positioning and Support.
2. Disconnect the battery plug at the chassis. Disconnect platform cable and foot switch cable, if applicable, from railing. Route the cables out through
the hole at the rear of the platform to free platform
of any constraints. If platform is equipped with an
outlet plug, disconnect and route cable out of
platform.
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 armstack and set aside.
NOTE: When attaching platform back onto scissor arm
assembly, follow removal procedures in reverse
order.
NOTICE
FOR MACHINES EQUIPPED WITH LOAD SENSING SYSTEM (LSS),
ENSURE ARROWS ON THE LSS PIN ARE POINTING DOWN
BEFORE INSERTING BOLTS INTO PIN. NOT APPLICABLE FOR
MACHINES WITHOUT LSS.
1. Remove platform (refer to Section 3.17, Platform
Removal).
2. Disconnect all wiring and cables attached to scissor arm assembly.
3. Remove lift cylinder (refer to Section 4.6, Lift Cylinder Removal).
4. 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.
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.
NOTE: Overhead crane and straps must be capable of lifting
at least 1545 lbs (701 kg).
3. Once slide blocks are clear of machine, the scissor
stack can be moved to a more desirable location
for further arm disassembly.
Removing scissor arms individually:
1. Start with the top arms (closest to platform).
2. Secure each arm section being removed using an
overhead crane with suitable lifting straps.
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.
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– JLG Lift –
3-63
SECTION 3 - CHASSIS & SCISSOR ARMS
NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT
WITH SAFETY PROPS, BLOCKING OR OVERHEAD
SLING.
STRAP
Figure 3-47. Arms and Platform Positioning and Support
3-64
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
3.19 PLATFORM CONTROL STATION
1. Disconnect the platform control box and remove
from the machine.
2. Place the platform control box on a suitable work
bench.
3. Loosen and remove the long through bolts that
hold the two side control housings together.
4. Loosen and remove the four bolts that hold the
bottom of the control box.
5. Disconnect the plug from the printed circuit
board.
6. Remove the bolts attaching the printed circuit
board to the control box.
7. Replace board and reassemble control box.
NOTE: You may have to only loosen the two power bolts
and remove the two closest the top in order to get to
the printed circuit board located in the top of the
control box where the drive/lift select switch is
located.
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– JLG Lift –
3-65
SECTION 3 - CHASSIS & SCISSOR ARMS
Joystick Controller
Figure 3-48. Joystick
Table 3-9. Joystick Specifications
Table 3-10. Connector Chart
Input Voltage
+5 (±0.1) VDC
Current Consumption
10 mA @ 12 VDC
Term
Color
Function
Output: Handle Centered
2.5 (±0.1) VDC
1
RED
HANDLE COM
Output: Full Positive (Reverse) Deflection
4 (±0.1) VDC
2
VIOLET
TRIGGER N.O.
Output: Full Negative (Forward) Deflection
1 (±0.1) VDC
3
--
SPARE
4
YELLOW
ROCKER RT
5
GREEN
ROCKER LT
6
--
SPARE
7
WHITE/RED
+5VDC
8
WHITE/BLACK
GROUND
9
BROWN
SIG OUTPUT
3-66
CONNECTOR PINOUT
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
SECTION 4. HYDRAULICS
4.1
Relief Valves
CYLINDERS - THEORY OF OPERATION
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 Lift circuit to prevent
retraction of the cylinder rod should a hydraulic line
rupture or a leak develop between the cylinder and its
related control valve.
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 spring-loaded to center position,
therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow
through the circuit.
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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 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 power is lost.
– JLG Lift –
4-1
SECTION 4 - HYDRAULICS
4.3
CYLINDER CHECKING PROCEDURE
4.4
LIFT PRESSURE SETTING PROCEDURE
NOTE: Cylinder check must be performed anytime a system
component is replaced or when improper system
operation is suspected.
Cylinders Without Counterbalance Valves and
Steer Cylinder
1. Using all applicable safety precautions, activate
pump motor and fully extend cylinder to be
checked.
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.
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.
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.
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.
1. Large Nut
2. Pressure Setting Screw
3. P port
Figure 4-1. Lift Pressure Setting
1. Place 120% of the rated load of the machine on
the platform.
2. Increase lift pressure to raise the platform and set
the safety prop.
3. Locate the Large Nut (1) on the underside of the
valve block.
4. Using a 7/8 in. wrench, remove the large nut (1).
This will expose the Pressure Setting Screw (2).
5. Remove plug from P port (3) and install a pressure
gauge.
6. Raise the platform and take a pressure reading.
7. Adjust the Pressure Setting Screw to reach the
proper lift pressure per model as listed in Table 41.
4-2
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
Table 4-1. Lift Pressure Settings
Model
Lift Relief
Steer Relief
1930ES
1800 psi ± 50 psi
(124 bar ± 3.5 bar)
1500 psi
(103.4 bar)
2030ES
1800 psi ± 50 psi
(124 bar ± 3.5 bar)
1500 psi
(103.4 bar)
2630ES
1950 psi +/- 50 psi
(134.5 bar ± 3.5 bar)
1500 psi
(103.4 bar)
2646ES
2000 psi +/- 50 psi
(138 bar ± 3.5 bar)
1500 psi
(103.4 bar)
3246ES
2000 psi +/- 50 psi
(138 bar ± 3.5 bar)
1500 psi
(103.4 bar)
CAUTION
ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.
NOTE: The 2630ES/2646ES/ 3246ES platforms will have to
be raised higher than the 1930ES and 2030ES in
order to access the oil plug.
8. Remove pressure gauge and replace the plug into
the P port.
9. Replace the bronze washer with a new bronze
washer and large nut over the pressure setting
screw. Do not use old bronze washer. Using the old
bronze washer will cause leakage.
3. Wipe all dirt and debris from the filler plug area.
4. Slowly remove the fill plug venting any pressure
that may be built up in the reservoir.
5. To check the oil level, lower platform so it rests on
the safety porp.
10. Torque the large nut to 160 in. lb (16 Nm).
Alternate Lift Pressure Setting Procedure:
1. Increase lift pressure to raise the platform and set
the safety prop.
2. Remove plug from port P (3) and install a pressure
gauge.
3. Remove the solenoid from the lift valve.
CAUTION
THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK.
6. With the plug removed, the oil level should be
completely full, at the top of the fill port with scissor arms resting on the safety prop. from the fill
port.
7. If additional oil is required, add proper grade of oil
by using a funnel with a flexible spout or a plastic
squeeze bottle. Fill until oil weeps out of opening.
4. Set the pressure actuating lift function from the
ground or platform.
5. Remove the pressure gauge from port P (3) and
replace plug.
6. Replace the solenoid on the lift valve.
4.5
HYDRAULIC OIL FILL
NOTE: The hydraulic oil level should be checked every 6
months. Always check the oil level any time any
maintenance is performed that would effect the
hydraulic oil level.
NOTE: Care should be taken not to introduce any impurities
(dirt, water etc.) while plug is removed.
Oil Check Procedure
8. Replace plug and torque to 40 ft. lbs. (56 Nm).
9. Any time a hydraulic component is removed or
replaced, cycle the scissor arms several times and
refer to steps 3 and 4 to recheck oil level.
1. With the scissor lift on a flat and level surface and
the platform empty, elevate machine and swing
safety prop out of it’s stowed position.
2. Continue to elevate the platform until the fill plug,
located on the right side of the tank attached to
the lift cylinder, is fully accessible.
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– JLG Lift –
4-3
SECTION 4 - HYDRAULICS
Slide Block Lubrication
4.6
LIFT CYLINDER REMOVAL
NOTE: If there is a pump failure, a crane or a forktruck can
be used to raise the platform. Refer to Figure 3-47.,
Arms and Platform Positioning and Support.
Lube - White Lithium Grease (GREDAG 741)
Interval - Every 6 months
1. With the platform empty, elevate machine and
swing safety prop out of it’s stowed position.
CAUTION
ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.
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 place on the safety prop. It
may be necessary to use an overhead crane or fork
truck to secure the platform and scissor arms
before lift cylinder removal begins. (See Figure 347.)
2. Cut any wire ties that attach any cables or hoses to
the lift cylinder.
2. Locate the Lower and Upper Slide Pads and wipe/
pressure wash all dirt and debris from the slide
channel area (1, 2).
3. Apply a layer of grease along the inside and bottom of the lower slide channel (1) on both sides of
the machine.
NOTICE
PULL THE BATTERY DISCONNECT BEFORE REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER ASSEMBLY.
3. Remove the valves connectors, the two battery
cables and the manual decent cable.
NOTE: To avoid having to readjust the manual descent,
remove the large nut located behind the manual
descent bracket as shown. (See Figure 4-2.)
Lower Slide Pad Channel
4. Apply a layer of grease along the inside and top of
the upper slide channel (2) on both sides of the
machine.
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 form the lower cylinder pin and
have someone assist you in lifting the cylinder
from the scissor arms.
6. Set the cylinder with pump and motor assembly
intact on a clean workbench.
7. Remove the 4 bolts that attach the pump/motor
assembly to the lift cylinder.
8. Remove the bolt from the bracket that attaches
the hydraulic reservoir to the lift cylinder.
9. Separate the cylinder from the pump/motor
assembly.
Upper Slide Pad Channel
4-4
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
1. Battery Cables
2. Valves
3. Manual Descent
4. Steer Hoses
5. Top Cylinder Bolt (Torque 41 ft. lb.)
6. Bottom Cylinder Bolt
Figure 4-2. LIft Cylinder Removal
3121166
– JLG Lift –
4-5
SECTION 4 - HYDRAULICS
4.7
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).
PUMP/MOTOR
Theory of Operation
The Power Module (see Figure 3-32., Sevcon Power
Module Location on page 3-38) is essentially a "lowside" 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.
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).
Line Contactor
+B
24V
P
Series DC
Pump Motor
-B
Power Module
4-6
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
Pump Motor Electrical Evaluation
2. Open-Circuit between Pump Motor Negative
Terminal and P Terminal
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 the Main Battery Disconnect and all
pump motor cables during this analysis.
• Resistance < 5 Ohms between Motor Termninals.
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 MegaOhms 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 post of the left battery in the left-side battery
compartment. The vehicle should be placed on a firm,
level surface for all analysis.
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.
3121166
– JLG Lift –
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.
Pull the Main Battery Disconnect 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 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
the Main Battery Disconnect.
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.
Pull the Main Battery Disconnect to completely
de-energize the Control System. Next, detach both
Pump Motor Terminals and insulate them independently. Re-connect the Main Battery Disconnect and re-try Lift Up. If the same symptoms
4-7
SECTION 4 - HYDRAULICS
persist (erratic PUMP PWM%, PUMP CUR around
150A), examine the cabling between the Pump
Motor and Power Module compartment for a
short-circuit (most likely near area where cylinder
retracts between frame side sheets or near pothole mechanism). If the symptoms change, suspect a short-circuited (or mechanically frozen)
pump motor.
Pump Removal
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.
1. Place the pump/motor assembly on a clean workbench.
NOTE: Drain the hydraulic oil by carefully removing the oil
fill plug located on the left side of the hydraulic reservoir.
2. Remove the oil tank from the lift cylinder as follows:
a. Slowly loosen and remove the four bolts that
hold the tank on to the cylinder.
b. Carefully remove the tank from the valve body
taking care not to damage internal pickup
tube or o-ring gasket on tank.
c. Place tank on a suitable work bench or work
area.
NOTE: The filter and bypass are located on the pickup tube
inside the tank.
The filter should be changed once a year.
4-8
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
3. If replacing filter, pull old filter off the end of the
tube and push new filter onto the end of tube.
4. Thoroughly clean the tank and clean any debris
from the magnet.
5. Wipe out tank with clean, lint free rag, taking care
not to introduce debris or dirt.
6. Replace the tank. Torque mounting bolts to 20-25
in-lb.
7. If only replacing the oil filter and maintenance is
complete, reinstall cylinder assembly on machine,
remove fill plug and refill tank with proper grade
of oil by using a funnel. Fill until oil weeps out of
opening.
8. Replace plug and torque to 40 ft. lbs (56 Nm).
11. Remove allen nut on the return/filter line and
rotate large retainer ring to remove return/filter
line.
12. Replace the return/filter line oring if necessary.
13. With the return line and the pickup tube removed,
the pump can be removed.
14. Loosen and remove the two hexhead nuts from
the pump and block. Remove pump from valve
body.
9. To remove the oil pickup line, squeeze retainer and
slide outward.
10. Replace the o-ring if necessary.
3121166
– JLG Lift –
4-9
SECTION 4 - HYDRAULICS
Motor Removal
NOTE: Be sure to remove and discard the plastic plug at the
oil inlet on the new pump before installing.
1. Remove the four bolts attaching the motor to the
valve body.
15. Check oring on valve body and replace if necessary before installing the new pump. Lubricate
orings before assembling.
NOTE: There are two orings used to seal the pump to the
valve body, one for the pump inlet (shown above)
and one on the pump boss around the drive coupler.
4-10
– JLG Lift –
2. Pull motor from valve body.
3. Once all maintenance is performed and lift cylinder assembly is reinstalled on the machine,
remove fill plug and refill tank with proper grade
of oil by using a funnel. Fill until oil weeps out of
opening.
4. Replace plug and torque to 40 ft. lbs.
3121166
SECTION 4 - HYDRAULICS
4.8
7. Being careful not to mar the surface of the rod, use
a punch or wooden dowel and hammer to drive
the rod guide about one inch down into the cylinder bore. Using a screw driver, carefully push one
end of the round retaining ring back towards the
inside of the cylinder and then slip the screwdriver
tip under that end. Pull the ring out of the groove
toward the wall mouth. Once one end of the
retaining ring is free from the groove, the remainder can be easily pried free using ones fingers or
pliers.
CYLINDER REPAIR
NOTE: The following are general procedures that apply to
all of the cylinders on this machine. Procedures that
apply to a specific cylinder will be so noted.
Disassembly
NOTICE
DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A
CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
1. Connect a suitable auxiliary hydraulic power
source to the port block fitting in the manifold
located on the cylinder.
DO NOT FULLY EXTEND C YLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
8. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
NOTICE
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.
9. With the barrel clamped securely, apply pressure
to the rod pulling device and carefully withdraw
the complete rod assembly from the cylinder barrel.
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
10. 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 - Cyl. p/n-1684456 on page 4-12 following.
Figure 4-3. Cylinder Barrel Support
5. Mark cylinder head and barrel with a center punch
for easy realignment. Loosen the cylinder head
setscrew.
NOTE: Steps 6 and 7 apply only to the steer cylinder.
6. Using a spanner wrench, loosen the spanner nut
retainer, and remove spanner nut from cylinder
barrel.
3121166
11. Loosen and remove the cap screw(s), if applicable,
which attach the tapered bushing to the piston.
12. 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.
13. Remove the bushing from the piston.
– JLG Lift –
4-11
SECTION 4 - HYDRAULICS
14. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.
15. Remove and discard the piston o-rings, seal rings,
and backup rings.
16. If applicable, remove the piston spacer from the
rod.
17. Remove the rod from the holding fixture. Remove
the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals,
and wiper seals.
Steer Cylinder Piston Removal - Cyl. p/n1684456
1. Using the spanner holes, rotate the piston until the
end of the retarining 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.
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.
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.
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.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
9. Inspect cylinder head inside diameter for scoring
or other damage and for ovality and tapering.
Replace as necessary.
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.
b. Inspect steel bushing for wear or other damage. If steel bushing is worn or damaged, rod/
barrel must be replaced.
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.
NOTE: Install pin into the Gar-Max bearing dry. Lubrication
is not required with nickel plated pins and bearings.
STEEL
BUSHING
Cleaning and Inspection
1. Clean all parts thoroughly in an approved cleaning
solvent.
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.
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.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
4-12
GAR-MAX
BUSHING
ARBOR
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.
16. Inspect the oil ports for blockage or the presence
of dirt or other foreign material. Repair as necessary.
17. If applicable, inspect piston rings for cracks or
other damage. Replace as necessary.
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
Assembly
NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual
(3121167).
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 C YLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
Figure 4-9. Installation of Head Seal Kit
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.
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.
5. Carefully slide the piston spacer on the rod.
NOTE: Upper telescope cylinder piston has an o-ring
installed inside the spacer.
6. If applicable, correctly place new o-ring in the
inner piston diameter groove. (The backup ring
side facing the O-ring is grooved.)
7. 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.)
Figure 4-7. Poly-Pak Piston Seal Installation
NOTE: 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.
3121166
– JLG Lift –
4-13
SECTION 4 - HYDRAULICS
7. Retorque the capscrews evenly and progressively
in rotation to the specified torque value.
8. Remove the cylinder rod from the holding fixture.
9. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 4-10.)
10. Position the cylinder barrel in a suitable holding
fixture.
PISTON
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.
BACKUP
RINGS
SPLIT SEAL
11. With the 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.
12. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
cylinder.
13. Secure the cylinder head gland using the washer
ring and socket head bolts.
SPLIT
BACKUP
RING
O-RING
T - RING
SEAL
SPLIT BACKUP RING
Figure 4-10. Piston Seal Kit Installation
1. Using suitable protection, clamp the cylinder rod
in a vise or similar holding fixture as close to piston
as possible.
2. Carefully thread the piston on the cylinder rod
hand tight, ensuring that the o-ring and back-up
rings are not damaged or dislodged.
3. Thread the piston onto the rod until it abuts the
spacer end and install the tapered bushing.
NOTE: When installing the tapered bushing, piston and
mating end of rod must be free of oil.
4. 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.
5. Tighten the capscrews evenly and progressively in
rotation to the specified torque value.
6. 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
contac t 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.
4-14
Figure 4-11. Rod Assembly Installation
14. 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.
15. If applicable, install the cartridge-type holding
valve and fittings in the rod port block, using new
o-rings as applicable. (See Table 4-3, Holding Valve
Torque Specifications).
Table 4-2. Cylinder Piston Nut Torque Specifications
– JLG Lift –
Description
Nut Torque
Value
Setscrew
torque Value
Lift Cylinder
250-300 ft lb
(339-407 Nm)
N/A
3121166
SECTION 4 - HYDRAULICS
16. Push the piston onto the rod until it abuts the
spacer end and install the attaching nut.
Table 4-3. Holding Valve Torque Specifications
Description
Torque Value
Integrated Steer
15 ft lb
(20 Nm)
Integrated Proportional Valve
15 ft lb
(20 Nm)
Integrated Blocking Valve
15 ft lb
(20 Nm)
Relief
33 ft lb
(45 Nm)
Coil Nuts
Hand Tighten
17. Remove the cylinder rod from the holding fixture.
18. 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.
WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #242 TO
THE PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT.
REFER TO TABLE 4-2, CYLINDER PISTON NUT TORQUE SPECIFICATIONS.
3121166
NOTE: Reverse the procedure Steer Cylinder Piston Removal
- Cyl. p/n-1684456 on page 4-12 for installing the
steer cylinder piston.
19. 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.
20. Continue pushing the rod into the barrel until the
cylinder head gland can be inserted into the barrel
cylinder.
21. If applicable, secure the cylinder head retainer
using a suitable chain wrench.
22. 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.
23. If applicable, install the cartridge-type holding
valve and fittings in the port block using new orings as applicable. Refer to Table 4-3, Holding
Valve Torque Specifications.
– JLG Lift –
4-15
SECTION 4 - HYDRAULICS
2
TOP VIEW
3
1
4
5
2
2
8
7
ET
RT
Figure 4-12. Lift Cylinder/Pump/Tank Assembly
Table 4-4. Valve Torque Values
4-16
Item
Description
Torque
1
Bi-directional Relief Valve
33 ft lbs (45 Nm)
2
Solenoid
NA
3
Proportional Valve
15 ft lbs (20 Nm)
4
Check Valve
33 ft lbs (45 Nm)
5
Blocking Valve
15 ft lbs (20 Nm)
6
4 Way Directional Valve
15 ft lbs (20 Nm)
7
Extend Port
NA
8
Retract Port
NA
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
4
6
5
3
2
1
8
9
7
14
1930ES
ONLY
11
10
12
11
OR
11
12
18
13
20
19
14
17
15
16
22
OPPOSITE SIDE OF
CYLINDER PORT BLOCK
24
21
26
27
25
23
28
23
28
29
1.
2.
3.
4.
5.
6.
Proportional Valve
Emergency Release Assy.
Coil
Relief Valve
Pump
Filter
7.
8.
9.
10.
11.
12.
Spring
Jam Nut
Bushing
Barrel
Wear Ring
Seal
13.
14.
15.
16.
17.
18.
Locknut
Piston
O-ring
Seal
Head
O-ring
19.
20.
21.
22.
23.
24.
Wear Ring
Spacer
Wiper
O-ring
Bushing
Cylinder Rod
25.
26.
27.
28.
29.
Check Valve
Dowel Pin
Directional Control Valve
Coil
Directional Control Valve
Figure 4-13. Lift Cylinder Assembly
3121166
– JLG Lift –
4-17
SECTION 4 - HYDRAULICS
NOTES:
4-18
– JLG Lift –
3121166
SECTION 5 - JLG CONTROL SYSTEM
SECTION 5. JLG CONTROL SYSTEM
5.1
HAND HELD ANALYZER
Analyzer Display
men u:
HELP:PRESS ENTER
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
To Connect the Hand Held Analyzer:
1. Connect the four pin end of the cable supplied
with the analyzer, to the diagnostic port (refer
toSection 3.1) 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.
