Models - Manor.org
Service & Maintenance Manual
Models
1930ES
2030ES
2630ES
2646ES
3246ES
3121166
June 1, 2010
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
SECTION A. INTRODUCTION - MAINTENANCE SAFETY
PRECAUTIONS
A.A GENERAL
A.C MAINTENANCE
This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS
LISTED IN THIS SECTION MAY RESULT IN MACHINE
DAMAGE, PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
• ENSURE REPLACEMENT PARTS OR COMPONENTS
ARE IDENTICAL OR EQUIVALENT TO ORIGINAL
PARTS OR COMPONENTS.
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.
• 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.
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.
• 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.
A.B HYDRAULIC SYSTEM SAFETY
• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.
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.
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
• BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.
• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.
– JLG Lift –
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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
b
– JLG Lift –
3121166
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A.A
A.B
A.C
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-a
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-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
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Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Pre-Delivery Inspection and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Components Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Lines and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
– JLG Lift –
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TABLE OF CONTENTS
2.4
2.5
2.6
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
Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
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TABLE OF CONTENTS
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
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
Ground Module Software Version 1.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 1.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
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TABLE OF CONTENTS
7.6
7.7
7.8
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.
3-39.
3-40.
3-41.
3-42.
3-43.
3-44.
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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
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
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TABLE OF CONTENTS
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.
7-30.
7-31.
7-32.
7-33.
7-34.
7-35.
7-36.
7-37.
7-38.
7-39.
7-40.
vi
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
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
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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
3121166
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 –
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TABLE OF CONTENTS
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viii
– JLG Lift –
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SECTION 1 - SPECIFICATIONS
SECTION 1. SPECIFICATIONS
1.1
SPECIFICATIONS
Table 1-1. Operating Specifications
Description
1930ES
2030ES
2630ES
2646ES
3246ES
Maximum Stowed Travel Grade
(Gradeability)
25%
25%
25%
25%
25%
Maximum Stowed Travel Grade
(Sideslope)
5°
5°
5°
5°
5°
18.75 ft.
5.7 m
20 ft.
6m
25.8 ft.
7.9 m
26 ft.
7.9 m
32 ft.
9.8 m
1365 lb (620 kg)
1540 lb (699 kg)
1660 (755)
1835 lb (832 kg)
1835 lb (832 kg)
1835 lb (832 kg)
2070 lb (939 kg)
2320 lb (1052 kg)
2070 lb (939 kg)
2320 lb (1052 kg)
109 psi
(7.7 kg/cm2 )
81 psi
(5.7 kg/cm2 )
90 psi
(6.3 kg/cm2 )
87 psi
(6.1 kg/cm2 )
87 psi
(6.1 kg/cm2 )
Ground Bearing Pressure (CE)
8.7 kg/cm2
(123 psi)
6.3 kg/cm2
(90 psi)
6.3 kg/cm2
(90 psi)
6.9 kg/cm2
(98 psi)
6.9 kg/cm2
(98 psi)
Maximum Drive Speed
3 mph
(4.8 kmh)
3 mph
(4.8 kmh)
2.75 mph
(4.4 kmh)
2.5 mph
(4 kmh)
2.5 mph
(4 kmh)
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°
90°
Maximum Platform Height
Maximum Tire Load:
ANSI
CE
Ground Bearing Pressure (ANSI)
Maximum Wind Speed
(Depending on model, market, and
indoor/outdoor selection)
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
28 mph
(12.5 m/s)
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°
90°
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)
1850 psi (dual)
90°
Outside Steer Angle
69°
73°
73°
67°
67°
Electrical System Voltage (DC)
24V
24V
24V
24V
24V
Approximate Gross Machine Weight ANSI/CSA
2685 lbs
3830 lbs
4815 lbs
4945 lbs
4945 lbs
Approximate Gross Machine Weight CE/Australia
1495 kg
2063.8 kg
2197.7 kg
2705.7 kg
2871.2 kg
Ground Clearance with pot hole
protection system up
Ground Clearance with pot hole
protection system down
3121166
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. Capacities
NOTE: All platform extension capacities are 250 lbs (120 kg)
MODEL
ANSI/CSA
CE INDOOR
AUSTRALIAN
INDOOR
CE OUTDOOR
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)
Batteries
Motors
Drive Motor
NOTICE
JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS
ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
Type: Shunt Wound, Sepex 24V DC
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.