3121166
– 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:
If ENTER is pressed again, the display moves to the following display:
l og:
HELP:
1:STARTUP ( 2/ 1)
MENU:
HELP:PRESS ENTER
( 211)
or
(machines with no MDI)
(machines with an MDI)
LOGGED HELP
1: STARTUP (2/1): (Or last recorded fault)
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
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
ACTIVATE TESTS
CALIBRATION
5-2
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:
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:
In platform mode,
HELP: (001)
EVERYTHING OK,
In ground mode,
HELP: (002)
GROUND MODE OK
LOG: (211)
1: Power Cycle (Or last recorded fault)
DRIVE
LIFT
STEER
GROUND
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–
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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. For example:
MENU:
ACCESS LEVEL 1
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:
3121166
– JLG Lift –
5-3
SECTION 5 - JLG CONTROL SYSTEM
Adjusting Parameters Using the Hand Held
Analyzer
Machine Setup
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:
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 5-3, Machine Model Adjustment
(Machines with Sevcon - 1600346 Power Module
Only), and Table 5-5, Machine Configuration Programming Information (Machines with Sevcon 1600346 Power Module Only) 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.
5-4
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
5.2
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.
NOTICE
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.
TILT SENSOR CALIBRATION
Be sure that the machine is parked and stowed on level
ground.
NOTE: Tilt Sensor Calibration can not be performed if the
main contactor switch is open due to an alarm.
Ground Module Software Version 1.5
1. Enter Access Level 1 and go to the CALIBRATION/
TILT SENSOR/LEVEL VEHICLE screen.
2. Choose the right arrow key to view the raw, uncalibrated tilt sensor values. If either raw angle reads
±5.0 or more, the machine is too unlevel and the
software will prohibit calibration. Therefore,
attempt to dissect the three areas of error to find
the primary contributor:
a. Machine mounting and/or grade:
Try to measure the top of the Ground Control
box for levelness. If unable to get a good reading, unbolt the Ground Control box and check
the box’s mounting surface for levelness.
b. Tilt sensor mounting on machine or wedged
crooked in control box:
If the machine mounting/grade appears
acceptable, remove and open the Ground Control box carefully. Observe whether the tilt sensor is properly seated in its grooves.
c. Tilt sensor has developed an offset shift:
Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and
Ground Control box electrically connected.
Level one axis of the tilt sensor and observe
the raw reading (should be within ± 2.0). Do
the same for the other axis. If either axis is
greater than ±2.0, replace the tilt sensor.
The flash code is indicated on the face of the platform
control box as shown:
SYSTEM FAULT
Diagnostic Trouble Codes are indicated on the MDI for
those machines that are equipped with an MDI. (refer to
Section 3.2).
NOTE: Flash codes and DTC’s are also displayed on the
handheld analyzer. For descriptions see, Table 5-2,
Flash Code Listing.
Ground Module Software Version 1.4
1. Enter Access Level 1 and go to the CALIBRATION/
TILT SENSOR/LEVEL VEHICLE screen.
2. Choose the right arrow key to view the raw, uncalibrated tilt sensor values. If either raw angle reads
±5.0 or more, the machine is too unlevel and the
software will prohibit calibration. Therefore,
attempt to dissect the three areas of error to find
the primary contributor:
a. Machine mounting and/or grade:
Try to measure the top of the Ground Control
box for levelness. If unable to get a good reading, unbolt the Ground Control box and check
the box’s mounting surface for levelness.
b. Tilt sensor mounting on machine or wedged
crooked in control box:
If the machine mounting/grade appears
acceptable, remove and open the Ground Con-
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– JLG Lift –
5-5
SECTION 5 - JLG CONTROL SYSTEM
trol box carefully. Observe whether the tilt sensor is properly seated.
c. Tilt sensor has developed an offset shift:
Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and
Ground Control box electrically connected.
Level one axis of the tilt sensor and observe
the raw reading (should be within ± 2.0). Do
the same for the other axis. If either axis is
greater than ± 2.0, replace the tilt sensor.
5.3
This basic check using the JLG Analyzer can be used to
test the Tilt Sensor.
• If angle measurements read +20.0, then a sensor/
wiring/connector fault exists. If the readings intermittently display expected angles, then there is likely
a wiring/connector problem and not a failed sensor.
In either case, open the ES Ground box. Disconnect
the sensor, check the wire terminations, and clean
any corrosion on the tilt sensor and control board
connections. Reconnect and test. If the fault persists,
replace the tilt sensor and return the faulty tilt sensor
to JLG with a detailed description of the diagnostic
steps taken.
NOTE: Check that the tilt switch is properly set by referring
to the Tilt Settings table in section 1 of this manual.
Failure Troubleshooting for The Field
Some possible reasons that the tilt sensor will not calibrate are:
a. The surface the machine is sitting on is off level
by a few degrees (flat doesn’t imply level; parking lots are often not level).
b. The tilt sensor has failed one or both of the
channels (X axis and Y axis).
c. Tilt sensor has moisture intrusion that has
shifted its output.
d. Water and/or corrosion in the box has corrupted electrical connections or caused a tilt
sensor o r ground control board failure
(observe any cracks in the box).
e. The Ground Control Box, as mounted on the
machine, does not allow the tilt sensor to be
level.
For the following troubleshooting steps, a bubble level
(smaller is better) will be needed and the machine must
be on a level surface:
5.4
ELEVATION ANGLE SENSOR ELECTRICAL
EVALUATION
These basic checks using the JLG Analyzer can be used
to test the Elevation Angle Sensor. If the problem is still
occurring, perform the Tilt vs. Allowed Height Evaluation described below.
1. On the Analyzer, go to the Diagnostics/System and
read the tilt angle. If either angle reports +20.0°,
there is an electrical/electronic failure (tilt sensor,
control board, electrical connections).
a. Take the Ground Control box off of the
machine and open the rear cover.
b. Disconnect the sensor and clean any corrosion
off of the tilt sensor and control board connections.
c. Reassemble and test. If fault persists, replace
tilt sensor.
2. If the Analyzer displays angles other than +20.0°,
attempt to calibrate. If machine won’t calibrate,
note the reason displayed on Analyzer:
a. SENSOR FAILURE – tilt sensor internal frequency is out of range (replace sensor).
b. NOT LEVEL - tilt sensor has either developed an
offset or it is too unlevel as mounted on the
machine.
5-6
TILT SENSOR ELECTRICAL EVALUATION
– JLG Lift–
• On a level surface, with the Analyzer under DIAGNOSTICS/ELEV SENSOR, verify that the elevation
angle sensor voltage increases (ranges from 0.2V0.8V to 3.6V-4.2V) with platform height. If not,
check the sensor mounting. If necessary, unbolt sensor and rotate by hand while monitoring with the
Analyzer to check the integrity of the sensor output.
• For machines equipped with an elevation proximity switch, if the Elevation Sensor appears satisfactory, verify that the Elevation Prox switch is
opening and closing appropriately by watching
the change of state between the stowed and elevated positions (monitor PROX SWITCH under DIAGNOSTICS/ELEV SENSOR). If a change of state is not
observed, check prox mounting and operability by
placing metal in front of the prox sensor face.
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SECTION 5 - JLG CONTROL SYSTEM
Tilt vs. Allowed Height Evaluation
Table 5-1. Tilt Settings
First, find a level surface (not just flat like a parking lot;
must be level). The surface should be a plane in which
the wheels are within 0°±0.2°. Find this surface by taking a digital level and measuring the areas on which the
wheels would rest in both the X and Y directions. Mark
the locations and drive the machine to these points. If a
level surface can not be found, flat shims or plates may
be place under the wheels to create a level plane for the
wheels.
Tilt Setting
(side to side)
Maximum Deck
Elevation
3°
1.5°
2°
2.5°
3°
18.75 ft (5.7 m)
14 ft (4.3 m)
11 ft (3.4 m)
9 ft (2.7 m)
3°
1.5°
2°
2.5°
3°
20 ft (6 m)
15 ft (4.5 m)
12 ft (3.7 m)
10 ft (3 m)
2630ES
3°
1.5°
2°
2.5°
3°
25.4 ft (7.7 m)
20 ft (6 m)
16 ft (4.9 m)
13 ft (4 m)
2646ES
3°
2°
2.5°
3°
26 ft (7.9 m)
22 ft (6.7 m)
20 ft (6 m)
3246ES
3°
2°
2.5°
3°
31.75 ft (9.7 m)
22 ft (6.7 m)
20 ft (6 m)
1930ES
2030ES
In determining the existing tilt angle, read the angle on
the Analyzer under DIAGNOSTICS/SYSTEM. Do not place
a hand-held level on the machine to determine whether
the machine is level and lifting to the appropriate
height. Such a measurement will likely be different than
the Ground box/tilt sensor angle reading due to manufacturing and mounting tolerances. The tilt angle in
both directions should read within ±0.5° while on a level
surface. If not, then either the machine has a drifting tilt
sensor or has been erroneously re-calibrated since the
original factory calibration.
Check the service records to determine whether a re calibration has been performed. If so, re-calibrate on the
level surface. If there is no record of an earlier calibration, we must assume that the sensor output has drifted.
Therefore, replace the sensor and return to JLG with a
detailed troubleshooting description.
Tilt Setting
(front to back)
Model
If the machine does not appear to track the lift cutout
heights and no fault exists as described above, stow the
machine and re calibrate the Elevation Sensor.
NOTE: There is a rare case in which an attempted calibration will be unsuccessful for machines with Ground
module software version P1.5 or earlier. If this occurs
while performing a calibration, the Analyzer will display:
LEVEL VEHICLE
TILT +20.0 +20.0
and the following fault will also be logged.
TILT SENSOR NOT CALIBRATED (2/3) [DTC 811]
If no other faults have been logged since the last
startup, this fault indicates that the software needs to be
updated to P1.6 or later. Update the software and continue troubleshooting evaluation before replacing any
components.
If the tilt sensor readings are within range for a level
machine, compare the allowed Tilt vs. Height in the
chart below. Being within 6” of the target height is considered acceptable.
3121166
– JLG Lift –
5-7
SECTION 5 - JLG CONTROL SYSTEM
5.5
ELEVATION SENSOR CALIBRATION
5.6
NOTICE
MACHINE MUST BE ON LEVEL GROUND BEFORE ELEVATION SENSOR CAN BE SET.
1. Be sure that the machine is parked and stowed on
level ground.
2. Attach the analyzer near the ground control station.
3. Go to Access Level 1 and scroll through to CALIBRATION.
4. Under Calibrations, go to SET ELEV SENSOR.
5. Press enter for Yes and the Elevation Sensor will
set.
Updating the ground 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 5-2. thru Figure 5-4.
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.
NOTE: Check the elevation sensor by lifting the scissor arms,
from the platform, and driving until the drive speed
cuts back. Refer to Table 1-13, High Drive Speed Cutout Height for proper speed cut out height.
5-8
UPDATING SOFTWARE
– JLG Lift–
1. Disconnect analyzer from diagnostic port.
2. Using the laptop connector cable, connect the laptop to the diagnostic port.
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
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.
c. Scroll through the settings to verify they are
the same as before the software update.
6. Disconnect Analyzer.
7. Software update is complete.
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SECTION 5 - JLG CONTROL SYSTEM
5.7
TROUBLESHOOTING
It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems.
It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and
electrical systems.
The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if
the circuit is lacking hydraulic oil and electrical control power. This can be ascertained by overriding the bypass valve
(mechanically or electrically) so that oil is available to the function valve, then overriding the function valve mechanically. If the function performs satisfactorily, the problem exists with the control circuit.
NOTE: It may also be helpful to do the following for intermittent or difficult problems: run a system test, ANALYZER -> SYSTEM
TEST; check the machine personalities, ANALYZER ->PERSONALITIES (refer to Table 5-3, Machine Model Adjustment
(Machines with Sevcon - 1600346 Power Module Only)); and check the machine setup, ANALYZER -> MACHINE SETUP
(refer to Table 5-5, Machine Configuration Programming Information (Machines with Sevcon - 1600346 Power Module
Only)).
These below flash codes apply only to machines without the MDI (refer to Section 3.2, MDI (Multifunction Digital Indicator) and brake release). For machines with the MDI, refer to Section 6, Diagnostic Trouble Codes.
Anytime a problem is resolved, recycle the EMS.
Table 5-2. Flash Code Listing
Flash
Code
Help Message
Cause
Possible Resolve
Help Messages with no flash code may occur during normal operation and explain various vehicle interlocks.
0 0
0 0
0 0
0 0
3121166
ALARM SOUNDING--TILTED AND ABOVE ELEVATION
Platform is elevated and the chassis is not level.
Platform Position Sensor (PPS) elevation status is elevated and
the vehicle is tilted and machine setup’s TILT CUTOUT is 0=YES.
No motion restrictions.
DRIVING AT CUTBACK -- ABOVE ELEVATION
Platform is elevated and the machine is in the drive mode of
operation.
In platform mode, Platform Position Sensor (PPS) elevation
status is elevated and the vehicle is driving and the drive speed
is drive elevated.
Driving at elevated speed.
DRIVE & LIFT UP PREVENTED -- TILTED & ELEVATED
Driving is not possible since the platform is elevated and the
chassis is not level.
In Platform Mode, Platform Position Sensor (PPS) elevation
status is elevated and the vehicle is tilted and machine setup’s
TILT CUTOUT is 1=YES.
Drive prevented.
LIFT UP PREVENTED -- MAX HEIGHT ZONE A
Applicable to 3246ES configured for the Zone A/B Capacity
Selection, and operating on Zone A. The vehicle has reached
the maximum height and further lift up motion is not possible.
Machine Setup’s CAPACITY SELECT is 1=ZONE A/B and Machine
Setup’s MODEL is 3246ES and Zone A Lift Up=False.
Lift up prevented.
– JLG Lift –
5-9
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
0 0
0 0
0 0
Help Message
Cause
Possible Resolve
DRIVING AT CUTBACK -- POTHOLE STILL ENGAGED
While stowed, drive speed is reduced (due to lower ground
clearance) since the control system detected that the pot-hole
protection mechanism is deployed (failed to retraced).
In platform mode with a healthy elevation sensor, elevation
sensor less than 0.15V and the elevation prox closed and pothole protection’s PHP switches detect down.
In platform mode with an unhealthy elevation sensor, the elevation prox is closed AND pot-hole protection’s PHP switches
detect down.
Clear the obstacle blocking the
pot-hole protection mechanism, repair the mechanical
problem, re-adjust the pot-hole
limit switches, or repair the wiring to correct the problem.
FUNCTIONS LOCKED OUT -- SYSTEM POWERD DOWN
Check batteries charge, condiAfter 2 hours without activity, the control system enters a low- tion, etc. Normal operation
should resume after a power
power state to preserve battery charge.
cycle.
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
DRIVE PREVENTED -- ELEVATED AND ABOVE DRIVE CUTCheck elevation switches
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is Greater
OUT HEIGHT
Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.
Help messages with the 2-1 flash code occur during after power-up of the vehicle control system.
2 1
2 1
STARTUP
This help message is issued at each power-up. This serves to
indicate which messages have been recorded in logged help
since the last power-up event.
No motion restrictions.
No motions restricted.
KEYSWITCH FAULTY -- PLATFORM & GROUND ACTIVE
TOGETHER
The platform and ground mode inputs from the keyswitch are
active at the same time. The control system will default to
ground mode when if this happens. The keyswitch and wiring Re-cycle power once the probinside the ground control box should be examined / repaired. lem has been resolved to clear
Platform EMS digital input energized and ground mode select this difficulty.
digital input energized.
Default to ground mode operation and lift up prevented
Help messages with the 2-2 flash code indicate difficulty with the platforms controls.
2 2
2 2
5-10
Horn switch in the platform control box was closed during
power-up.
In platform mode, the Indoor/Outdoor switch digital input is
FUNCTION PROBLEM -- HORN PERMANENTLY SELECTED
energized and power-up is active. Retained until either is
momentarily de-energized.
Previously selected Indoor/Outdoor mode maintained.
FUNCTION PROBLEM -- INDOOR / OUTDOOR PERMANENTLY SELECTED
Release or repair the switch to
clear the message.
Indoor / Outdoor switch in the platform control box was closed
during power-up.
In Platform Mode, the Indoor / Outdoor Switch Digital Input is Release or repair the switch to
Energized and Power-up is Active. Retained until Digital Input clear the message.
is momentarily De-energized.
Previously selected Indoor / Outdoor Mode maintained
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
Help Message
Cause
Possible Resolve
FUNCTION PROBLEM -- DRIVE & LIFT ACTIVE TOGETHER
The Drive - Lift selector switch indicates that both functions are
selected simultaneously.
Repair the wiring or switch to
In Platform Mode, the Drive and Lift Digital Inputs are Energized at the same time. Retained until either is momentarily clear the message.
De-energized.
Drive, Steer, & Lift Prevented
FUNCTION PROBLEM -- STEER LEFT PERMANENTLY
SELECTED
Steer left switch in the platform control box was closed during
power-up.
In Platform Mode, the Left Steer Digital Input Switch is Ener- Release or repair the switch to
gized AND Power-up is Active. Retained until Digital Input is clear the message.
momentarily De-energized.
Steer & Drive Prevented
FUNCTION PROBLEM – STEER RIGHT PERMANENTLY
SELECTED
Steer right switch in the platform control box was closed during power-up.
In Platform Mode, the Right Steer Digital Input Switch is Ener- Release or repair the switch to
clear the message.
gized and Power-up is Active. Retained until Digital Input is
momentarily De-energized.
Steer & Drive Prevented.
ACCELERATOR FAULTY – WIPER OUT OF RANGE
The joystick (accelerator) wiper signal input is outside the
acceptable voltage range.
In Platform Mode, the Joystick (accelerator) Analog Input
Switch is > 4.50V OR < 0.50V. Retained until Analog Input is
measured within proper range.
Drive, Steer, & Lift Prevented.
2 2
ACCELERATOR FAULTY – STEER SWITCHES ACTIVE
TOGETHER
Both the steer left and steer right inputs are closed as the same
time.
A short in the steer switch wirIn Platform Mode, the Steer Left Digital Input is Energized and
ing or a failed steer switch can
the Steer Right Digital Input is Energized. Retained until either
cause this difficulty.
Digital Input is momentarily De-energized.
Drive & Steer Prevented.
2 2
Selected function (drive or lift) is not allowed because the joystick (accelerator) was not centered at power-up.
In Platform Mode, scaled Joystick (accelerator) position was Return joystick to center
FUNCTION LOCKED OUT – ACCELERATOR NOT CENTERED
something other than 0% AND Power-up was Active. Retained momentarily and re-initiate.
until the Joystick is momentarily centered.
Drive, Steer, & Lift Prevented.
2 2
Trigger switch in the platform control box was closed at powerup.
Release switch or repair the
FUNCTION PROBLEM – TRIGGER PERMANENTLY CLOSED In Platform Mode, the Trigger Digital Input was Energized AND
switch / wiring to clear the diffiPower-up was Active. Retained until the Trigger Digital Input is
culty.
momentarily De-energized.
Drive, Steer, & Lift Prevented.
2 2
2 2
2 2
2 2
2 2
3121166
TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
The wiper wire being off, the
wiper wire shorted to +B, or the
wiper wire shorted to –B
(ground) could cause this difficulty.
Trigger switch in the platform control box was closed for more
than ten seconds while the joystick (accelerator) was in the
neutral position (centered).
In Platform Mode, the Trigger Digital Input was Energized for Release switch or repair the
10,000mS AND Drive was In-Active AND Lift was In-Active.
switch / wiring to clear the difficulty.
Retained until the Trigger Digital Input is momentarily Deenergized.
Drive, Steer, & Lift Prevented.
– JLG Lift –
5-11
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
Help Message
Cause
Possible Resolve
Help messages with the 2-3 flash code indicate difficulty with the ground controls.
2 3
FUNCTION PROBLEM – LIFT PERMANENTLY SELECTED
Lift switch (up or down) in the ground control box was closed
during power-up.
In Ground Mode, [Lift Up Digital Input is Energized or Lift Down
Release or repair the switch to
Digital Input is Energized] AND Power-up is Active. Retained
clear the message.
until the respective Digital Input is momentarily De-energized.
Lift Prevented
GROUND LIFT UP/DOWN ACTIVE TOGETHER
In ground mode, the control system has detected the lift up
and down are active simultaneously.
Check the lift switch and associIn Ground Mode, Ground Lift Up Digital Input is Energized and
ated wiring in the ground conGround Lift Down Digital Input is Energized. Retained until
trol box.
both the Digital Inputs are momentarily De-energized.
Lift Prevented
NO DATA FROM TILT SENSOR – NOT CONNECTED OR
FAULTY
No signal from the tilt sensor mounted inside the ground control box.
Transitions on the Tilt X OR Tilt Y signals not detected for
Check wiring and plug connec2000mS. Retained until transitions on both are sensed.
tions at the tilt sensor and at the
Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed
ground control board.
Demand limited as in Worst-Case Slope Descent Functionality
for both Forward and Reverse
Drive will be slow in the Forward direction.
2 3
TILT SENSOR NOT CALIBRATED
The Tilt Sensor’s Calibration EEPROM is set to the signature
implanted by the In-Circuit Test Fixture. Retained until CalibraCalibrate the Tilt Sensor using
tion EEPROM is over-written by a valid calibration.
the calibration procedure to
Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed
Demand limited as in Worst-Case Slope Descent Functionality clear the message.
for both Forward and Reverse
Drive will be slow in the forward direction.
2 3
Check if the lift switch is
obstructed or jammed. Check
FUNCTION PROBLEM -- BRAKE RELEASE PERMANENTLY The ground control box lift switch was closed up or down, durthe lift switch signal and wiring
SELECTED
ing power-up in ground mode.
to the ground board. Replace
ground board.
2 3
2 3
Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout.
2 5
5-12
The input voltage from the sensor that measures lower arm
motion is outside acceptable range. This may be caused by
ELEV ANGLE SENSOR FAULTY – NOT MOUNTED OR VOLT- improper sensor mounting, difficulty with the sensor wiring,
or a faulty sensor.
AGE OUT OR RANGE
The elevation sensor is unhealthy
Platform height assumed to be full elevation.
– JLG Lift–
Check mounting, review sensor
wiring against the electrical
schematic, or replace the sensor
to clear the message.
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
2 5
2 5
2 5
2 5
2 5
3121166
Help Message
Cause
Possible Resolve
ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED
The Elevation Sensor’s Calibration EEPROM is set to the signature implanted by the In-Circuit Test Fixture. Retained until
Calibration EEPROM is over-written by a valid calibration.
Platform Height assumed to be Full Elevation.
The Elevation Proximity Switch is Open to indicate that the
Calibrate the elevation angle
Platform is Elevated, but the Elevation Sensor’s Voltage indi- sensor using the calibration procates that the Platform is Stowed. To be conservative, the con- cedure to clear the message.
trol system will assume that the Platform is Elevated.
Elevation Sensor is “Healthy” AND the Elevation Sensor’s
Zeroed Voltage is < 0.04V AND the Elevation Prox Switch is
Open for 2000mS. Retained until situation changes.
DRIVE PREVENTED – CHARGER CONNECTED
Driving is not possible since the vehicle is charging and it is configured to only allow lifting.
In Platform Mode, the Battery Charger is Charging AND the
Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 0=DRIVE ONLY.
Drive & Steer Prevented
DRIVE & LIFT UP PREVENTED – CHARGER CONNECTED
Driving and lifting are not possible since the vehicle is charging
and it is configured to prevent all motion.
In Platform Mode, the Battery Charger is Charging AND the
Disconnect battery charger
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 1=DRV & LIFT UP.
Drive & Lift Up Prevented.
PLATFORM OVERLOADED
While the Load Sensing System is enabled, the platform load
measured by the Load Sensing System is excessive. Functions
from platform control are prevented, and functions from
ground control may be prevented, depending on machine conRemove excess weight from
figuration.
platform.
The Load Sensing System Functionality’s Overload is True AND
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
Drive, Steer, & Lift Prevented (except 3246ES CE, Indoor Mode,
Height >24 Ft and < 26Ft, Lift Dn allowed).
DRIVE PREVENTED – POTHOLE NOT ENGAGED
While elevated, driving is not possible since the control system
detected that the pot-hole protection mechanism failed to
deploy.
In Platform Mode with a Healthy Elevation Sensor, the Elevation Sensor Voltage > 0.15V AND Pot-Hole Protection’s PHP
Switches detect Up.
In Platform Mode with an Unhealthy Elevation Sensor, the Elevation Prox Sensor is Open (no Arm Detected) AND Pot-Hole
Protection’s PHP Switches detect Up.
Drive & Steer Prevented.
– JLG Lift –
Clear the obstacle blocking the
pot-hole protection mechanism, repair the mechanical
problem, re-adjust the pot-hole
limit switches, or repair the wiring to correct the problem.
5-13
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
Help Message
2 5
ELEV PROX PERMANENTLY CLOSED – CHECK PROX AND
ANGLE ADJUSTMENT
2 5
DRIVE & LIFT PREVENTED – BRAKES ELECTRICALLY
RELEASED FOR TOWING
Cause
Possible Resolve
The Elevation Proximity Switch is closed to indicate that the
platform is stowed, but the elevation sensor’s voltage indicates
that the platform is elevated. To be conservative, the control
system will assume that the platform is elevated, and the drive
Check elevation switches.
speed will be restricted to elevated.
Replace if necessary.
Elevation Sensor is “Healthy” AND the Elevation Sensor’s
Zeroed Voltage is > 0.15V AND the Elevation Prox Switch is
Closed for 2000mS. Retained until situation changes.
Refer to Platform Position Sensor Functionality.
The manual brake release has been activated to allow the vehiDisengage the manual brake
cle to be towed.
release.
Brake release digital input is energized
Drive and Lift Prevented
2 5
DRIVE PREVENTED – ELEVATED ABOVE DRIVE CUTOUT
HEIGHT
The Drive Cutout functionality is enabled, and the platform is
elevated above the calibrated cutout height.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
Check elevation switches
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is Greater Check pothole switches.
Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.
2 5
MODEL CHANGED -- HYDRAULICS SUSPENDED - CYCLE
EMS
The model selection has been changed.
DRIVE PREVENTED -- BRAKES NOT RELEASING
Ensure vehicle is not stuck on
something preventing moveWhile driving on a level surface, armature current was > 150A
ment. Check/repair drive motor
for five seconds. Brakes assumed to not be releasing properly.
wiring, brakes or mechanical
issues.
2 5
Check ANALYZER -> MACHINE
SETUP -> MODEL NUMBER.
Replace ground board.
Help messages with the 3-1 flash code indicate that a contactor did not close when energized.
3 1
3 1
OPEN CIRCUIT LINE CONTACTOR
The Power Module’s line contactor drive circuitry passed
power-up self-tests, but the line contactor did not close when
Refer to CANbus documentation
energized.
for Power Module Message The Power Module is reporting a “Contactor Did Not Close”
Status.
Fault Code (15d).
Drive, Steer, & Lift Up Prevented.
CONTACTOR DRIVER PERMANENTLY OFF
The Power Module’s Line Contactor drive circuitry failed to
energize during power-up self-tests.
The Power Module is reporting a “Contactor Driver 1 Permanently Off” Fault Code (22d).
Drive, Steer, & Lift Up Prevented.
Refer to CANbus documentation
for Power Module Message Status.
Help messages with the 3-2 flash code indicate that a contactor did not open when de-energized.
3 2
5-14
LINE CONTACTOR MISWIRED ON OR WELDED
The Power Module’s Line Contactor Drive Circuitry passed
power-up self-tests, but the line contactor did not open when
Refer to CANbus documentation
de-energized.
for Power Module Message The Power Module is reporting a “Contactor Welded” Fault
Status.
Code (14d).
Drive, Steer, & Lift Up Prevented.
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
3 2
Help Message
CONTACTOR DRIVER PERMANENTLY ON
Cause
Possible Resolve
The Power Module’s Line Contactor Drive Circuitry failed to deenergize during power-up self-tests.
Refer to CANbus documentation
The Power Module is reporting a “Contactor Driver 1 Permafor Power Module Message nently On” Fault Code (23d). Refer to CANbus documentation
Status.
for Power Module Message – Status.
Drive, Steer, & Lift Up Prevented.
Help messages with the 3-3 flash code indicate an output driver problem.
NOTE: Certain output driver problems cannot be detected because stimulation of the load could result in safety concerns or annoyance (brake open circuit, lift down open circuit, ground alarm open circuit). 3-3 help messages
shall be latched until the next power cycle.
3 3
3 3
3 3
3 3
3 3
3 3
3 3
3121166
BRAKE SHORT TO BATTERY
Voltage was detected on the brake solenoid when the output
driver was commanded off during power-up.
Brake INPUT driven Low AND Brake STAT detected Low during
power-up.
Drive, Steer, & Lift Prevented.
BRAKE OPEN CIRCUIT
Current flow to the brake solenoid was not detected during
normal brake operation.
Brake INPUT driven High (normal operation) AND Brake STAT
detected Low.
Drive & Steer Prevented
LIFT UP SHORT TO BATTERY
Voltage was detected on the lift up solenoid when the output
driver was commanded off during power-up.
Lift Up INPUT driven Low AND Lift Up STAT detected Low during
power-up.
Drive, Steer, & Lift Up Prevented.
LIFT UP OPEN CIRCUIT
Current flow to the lift up solenoid was not detected during
power-up.
Lift Up INPUT driven High (momentarily) AND Lift Up STAT
detected Low during power-up.
No motion interlocks.
LIFT DN SHORT TO BATTERY
Voltage was detected on the lift down solenoid when the output driver was commanded off during power-up.
Lift Down INPUT driven Low AND Lift Down STAT detected Low
during power-up.
No motion interlocks.
LIFT DN OPEN CIRCUIT
Current flow to the lift down solenoid was not detected during
normal lift down motion.
Lift Down INPUT driven High (normal operation) AND Lift
Down STAT detected Low.
Lift Up Prevented.
STEER LEFT SHORT TO BATTERY
Voltage was detected on the steer left solenoid when the output driver was commanded off during power-up.
Left Turn INPUT driven Low AND Left Turn STAT detected Low
during power-up.
Drive & Steer Prevented.
– JLG Lift –
5-15
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
3 3
3 3
3 3
3 3
3 3
3 3
3 3
3 3
3 3
5-16
Help Message
Cause
STEER LEFT OPEN CIRCUIT
Current flow to the steer left solenoid was not detected during
power-up.
Left Turn INPUT driven High (momentarily) AND Left Turn STAT
detected Low during power-up.
Drive & Steer Prevented.
STEER RIGHT SHORT TO BATTERY
Voltage was detected on the steer right solenoid when the output driver was commanded off during power-up.
Right Turn INPUT driven Low AND Right Turn STAT detected
Low during power-up.
Drive & Steer Prevented.
STEER RIGHT OPEN CIRCUIT
Current flow to the steer right solenoid was not detected during power-up.
Right Turn INPUT driven High (momentarily) AND Right Turn
STAT detected Low during power-up.
Drive & Steer Prevented.
GROUND OVERLOAD LAMP SHORT TO BATTERY
While the load sensing system was enabled, voltage was
detected on the ground control box’s overload lamp when the
output driver was commanded off during power-up.
Ground Overload INPUT driven Low AND Ground Overload STAT
detected Low during power-up AND [Machine Setup’s LOAD
set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
No motion interlocks.
GROUND OVERLOAD LAMP OPEN CIRCUIT
While the Load Sensing System was enabled, current flow to
the ground control box’s overload lamp was not detected during power-up.
Ground Overload INPUT driven High (momentarily) AND
Ground Overload STAT detected Low during power-up AND
[Machine Setup’s LOAD set to 1=CUTOUT PLT OR 2=CUTOUT
ALL].
No motion interlocks.
GROUND ALARM SHORT TO BATTERY
Possible Resolve
While enabled, voltage was detected on the ground alarm
when the output driver was commanded off during power-up.
Ground Alarm INPUT driven Low AND Ground Alarm STAT
detected Low during power-up AND [Machine Setup’s
GROUND ALARM set to 1=DECENT OR 2=MOTION].
No motion interlocks.
Check for continuity through
this circuit. Inspect the wiring
for physical damage.
Replace ground board.
LEFT BRAKE SHORT TO BATTERY
The ground board detected voltage while the left brake was
commanded off.
LEFT BRAKE OPEN CIRCUIT
Check for continuity through
Current flow to the left brake solenoid was not detected during this circuit. Inspect the wiring
for physical damage.
normal left brake operation.
Replace ground board.
RIGHT BRAKE SHORT TO BATTERY
Voltage was detected on the right brake solenoid when the
ground board output was commanded off during power-up.
– JLG Lift–
Check for continuity through
this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
3 3
Help Message
Cause
Possible Resolve
Check for continuity through
The ground board did not detect current flow to the right brake this circuit. Inspect the wiring
for physical damage.
during normal operation.
Replace ground board.
RIGHT BRAKE OPEN CIRCUIT
Help messages with the 4-2 flash code indicate a thermal problem.
4 2
4 2
4 2
POWER MODULE TOO HOT – PLEASE WAIT
DRIVING AT CUTBACK -- POWER MODULE CURRENT
LIMIT
The Power Module for drive, steer, and lift up has reached thermal cutout. Allow to cool by powering down.
The power Module is reporting a "Unit Too Hot" fault code.
The drive portion of the Power Module has reached thermal
limit. Allow to cool by waiting for temperature to fall.
The Power Module is reporting a "I2T Drive Current LImit" fault
code.
The lift up portion of the power module has reached thermal
LIFT UP AT CUTBACK -- POWER MODULE CURRENT LIMIT limit. Allow to cool by waiting for temperature to fall.
The POwer Module is reporting "I2Pump Current LImit" fault
code.
Help messages with the 4-4 flash code indicate a battery supply problem.
4 4
4 4
4 4
4 4
3121166
BATTERY VOLTAGE TOO LOW – SYSTEM SHUTDOWN
BATTERY VOLTAGE TOO HIGH – SYSTEM SHUTDOWN
LSS BATTERY VOLTAGE TOO HIGH
LSS BATTERY VOLTAGE TOO LOW
Battery Voltage momentarily dropped below 14.5V. With a
low battery charge, this can occur during heavy current
demand due to drive, steer, or lift up.
The Power Module is reporting a “Low Battery” Fault Code
(7d).
Drive, Steer, & Lift Up Prevented
Recharge batteries or check for
damaged batteries.
The Power Module momentarily measured excessively high
battery voltage (>37.0v) and the ground module de-energized the ignition relay to protect system devices.
The Power Module is reporting a “High Battery” Fault Code (8d) This may be due to improper
OR a “High Battery without Line” Fault Code (10d). In response, battery charging or incorrect
the Ground Module shall de-energize the Ignition Relay and voltage batteries being used.
suppress all Help Messages caused by the lack of Ignition Signal. This fault is latched until the next power-cycle.
Drive, Steer, & Lift Prevented.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage >34.0Vdc, which
may compromise ability to predict weight.
This may be due to improper
LSS Module Message – Status Message (0x81) is reporting
battery charging or incorrect
“BATT TOO HIGH” AND [Machine Setup’s LOAD is set to 1=CUT- voltage batteries being used.
OUT PLT OR 2=CUTOUT ALL]. Vehicle assumed to be Overloaded.
While the Load Sensing System is enabled, the Load Sensing
System module measured battery voltage <9.0vdc, which
may compromise ability to predict weight. With a low battery
charge, this can occur during heavy current demand due to
drive, steer, or lift up.
Recharge batteries or check for
LSS Module Message – Status Message (0x81) is reporting
damaged batteries.
“BATT TOO LOW” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
– JLG Lift –
5-17
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
Help Message
Cause
Possible Resolve
Help messages with the 6-6 flash code indicate vehicle communication (CANbus) problems. These faults shall not be latched. Normal operation shall
resume if difficulty is resolved.
6 6
6 6
6 6
6 6
CANBUS FAILURE: POWER MODULE
CANBUS FAILURE: PLATFORM MODULE
CANBUS FAILURE: LOAD SENSING SYSTEM MODULE
ACCESSORY CAN COMMUNICATION LOST
The control system failed to receive messages from the Power
Module.
Check wiring at the ground conPower Module Message – Status (0x24) not received for
trol box and power module.
1000mS or Power Module is reported a “CANbus Bus Difficulty”
Recycle power to clear difficulty.
Fault Code (0x09).
Drive, Steer, & Lift Up Prevented.
In Platform Mode, the control system failed to receive messages from the platform module.
Digital Input Message – Motion (0x00) not received for
1000mS AND Platform Mode selected. Retained until power is
re-cycled.
All Platform functions Prevented. Normal operation from
Ground Mode.
Check wiring at the platform
and ground control boxes. Check
wiring along scissor arms leading up to Platform.
With the Load Sensing System enabled, the control system
failed to receive messages from the Load Sensing System Module.
LSS Module Message – Load Cell Message (0x80) not received
for 1000mS AND [Machine Setup’s LOAD set to 1=CUTOUT PLT
OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
Check wiring at the Load Sensing System Module and along
scissor arms leading up to platform.
A JLG Accessory Module has failed to maintain CANbus communications with the ground module.
Refer to documentation for the
The control system received Accessory Message – Control 1
from an Accessory Module, but failed to receive another within JLG Accessory to clear difficulty.
1000mS. Retained until power is re-cycled.
No motion interlocks.
Help messages with the 6-7 flash code indicate JLG accessory problems. These faults shall not be latched. Normal operation shall resume if difficulty
is resolved.
6 7
A JLG Accessory Module has encountered a fault condition and
reported it via the host control system.
Refer to documentation for the
Accessory Message – Control 1’s Request Accessory Fault flag is
JLG Accessory to clear difficulty.
set to YES. Retained or cleared based on status of flag.
No motion interlocks.
ACCESSORY FAULT
Help messages with the 7-7 flash code indicate motor problems.
7 7
OPEN-CIRCUIT DRIVE MOTOR FIELD WIRING
The Power Module detected an error in the power wiring (F1 &
F2 Terminals) for the drive motors.
Check power wiring and reThe Power Module is reporting a “Field Open Circuit” Fault
cycle power to clear difficulty.
Code (16d). Retained until power is re-cycled.
Drive & Steer Prevented
Help messages with the 8-x flash codes indicate problems with the platform load sensing system. The second digit of the flash code is used to indicated channel.
8 1
5-18
LSS CELL #1 ERROR
Cell #1’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #1’s Internal Memory.
8-1 Flash Code
LSS Module Message – Status Message (0x81) is reporting
“CELL 1 ERROR” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
– JLG Lift–
This situation indicates that the
sensor is unplugged, or the sensor is damaged.
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
8 2
8 3
8 4
Help Message
LSS CELL #2 ERROR
LSS CELL #3 ERROR
LSS CELL #4 ERROR
Cause
Cell #2’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #2’s Internal Memory.
8-2 Flash Code
LSS Module Message – Status Message (0x81) is reporting
“CELL 2 ERROR” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
Possible Resolve
This situation indicates that the
sensor is unplugged, or the sensor is damaged.
Cell #3’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #3’s Internal Memory.
8-3 Flash Code
LSS Module Message – Status Message (0x81) is reporting
“CELL 3 ERROR” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
This situation indicates that the
sensor is unplugged, or the sensor is damaged.
Cell #4’s Bridge <2Vdc, >3Vdc, or could the LSS Module could
not read Cell #4’s Internal Memory.
8-4 Flash Code
LSS Module Message – Status Message (0x81) is reporting
“CELL 4 ERROR” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
This situation indicates that the
sensor is unplugged, or the sensor is damaged.
Help messages with the 9-x flash codes indicate controller (module) problems. The second digit of the flash code provides additional information
about the difficulty.
9 1
LSS WATCHDOG RESET
The Watchdog Timer on Load Sensing System Module’s microprocessor was triggered by exposure to excessive electrical
noise, or by a hardware difficulty.
9-1 Flash Code
Re-cycle power to clear diffiLSS Module Message – Status Message (0x81) is reporting
culty
“WATCHDOG RST” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until power is recycled.
No motion interlocks.
9 2
Memory used to retain settings on Load Sensing System Module has been corrupted and must be reset by verifying all
entries / re-calibrating.
9-2 Flash Code
After resolution, re-cycle power
LSS Module Message – Status Message (0x81) is reporting
to clear difficulty.
“EEPROM ERROR” AND [Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded
9 3
9-3 Flash Code
The Load Sensing System’s Calibration EEPROM for Empty Platform Load is set to Never Set (signature implanted by the In- Calibrate the Load Sensing SysCircuit Test Fixture) AND [Machine Setup’s LOAD is set to
tem using the calibration proce1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained until Calibration dure to clear the message.
EEPROM is over-written by a valid calibration.
Vehicle assumed to be Overloaded.
LSS EEPROM ERROR
3121166
LSS HAS NOT BEEN CALIBRATED
– JLG Lift –
5-19
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
9 9
9 9
Help Message
LSS INTERNAL ERROR – PIN EXCITATION
LSS INTERNAL ERROR – DRDY MISSING FROM A/D
Cause
Possible Resolve
The Excitation Voltage for the Load Sensors < 4.25V.
9-9 Flash Code
LSS Module Message – Status Message (0x81) is reporting
“INTERNAL ERROR – PIN EXCITATION < 4.25V” AND [Machine
Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
The sensors may be excessively
loading the Excitation Supply
due to wiring damage, or the
Load Sensing System Module
may have hardware difficulty.
The DRDY Interrupt from the Load Sensing System Module’s A/
D Converter is missing.
9-9 Flash Code
This may indicate Load Sensing
LSS Module Message – Status Message (0x81) is reporting
System Module hardware diffi“INTERNAL ERROR – DRDY INTERRUPT FROM A/D” AND
culty.
[Machine Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL]. Retained until power is re-cycled.
Vehicle assumed to be Overloaded.
9 9
The Power Module detected an out-of-range or corrupt personality setting.
9-9 Flash Code
POWER MODULE FAILURE: PERSONALITY RANGE ERROR
The Power Module is reporting a “Configuration Range” Fault
Code (11d) OR a “Configuration CRC” Fault Code (12d) OR a
“Motor Setup” Fault Code (13d). Retained until power is recycled.
9 9
The Power Module detected an internal error via self-test.
9-9 Flash Code
The Power Module is reporting a “Two Direction” Fault Code
(4d) OR a “Sequence” Fault Code (5d) OR a “CANbus Input”
Fault Code (6d) OR a “12V Supply Detection” Fault Code (18d)
OR a “System Monitor Activated” Fault Code (24d). Retained
until power is re-cycled.
9 9
9 9
9 9
5-20
POWER MODULE FAILURE: INTERNAL ERROR
POWER MODULE FAILURE: CHECK POWER CIRCUITS OR
MOSFET SHORT CIRCUIT
POWER MODULE FAILURE: SYSTEM MONITOR
EEPROM FAILURE – CHECK ALL SETTINGS
Reset control system Personalities to default settings to clear
difficulty.
Re-cycle power to clear difficulty.
The Power Module detected an error in the Power Wiring for
the Drive or Pump. Alternately, the Power Module has failed a
self-test.
9-9 Flash Code
Check wiring and motors or
The Power Module is reporting an “Armature MOSFET Short
replace the Power Module. ReCircuit” Fault Code (17d) OR an “Armature MOSFET’s Off” Fault cycle power to clear difficulty.
Code (19d) OR an “Armature MOSFET’s On” Fault Code (20d) OR
an “Armature Pullup MOSFET Short Circuit” Fault Code (21d).
Retained until power is re-cycled.
The ground board detected armature, field, or pump current
while function was not commanded.
Refer to Drive Motor Electrical
Evaluation in Section 3.7.