Hydraulic Pump/Electric Motor Assembly (All Models)
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.
Power: 0.65 Horsepower @ 3750 rpm
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
25 - 30
3
5.5 - 6.2
4.8
5.5 - 6.2
2030ES
0.5
28-37
0.8
25 - 30
2.75
6.18 - 6.6
4.8
6.18 - 6.6
2630ES
0.5
28-37
0.8
30 - 35
2.75
6.18 - 6.6
4
6.18 - 6.6
2646ES
0.5
28-37
0.8
25 - 30
2.5
7-8
4
7-8
3246ES
0.5
28-37
0.8
33 - 38
2.5
7-8
3.7
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)
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 Up
Overall Stowed Machine Height - Rails Collapsed
3121166
– JLG Lift –
1-5
SECTION 1 - SPECIFICATIONS
1.2
TORQUE REQUIREMENTS
Table 1-9. Hydraulic Oil
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
Torque Value (Dry)
Interval Hours
Rear Wheel Spindle Nut
30-40 ft lb
(40-54 Nm)
50
105 -120 ft lb
(142-163 Nm)
50
Wheel Bolts
Table 1-10. Lubrication Specifications
NOTE: Anytime a wheel bolt is replaced, be sure one of the
same length is used. Use bolt shown below on
wheels that use the 1/4" (6.4mm) ring.
Key
Specifications
MPG
Multipurpose Grease having a minimum dripping
point of 350°F. Excellent water resistance and adhesive qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL
Extreme Pressure Gear Lube (oil) meeting API service
classification GL-5 or MIL-Spec MIL-L-2105.
HO
Hydraulic Oil. API service classification GL-3,e.g.
DTE 11M.
Table 1-11. Hydraulic Oil Specifications (Standard)
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
SPECIFICATION
MOBIL DTE 11M
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)
VISCOSITY SPECIFICATIONS
at 40°C
LUBRICATION
15 cSt
33.1 cSt
at 100°C
4.1 cSt
6.36 cSt
Hydraulic Oil
at 100°F
80 SUS
—
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.
at 210°F
43 SUS
—
cp at -30°F
3.200
—
Viscosity Index
140
147
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
LIMIT SWITCHES
High Drive Speed Cutout
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
Model
High Drive Speed Cutout
Maximum Deck
Elevation
1930ES
54 in (1.4 m)
2030ES
66 in (1.7 m)
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)
2630ES
76 in (1.9 m)
2646ES
76 in (1.9 m)
3246ES
76 in (1.9 m)
1.5°
2°
2.5°
3°
20 ft (6 m)
15 ft (4.5 m)
12 ft (3.7 m)
10 ft (3 m)
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)
Tilt Setting
Tilt Setting
(front to back) (side to side)
3°
3°
3°
Pressure Settings
Table 1-14. Pressure Settings
Model
Lift Relief
Steer Relief
1930ES
1800 psi ± 50 psi
(124 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)
2030ES
1800 psi ± 50 psi
(124 bar ± 3.4 bar)
1500 psi
(103 bar)
3246ES
3°
2°
2.5°
3°
31.75 ft (9.7 m)
22 ft (6.7 m)
20 ft (6 m)
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)
3121166
– 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
2030ES
2630ES
100 lbs
(45 kg)
Platform
133 lbs
(61 kg)
176 lbs
(80 kg)
45 lbs
(20 kg)
Manual Platform Extension
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
1930 ES
Counterweight(s) (CE, AUS)
582 lbs
(264 kg)
Counterweight (ANSI, CSA, JPN)
N/A
2030ES
2630ES
721 lbs
(327 kg)
2646ES
3246ES
1592 lbs
(722 kg)
1956 lbs
(887 kg)
721 lbs
(327 kg)
N/A
589 lbs
(267 kg)
Wheel and Tire Assembly (each)
22 lbs (9.8 kg)
42 lbs (19 kg)
Wheel/Tire and Drive Assembly (each)
117 lbs (53 kg)
162 lbs (73.4 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
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
Sq In
0.00604
0.00661
0.00909
0.01015
0.01400
0.01474
0.01750