Refer to Pump Motor Electrical
Evaluation in Section 4.7.
Refer to Power Module Electrical
Evaluation in Section 3.8.
The control system detected an EEPROM failure. Personalities
and Machine Setup settings may be reset to default values.
Check / correct all settings and
9-9 Flash Code
re-cycle power to clear diffiThe control system’s EEPROM checksum indicates corruption.
culty.
Retained until EEPROM settings are corrected and power is recycled.
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
Flash
Code
9 9
9 9
9 9
9 9
3121166
Help Message
FUNCTIONS LOCKED OUT – MACHINE NOT CONFIGURED
FUNCTIONS LOCKED OUT – PLATFORM MODULE SOFTWARE VERSION IMPROPER
Cause
Possible Resolve
The control system has not been configured for the first time.
9-9 Flash Code
The control system’s EEPROM flag indicates that the vehicle has
not been configured (new control system components).
Retained until EEPROM flag is cleared and power is re-cycled.
Use the JLG Analyzer to adjust all
Machine Setup and Personality
settings and re-cycle power to
clear difficulty.
The control system will not function because the Platform
Module Software Version is not compatible with the rest of the
system.
Re-program or replace with a
9-9 Flash Code
Version 1.xx module.
The Platform Module reported a Software Major Version that
was not equal to “1”. The control system may resume operation
once the difficulty has been corrected.
The control system will not function because the Power Module Software Version is not compatible with the rest of the system.
FUNCTIONS LOCKED OUT – POWER MODULE SOFTWARE
Re-program or replace with a
9-9 Flash Code
VERSION IMPROPER
The Power Module reported a Software Major Version that was Version 1.xx module.
not equal to “1”. The control system may resume operation
once the difficulty has been corrected.
FUNCTIONS LOCKED OUT – LSS MODULE SOFTWARE
VERSION IMPROPER
The control system will not function because the LSS Module
Software Version is not compatible with the rest of the system.
9-9 Flash Code
Re-program or replace with a
Machine Setup’s LOAD=1 or 2 AND the LSS Module reported a
Version 7.xx module.
Software Major Version that was not equal to “7”. The control
system may resume operation once the difficulty has been corrected.
– JLG Lift –
5-21
5-22
LIFT:
DECEL 0.1 - 1.0 S
LIFT:
UP MIN 0 - 50%
LIFT:
UP MAX 0 - 100%
LIFT:
DN MIN 0 - 60%
DRIVE:
ACCEL 0.1 - 5.0 S
DRIVE:
DECEL 0.1 - 10.0 S
DRIVE:
MINIMUM 0 - 25%
DRIVE:
MAXIMUM 0 - 100%
DRIVE:
ELEV. MAX 0 - 25%
– JLG Lift–
Continued
on sheet 2
MENU:
CALIBRATIONS
MENU:
MACHINE SETUP
LIFT:
ACCEL 0.1 - 5.0 S
PERSONALITIES:
DRIVE
MENU:
PERSONALITIES
MARKET:
1 = ANSI EXPORT
MARKET:
2 = CSA
MARKET:
3 = CE
MARKET:
4 = AUSTRALIA
MODEL NUMBER:
2030ES
MODEL NUMBER:
2630ES
MODEL NUMBER:
2646ES
MODEL NUMBER:
3246ES
*
DRIVE CUTOUT: *
YES:ENTR, NO:ESC
CALIBRATIONS:
DRIVE CUTOUT
DRIVE CUTOUT:
1 = YES
DRIVE CUTOUT:
0 = NO
ACCELERATOR:
REV MAX 3.80V
ACCELERATOR:
REV MIN 2.75V
ACCELERATOR:
FWD MAX 1.20V
ACCELERATOR:
FWD MIN 2.25V
PERSONALITIES:
ACCELERATOR
BATTERY:
1 = AGM
ELEV PROX: *
1 = INSTALLED
FOOTSWITCH:
1 = YES
FOOTSWITCH:
0 = NO
LOAD:
2 = CUTOUT ALL
GROUND ALARM: *
2 = MOTION
BATTERY:
0 = FLOODED
LOAD:
1 = CUTOUT PLT
GROUND ALARM: *
1 = DESCENT
*
LOAD:
0 = NOT INSTALLED
*
GROUND ALARM:
0 = NOT INSTALLED
*
*
*
*
*
LOAD:
OVR HOLD 5.0 S
LOAD:
OVR DBNCE 3.0 S
LOAD:
ACC’Y 0 - 200 KG
PERSONALITIES:
LOAD
*
ELEV PROX:
0 = NOT INSTALLED
CHRGER INTRLOC:
1 = DRV & LIFT UP
CHRGER INTRLOC:
0 = DRIVE ONLY
GROUND:
ALARM 87 DB
GROUND:
HORN 107 DB
PERSONALITIES:
GROUND
Figure 5-2. Analyzer Flow Chart (Sevcon) - Sheet 1 of 3
*
SET ELEV SENSOR:
0.10 - 1.20V X.XXV
*
LOAD:
YES:ENTR, NO:ESC
*
SET ELEV SENSOR:
YES:ENTR, NO ESC
LEVEL VEHICLE:
YES:ENTR, NO:ESC
UNCALED TILT:
+X.XX, +Y.YY
CALIBRATIONS: *
LOAD
*
*
CALIBRATIONS: *
SET ELEV SENSOR
TILT CUTOUT:
1 = YES
TILT CUTOUT:
0 = NO
STEER:
DRIVE 0 - 100%
STEER:
STATIC 0 - 100%
PERSONALITIES:
STEER
CALIBRATIONS:
TILT SENSOR
MARKET:
5 = JAPAN
MARKET:
0 = ANSI USA
MODEL NUMBER:
1930ES
LIFT:
DN MAX 0 - 100%
PERSONALITIES:
LIFT
ACCESS LEVEL:
CODE 00000
MENU:
ACCESS LEVEL 1
ACCESS LEVEL:
CODE 33271
*
*
GROUND ALARM:
1 = ADVANCED DC
DRIVE MOTORS:
0 = PEERLESS
SECTION 5 - JLG CONTROL SYSTEM
Analyzer Flow Chart
3121166
3121166
– JLG Lift –
Continued
on sheet 3
MENU:
SYSTEM TEST
MENU:
SYSTEM TEST
ACTIVATE TEST:
YES:ENTR, NO:ESC
ACTIVATE TEST:
YES:ENTR, NO:ESC
RUN SYS TEST:
GND LIFT UP
RUN SYS TEST:
GND LIFT DN
RUN SYSTEM TEST:
LT STEER
RUN SYSTEM TEST:
RT STEER
RUN SYS TEST:
ALARM ON
RUN SYS TEST:
HORN ON
RUN SYS TEST:
OVERLOAD ON
RUN SYS TEST: (3)
TEST OVLD & ALRM?
RUN SYS TEST:
SELECT LIFT
RUN SYS TEST:
SELECT DRIVE
RUN SYS TEST:
PLAT ALARM ON
RUN SYS TEST:
OPEN HORN SW
RUN SYS TEST:
INDOOR ON
RUN SYS TEST:
CLOSE IN/OUT SEL
RUN SYS TEST:
OVERLOAD ON
RUN SYS TEST:
TILT LAMP ON
RUN SYS TEST:
CLOSE TRIGGER
RUN SYS TEST:
CLOSE HORN SW
RUN SYS TEST:
SYS DISTRESS ON
RUN SYS TEST:
OPEN IN/OUT SEL
RUN SYS TEST:
OUTDOOR ON
RUN SYS TEST:
CNTRL BACK TO MN
RUN SYS TEST:
BATTERY 4 (FULL)
RUN SYS TEST:
OPEN RT STEER
RUN SYS TEST:
OPEN TRIGGER
RUN SYS TEST:
CNTRL BACK TO MX
RUN SYS TEST:
CNTRL FWD TO MIN
RUN SYS TEST:
CNTRL FWD TO MAX
RUN SYS TEST: (4)
TEST PROP CNTRL?
RUN SYS TEST:
BATTERY 3 (3/4)
RUN SYS TEST:
BATTERY 2 (½)
RUN SYS TEST:
BATTERY 1 (1/4)
RUN SYS TEST: (4)
TEST LEDS & ALRM?
RUN SYS TEST:
CLOSE RT STEER
RUN SYS TEST:
OPEN STEER LT
RUN SYS TEST:
CLOSE STEER LT
RUN SYS TEST: (4)
TEST PLT SW?
Figure 5-3. Analyzer Flow Chart (Sevcon) - Sheet 2 of 3
RUN SYSTEM TEST:
TEST VALVES?
RUN SYSTEM TEST:
LIFT UP
RUN SYS TEST: (3)
TEST GND SW?
RUN SYSTEM TEST:
TEST VALVES?
RUN SYS TEST:
TEST COMPLETE
SECTION 5 - JLG CONTROL SYSTEM
5-23
MENU:
PERSONALITIES
5-24
*
– JLG Lift–
TRACTION:
FLD PWM 0 - 100%
TRACTION:
FLD CUR XX.XA
TRACTION:
TEMP XXC
PLATFORM:
TRIGGER OPEN
PLATFORM:
JOYSTICK 0%
*
PLATFORM:
FOOTSWITCH OPEN
rev 9-14
*
DATALOG:
ERASE RENTAL?
DATALOG:
YES:ENTR, NO:ESC
*
LOAD:
CELL 1 XXXXKG
*
LOAD:
CELL 2 XXXXKG
*
LOAD:
CELL 4 XXXXKG
*
LOAD:
CELL 3 XXXXKG
DATALOG:
RENTAL XXH XXM
*
LOAD:
OVERLOADED? YES
SYSTEM:
HORN ON/OFF
DATALOG:
LIFT XXH XXM
*
LOAD:
PLTGROSS XXXXKG
*
SYSTEM:
PHP RET/EXT/FAULTY
DATALOG:
DRIVE XXH XXM
*
LOAD:
PLT LOAD XXXXKG
DIAGNOSTICS:
DATALOG
*
SYSTEM:
RT PHP OPEN/CLSD
*
DIAGNOSTICS:
LOAD
*
VALVES:
LIFT DN 0 - 100%
VALVES:
LIFT UP OFF/ON
VALVES:
STEER RT OFF/ON
VERSIONS:
LSS HW?
VERSIONS:
LSS SW P?.?
*
*
VERSIONS:
POWER MOD V?.??
VERSIONS:
PM SN?????
VERSIONS:
PM HW REV?
VERSIONS:
PM SW P?.?
VERSIONS:
GM SN ?????
VERSIONS:
GM HW REV?
VERSIONS:
GM SW P?.?
DIAGNOSTICS:
VERSIONS
CHARGER:
AC (NOT)CONNECTED
DIAGNOSTICS:
CHARGER
*
SYSTEM:
LT PHP OPEN/CLSD
ELEV SENSOR:
CALIB X.XXV
ELEV SENSOR:
PPS SPEED STOWED
*
ELEV SENSOR:
PLATFORM STOWED
ELEV SENSOR:
PROX SW OPEN
*
VALVES:
STEER LT OFF/ON
*
ELEV SENSOR:
ANGLE SNSR XX.XV
ELEV SENSOR:
ZEROED X.XXV
DIAGNOSTICS:
VALVES
DIAGNOSTICS:
ELEV SENSOR
Figure 5-4. Analyzer Flow Chart (Sevcon) - Sheet 3 of 3
* = This option may be available
depending on Machine Setup.
(4) = This option and all below it are
available in Platform Mode only.
(3) = This option and all below it are
available in Ground Mode only.
Notes:
SYSTEM:
BRK RELES OPEN
TRACTION:
FLD VOLT SS.SV
PLATFORM:
HORN OPEN
*
*
*
SYSTEM:
PHP OPEN/CLOSED
SYSTEM:
BRAKE ON/OFF
SYSTEM:
FIXED TILT +X.X
SYSTEM:
TILT +X.X +Y.Y
SYSTEM:
PLT BATT XX.XV
SYSTEM:
BATTERY XX.XV
SYSTEM:
MODE GROUND
DIAGNOSTICS:
SYSTEM
TRACTION:
ARM CUR XXX.XA
TRACTION:
ARM PWM 0 - 100%
PUMP:
PUMP CUR XXX.XA
PUMP:
PUMP PWM 0 - 100%
PUMP:
MODE: NEUTRAL
DIAGNOSTICS:
PUMP
DIAGNOSTICS: *
ZONE A/B OPEN
PLATFORM:
IN/OUT OPEN
TRACTION:
ARM VOLT XX.XV
TRACTION:
SPEED 0 - 100%
PLATFORM:
STEER RT OPEN
GROUND:
LIFT DN OPEN
PLATFORM:
LIFT SEL OPEN
TRACTION:
MODE: NEUTRAL
TRACTION:
DRV VOLT XX.XV
GROUND:
LIFT UP OPEN
PLATFORM:
DRIVE SEL OPEN
DIAGNOSTICS:
TRACTION
PLATFORM:
STEER LT OPEN
DIAGNOSTICS:
GROUND
DIAGNOSTICS:
PLATFORM
SECTION 5 - JLG CONTROL SYSTEM
3121166
SECTION 5 - JLG CONTROL SYSTEM
Figure 5-5. Analyzer Flow Chart (ZAPI) - Sheet 1 of 3
Analyzer Flow Chart
3121166
– JLG Lift –
5-25
Figure 5-6. Analyzer Flow Chart (ZAPI) - Sheet 2 of 3
SECTION 5 - JLG CONTROL SYSTEM
5-26
– JLG Lift–
3121166
Figure 5-7. Analyzer Flow Chart (ZAPI) - Sheet 3 of 3
SECTION 5 - JLG CONTROL SYSTEM
3121166
– JLG Lift –
5-27
SECTION 5 - JLG CONTROL SYSTEM
5.8
MACHINE MODEL ADJUSTMENT - SEVCON - 1600346 POWER MODULE
Table 5-3. Machine Model Adjustment
(Machines with Sevcon - 1600346 Power Module Only)
Adjustment
Adjustment Range
1930ES
2030ES
2630ES
2646ES
3246ES
ACCEL
0.1 - 5.0 (Sec)
0.7
0.7
0.7
0.7
0.7
DRIVE
DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
0.1
MINIMUM
0 - 25%
0
0
0
0
0
MAXIMUM
0 -100%
100
100
100
100
100
ELEV. MAX.
0 - 25%
18
16
16
20
20
ACCEL
0.1 - 5.0 (Sec)
0.5
0.5
0.5
0.5
0.5
DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
0.1
UP MIN
0 - 50%
20
20
20
20
20
UP MAX
0 - 100%
100
100
100
100
100
DN MIN
1 - 60%
18
45
42
52
52
DN MAX
1 - 100%
60
85
63
80
80
STATIC
0 - 100%
50
50
50
50
50
DRIVE
0 - 100%
30
30
30
30
30
2.20 - 2.40 V
2.25
2.25
2.25
2.25
2.25
LIFT
STEER
ACCELERATOR
FWD MIN
FWD MAX
1.00 - 1.50 V
1.20
1.20
1.20
1.20
1.20
REV MIN
2.60 - 2.80 V
2.75
2.75
2.75
2.75
2.75
REV MAX
3.50 - 4.00 V
3.80
3.80
3.80
3.80
3.80
GROUND
HORN
87 - 107 dB
107
107
107
107
107
ALARM
87 - 107 dB
87
87
87
87
87
ACCY
0 - 200 Kg
0
0
0
0
0
OVR DBNCE
0.0 - 5.0 Sec
3.0
3.0
3.0
3.0
3.0
OVR HOLD
0.0 - 5.0 Sec
5.0
5.0
5.0
5.0
5.0
LOAD
4150472-I *
* Rev. I - Obsoleted by 1001115626
NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.
5-28
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
5.9
MACHINE MODEL ADJUSTMENT - ZAPI - 1001092456 POWER MODULE
Table 5-4. Machine Model Adjustment
(Machines with ZAPI - 1001092456 Power Module Only)
Adjustment
Adjustment Range
1930ES
2030ES
2630ES
2646ES
3246ES
ACCEL
0.1 - 5.0 (Sec)
0.7
0.7
0.7
0.7
0.7
DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
0.1
DRIVE
MINIMUM
0 - 25%
0
0
0
0
0
MAXIMUM
0 -100%
100
100
100
100
100
ELEV. MAX.
0 - 25%
25
25
25
25
25
LIFT
ACCEL
0.1 - 5.0 (Sec)
0.5
0.5
0.5
0.5
0.5
DECEL
0.1 - 1.0 (Sec)
0.1
0.1
0.1
0.1
0.1
UP MIN
0 - 50%
20
20
20
20
20
UP MAX
0 - 100%
100
100
100
100
100
DN MIN
1 - 60%
45
45
45
45
45
DN MAX
1 - 100%
75
75
75
75
75
STATIC
0 - 100%
70
70
70
70
70
DRIVE
0 - 100%
30
30
30
30
30
FWD MIN
2.20 - 2.40 V
2.23
2.23
2.23
2.23
2.23
FWD MAX
1.00 - 1.50 V
1.19
1.19
1.19
1.19
1.19
STEER
ACCELERATOR
REV MIN
2.60 - 2.80 V
2.74
2.74
2.74
2.74
2.74
REV MAX
3.50 - 4.00 V
3.78
3.78
3.78
3.78
3.78
HORN
10 - 100%
94
94
94
94
94
ALARM
10 - 100%
19
19
19
19
19
ACCY
0 - 200 Kg
0
0
0
0
0
OVR DBNCE
0.0 - 5.0 Sec
3.0
3.0
3.0
3.0
3.0
OVR HOLD
0.0 - 5.0 Sec
5.0
5.0
5.0
5.0
5.0
GROUND
LOAD
1001115627-D
NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.
3121166
– JLG Lift –
5-29
SECTION 5 - JLG CONTROL SYSTEM
5.10 MACHINE CONFIGURATION PROGRAMMING INFORMATION - SEVCON - 1600346
NOTE: When configuring an ES 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.
Shaded entries are not available for the selected Market.
Table 5-5. Machine Configuration Programming Information
(Machines with Sevcon - 1600346 Power Module Only)
* Market Default Setting
Configuration
Digit
Setting
Description
1
(Model #)
1
2
3
4
5
1930ES
2030ES
2630ES
2646ES
3246ES
(Set to your applicable ES Model
1 through 5)
2
(Market *)
0
1
2
3
4
5
ANSI USA
ANSI EXPORT
CSA
CE
AUSTRALIA
JAPAN
0 - (ANSI USA)
(Set to your applicable market)
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
(Drive Cutout)
0
1
No - Drive and lift up not prevented while elevated.
Yes - Drive and lift up prevented while elevated.
0
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
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 motion.
2
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
5
(Charger Interlock)
1
0
6
(Ground Alarm)
1
2
7
(LSS Load Sensing
System)
8
(Drive Motors)
0
1
2
0
1
1
1
2
3
1
1
1
0
0
0
0
2
2
0
2
2
1
0
1
0
1
0
0
1
0
PEERLESS - Vehicle is fitted with Peerless drive motors.
ADVANCED DC - Vehicle is fitted with ADvanced DC drive motors.
1
0
NOT INSTALLED - Vehicle is not fitted with an Elevation Prox Sensor. Vehicle has Left and
Right Brake Release Outputs, and Maintained Brake Release functionality.
INSTALLED - Vehicle is fitted with an Elevation Prox Sensor (original ES-Series). Vehicle has
a single Brake Release Output, and Momentary Brake Release functionality.
0
0
1
10
(Battery)
0
1
FLOODED - Batteries are conventional lead-acid type.
AGM - Batteries are absorbed glass mat type.
11
(Footswitch)
0
1
NO - Vehicle is not fitted with a footswitch
YES - Vehicle is fitted with a footswitch
5
0
0
1
9
(Elev Prox)
4
0
0
0
4150473-F
5-30
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
5.11 MACHINE CONFIGURATION PROGRAMMING INFORMATION - ZAPI - 1001092456
NOTE: When configuring an ES 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.
Shaded entries are not available for the selected Market.
Table 5-6. Machine Configuration Programming Information
(Machines with ZAPI - 1001092456 Power Module Only)
* Market Default Setting
Configuration
Digit
Setting
Description
1
(Model #)
1
2
3
4
5
1930ES
2030ES
2630ES
2646ES
3246ES
2
(Market *)
0
1
2
3
4
5
ANSI USA
ANSI EXPORT
CSA
CE
AUSTRALIA
JAPAN
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
(Drive Cutout)
0
1
NO - Drive and lift up not prevented while elevated.
YES - Drive and lift up prevented while elevated.
0
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
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 motion.
2
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
5
(Charger Interlock)
1
0
6
(Ground Alarm)
1
2
7
(LSS Load Sensing
System)
0
1
2
8
(Battery)
0
1
FLOODED - Batteries are conventional lead-acid type.
AGM - Batteries are absorbed glass mat type.
9
(Footswitch)
0
1
NO - Vehicle is not fitted with a footswitch
YES - Vehicle is fitted with a footswitch
0
1
2
3
4
5
(Set to your applicable ES Model
1 through 5)
0 - (ANSI USA)
(Set to your applicable market)
1
1
1
0
1
1
0
0
0
0
2
2
0
2
2
1
0
1
1
1
0
0
1
0
0
0
0
0
1001115626-C
3121166
– JLG Lift –
5-31
SECTION 5 - JLG CONTROL SYSTEM
NOTES:
5-32
– JLG Lift–
3121166
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). This section should only be used for machines equipped with a MDI and SEVCON Power Module-(ground
board software version P1.13 or higher) or ZAPI Power Module-(ground board software version P1.0 or higher). For
more information on the MDI or any sensors or indicators, refer to the appropriate section for the machine area.
Many of the checks below require configuring and using a multimeter. Refer to Section 7: General Electrical Information & Schematics for multimeter basics. DTCs are sorted in groups by the first two digits, which is also the system
distress lamp flash code. 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.
6.2 DTC INDEX
Error
Error (Displayed on MDI) ................................................................................................................................................................................. 6-3
0-0
001 EVERYTHING OK ......................................................................................................................................................................................... 6-3
002 GROUND MODE OK .................................................................................................................................................................................. 6-3
003 ALARM SOUNDING - TILTED & ABOVE ELEVATION ....................................................................................................................... 6-3
004 DRIVING AT CUTBACK - ABOVE ELEVATION .................................................................................................................................... 6-3
005 DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED ...................................................................................................................... 6-4
006 LIFT UP PREVENTED - MAX HEIGHT ZONE A .................................................................................................................................... 6-4
007 DRIVING AT CUTBACK - POTHOLE STILL ENGAGED ...................................................................................................................... 6-4
008 FUNCTIONS LOCKED OUT - SYSTEM POWERED DOWN .............................................................................................................. 6-4
009 DRIVE PREVENTED - ELEVATED ABOVE DRIVE CUTOUT HEIGHT .............................................................................................. 6-4
2-1
211 POWER CYCLE ............................................................................................................................................................................................. 6-4
212 KEYSWITCH FAULTY ................................................................................................................................................................................. 6-5
2-2
221 FUNCTION PROBLEM - HORN PERMANENTLY SELECTED ........................................................................................................... 6-5
222 FUNCTION PROBLEM - INDOOR / OUTDOOR PERMANENTLY SELECTED ............................................................................. 6-5
223 FUNCTION PROBLEM - DRIVE & LIFT ACTIVE TOGETHER ............................................................................................................ 6-5
224 FUNCTION PROBLEM - STEER LEFT PERMANENTLY SELECTED ................................................................................................. 6-5
225 FUNCTION PROBLEM - STEER RIGHT PERMANENTLY SELECTED .............................................................................................. 6-5
226 ACCELERATOR FAULTY - WIPER OUT OF RANGE ........................................................................................................................... 6-5
227 STEER SWITCHES FAULTY ....................................................................................................................................................................... 6-6
228 FUNCTION LOCKED OUT - ACCELERATOR NOT CENTERED ....................................................................................................... 6-6
229 FUNCTION PROBLEM - TRIGGER PERMANENTLY CLOSED .......................................................................................................... 6-6
2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL ...................................................................................................................... 6-6
2232 FUNCTION PROBLEM - DRIVE & LIFT BOTH OPEN ........................................................................................................................ 6-6
2-3
231 FUNCTION PROBLEM - LIFT PERMANENTLY SELECTED ............................................................................................................... 6-6
232 GROUND LIFT UP / DOWN ACTIVE TOGETHER ............................................................................................................................... 6-6
233 FUNCTION PROBLEM - BRAKE RELEASE PERMANENTLY SELECTED ........................................................................................ 6-6
2-5
251 ELEV ANGLE SENSOR FAULTY - VOLTAGE OUT OF RANGE ........................................................................................................ 6-7
252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED ...................................................................................................................... 6-7
253 DRIVE PREVENTED - CHARGER CONNECTED ................................................................................................................................... 6-7
254 DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED ............................................................................................................... 6-7
255 PLATFORM OVERLOADED ...................................................................................................................................................................... 6-7
256 DRIVE PREVENTED - POTHOLE NOT ENGAGED .............................................................................................................................. 6-7
257 ELEV PROX PERMANENTLY CLOSED - CHECK PROX AND ANGLE ADJUSTMENT ............................................................... 6-8
258 DRIVE & LIFT PREVENTED - BRAKES ELECTRICALLY RELEASED FOR TOWING ..................................................................... 6-8
259 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS ................................................................................................... 6-8
3121166
– JLG Lift –
6-1
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2510 DRIVE PREVENTED - BRAKES NOT RELEASING .............................................................................................................................. 6-8
2511 ELEV ANGLE SENSOR FAULTY - NOT MOUNTED .......................................................................................................................... 6-8
2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE ......................................................................................................................... 6-8
3-1
311 OPEN CIRCUIT LINE CONTACTOR ......................................................................................................................................................... 6-8
312 CONTACTOR DRIVER PERMANENTLY OFF ........................................................................................................................................ 6-8
314 AUXILIARY RELAY - OPEN CIRCUIT ...................................................................................................................................................... 6-8
3-2
321 LINE CONTACTOR MISWIRED ON OR WELDED ............................................................................................................................... 6-9
322 CONTACTOR DRIVER PERMANENTLY ON ......................................................................................................................................... 6-9
3-3
331 BRAKE SHORT TO BATTERY .................................................................................................................................................................... 6-9
332 BRAKE OPEN CIRCUIT ............................................................................................................................................................................... 6-9
333 LIFT UP SHORT TO BATTERY .................................................................................................................................................................. 6-9
334 LIFT UP OPEN CIRCUIT ............................................................................................................................................................................. 6-9
335 LIFT DN SHORT TO BATTERY .................................................................................................................................................................. 6-9
336 LIFT DN OPEN CIRCUIT ...........................................................................................................................................................................6-10
337 STEER LEFT SHORT TO BATTERY .........................................................................................................................................................6-10
338 STEER LEFT OPEN CIRCUIT ....................................................................................................................................................................6-10
339 STEER RIGHT SHORT TO BATTERY ......................................................................................................................................................6-10
3310 STEER RIGHT OPEN CIRCUIT ..............................................................................................................................................................6-10
3311 GROUND ALARM SHORT TO BATTERY ...........................................................................................................................................6-10
3312 LEFT BRAKE SHORT TO BATTERY .....................................................................................................................................................6-10
3313 RIGHT BRAKE SHORT TO BATTERY ..................................................................................................................................................6-10
3314 LEFT BRAKE OPEN CIRCUIT ................................................................................................................................................................6-11
3315 RIGHT BRAKE OPEN CIRCUIT .............................................................................................................................................................6-11
33297 LEFT BRAKE - SHORT TO GROUND................................................................................................................................................6-11
33298 STEER LEFT VALVE - SHORT TO GROUND...................................................................................................................................6-11
33299 LINE CONTACTOR COIL - SHORT TO BATTERY .........................................................................................................................6-11
33302 NEGATIVE SUPPLY - SHORT TO BATTERY ...................................................................................................................................6-11
33303 NEGATIVE SUPPLY - SHORT TO GROUND ..................................................................................................................................6-11
33304 RIGHT BRAKE - SHORT TO GROUND.............................................................................................................................................6-11
33305 STEER RIGHT VALVE - SHORT TO GROUND................................................................................................................................6-11
33406 LIFT UP VALVE - SHORT TO GROUND ..........................................................................................................................................6-11
33407 LIFT DN VALVE - SHORT TO GROUND..........................................................................................................................................6-11
4-2
421 POWER MODULE TOO HOT - PLEASE WAIT ....................................................................................................................................6-12
422 DRIVING AT CUTBACK - POWER MODULE CURRENT LIMIT ......................................................................................................6-12
423 LIFT UP AT CUTBACK - POWER MODULE CURRENT LIMIT .........................................................................................................6-12
4-4
441 BATTERY VOLTAGE TOO LOW - SYSTEM SHUTDOWN ................................................................................................................6-12
442 BATTERY VOLTAGE TOO HIGH - SYSTEM SHUTDOWN ...............................................................................................................6-12
443 LSS BATTERY VOLTAGE TOO HIGH ....................................................................................................................................................6-12
444 LSS BATTERY VOLTAGE TOO LOW .....................................................................................................................................................6-12
446 LOGIC SUPPLY VOLTAGE OUT OF RANGE.......................................................................................................................................6-12
4421 LOGIC SUPPLY VOLTAGE OUT OF RANGE .....................................................................................................................................6-12
4422 LOGIC SUPPLY VOLTAGE OUT OF RANGE .....................................................................................................................................6-13
6-6
661 CANBUS FAILURE - POWER MODULE ...............................................................................................................................................6-13
662 CANBUS FAILURE - PLATFORM MODULE ........................................................................................................................................6-14
663 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE ...............................................................................................................6-15
664 CANBUS FAILURE - ACCESSORY MODULE ......................................................................................................................................6-15
6635 CANBUS FAILURE - CHASSIS TILT SENSOR ....................................................................................................................................6-15
6-7
671 ACCESSORY FAULT ..................................................................................................................................................................................6-15
7-7
771
772
773
774
775
776
6-2
OPEN CIRCUIT DRIVE MOTOR WIRING .............................................................................................................................................7-15
STALLED TRACTION MOTOR OR POWER WIRING ERROR..........................................................................................................7-16
CAPACITOR BANK FAULT - CHECK POWER CIRCUITS .................................................................................................................7-16
SHORT CIRCUIT FIELD WIRING ............................................................................................................................................................7-16
OPEN CIRCUIT FIELD WIRING...............................................................................................................................................................7-16
STALLED PUMP MOTOR OR POWER WIRING ERROR...................................................................................................................7-16
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
777 OPEN CIRCUIT PUMP MOTOR WIRING............................................................................................................................................. 7-16
778 TRACTION T HIGH - CHECK POWER CIRCUITS............................................................................................................................... 7-16
779 TRACTION T LOW - CHECK POWER CIRCUITS................................................................................................................................ 7-16
7710 PUMP P HIGH - CHECK POWER CIRCUITS..................................................................................................................................... 7-16
7711 PUMP P LOW - CHECK POWER CIRCUITS...................................................................................................................................... 7-16
7741 ARMATURE BRAKING CURRENT TOO HIGH ................................................................................................................................. 7-16
7742 FIELD VOLTAGE IMPROPER ............................................................................................................................................................... 7-17
8-1
811 TILT SENSOR NOT CALIBRATED .......................................................................................................................................................... 6-17
812 NO DATA FROM TILT SENSOR - NOT CONNECTED OR FAULTY .............................................................................................. 6-17
8-2
821 LSS CELL #1 ERROR ................................................................................................................................................................................. 6-17
822 LSS CELL #2 ERROR ................................................................................................................................................................................. 6-17
823 LSS CELL #3 ERROR ................................................................................................................................................................................. 6-17
824 LSS CELL #4 ERROR ................................................................................................................................................................................. 6-17
825 LSS HAS NOT BEEN CALIBRATED ....................................................................................................................................................... 6-17
9-9
991 LSS WATCHDOG RESET ......................................................................................................................................................................... 6-17
992 LSS EEPROM ERROR ................................................................................................................................................................................ 6-17
993 LSS INTERNAL ERROR - PIN EXCITATION ......................................................................................................................................... 6-17
994 LSS INTERNAL ERROR - DRDY MISSING FROM A/D ..................................................................................................................... 6-17
995 POWER MODULE FAILURE - PERSONALITY RANGE ERROR ...................................................................................................... 6-17
996 POWER MODULE FAILURE - INTERNAL ERROR ............................................................................................................................. 6-18
997 POWER MODULE FAILURE - CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT ...................................................... 6-18
998 EEPROM FAILURE - CHECK ALL SETTINGS ...................................................................................................................................... 6-18
999 FUNCTION LOCKED OUT - POWER MODULE SOFTWARE VERSION IMPROPER ................................................................ 6-18
9910 FUNCTION LOCKED OUT - PLATFORM MODULE SOFTWARE VERSION IMPROPER ......................................................6-18
9911 FUNCTION LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER ...................................................................... 6-18
9912 POWER MODULE FAILURE - SYSTEM MONITOR ......................................................................................................................... 6-18
9917 HIGH RESOLUTION ANALOG TO DIGITAL FAILURE - INTERUPT LOST................................................................................. 6-18
9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED .................................................................................................... 6-18
9950 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9951 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9952 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9953 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9954 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9955 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-19
9956 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9957 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9958 POWER MODULE FAILURE - INTERNAL ERROR............................................................................................................................ 9-20
9960 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9962 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9963 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9964 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9969 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9970 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
9971 POWER MODULE FAILURE - INTERNAL ERROR........................................................................................................................... 9-20
99143 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-20
99144 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-20
99145 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-21
99146 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-21
99147 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-21
99148 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-21
99149 POWER MODULE FAILURE - INTERNAL ERROR ........................................................................................................................ 9-21
3121166
– JLG Lift –
6-3
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6.3 DTC CHECK TABLES
0-0 Help Comments
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
Error (Displayed on MDI) The MDI is powered, but cannot • Check the MDI connector.
communicate with the control • Check the diagnostic connector.
• Check continuity between MDI connector socket 6
system.
and ground board connector socket J1-4.
• Check continuity between MDI connector socket 4
and ground board connector socket J1-3.
• Check that the ground board software version is P1.13
or higher.
001 EVERYTHING OK
The normal help message in
platform mode. Displays on the
analyzer only.
002 GROUND MODE OK
The normal help message in
ground mode. Displays on the
analyzer only.
Control system senses that the • Check that the machine is tilted. If so, lower the plat003 ALARM SOUNDING form and reposition the machine to a level surface.
TILTED & ABOVE ELEVA- platform is elevated and the
vehicle is tilted, and the machine • Fully stow the platform.
TION
• The tilt sensor is part of the ground control box. Check
not configured to cutout.
that the ground control box is secured to the
machine.
• Check that the pothole protection switches are
securely mounted.
• Check that the elevation angle sensor is securely
mounted.
• Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to CE, ensure ANALYZER -> MACHINE
SETUP -> TILT CUTOUT parameter is set as desired.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Check pothole protection switch adjustment.
• Calibrate the elevation sensor, see Section 5.5.
• Calibrate the tilt sensor, see Section 5.2.
004 DRIVING AT CUTBACK ABOVE ELEVATION
6-4
The platform is elevated and the • Fully stow the platform.
machine is driving.
• Check that the elevation angle sensor is securely
mounted.
• Check that the pothole protection switches are
securely mounted.
• Check the lift/drive switch.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Check function of elevation angle sensor. ANALYZER > DIAGNOSTICS -> ELEV SENSOR -> ZEROED should
be about 0V when stowed and about 0.15V at cutback.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
0-0 Help Comments
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
005 DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED
Driving is not possible since the • Check that the machine is tilted. If so, lower the platform and reposition the machine to a level surface.
platform is elevated and the
• Fully stow the platform.
chassis is not level.
• The tilt sensor is part of the ground control box. Check
that the ground control box is secured to the
machine.
• Check that the pothole protection switches are
securely mounted.
• Check that the elevation angle sensor is securely
mounted.
• Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to CE, ensure ANALYZER -> MACHINE
SETUP -> TILT CUTOUT parameter is set as desired.
• Check pothole protection switch adjustment.
• Backprobing ground board J1-18 should show about
0 volts.
• Backprobing ground board J1-10 should show about
0 volts.
• Calibrate the elevation sensor, see Section 5.5.
• Calibrate the tilt sensor, see Section 5.2.
006 LIFT UP PREVENTED MAX HEIGHT ZONE A
• Check that the zone is set appropriately for the platThe vehicle has reached the
maximum height and further lift form load.
up motion is not possible. Appli- • Check that the platform height is at the rated maximum height specification (20’ for 2630 or 26’ for the
cable to 2630ES or 3246ES.
3246).
• Check that the elevation angle sensor is securely
mounted.
• If there are any elevation sensor faults (DTC 251, 252,
2511, or 2512), troubleshoot those first.
• Check that ANALYZER -> MACHINE SETUP -> MODEL
setting is correct.
• Check that ANALYZER -> MACHINE SETUP -> MARKET
setting is correct.
• Check ANALYZER -> DIAGNOSTICS -> ELEV SENSOR ->
ZEROED is about 1.53V for the 3246 or about 1.22V for
the 2630 when at full height. If not, repair or replace
the elevation angle sensor.
007 DRIVING AT CUTBACK POTHOLE STILL
ENGAGED
• Check for obstructions around the pot-hole protecWhile stowed, drive speed is
tion mechanisms.
reduced since the control system detected that the pot-hole • Check that the PHP switches are securely mounted.
protection mechanism failed to • Check PHP switches wiring from the ground board
and for proper operation. The left PHP input (24V) is
retract.
from J1-9 and its output (24V when deployed) is to J110. The right PHP input (24V) is from J1-17 and its
output (24V when deployed) is to J1-18.
008 FUNCTIONS LOCKED
OUT - SYSTEM POWERED DOWN
• Normal operation should resume after a power cycle.
After 2 hours without activity,
the control system enters a low- • Check batteries charge, condition, etc.
power state to preserve battery
charge.
3121166
– JLG Lift –
6-5
SECTION 6 - DIAGNOSTIC TROUBLE CODES
0-0 Help Comments
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
009 DRIVE PREVENTED - ELE- The platform is elevated above
the calibrated cutout height.
VATED ABOVE DRIVE
CUTOUT HEIGHT
• Check that the elevation angle sensor is securely
mounted.
• Check the ANALYZER -> MACHINE SETUP -> MARKET
configuration.
• If MARKET is set to Japan, ensure ANALYZER ->
MACHINE SETUP -> DRIVE CUTOUT parameter is set as
desired.
2-1 Power-Up
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
Normal operation. No check necessary.
211 POWER CYCLE
This help message is issued at
each power cycle. Displays on
the analyzer only.
212 KEYSWITCH FAULTY
• Check key switch function.
Both platform and ground
modes are selected simultane- • Backprobe J2-3 with the keyswitch in the ground
ously. Defaults to ground mode. position. Voltage should be under 6V. Otherwise, keyswitch or wiring faulty.
• Backprobe J2-4 with the keyswitch in the platform
position. Voltage should be under 6V. Otherwise, keyswitch or wiring faulty.
• Check key switch wiring to ground board J2-3 and J24 and to emergency stop switch.
• Replace ground board.
2-2 Platform Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
221 FUNCTION PROBLEM HORN PERMANENTLY
SELECTED
The horn switch was closed dur- • Check if the horn switch is damaged, obstructed or
ing power-up in platform mode. jammed.
• Disconnect the horn switch ribbon cable on the platform board. If DTC still present, replace the platform
board. If DTC 221 is no longer present, replace the
horn switch or platform board.
222 FUNCTION PROBLEM INDOOR / OUTDOOR
PERMANENTLY
SELECTED
The indoor / outdoor (zone A / • Check if the indoor/outdoor (zone A / zone B) capacity
switch is damaged, obstructed or jammed.
zone B) switch was closed during power-up in platform mode. • Replace platform board.
223 FUNCTION PROBLEM DRIVE & LIFT ACTIVE
TOGETHER
The drive and lift inputs are
closed simultaneously in platform mode.
6-6
• 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 platform board. Its input (0V) is from platform board terminal J1-11. "Lift" selection output (0V when selected)
is to platform board terminal J1-9. "Drive" selection
output (0V when closed) is to platform board terminal
J1-10.
• Replace platform board.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-2 Platform Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
224 FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED
The steer left switch was closed • Check if the steer left switch is obstructed or jammed.
• Check steer left switch and its wiring. The steer left
during power-up in platform
switch input (24V) is from platform board terminal J1mode.
1, and its output (24V when closed) is to platform
board terminal J1-15.
• Replace platform board.
225 FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED
• Check if the steer right switch is obstructed or
The steer right switch was
jammed.
closed during power-up in plat• Check steer right switch and its wiring to the platform
form mode.
board. The steer right switch input (24V) is from platform board terminal J1-1, and its output (24V when
closed) is to platform board terminal J1-16.
• Replace platform board.
226 ACCELERATOR FAULTY - The joystick signal is outside the • Center joystick and check to see if a power cycle will
WIPER OUT OF RANGE acceptable range of 0.50V - 4.5V, clear DTC.
• Check the joystick signal and its wiring. The joystick
or is unstable.
input (5V) is from the platform board terminal J1-5, its
output (2.5V with joystick at center) to the platform
board terminal J1-6, and its ground (0V) is to the platform board terminal J1-7. Observe output signal while
slowly operating joystick.
• Replace platform board.
• Check if the steer switches are damaged, obstructed
or jammed.
• Check the steer switch signals and wiring to the platform board. The steer switch input (24V) is from platform board terminal J1-1, outputs (24V when closed)
are to platform board terminals J1-15 and J1-16 (left
and right).
• Replace platform board.
227 STEER SWITCHES
FAULTY
The steer left and steer right
inputs were closed simultaneously.
228 FUNCTION LOCKED
OUT - ACCELERATOR
NOT CENTERED
The joystick was not centered at • Release joystick and allow to center.
power-up.
• Check if the joystick is obstructed or jammed.
• Check the joystick signal and its wiring. The joystick
input (5V) is from the platform board terminal J1-5, its
output (2.5V with joystick at center) to the platform
board terminal J1-6, and its ground (0V) is to the platform board terminal J1-7. Observe output signal while
slowly operating joystick.
• Replace platform board.
229 FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED
The trigger switch was closed
during power-up in platform
mode.
2210 TRIGGER CLOSED TOO
LONG WHILE IN NEUTRAL
The trigger switch was closed for • Check if the trigger switch is obstructed or jammed.
• Check the trigger switch signal and wiring to the platmore than five seconds while
form board. The trigger input (24V) is from platform
the joystick was centered.
board terminal J1-1, and its output (24V when closed)
is to platform board terminal J1-8.
• Replace platform board.
3121166
• Check if the trigger switch is obstructed or jammed.
• Check the trigger switch signal and wiring to the platform board. The trigger input (24V) is from platform
board terminal J1-1, and its output (24V when closed)
is to platform board terminal J1-8.
• Replace platform board.
– JLG Lift –
6-7
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-2 Platform Controls
DTC
FAULT MESSAGE
2232 FUNCTION PROBLEM DRIVE & LIFT BOTH
OPEN
DESCRIPTION
CHECK
The drive and lift inputs are both • Check if either function is active, if Yes;
de-energized in Platform Mode. • Repair the wiring or switch to clear the message.
• ZAPI - HEALTH (Status LED) - ON
2-3 Ground Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
231 FUNCTION PROBLEM LIFT PERMANENTLY
SELECTED
The ground control box lift
switch was closed up or down,
during power-up in ground
mode.
• Check if the lift switch is obstructed or jammed.
• Check the lift switch signal and wiring to the ground
board. The lift switch input (24V) is from ground
board terminal J2-4, and its outputs (24V when
closed) are to ground board terminals J2-6, J2-7 (up
and down).
• Replace ground board.
232 GROUND LIFT UP /
DOWN ACTIVE
TOGETHER
The lift up / down inputs are
closed simultaneously.
• Check if the lift switch is obstructed or jammed.
• Check the lift switch signal and wiring to the ground
board. The lift switch input (24V) is from ground
board terminal J2-4, and its outputs (24V when
closed) are to ground board terminals J2-6 (up), J2-7
(down).
• Replace ground board.
233 FUNCTION PROBLEM - The manual brake release switch • Check if the brake release switch is obstructed or
jammed.
BRAKE RELEASE PERMA- was closed during power-up.
• Check the brake release switch signal and wiring to
NENTLY SELECTED
the ground board. The brake release switch input
(24V) is from ground board terminal J1-19, and its output (24V when closed) is to ground board terminal J120.
• If the brakes are released, the machine can be pushed
or moved without drive motor power.
• Replace ground board.
2-5 Function Prevented
DTC
FAULT MESSAGE
251 ELEV ANGLE SENSOR
FAULTY - VOLTAGE OUT
OF RANGE
6-8
DESCRIPTION
CHECK
The elevation angle sensor
input voltage is outside the
acceptable range of 0.10V 4.50V.
• Check that the platform elevation sensor is securely
mounted and undamaged.
• Check voltage as displayed on ANALYZER -> DIAGNOSTICS -> ELEV SENSOR -> ANGLE SNSR. Backprobe
ground board J1-15. If this voltage disagrees with the
ANGLE SNSR voltage, replace the ground board.
• Backprobe the elevation angle sensor connector. Terminal A should be 4.7V, terminal C should be 0V.
• Check the elevation angle sensor signal and wiring to
the ground board. The elevation angle sensor input is
from ground board terminal J1-14 (4.7V), its output
(0.1 - 1.2V when stowed) is to ground board terminal
J1-15, and its ground is to ground board terminal J116.
• Replace the ground board.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-5 Function Prevented
DTC
FAULT MESSAGE
252 ELEV ANGLE SENSOR
HAS NOT BEEN CALIBRATED
DESCRIPTION
CHECK
The elevation angle sensor has
not been calibrated.
• Calibrate the elevation angle sensor to clear fault. See
Section 5.5.
253 DRIVE PREVENTED Driving is not possible while the • Check if the charger is connected to off board power
CHARGER CONNECTED vehicle is charging.
source and disconnect if desired.
• 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 J1-29, where 0VDC
indicates charging in process.
254 DRIVE & LIFT UP PREVENTED - CHARGER
CONNECTED
Drive or lift is not possible while • Check if the charger is connected to off board power
source and disconnect if desired.
the vehicle is charging AND is
• Check ANALYZER -> MACHINE SETUP -> CHARGER
configured to prevent all
INTERLOC is set as desired. (Must be in ACCESS LEVEL
motion.
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 J1-29, where 0VDC
indicates charging in process.
255 PLATFORM OVERLOADED
The load sensing system mea- • Remove excess weight from the platform.
sured platform load is excessive. • 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 Section 2.3: Troubleshooting in the LSS manual, 3124288.
256 DRIVE PREVENTED POTHOLE NOT
ENGAGED
Driving is not possible while ele- • Check for obstructions or mechanical problems
vated since the pot-hole protec- around the pot-hole protection mechanisms.
• Check that the PHP switches are securely mounted.
tion system failed to deploy.
• Adjust pot-hole protection switches.
• Check the pothole protection switches signal and wiring to the ground board. The left pot-hole protection
switch input (24V) is from ground board terminal J1-9,
and its output (24V when deployed) is to ground
board terminal J1-10. The right pot-hole protection
switch input (24V) is from ground board terminal J117, and its output (24V when deployed) is to ground
board terminal J1-18.
257 ELEV PROX PERMANENTLY CLOSED CHECK PROX AND
ANGLE ADJUSTMENT
The elevation proximity switch • Verify that an elevation proximity switch is present on
the machine. If not, ensure ANALYZER -> MACHINE
shows the platform to be
SETUP -> ELEV PROX is set to NOT INSTALLED. If the
stowed, while the elevation
angle sensor shows the platform switch is present, set ELEV PROX to INSTALLED and
check switch continuity. The switch should close
to be raised. The elevation proximity switch is only found on cer- when placed in close proximity to ferrous metal.
tain older lifts. This switch is not
used on current machines so
this DTC should not occur.
3121166
– JLG Lift –
6-9
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-5 Function Prevented
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
258 DRIVE & LIFT PREVENTED - BRAKES ELECTRICALLY RELEASED
FOR TOWING
• Push manual brake release switch again or cycle
Manual brake release mode is
power to clear manual brake release mode.
activated with the switch in the
• Check if the brake release switch is obstructed or
battery box near the ground
jammed.
control box. Drive or lift is not
• Check the brake release switch signal and wiring to
possible.
the ground board. The switch input (24V) is from
ground board terminal J1-19, and its output (24V
when closed) is to ground board terminal J1-20.
• Replace ground board.
259 MODEL CHANGED HYDRAULICS SUSPENDED - CYCLE EMS
The model selection has been
changed.
• Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER.
• Replace ground board.
2510 DRIVE PREVENTED While driving on a level surface, • Ensure vehicle is not stuck on something preventing
BRAKES NOT RELEASING armature current was > 150A for movement.
five seconds. Brakes assumed to • Check / repair drive motor wiring, brakes or mechanical issues.
not be releasing properly.
2511 ELEV ANGLE SENSOR
The input voltage from the ele- • Check that the elevation angle sensor is securely
mounted.
FAULTY - NOT MOUNTED vation angle sensor indicates
the elevation angle sensor is not • Check that the elevation angle sensor mechanisms
are intact.
mounted.
• Replace elevation angle sensor.
2512 ELEV ANGLE SENSOR
NOT DETECTING
CHANGE
The input voltage from the ele- • Check that the elevation angle sensor is securely
mounted.
vation angle sensor did not
change while vehicle was lifting • Check elevation angle sensor is not jammed or
obstructed.
up.
• If there are any other elevation angle sensor, joystick,
or lift up faults, troubleshoot them before continuing.
• Replace elevation angle sensor.
3-1 Line Contactor Open Circuit
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
311 OPEN CIRCUIT LINE
CONTACTOR
The power modules line contac- • Check contactor main contact wiring to battery (+)
terminal and power controller terminal B+.
tor did not close when ener• Contactor solenoid resistance should measure about
gized. Drive, steer and lift up
52 Ohms.
prevented.
• Check contactor solenoid wiring to power module 12
position connector terminal 8 and ground board terminal J1-19.
• Check that power module 12 position connector terminal 8 goes from 24V to near 0V while contactor
should be closing. If this happens replace contactor.
• Replace the line contactor.
312 CONTACTOR DRIVER
PERMANENTLY OFF
The power modules line contac- • Check continuity between contactor connector pin 1
and ground board socket J1-19.
tor drive circuitry failed to ener• Contactor solenoid resistance should measure about
gize when requested. Drive,
52 Ohms.
steer and lift up prevented.
• Check continuity between contactor connector pin 2
and power module connector socket 8.
• Replace power module.
6-10
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-1 Line Contactor Open Circuit
DTC
314
FAULT MESSAGE
AUXILIARY RELAY - OPEN
CIRCUIT
DESCRIPTION
CHECK
The auxiliary relay did not close • Check the auxiliary relay coil and associated wiring to
when energized.
J1-13 and J1-32.
• No voltage on J1-28.
• HEALTH (Status LED) - ON
3-2 Line Contactor Short Circuit
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
321 LINE CONTACTOR
MISWIRED ON OR
WELDED
Battery voltage was present at • Check wiring of contactor.
the power module B+ terminal • Check resistance between the studs of the contactor
while disconnected from the machine.
at power up. Drive, steer and lift
• Check contactor main contact wiring to battery (+)
up prevented.
terminal and power module terminal B+.
• Check continuity between contactor connector pin 1
and ground board socket J1-19.
• Check continuity between contactor connector pin 2
and power module 12 position connector terminal 8.
• Measure voltage between power model B+ and B- terminals. If 24V is present, replace line contactor.
• Replace power module.
322 CONTACTOR DRIVER
PERMANENTLY ON
The power modules line contac- • Check continuity between contactor connector pin 1
and ground board socket J1-19.
tor drive circuitry failed to deenergize when requested. Drive, • Check continuity between contactor connector pin 2
and power module 12 position connector terminal 8.
steer and lift up prevented.
• Replace power module.
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is
set to NOT INSTALLED.
331 BRAKE SHORT TO BATTERY
The ground board detected
voltage while the brake solenoid was commanded off.
332 BRAKE OPEN CIRCUIT
• Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is
The ground board did not
set to NOT INSTALLED.
detect current flow to the brake
solenoid during normal operation.
333 LIFT UP SHORT TO BATTERY
The ground board detected
voltage while the lift up solenoid was commanded off at
power up.
334 LIFT UP OPEN CIRCUIT
• Check for continuity through this circuit. The lift up
The ground board did not
solenoid resistance should measure about 30 Ohms.
detect current flow to the lift up
The lift up solenoid is powered with 24V from ground
solenoid during power up.
board J1-25, and its ground is to ground board J1-30,
37.
• Inspect the wiring for physical damage.
• Replace ground board.
3121166
• Check for continuity through this circuit. The lift up
solenoid resistance should measure about 30 Ohms.
The lift up solenoid is powered with 24V from ground
board J1-25, and its ground is to ground board J1-30,
37.
• Inspect the wiring for physical damage.
• Replace ground board.
– JLG Lift –
6-11
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• Check ANALYZER -> MACHINE SETUP -> ELEV PROX is
335 LIFT DN SHORT TO BAT- The ground board detected
set to NOT INSTALLED
TERY
voltage while the lift down sole• Check for continuity through this circuit. The lift down
noid was commanded off.
solenoid resistance should measure about 20 Ohms.
The lift down solenoid is powered (PWM) by ground
board J1-26, and its ground is to ground board J1-27.
• Inspect the wiring for physical damage.
• Replace ground board.
• 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 J1-26, and its ground is to ground board J1-27.
• Inspect the wiring for physical damage.
• Replace ground board.
336 LIFT DN OPEN CIRCUIT
The ground board did not
detect current flow to the lift
down solenoid during normal
operation.
337 STEER LEFT SHORT TO
BATTERY
• Check for continuity through this circuit. Steer left
The ground board detected
solenoid resistance should measure about 30 Ohms.
voltage while the steer left soleThe steer left solenoid is powered with 24V from
noid was commanded off at
ground board J1-21, and its ground is to ground
power up.
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
338 STEER LEFT OPEN CIRCUIT
The ground board did not
detect current flow to the steer
left solenoid during normal
operation.
• 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 J1-21, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
339 STEER RIGHT SHORT TO The ground board detected
BATTERY
voltage while the steer right
solenoid was commanded off.
• Check for continuity through this circuit. Steer right
solenoid resistance should measure about 30 Ohms.
The steer right solenoid is powered with 24V from
ground board J1-22, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3310 STEER RIGHT OPEN CIR- The ground board did not
CUIT
detect current flow to the steer
right solenoid during normal
operation.
• Check for continuity through this circuit. Steer right
solenoid resistance should measure about 30 Ohms.
The steer right solenoid is powered with 24V from
ground board J1-22, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3311 GROUND ALARM
SHORT TO BATTERY
6-12
• Check for continuity through this circuit. The ground
The ground board detected
alarm solenoid is powered with 24V from ground
voltage while the ground alarm
board J1-19, its PWM signal is from ground board J1was commanded off.
28, and its ground is to ground board J1-30, 37. There
should be about 1500 Ohms between ground alarm
connector pin 1 and pin 3.
• Inspect the wiring for physical damage.
• Replace ground board.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
3312 LEFT BRAKE SHORT TO
BATTERY
DESCRIPTION
CHECK
• Check for continuity through this circuit. The left
The ground board detected
brake is powered with 24V from ground board J1-23,
voltage while the left brake was
and its ground is to ground board J1-30, 37. Brake
commanded off.
solenoid resistance should measure about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
• Check for continuity through this circuit. Brake sole3313 RIGHT BRAKE SHORT TO Voltage was detected on the
noid resistance should measure about 20 Ohms. The
BATTERY
right brake solenoid when the
right brake is powered with 24V from ground board
ground board output was comJ1-24, and its ground is to ground board J1-30, 37.
manded off during power-up.
• Inspect the wiring for physical damage.
• Replace ground board.
3314 LEFT BRAKE OPEN CIRCUIT
• Check for continuity through this circuit. The left
Current flow to the left brake
brake is powered with 24V from ground board J1-23,
solenoid was not detected durand its ground is to ground board J1-30, 37. Brake
ing normal left brake operation.
solenoid resistance should measure about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
• Check for continuity through this circuit. Brake sole3315 RIGHT BRAKE OPEN CIR- The ground board did not
noid resistance should measure about 20 Ohms. The
CUIT
detect current flow to the right
right brake is powered with 24V from ground board
brake during normal operation.
J1-24, and its ground is to ground board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
33297 LEFT BRAKE - SHORT TO Drive and Steer Prevented
GROUND
• Excessive current flow to the Left Brake Solenoid was
detected (J1-34 NLB).
• ZAPI - HEALTH (Status LED) - ON
33298 STEER LEFT VALVE SHORT TO GROUND
• Excessive current flow to the steer left solenoid
detected (J2-9 NLV).
• ZAPI - HEALTH (Status LED) - ON
Drive, Steer and Lift Up Prevented
33299 LINE CONTACTOR COIL - Drive, Lift and Steer Prevented
SHORT TO BATTERY
• Voltage from an external source was detected on the
Negative Main Line Contactor.
• ZAPI - HEALTH (Status LED) - ON
33302 NEGATIVE SUPPLY SHORT TO BATTERY
Drive, Lift, and Steer Prevented
• At power-up, the system module detected an external
short on J1-12, J1-17, J1-23, J2-14 or J2-15. Normally
these pins are grounded by the System Module. All
functions are prevented to protect the control system.
• ZAPI - HEALTH (Status LED) - ON
33303 NEGATIVE SUPPLY SHORT TO GROUND
Drive, Lift and Steer Prevented
• At power-up, the System Module detected an external
short on J1-12, J1-17, J2-14 or J2-15. Normally these
pins are grounded by the System Module. Since the
external ground may compromise integrity, all functions will be prevented.
• ZAPI - HEALTH (Status LED) - ON
33304 RIGHT BRAKE - SHORT
TO GROUND
Drive, and Steer Prevented
• Excessive current flow to the Right Brake solenoid was
detected (J1-33 NRB).
• ZAPI - HEALTH (Status LED) - ON
3121166
– JLG Lift –
6-13
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
33305 STEER RIGHT VALVE SHORT TO GROUND
Drive, Steer, and Lift Up Prevented
• Excessive current flow to the Steer Right Solenoid was
detected (J2-18 NRV).
• ZAPI - HEALTH (Status LED) - ON
33406 LiFT UP VALVE - SHORT
TO GROUND
Drive, Steer, and Lift Up Prevented
• Excessive current flow to the Lift Up Solenlid was
detected at (J2-2 PDV or J2-16 NDV).
• ZAPI - HEALTH (Status LED) - ON
33407 LIFT DN VALVE - SHORT Lift Up and Down Prevented
TO GROUND
• Excessive current flow to the Lift Down Solenoid was
detected (J2-16 NDV).
• ZAPI - HEALTH (Status LED) - ON
4-2 Thermal Limit (SOA)
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
421 POWER MODULE TOO
HOT - PLEASE WAIT
The power module has reached • Power down and allow to cool.
thermal cutout.
• Do not operate in ambients over 140° F (60° C).
• 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.
422 DRIVING AT CUTBACK POWER MODULE CURRENT LIMIT
The drive portion of the power
module has reached thermal
limit.
423 LIFT UP AT CUTBACK POWER MODULE CURRENT LIMIT
The lift up portion of the power • Check for jammed or obstructed arm stack or pivot
bushing.
module has reached thermal
• Check for excessively high current consumption in the
limit.
pump, ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP
CUR over 130 Amps with an empty deck.
• Refer to Pump Motor Electrical Evaluation in Section
4.8.
• Check for jammed or obstructed drive motors.
• Check for excessively high traction current consumption, ANALYZER -> DIAGNOSTICS -> TRACTION ->
ARM CUR over 120 Amps while driving on the level.
4-4 Battery Supply
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• Recharge batteries or check for damaged batteries.
441 BATTERY VOLTAGE TOO The power module momentarily measured battery voltage • Check battery charger function.
LOW - SYSTEM SHUTunder 14.5V between ground
DOWN
board J1-39 and ground board
J1-40.
• May be due to improper battery charging or incorrect
442 BATTERY VOLTAGE TOO The power module momenvoltage batteries being used.
HIGH - SYSTEM SHUT- tarily measured battery voltage
> 37.0V.
DOWN
443 LSS BATTERY VOLTAGE
TOO HIGH
6-14
The load sensing system mod- • May be due to improper battery charging or incorrect
voltage batteries being used.
ule momentarily measured bat• Refer to Section 2.3: Troubleshooting in the LSS mantery voltage > 34.0V.
ual, 3124288.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
4-4 Battery Supply
DTC
FAULT MESSAGE
444 LSS BATTERY VOLTAGE
TOO LOW
DESCRIPTION
CHECK
The load sensing system mod- • Recharge batteries or check for damaged batteries.
ule momentarily measured bat- • Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
tery voltage < 9V.
446 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
severely discharged batteries, damaged battery, or an
OUT OF RANGE
voltage was measured to be out
improper wire harness connection.
of normal operating range by
• Drive, Steer, and Lift Prevented
the interface PCB (<11V).
• ZAPI - HEALTH (Status LED) - ON
4421 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
severely discharged batteries, damaged battery, or an
OUT OF RANGE
voltage was measured by the
improper wire harness connection.
power PCB to be more than 34V
• Drive, Steer, and Lift Prevented
for 10uS.
• ZAPI - HEALTH (Status LED) - ON
4422 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal,
severely discharged batteries, damaged battery, or an
OUT OF RANGE
voltage was measured by the
improper wire harness connection.
power PCB to be less than 11V
• Drive, Steer, and Lift Prevented
for 10uS.
• ZAPI - HEALTH (Status LED) - ON
6-6 Communication
DTC
FAULT MESSAGE
661 CANBUS FAILURE POWER MODULE
3121166
DESCRIPTION
CHECK
The control system failed to
receive messages from the
power module.
• Check for 24V between power module 12 position
connector terminal 1 and the power module B- terminal. If this is the problem, the line contactor may be
cycling on and off, making a clicking noise when the
machine is powered.
• Disconnect ground board J1 and power module connector. Ground board socket J1-31 to power module
connector socket 10 should have continuity. Ground
board socket J1-32 to power module connector
socket 11 should have continuity.
• Turn on machine in platform mode. If DTC 662 is present, troubleshoot that DTC before continuing.
– JLG Lift –
6-15
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6-6 Communication
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
662 CANBUS FAILURE - PLAT- In platform mode, the control
FORM MODULE
system failed to receive messages from the platform board.
6-16
• Turn on machine in ground mode. If DTC 661 is not
present check for 24V between platform box connector terminals D and A. If not 24V, test continuity from
platform box connector socket A to ground board
connector socket J1-6 and test continuity from platform box connector socket D to ground board connector socket J1-7.
• If DTC 661 was present in the previous check, disconnect armstack passthru connector located near the
ladder on the left. Turn on in ground mode. If DTC 661
is not present then there is a problem in armstack harness. Armstack passthru socket 5 to platform box terminal E should have continuity. Armstack passthru
socket 6 to platform box connector terminal F should
have continuity. Armstack passthru socket 7 to platform box connector terminal G should have continuity. Armstack passthru socket 5 to armstack passthru
socket 6 resistance should be 120 Ohms +/- 5%. Armstack passthru socket 5 to armstack passthru socket 7
should measure open circuit. Armstack passthru
socket 6 to armstack passthru socket 7 should measure open circuit.
• Disconnect armstack passthru and ground board J1.
Armstack passthru pin 5 to ground board socket J1-11
should have continuity. Armstack passthru pin 6 to
ground board socket J1-12 should have continuity.
Armstack passthru pin 7 to ground board socket J1-13
should have continuity. Armstack passthru pin 5 to
armstack passthru pin 6 should measure open circuit.
Armstack passthru pin 5 to armstack passthru pin 7
should measure open circuit. Armstack passthru pin 6
to armstack passthru pin 7 should measure open circuit.
• Disconnect ground board J1 and power module connector. Ground board socket J1-31 to power module
connector socket 10 should have continuity. Ground
board socket J1-32 to power module connector
socket 11 should have continuity. Ground board
socket J1-31 to J1-32 should measure open circuit.
Ground board socket J1-31 to J1-33 should measure
open circuit. Ground board socket J1-32 to J1-33
should measure open circuit.
• Ensure all connections opened above are reconnected. Disconnect power module connector. Turn on
in platform mode. If DTC 662 is no longer present
replace power module.
• If DTC 661 and 662 have been present through above
steps replace ground board.
Continued Next Page
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
6-6 Communication
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
662 CANBUS FAILURE - PLAT- In platform mode, the control
system failed to receive mes(Cont. FORM MODULE
sages from the platform board.
(Continued)
)
• Disconnect platform box connector. Open platform
box. Disconnect platform board connector. Platform
box socket E to platform board J1-3 should have continuity. Platform box socket F to platform board J1-4
should have continuity. Platform box pin E to pin F
should measure open circuit. Platform box pin E to pin
G should measure open circuit. Platform box pin F to
pin G should measure open circuit. If these checks are
OK replace platform board.
• Check ANALYZER -> MACHINE SETUP -> MODEL NUM663 CANBUS FAILURE - LOAD With load sensing system
BER is correct.
SENSING SYSTEM MOD- enabled, the control system
failed to receive messages from • Check ANALYZER -> MACHINE SETUP -> MARKET is
ULE
correct.
the load sensing system mod• Check ANALYZER -> MACHINE SETUP -> LOAD is corule.
rect.
• Check for 24V between load sense system module
connector J1-1 and J1-2.
• Turn on machine in platform mode. If DTC 662 is present, troubleshoot that DTC before continuing.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
664 CANBUS FAILURE ACCESSORY MODULE
An accessory module has
stopped communication.
• Turn on machine in platform mode. If DTC 662 is present, troubleshoot that DTC before continuing.
• See accessory module documentation for troubleshooting.
6635 CANBUS FAILURE CHASSIS TILT SENSOR
Chassis Tilt Sensor messages not • The control system failed to receive messages from
the Chassis Tilt Sensor located inside the Ground Conreceived for 1000 mS while B+ is
trol Box.
present on J1-28
• Ensure that +B is present on pin 1 of the sensor, and -B
is present on pin 4. Check the CANbus wiring to pins 2
and 3 of the sensor.
• ZAPI - HEALTH (Status LED) - ON
6-7 Accessory
DTC
FAULT MESSAGE
671 ACCESSORY FAULT
DESCRIPTION
CHECK
An accessory module is reporting a fault.
• See accessory module documentation for troubleshooting.
DESCRIPTION
CHECK
7-7 Electric Motor
DTC
FAULT MESSAGE
The power module detected a
problem in the drive motors'
power circuit wiring.
• Refer to Drive Motor Electrical Evaluation in Section
3.5.
• Refer to Power Module Electrical Evaluation in Section
3.6.
Drive, Steer, and Lift Prevented
772 STALLED TRACTION
MOTOR OR POWER WIRING ERROR
• The System Module detected armature current feedback > 4.5V or < 0.5V. This is mostly likely caused by a
stalled traction motor or power wiring issue. Alternately, it could be an internal fault.
• ZAPI - HEALTH (Status LED) - ON
771 OPEN CIRCUIT DRIVE
MOTOR WIRING
3121166
– JLG Lift –
6-17
SECTION 6 - DIAGNOSTIC TROUBLE CODES
7-7 Electric Motor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
773 CAPACITOR BANK
FAULT - CHECK POWER
CIRCUITS
Drive, Steer, and Lift Prevented
• There is an internal or external fault that prevents the
System Module’s capacitor bank from charging.
• The System Module detected that the VMN of the
pump and traction has not increased more than 1.3V
in 1000mS. Alternately, 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.
• ZAPI - HEALTH (Status LED) - ON
774 SHORT CIRCUIT FIELD
WIRING
Drive, Steer, and Lift Prevented
• The field wiring passed System Module power-up
diagnostics. However, an external short circuit was
detected when current was applied to F1 / F2. This situation is caused by improper field wiring or a damaged motor.
• ZAPI - HEALTH (Status LED) - ON
NOTE: Tilt Sensor Calibration is not available when this
condition is present.
775
Drive, Steer, and Lift Prevented
• The System Module applied field current, but could
regulate the desired current. The situation is caused
by improper field wiring or a damaged motor.
• ZAPI - HEALTH (Status LED) - ON
776 STALLED PUMP MOTOR Drive, Steer, and Lift Prevented
OR POWER WIRING
ERROR
• The System Module measured 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.
• ZAPI - HEALTH (Status LED) - ON
777 OPEN CIRCUIT PUMP
MOTOR WIRING
Drive, Steer, and Lift Prevented
• The System Module measured pump current less
than 8A while the motor voltage was greater than 7V
for 1200mS. This indicates there is an open-circuit
between the System Module’s –P terminal and the
pump motor.
• ZAPI - HEALTH (Status LED) - ON
778 TRACTION T HIGH CHECK POWER CIRCUITS
Drive, Steer, and Lift Prevented
• While driving, the voltage measured at the System
Module’s T terminal did not agree with the predicted
value for at least 300mS. This issue may be caused by
a power wiring error or an internal fault.
• ZAPI - HEALTH (Status LED) - ON
779 TRACTION T LOW CHECK POWER CIRCUITS
Drive, Steer, and Lift Prevented
• While driving, the voltage measured at the System
Module’s T terminal did not agree with the predicted
value for at least 1000mS. This issue may be caused by
an opencircuit of the armature wiring (+B and –T terminals) or an internal fault.
• VMN does not increase more than 1.3V
• VMN is less than 20% Battery Voltage
• Battery Voltage . VMN is greater than 4V
• ZAPI - HEALTH (Status LED) - ON
6-18
OPEN CIRCUIT FIELD
WIRING
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
7-7 Electric Motor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
7710 PUMP P HIGH - CHECK
POWER CIRCUITS
Drive, Steer, and Lift Prevented
• While steering or lifting up, the voltage measured at
the System Module’s P terminal did not agree with
the predicted value for at least 240mS. This issue may
be caused by a power wiring error or an internal fault.
• Pump Feedback . Predicted >7V
• ZAPI - HEALTH (Status LED) - ON
7711 PUMP P LOW - CHECK
POWER CIRCUITS
Drive, Steer, and Lift Prevented
• While steering or lifting up, the voltage measured at
the System Module’s P terminal did not agree with
the predicted value for at least 1000mS. This issue
may be caused by an open-circuit of the pump wiring
(+BF2 and –P terminals) or an internal fault.
• Pump feedback does not increase more than 1.3V
• Pump feedback is less than 20% Battery Voltage
• Battery Voltage - pump feedback is greater than 4V
• ZAPI - HEALTH (Status LED) - ON
7741 ARMATURE BRAKING
CURRENT TOO HIGH
Drive, Steer, and Lift Prevented
• The System Module detected excessive braking current for more than 5000mS. This can be caused by
transporting an excessive load on a steep grade.
Alternately, this may indicate an internal fault.
• ZAPI - HEALTH (Status LED) - ON
7742 FIELD VOLTAGE
IMPROPER
Drive, Steer, and Lift Prevented
• 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 shortcircuit 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.
• ZAPI - HEALTH (Status LED) - ON
8-1 Tilt Sensor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
811 TILT SENSOR NOT CALI- The tilt sensor calibration has
BRATED
not been performed.
812 NO DATA FROM TILT
SENSOR - NOT CONNECTED OR FAULTY
No signal from tilt sensor.
• Calibrate the tilt sensor, see Section 5.2.
• Replace then calibrate tilt sensor, see Section 5.2.
• Check tilt sensor connections and wiring in ground
control box.
• Calibrate the tilt sensor, see Section 5.2.
• Replace then calibrate tilt sensor, see Section 5.2.
NOTE: Tilt Sensor cannot be calibrated if main contactor is open due to an alarm.
8-2 Platform Load Sense
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
821 LSS CELL #1 ERROR
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
822 LSS CELL #2 ERROR
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
823 LSS CELL #3 ERROR
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
3121166
– JLG Lift –
6-19
SECTION 6 - DIAGNOSTIC TROUBLE CODES
8-2 Platform Load Sense
DTC
FAULT MESSAGE
824 LSS CELL #4 ERROR
DESCRIPTION
CHECK
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
825 LSS HAS NOT BEEN CAL- The load sensing system modIBRATED
ule has not been calibrated
• Empty platform. Calibrate LSS, see Section 2.2: Calibration in the LSS manual, 3124288.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
991 LSS WATCHDOG RESET A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
992 LSS EEPROM ERROR
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
993 LSS INTERNAL ERROR PIN EXCITATION
A problem has been detected
with the load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
994 LSS INTERNAL ERROR - A problem has been detected
DRDY MISSING FROM A/ with the load sense system.
D
• Refer to Section 2.3: Troubleshooting in the LSS manual, 3124288.
995 POWER MODULE FAILURE - PERSONALITY
RANGE ERROR
The power module detected an • Record all personality settings in ANALYZER -> PERSONALITIES and ANALYZER -> MACHINE SETUP. Reset
out-of-range or corrupt personcontrol system personalities to default settings by
ality setting
selecting a different model than indicated, cycle
power then select proper model. Then, enter personality settings recorded above.
996 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s analog to digital converter does
not respond for the power PCB. This is an internal failure.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
997 POWER MODULE FAILURE - CHECK POWER
CIRCUITS OR MOSFET
SHORT CIRCUIT
The power module detected an • Refer to Drive Motor Electrical Evaluation in Section
3.5.
error in the power wiring for the
• Refer to Pump Motor Electrical Evaluation in Section
drive or pump.
4.8.
• Refer to Power Module Electrical Evaluation in Section 3.6.
998 EEPROM FAILURE CHECK ALL SETTINGS
The control system detected an • Replace ground board.
EEPROM failure.
The power module software ver- • Replace power module to clear fault.
999 FUNCTION LOCKED
OUT - POWER MODULE sion is not compatible with the
rest of the system.
SOFTWARE VERSION
IMPROPER
The platform board software
9910 FUNCTION LOCKED
OUT - PLATFORM MOD- version is not compatible with
the rest of the system.
ULE SOFTWARE VERSION IMPROPER
6-20
• Reprogram platform board.
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
9911 FUNCTION LOCKED
OUT - LSS MODULE
SOFTWARE VERSION
IMPROPER
DESCRIPTION
CHECK
The load sensing system mod- • Replace LSS module to clear fault.
ule software version is not compatible with the rest of the
system.
• Refer to Drive Motor Electrical Evaluation in Section
9912 POWER MODULE FAIL- The ground board detected
URE - SYSTEM MONITOR armature, field, or pump current 3.5.
• Refer to Pump Motor Electrical Evaluation in Section
while function was not com4.8.
manded.
• Refer to Power Module Electrical Evaluation in Section 3.6.
9917 HIGH RESOLUTION
ANALOG TO DIGITAL
FAILURE - INTERRUPT
LOST
• Pump Motor being turned backwards by a faulty
The ground board detected
armature, field, or pump current check valve in the hydraulic system.
• Software issue on the controller. Update software.
while function was not commanded.
9924 FUNCTIONS LOCKED
OUT - MACHINE NOT
CONFIGURED
• Use the JLG analyzer to adjust all machine setup and
The control system's memory
personality settings, refer to 5.7 Machine Configuraindicates that the vehicle has
tion Programming Information.
not been configured (new control system components).
9950 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s armature power circuitry is
driven without PWM command for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9951 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s pump power circuitry is driven
without enable from the interface PCB for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9952 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s pump power circuitry is driven
without PWM command for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9953 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s field power circuitry is driven
without enable from the interface PCB for 100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9954 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s field power circuitry is driven
without reverse direction from the power PCB for
100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9955 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s field power circuitry is driven
without forward selection from the power PCB for
100mS.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
9956 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s field current control or MOSFET’s are malfunctioning.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9957 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s hardware that generates an
interrupt at 36V and 12V did not respond properly at
power-up.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9958 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s pump current measurement or
MOSFET are malfunctioning.
• Pump current measurement >2.74V or <2.26V for
200mS while idle.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9960 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module detected an issue with the traction current measurement or the MOSFET’s.
• Armature current feedback >2.74V or < 2.26V while
idle
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9962 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s temperature feedback is >4.9V
or <0.1V.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9963 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module detected a mismatch in the
redundant RAM information stored in the power PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - ON
9964 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s analog to digital converter does
not respond for the interface PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
9969 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s MC/EB/EV/DV Enable is always
on. This is internal fault.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
6-22
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
9970 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module detected a mismatch in the
redundant RAM information stored in the interface
PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - ON
9971 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s MC/EB valve activation pin is
shorted. This is an internal fault.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99143 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s power and interface PCB digital
inputs do not agree.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99144 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s MC feedback from the interface
PCB disagrees with the feedback from the power PCB.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99145 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s enable for the power PCB
requested a drive motor or valve activation when not
expected.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99146 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s lift down feedback voltage to
the interface and power PCB’s disagrees.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99147 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s VMN feedback voltage to the
interface and power PCB’s disagrees.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99148 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module’s setpoint request from the interface PCB does not match the input state.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
99149 POWER MODULE FAIL- Drive, Steer, & Lift Prevented
URE - INTERNAL ERROR
• The System Module encountered an unexpected
software issue.
• Cycle machine, if error still exists, replace System
Module.
• ZAPI - HEALTH (Status LED) - FLASHING
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
NOTES:
6-24
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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
7-2
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)
• Use firm contact with meter leads
• First test meter and leads by touching leads
together. Resistance should read a short circuit
(very low resistance)
• 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
• Disconnect component from circuit before testing
• Use firm contact with meter leads
• First test meter and leads by touching leads
together. Meter should produce an audible alarm,
indicating 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
• If meter is not auto ranging, set it to the correct
range (See multi meter’s operation manual)
• Use firm contact with meter leads
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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:
1.
2.
3.
4.
Figure 7-6. Connector Assembly (1 of 4)
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)).
Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See
Figure 7-7. Connector Assembly (2 of 4)).
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)).
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.
7-8
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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.
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.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
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.
2.
3.
4.
De-energize the circuit.
Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
Access the terminals to the switch.
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.
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.
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
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.
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
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Table 7-1. Ground Board J1 (1600346 Power Module ONLY)
Function
Type
Range (V)
Ground
Analyzer Power
RS-232 Receive
RS-232 Transmit
Platform EMS
Ground
Ignition
Platform EMS Source
Ignition
Left PHP Switch
CAN Bus high
CAN Bus Low
CAN Bus Shield
Analog Power
Elevation Angle Sensor
Ground
Ignition
Right PHP Switch
Ignition
Brake Release Swtich
Steer Left Coil
Steer Right Coil
Left Brake Release
Right Brake Release
Lift Up Coil
Lift Down Coil
Ground
Ground Alarm
Charger Interlock
Ground
CAN Bus High
Power Output
Power Output
Input/Output
Input/Output
Input
Power Output
Power Output
Power Output
Power Output
Input
Input/Output
Input/Output
Power Output
Power Output
Input
Power Output
Power Output
Input
Power Output
Input
Output
Output
Output
Output
Output
Output
Power Output
Output
Input
Power Output
Input/Output
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0
12
Comm
Comm
Vbatt
0
Vbatt
Vbatt
Vbatt
Vbatt
Comm
Comm
0
5
5
0
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
PWM
0
PWM
Vbatt
0
Comm
7-13
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
32
33
34
35
36
37
38
39
40
Pin
1
2
3
4
5
6
7
8
9
Pin
1
2
3
4
7-14
Table 7-1. Ground Board J1 (1600346 Power Module ONLY)
Function
Type
Range (V)
CAN Bus Low
CAN Bus Shield
CAN Bus High
CAN Bus Low
CAN Bus Shield
Ground
Ground Enable
Master Ignition Connection
Master Ground Connection
Input/Output
Output
Input/Output
Input/Output
Output
Power Output
Power Output
Power Input
Power Input
Table 7-2. Ground Board J2
Function
Type
Ignition
Ground EMS
Platform EMS Source
Ground Mode Select
Ground
Ground Lift Up
Ground Lift Down
Hour Meter
Ground Overload Lamp
Power Output
Power Input
Power Input
Input
Power Output
Input
Input
Output
Output
Table 7-3. Ground Board J3
Function
Type
Tilt Sensor Power
Tilt Sensor X-Axis (PWM)
Tilt Sensor Y-Axis (PWM)
Ground
Power Output
Input
Input
Power Output
– JLG Lift –
Comm
0
Comm
Comm
0
0
0
Vbatt
0
Range (V)
Vbatt
Vbatt
Vbatt
Vbatt
0
Vbatt
Vbatt
Vbatt
Vbatt
Range (V)
12
12
12
0
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Pin
1
2
3
4
5
6
7
Pin
1
2
3
4
5
6
7
3121166
Table 7-4. Platform Board J1
Function
Type
Master Ignition
Master Ground
CAN Bus High
CAN Bus Low
Joystick Power Supply
Joystick Signal
Ground
Trigger Switch
Lift Select Switch (Active Low)
Drive Select Switch (Active Low)
Ground
Platform Alarm (Active Low)
Indoor/Outdoor Select Swtich
Horn Switch
Steer Left Switch
Steer Right Switch
Power Input
Power Input
Input/Output
Input/Output
Power Output
Input
Power Output
Input
Input
Input
Power Output
Output
Power Output
Power Output
Input
Input
Table 7-5. Platform Board J3
Function
Type
Ground
Swtich Shield (Grounded)
Not Used
Not Used
Not Used
Not Used
Indoor/Outdoor Select Switch (Active
Low)
Power Output
Output
----Input
Table 7-6. Platform Board J4
Function
Type
Ground
Switch Shield (Ground)
Not Used
Not Used
Not Used
Not Used
Horn Switch (Active Low)
Power Output
Power Output
----Input
– JLG Lift –
Range (V)
Vbatt
0
Comm
Comm
5
5
0
Vbatt
Vbatt
Vbatt
0
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
Range (V)
0
0
----Vbatt
Range (V)
0
0
----Vbatt
7-15
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
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
7-16
Table 7-7. Power Module (1600346 Power Module ONLY)
Function
Type
Range (V)
Ignition
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Line Contactor High Side
Not Used
CAN Bus High
CAN Bus Low
Not Used
Power Input
------Power Output
-Input/Output
Input/Output
--
Vbatt
------Vbatt
-Comm
Comm
--
Table 7-8. Power Module - J1 (1001092456 Power Module ONLY)
Function
Type
Primary Elevation Sensor Analog Input (0-5V)
Spare - Analog Input
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)
Ground Lift Up Switch (High-Sensing)
Right Pothole Switch (High-Sensing)
Ground Lift Down Switch (High-Sensing)
Left Pothole Switch (High-Sensing)
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)
Positive Rotary Sensor Reference (+5V)
Negative for Rotary Sensor
Positive Left Pothole Switch Reference (Connect to +BATT)
Positive Right Pothole Switch Reference (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)
– JLG Lift –
Analog
Analog
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Power
Power
Input
Input
Output
Output
Input
Output
Output
Input
Input
Input
Input
Output
Output
Digital
Digital
Power
Power
Power
Power
Input
Input
Output
Output
Output
Output
Serial
Serial
Power
Power
Digital
Input
Output
Output
Output
Input
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
25
26
27
28
29
30
31
32
33
34
35
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3121166
Table 7-8. Power Module - J1 (1001092456 Power Module ONLY)
Function
Type
Elevation Proximity Switch (High-Sensing; 1230ES only)
Charger Interlock (High-Sensing)
Foot Switch (High-Sensing; 1230ES only)
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 (HighSensing)
Digital
Digital
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
Table 7-9. Power Module - J2 (1001092456 Power Module ONLY)
Function
Type
Spare - (Connect to +BATT)
Positive Lift Down Valve (High-Side Driver)
Spare Digital Input (High-Sensing)
Spare Digital Input (High-Sensing)
CANbus Low
CANbus High
Spare Positive Analog Reference (+5V )
Platform EMS (Logic Supply for Platform Mode)
Negative Steer Left Solenoid Valve (Low-Side Driver)
Switch Manual Brake Release (High-Sensing)
Spare Digital Input (High-Sensing)
Spare Digital Input (High-Sensing)
Spare Digital Input (High-Sensing)
Spare Negative Analog Reference (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)
Spare Analog Input (0-5V)
Spare Digital Output (Low-Side Driver)
Spare Digital Output (Low-Side Driver)
Negative for Overload Lamp (Low-Side Driver)
Negative for Hourmeter (Low-Side Driver)
– 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
7-17
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.7
ELECTRICAL SCHEMATICS AND LAYOUTS
Electrical Schematic - 1870164G - Sheet 1 of 2
Figure 7-18. Electrical Schematic - 1870164 G - Sheet 1 of 2
7-18
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870164G - Sheet 2 of 2
1930ES USA Built Machines Prior to S/N 0200150266
1930ES Belgium Built Machines Prior to S/N 1200007882
2030ES/2630ES USA Built Machines Prior to S/N 0200152825
2030ES/2630ES Belgium Built Machines Prior to S/N 1200008481
2646ES/3246ES USA Built Machines Prior to S/N 0200151606
2646ES/3246ES Belgium Built Machines Prior to S/N 1200008265
1870164 G
Figure 7-19. Electrical Schematic - 1870164 G - Sheet 2 of 2
3121166
– JLG Lift –
7-19
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870205B - Sheet 1 of 2
Figure 7-20. Electrical Schematic - 187205 C - Sheet 1 of 2
7-20
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870205B - Sheet 2 of 2
1930ES USA Built Machines S/N 0200150266 to Present
1930ES Belgium Built Machines S/N 1200007882 to Present
2030ES/2630ES USA Built Machines S/N 0200152825 to Present
2030ES/2630ES Belgium Built Machines S/N 1200008481 to Present
2646ES/3246ES USA Built Machines S/N 0200151606 to Present
2646ES/3246ES Belgium Built Machines S/N 1200008265 to Present
Obsoleted by 1001114879
1870205 C
Figure 7-21. Electrical Schematic - 187205 C - Sheet 2 of 2
3121166
– JLG Lift –
7-21
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
6:CAL DATA
RED 6
1
3
ORN/RED49-100
4
ORN/RED49-200
BLACK
2
BLACK 1
RED 1-1-1 (16)
G
F
SHIELD
SHIELD (J1-13)
CAN LOW (J1-12)
GND (J1-6)
CAN HIGH (J1-11)
RED
BLACK 3
IGN (J1-7)
GNDE (J2-2)
B+ (J2-1)
VTLT POWER (J3-1)
TILTX (J3-2)
CAN
INTERFACE
X003
TILTY (J3-3)
GND (J3-4)
B- (J1-40)
B+ (J1-39)
NEG
4
3
3
CHARGER
INTERLOCK (J1-29)
2
ORN/RED49-5
3
BLACK 14
1
MDI
X101
X010
7
NC
SHIELD (J1-36)
4
ORN/RED49-6
2
STBY
1
ON
DIAGNOSTIC
CONNECTOR
X011
YEL/RED 2-100
1
3
4
6
2
6
GND (J1-1)
5
ORN/RED49-7
TX (J1-4)
5
RX (J1-3)
6
4
YEL/RED 2-5-6
ORN/RED 49-91
3
RED
POS
8
CAN LOW (J1-35)
ANLP (J1-2)
X020
INVERTER/
CHARGER
GNDE (J1-38)
CAN HIGH (J1-34)
REMOTE LED'S
(LOCATED IN GC)
X028
SHIELD (J1-33)
RED 1-1
DIGITAL INPUT FILTER
(24 V DIGITAL INPUTS)
POWER
(ACTIVE HIGH)
DISTRIBUTION
AND
REGULATION
(TO ALL
AREAS OF THE
SYSTEM)
UPG (J2-6)
2
ORN/RED 49-90
4
BLACK 78
SHIELD
TILT
SENSOR
X034
CIR_BREAKER
F01
WHT/RED57-100
DNG (J2-7)
CAN LOW (J1-32)
X033
RED 1-2
OVLD (J2-9)
BLACK
YEL/RED 2-1-1
YEL/RED
YEL/RED 2-4
PLTS (J2-3)
120 /.25 WATT
RESISTOR ASSEMBLED
IN CANNON PLUG OF
PLATFORM CABLE
CAN HIGH (J1-31)
GROUND
RED/YEL 54-1
X029
TAN 4-1
TAN 3-1
X036 ESTOP X035
S01
E
GREEN
7
BLACK
6
SHIELD
5
GNDS (J2-4)
HOUR METER
BLU/ORN 52-2
X032
LIFT SWITCH
HOUR METER (J2-8)
00000
S03
X031 BLACK
BLACK
GND (J2-5)
LIFT
X037 DOWN
LAMP 01
X002
OVERLOAD
X030
A
YELLOW
4
PLTS (J1-8)
YEL/RED 2-2-1
X038
D
BLACK
3
YEL/RED 2-3-1
YEL/RED 2-3-2
GROUND
CONTROL
BOX
C
ORANGE
2
2-5-1
BLUE
1
X017
PLATFORM
BULKHEAD
FOOTSWITCH
(REQUIRES LSS MODULE)
YEL/RED 2-1-2
RED
X045
BLK
PLATFORM
B
GREEN
YELLOW
BLACK
ORANGE
WHITE
B
J1-4
SHIELD
YEL/RED 2-2-2
BLACK
LIFT
UP
X039
J1-2
J1-3
YELLOW
X046
PLATFORM CABLE THAT
ROUTES UP ARMSTACK;
HAS BREAK-OUT
POINT NEAR PLATFORM
RED
3
GREEN
PLTE (J1-5)
YEL/RED 2-30
1
5
2 CANBUS & 4
3 POWER 3
EXTENDER
4
1
5
2
SHIELD
X040
1
J1-1
BLACK
SHIELD
BREAK-OUT SPLICED INTO
PLATFORM CABLE TO
PROVIDE ACCESSORY
CANBUS, IGNITION AND
GROUND CONNECTION
J1-1
J1-2
J1-3
J1-4
J1-5
J1-6
J1-7
J1-8
J1-9
J1-10
J1-11
J1-12
J2-10
J2-6
J2-3
J2-4
J2-5
J2-9
J2-7
J2-8
ORANGE15
ESTOP X048
S02
RED 16
LSS MODULE LOCATED ON TOP
ARMSTACK UNDER PLATFORM
CAL DATA-6
-SIGNAL-5
2:CAL CLOCK
5:-SIGNAL
GREY 5
+EXCITE-4
1:+SIGNAL
3:-EXCITE
BLUE 3
GREEN 4
-EXCITE-3
RED 14-1
X047
J8
RED 6
WHITE 2
BROWN1
+SIGNAL-1
CAL CLOCK-2
CAL DATA-6
4:+EXCITE
RR
PIN
RL
PIN
6:CAL DATA
3:-EXCITE
2:CAL CLOCK
5:-SIGNAL
-SIGNAL-5
J7
1:+SIGNAL
4:+EXCITE
GREY 5
GREEN 4
+EXCITE-4
BLUE 3
-EXCITE-3
6:CAL DATA
RED 6
WHITE 2
BROWN 1
+SIGNAL-1
CAL DATA-6
CAL CLOCK-2
3:-EXCITE
5:-SIGNAL
-SIGNAL-5
2:CAL CLOCK
1:+SIGNAL
4:+EXCITE
GREY 5
+EXCITE-4
BLUE 3
GREEN 4
-EXCITE-3
J6
6:CAL DATA
BROWN 1
WHITE 2
+SIGNAL-1
CAL DATA-6
CAL CLOCK-2
4:+EXCITE
3:-EXCITE
5:-SIGNAL
RED 6
-SIGNAL-5
2:CAL CLOCK
BLUE 3
WHITE 2
GREY 5
J2-12
J2-11
J2-2
BROWN 1
GREEN 4
+EXCITE-4
J5
-EXCITE-3
+SIGNAL-1
PLATFORM MOUNTING ARM
PINS FOR LOAD SENSE
BLACK
J2-1
LOAD SENSE
MODULE
CAL CLOCK-2
1:+SIGNAL
FL
PIN
FR
PIN
Electrical Schematic - Sheet 1 of 2 (Machines with MDI)
2
BAT. CABLE
X059
(4 GA)
2-5-5
CONTACTOR
X058
X061
M2 OR A
M1 OR S
(4 GA)
RED 1-3 (10 GA)
BATTERY CABLE (2/0 GA)
11
8
1
10
POWER
CONTROLLER
X026
YEL/RED 2-5-7
P
F1
CABLE
X027
X008
B-
B+
F2
3
BLACK 14
BLACK
3
YELLOW
RED
BLUE
X062
X028
REMOTE LED'S
(LOCATED IN GC)
2
1
X010
CHARGER INTERLOCK
2
1
X018
4
4
ORANGE WIRE IN
DRIVE MOTOR CABLES
CONNECTED EITHER
WITH A BUTT SPLICE
OR JUMPER HARNESS
ORANGE
X098
X096
BLACK
X094
X090
X091
A
A1
X021
X099
A1 F1
A2
F2
YEL/RED 2-5-9
X095
X092
LEFT
MOTOR
F1
BRAKE
ORN/RED 49-4
BROWN
RED
MOUNTED IN
VEHICLE
CHASSIS
ORN/RED49-6
ORN/RED49-5
BRAKE
NEG
ORN/RED49-7
A
5
CHARGER
RIGHT
MOTOR
6
POS
X019
BLUE
X020
BLACK(10 GA)
G03
- 6V +
G02
- 6V +
G01
- 6V +
YEL/RED
1
BATTERY
DISCONNECT
LOCATED
BETWEEN
THESE TWO
BATTERIES
X075
BLACK
INSIDE BATTERY COMPARTMENT, GROUND CONTROL BOX SIDE;
OPTIONAL
INVERTER/CHARGER
G04
- 6V +
BATTERY CABLE (2/0 GA)
X018
A2 F2
X093
X097
YELLOW
BROWN
Figure 7-22. Electrical Schematic - Sheet 1 of 2 (Machines with MDI)
7-22
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - Sheet 2 of 2 (Machines with MDI)
PLATFORM
CONTROL BOX
X057
X050
X053
RED 13
ORANGE J1-12-9
J1-8
J1-15
GRAY J1-8-8
X049
BLUE J1-15-11
1 COMMON RED (22GA)
BROWN J1-16-12
J1-16
5 ROCKER LEFTGREEN (24 GA)
LT
PURPLE J1-7-6
J1-7
RT
4 ROCKER RIGHTYELLOW (24 GA)
WHITE J1-6-7
7 +5VDC WHT/RED
CAPACITY SWITCH
HORN SWITCH
JOYSTICK
2 TRIGGER VIOLET (22 GA)
PINK J1-5-55
J1-5
J1-6
ALARM
WHITE/GREEN J1-10-18
J1-12
CAN
INTERFACE
X052
RED 16
ORANGE/WHITE J1-9-17
J1-10
DIGITAL
OUTPUT
DRIVERS
(24 V WHEN
OUTPUT IS ON)
LIFT
J1-9
DRIVE
BROWN/PURPLEJ1-11-19
J1-11
ANALOG INPUT
FILTER
0 TO 5 VOLT
DIGITAL INPUT FILTER
(24 V DIGITAL INPUTS)
POWER
(ACTIVE HIGH)
DISTRIBUTION
AND
REGULATION
(TO ALL
AREAS OF THE
SYSTEM)
MICROPROCESSOR
8 GROUNDWHT/BLACK
0-5 VOLT
OUTPUT
9 SIG OUTPUT BROWN
MEMBRANE SWITCHES
MOUNTED DIRECTLY ON BOARD
1
APWR (J1-14)
IGN (J1-9)
IGN (J1-17)
RH PHP (J1-18)
STEER LEFT (J1-21)
STEER RIGHT (J1-22)
RH BRAKE (J1-24)
LH BRAKE (J1-23)
GND (J1-30)
GND (J1-37)
IGN (J1-19)
BRAKE REL (J1-20)
GALR (J1-28)
X042
MOUNTED ON
BOTTOM ARM PIVOT
PIN, GROUND
CONTROL BOX SIDE.
BLACK 6
BLACK 5
X043
LIFT DOWN
VALVE
BRAKE
RELEASE
SWITCH
X041
**OPTIONAL ACC'Y
LOCATED ON VEHICLE
CHASSIS; COILED
UP, HANGING ON
HOOK, INSIDE
BATTERY DOOR
OPPOSITE GROUND
CONTROL BOX.
ORANGE 55-1-1
ORANGE 55-1-2
BLACK 2
BLACK 18
BLU/ORN 52-1
X022
2
YEL/RED 2-5-10
BEACON
X014
YEL/RED
2-5-4
STEER RIGHT
VALVE
LIFT UP
VALVE
BLACK 26
GND (J1-27)
RS232
X044
YELLOW10-2
TAN 4-2
LIFT DOWN (J1-26)
DIGITAL
OUTPUT
DRIVERS
(24 V WHEN
OUTPUT IS ON)
ROTARY
SWITCH
3
SHIELD
LH-PHP
SWITCH *POTHOLE SWITCHES
YEL/RED 2-5-3
ARE CLOSED WHEN PHP
X023
MECHANISM IS DEPLOYED
ORN/RED49-1
RH-PHP
BULKHEAD CONNECTION AT ARM PIVOT
SWITCH
YEL/RED 2-5-2
IN HARNESS; GND WIRE FOR STEER &
X009
LIFT UP COILS ARE SPLICED TOGETHER;
ORN/RED49-3
X016
STEER LEFT
BLACK 7
YELLOW9-2
VALVE
TAN 3-2
LIFT UP (J1-25)
MICROPROCESSOR
X015
BLACK
GND (J1-16)
LH PHP (J1-10)
ANALOG INPUT
FILTER
0 TO 5 VOLT
2
WHITE
ANGL (J1-15)
X001
RED
1
ALARM
3
BLACK 9
BLACK 15
YEL/RED 2-5-8
ORANGE 55-2
X013
BRAKE RELEASE
IGN
BLK
BRAKE RELEASE
POWER
BATTERY CABLE
PUMP
(4 GA)
LOCATED ON
BULKHEAD CONNECTION AT ARM
CYLINDER
PIVOT FOR PUMP CABLES
BATTERY CABLE (4 GA)
WHITE
YEL/RED 2-5-11
X012
PUSH BUTTON SWITCH
MOUNTED ON CHASSIS
INSIDE BATTERY DOOR
NEAR GOUND CONTROL BOX.
LH-BRAKE
CONNECTOR
X024
BLACK 10
RH-BRAKE
CONNECTOR
X025
BLACK 11
Obsoleted by 1001114879
POWER MODULE & CONTACTOR ARE
MOUNTED IN FRONT COMPARTMENT
OF CHASSIS BETWEEN DRIVE
MOTORS; COMPARTMENT IS
COVERED, DRIVE MOTOR CABLES
ENTER COMPARTMENT;
1870205 C
OPTIONAL EQUIPMENT CONNECTION
Figure 7-23. Electrical Schematic - Sheet 2 of 2 (Machines with MDI)
3121166
– JLG Lift –
7-23
X021
X088
X019
G03
- 6V +
G04
- 6V +
X008
X086
RED 1-3 (10 GA)
G02
- 6V +
– JLG Lift –
G01
- 6V +
7-24
BLACK (10 GA)
NEG
POS
MOUNTED IN
VEHICLE
CHASSIS
INVERTER/
CHARGER
NC
CONTROL CABLE
7
8
6
5
4
3
2
1
X082
X056
X057
6
5
4
3
X020
2
1
X018
ORN/RED49-7
ORN/RED49-6
ORN/RED49-5
BLACK 14
CHARGER INTERLOCK
J1-29
ORN/RED 49-4
3
2
4
1
X010
J1-19
YEL/RED 2-5-9
4
2
3
1
(LOCATED IN GC)
REMOTE LED'S
X028
GROUND MODULE
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Inverter/Charger Schematic
Figure 7-24. Battery Inverter/Charger Schematic
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTES:
3121166
– JLG Lift –
7-25
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-25. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3
7-26
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001114879_F-1
Figure 7-26. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-27. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001114879_F-2
Figure 7-28. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001114879_F-3
Figure 7-29. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 3 of 3
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTES:
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 1 of 2
Figure 7-30. Electrical Components - Sheet 1 of 2
NOTE: (USA Built Machines Prior to S/N 0200135154) (Belgium Built Machines Prior to S/N 1200004293)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 2 of 2
POTHOLE
PROTECTION
SWITCHES
INVERTER
ALARM
BEACON LIGHT
INVERTER
POWER
SWITCH
BATTERIES
CONTACTOR
RELAY
PUMP/MOTOR/RESERVOIR
POWER
BATTERY
CHARGER
*
*NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED.
Figure 7-31. Electrical Components - Sheet 2 of 2
NOTE: (USA Built Machines Prior to S/N 0200135154) (Belgium Built Machines Prior to S/N 1200004293)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 1 of 2
PLATFORM
CONSOLE
BOX
BRAKE
DISCONNECT
SWITCH
LIFT
CYLINDER
VALVE
BLOCK
PLATFORM
RECEPTACLE
TO
LSS
ROTARY ANGLE
SENSOR
PROXIMITY
SENSOR
GROUND
CONTROL
BOX
DRIVE
MOTORS
Figure 7-32. Electrical Components - Sheet 1 of 2
NOTE: 1930ES: USA Built Machines S/N 0200135154 to S/N 0200151266, Belgium Built Machines S/N 1200004293 to SN
1200007882; 2030ES/2630ES: USA Built Machines S/N 0200135154 to S/N 0200152528, Belgium Built Machines S/N
1200004293 to S/N 1200008481; 2646ES/3246ES: USA Built Machines S/N 0200135154 to S/N 0200151606, Belgium
Built Machines S/N 1200004293 to S/N 1200008265
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 2 of 2
POTHOLE
PROTECTION
SWITCHES
INVERTER
ALARM
BEACON LIGHT
INVERTER
POWER
SWITCH
BATTERIES
CONTACTOR
RELAY
PUMP/MOTOR/RESERVOIR
POWER
MODULE
BATTERY
CHARGER
*
*NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED.
Figure 7-33. Electrical Components - Sheet 2 of 2
NOTE: 1930ES: USA Built Machines S/N 0200135154 to S/N 0200151266, Belgium Built Machines S/N 1200004293 to SN
1200007882; 2030ES/2630ES: USA Built Machines S/N 0200135154 to S/N 0200152528, Belgium Built Machines S/N
1200004293 to S/N 1200008481; 2646ES/3246ES: USA Built Machines S/N 0200135154 to S/N 0200151606, Belgium
Built Machines S/N 1200004293 to S/N 1200008265
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 1 of 2
PLATFORM
CONSOLE
BOX
BRAKE
RELEASE
SWITCH
OR
BRAKE
DISCONNECT
SWITCH
LIFT
CYLINDER
VALVE
BLOCK
PLATFORM
RECEPTACLE
DIAGNOSTIC
ANALYZER
ROTARY ANGLE
SENSOR
GROUND
CONTROL
BOX
DRIVE
MOTORS
Figure 7-34. Electrical Components - Sheet 1 of 2
NOTE: 1930ES: USA Built Machines S/N 0200151266 to Present, Belgium Built Machines SN 1200007882 to Present; 2030ES/
2630ES: USA Built Machines S/N 0200152528 to Present, Belgium Built Machines S/N 1200008481 to Present; 2646ES/
3246ES: USA Built Machines S/N 0200151606 to Present, Belgium Built Machines S/N 11200008265 to Present
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 2 of 2
POTHOLE
PROTECTION
SWITCHES
ALARM
INVERTER
POWER
SWITCH
BEACON LIGHT
BATTERY
CHARGER/
INVERTER
BATTERIES
CONTACTOR
RELAY
PUMP/MOTOR/
RESERVOIR
POWER
MODULE
*
BATTERY
CHARGER
*NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED.
Figure 7-35. Electrical Components - Sheet 2 of 2
NOTE: 1930ES: USA Built Machines S/N 0200151266 to Present, Belgium Built Machines SN 1200007882 to Present; 2030ES/
2630ES: USA Built Machines S/N 0200152528 to Present, Belgium Built Machines S/N 1200008481 to Present; 2646ES/
3246ES: USA Built Machines S/N 0200151606 to Present, Belgium Built Machines S/N 11200008265 to Present
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 1 of 2 (Machines with MDI)
PLATFORM
CONSOLE
BOX
X051
X050
BRAKE
DISCONNECT
SWITCH
X044
BRAKE
RELEASE
SWITCH
X012
X042
LIFT
CYLINDER
VALVE
BLOCK
X013
PLATFORM
RECEPTACLE
X041
X047
X048
X043
X049
X016
X046
X103
X102
X011
X045
OR
X015
DIAGNOSTIC
ANALYZER
X017
X100
ROTARY ANGLE
SENSOR
X101
MDI
X025
X001
X081
X080
X010
X031
X032
X002
X024
X033
X034
X003
X028
X029
X030
X035
X036
X097
X099
X096
X098
X037
X038
X039
X040
GROUND
CONTROL
BOX
DRIVE
MOTORS
X095
X093
X091
X090 X092
X094
Figure 7-36. Electrical Components - Sheet 1 of 2 (Machines with MDI)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Components - Sheet 2 of 2 (Machines with MDI)
POTHOLE
PROTECTION
SWITCHES
X075
X009
X110
X111
X023
X020
X074
X082
X076
X073
ALARM
X077
X018
X022
X056
X057
X087
X072
X014
INVERTER
POWER
SWITCH
BEACON LIGHT
X078
X086
BATTERY
CHARGER/
INVERTER
X008
X089
X021
X071
X079
X088
BATTERIES
CONTACTOR
RELAY
X070
X026
X058
X059
PUMP/MOTOR/
RESERVOIR
X069
X019
POWER
MODULE
X060
X068
X018
X020
X062
X061
X083
X064
X065
X084
X027
X067
X085
BATTERY
CHARGER
X063
X112
X066
*NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED
Figure 7-37. Electrical Components - Sheet 2 of 2 (Machines with MDI)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTE: THIS ILLUSTRATION USED WITH 1001092456 POWER MODULE.
BRAKE
RELEASE
SWITCH
OR
LIFT
CYLINDER
VALVE
BLOCK
BRAKE DISCONNECT
SWITCH
PLATFORM
CONSOLE
BOX
PLATFORM
RECEPTACLE
DIAGNOSTIC
ANALYZER
ROTARY ANGLE
SENSOR
MDI/HOUR
METER
RELAY
GROUND
CONTROL
BOX
RIGHT DRIVE
MOTOR
LEFT DRIVE
MOTOR
Figure 7-38. Electrical Components - (Machines with 1001092456 Power Module) - Sheet 1 of 2
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTE: THIS ILLUSTRATION USED WITH 1001092456 POWER MODULE.
POTHOLE
PROTECTION
SWITCHES
BATTERY DISCONNECT
BATTERIES
ALARM
INVERTER
POWER
SWITCH
BEACON LIGHT
BATTERY
CHARGER/
INVERTER
CONTACTOR (POWER)
RELAY
PUMP/MOTOR/
RESERVOIR
POWER MODULE
1001092456
+BF1
–T
J1
*
+B
+BF2
–B
J2
BATTERY
CHARGER
–P
F1 F2
Figure 7-39. Electrical Components - (Machines with 1001092456 Power Module) - Sheet 2 of 2
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.8
HYDRAULIC SCHEMATIC
Figure 7-40. Hydraulic Schematic (Sht. 1 of 2)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001143663_B
Figure 7-40. Hydraulic Schematic (Sht. 2 of 2)
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTES:
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CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause cancer
and reproductive harm.
Batteries also contain other
harmful chemicals known
to the State of California.
WASH HANDS
AFTER HANDLING!
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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
+61 2 65 811111
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
+44 (0)161 654 1000
+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
+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
Oshkosh-JLG Singapore
Technology Equipment Pte Ltd.
29 Tuas Ave 4
Jurong Industrial Estate
639379 - Singapore
+65-6591-9030
+65-6591-9031
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
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