0.02000
0.0318
0.0364
IN-LB
[N.m]
IN-LB
[N.m]
40
48
32
40
32
36
24
32
20
28
In
0.1120
0.1120
0.1380
0.1380
0.1640
0.1640
0.1900
0.1900
0.2500
0.2500
LB
4
1320
1580
1800
2860
3280
43
60
68
143
164
5
7
8
16
19
129
148
15
17
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
In
0.3125
0.3125
0.3750
0.3750
0.4375
0.4375
0.5000
0.5000
0.5625
0.5625
0.6250
0.6250
0.7500
0.7500
0.8750
0.8750
1.0000
1.0000
1.1250
1.1250
1.2500
1.2500
1.3750
1.3750
1.5000
1.5000
Sq In
0.0524
0.0580
0.0775
0.0878
0.1063
0.1187
0.1419
0.1599
0.1820
0.2030
0.2260
0.2560
0.3340
0.3730
0.4620
0.5090
0.6060
0.6630
0.7630
0.8560
0.9690
1.0730
1.1550
1.3150
1.4050
1.5800
LB
4720
5220
7000
7900
9550
10700
12750
14400
16400
18250
20350
23000
30100
33600
41600
45800
51500
59700
68700
77000
87200
96600
104000
118100
126500
142200
FT-LB
25
25
45
50
70
80
105
120
155
170
210
240
375
420
605
670
860
995
1290
1445
1815
2015
2385
2705
3165
3555
[N.m]
35
35
60
70
95
110
145
165
210
230
285
325
510
570
825
910
1170
1355
1755
1965
2470
2740
3245
3680
4305
4835
FT-LB
20
25
40
45
65
70
95
110
140
155
190
215
340
380
545
600
770
895
1160
1300
1635
1810
2145
2435
2845
3200
[N.m]
25
35
55
60
90
95
130
150
190
210
260
290
460
515
740
815
1045
1215
1580
1770
2225
2460
2915
3310
3870
4350
6
8
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
NOTES:
IN-LB
[N.m]
FT-LB
20
20
35
35
50
60
80
90
115
130
160
180
280
315
455
500
645
745
965
1085
1365
1510
1785
2030
2370
2665
[N.m
25
25
50
50
70
80
110
120
155
175
220
245
380
430
620
680
875
1015
1310
1475
1855
2055
2430
2760
3225
3625
NO. 5000059
REV. J
1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%
3. * ASSEMBLY USES HARDENED WASHER
Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7))
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)
TITETM 111 or
140)
[N.m]
[N.m]
3
0.5
5.03
2.19
1.3
1.0
1.2
1.4
3.5
0.6
6.78
2.95
2.1
1.6
1.9
2.3
4
0.7
8.78
3.82
3.1
2.3
2.8
3.4
5
0.8
14.20
6.18
6.2
4.6
5.6
6.8
6
1
20.10
8.74
11
7.9
9.4
12
7
1
28.90
12.6
18
13
16
19
8
1.25
36.60
15.9
26
19
23
28
10
1.5
58.00
25.2
50
38
45
55
12
1.75
84.30
36.7
88
66
79
97
14
16
2
2
115
157
50.0
68.3
140
105
126
154
219
164
197
241
18
2.5
192
83.5
301
226
271
331
20
2.5
245
106.5
426
320
383
469
22
2.5
303
132.0
581
436
523
639
24
3
353
153.5
737
553
663
811
27
3
459
199.5
1080
810
970
1130
30
3.5
561
244.0
1460
1100
1320
1530
33
3.5
694
302.0
1990
1490
1790
2090
36
4
817
355.5
2560
1920
2300
2690
42
4.5
1120
487.0
4090
3070
3680
4290
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7))
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]
11
3
0.5
5.03
3.5
0.6
6.78
4
0.7
8.78
5
0.8
14.20
6
1
20.10
12.5
13
12
7
1
28.90
18.0
21
20
19
8
1.25
36.60
22.8
31
29
27
10
1.5
58.00
36.1
61
58
54
12
1.75
84.30
52.5
105
100
95
14
16
2
2
115
157
71.6
170
160
150
97.8
265
250
235
18
2.5
192
119.5
365
345
325
20
2.5
245
152.5
520
490
460
22
2.5
303
189.0
705
665
625
24
3
353
220.0
900
845
790
27
3
459
286.0
1315
1235
1160
30
3.5
561
349.5
1780
1680
1575
33
3.5
694
432.5
2425
2285
2140
36
4
817
509.0
3115
2930
2750
42
4.5
1120
698.0
4985
4690
4395
NO. 5000059 REV. J
NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS
2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT
METHODS TOLERANCE = ±10%
*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED
STEEL OR RAW ALUMINUM
4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT
REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,
ADDITIONAL TESTING IS REQUIRED.
Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7)
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 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 this inspection must be
increased as environment, severity and frequency of
usage requires.
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-Certified 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-Certified 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
Frequency
Primary
Responsibility
Service
Qualification
Reference
Pre-Start
Inspection
Prior to use each day; or
At each Operator change.
User or Operator
User or Operator
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-Certified
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 SERVICE AND GUIDELINES
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.
General
The following information is provided to assist you in the
use and application of servicing and maintenance procedures contained in this book.
Components Removal and Installation
Safety and Workmanship
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.
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.
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°.
Cleanliness
1. The most important single item in preserving the
long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this.
Shields, covers, seals, and filters are provided to
keep air, fuel, and oil supplies clean; however, these
items must be maintained on a scheduled basis in
order to function properly.
2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings
and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to
prevent entry of foreign matter.
2-2
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.
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.
– JLG Lift –
3121166
SECTION 2 - GENERAL
Pressure-Fit Parts
Hydraulic Lines and Electrical Wiring
When assembling pressure-fit parts, use an anti-seize or
molybdenum disulfide base compound to lubricate the
mating surface.
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. Disassemble and reassemble parts on clean work
surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
required, to aid assembly.
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.
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.
Bolt Usage and Torque Application
1. Self locking fasteners, such as nylon insert and
thread deforming locknuts, are not intended to be
reinstalled after removal. Always use new replacement hardware when installing locking fasteners.
2. Use bolts of proper length. A bolt which is too long
will bottom before the head is tight against its related
part. If a bolt is too short, there will not be enough
thread area to engage and hold the part properly.
When replacing bolts, use only those having the
same specifications of the original, or one which is
equivalent.
3. Unless specific torque requirements are given within
the text, standard torque values should be used on
heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See
Torque Chart Section 1.)
3121166
– JLG Lift –
2-3
SECTION 2 - GENERAL
2.3 LUBRICATION AND INFORMATION
Changing Hydraulic Oil
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.
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.
Hydraulic Oil
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
Maximum acceptable cylinder drift is to be measured
using the following methods.
2.5 PINS AND COMPOSITE BEARING REPAIR
GUIDELINES
Filament wound bearings.
Platform Drift
1. Pinned joints should be disassembled
inspected if the following occurs:
Measure the drift of the platform to the ground. Fully elevate the platform. Maximum allowable drift is 2 inches (5
cm) in 10 minutes. If the machine does not pass this test,
proceed with the following.
Cylinder Drift
and
a. Excessive sloppiness in joints.
b. Noise originating from the joint during operation.
2. Filament wound bearings should be replaced if any
of the following is observed:
a. Frayed or separated fibers on the liner surface.
b. Cracked or damaged liner backing.
Table 2-2. Cylinder Drift
Cylinder Bore Diameter
c. Bearings that have moved or spun in their housing.
Max. Acceptable Drift
in 10 Minutes
d. Debris embedded in liner surface.
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
b. Flaking, pealing, scoring, or scratches on the pin
surface.
7
177.8
0.005
0.13
c. Rusting of the pin in the bearing area.
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.
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
– 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
NOTE: This machine requires periodic safety and maintenance inspections by a JLG Dealer. Notify dealer if
inspection is overdue.
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 inspection and maintenance code numbers are as follows:
1. Check for proper and secure installation.
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.
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.
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.
NOTICE
JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL
INSPECTION BE PERFORMED IN ACCORDANCE WITH THE
"ANNUAL MACHINE INSPECTION REPORT" FORM.
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
1. Controller
1,11
2. Switches
1,11
3. Placards and Decals
1,2
4. Control Tags
1,2
5. Hoses and Cables
4,8
6. Wear Pads
8,12
7. Handrails and Chains
1,4
CHASSIS
1. Battery
3
5
2. Hydraulic Pump
1
5
3. Valves
1
5
1
5
5
3,4
8. Lift Cylinder
1,12
5,6,13
4
9. Limit Switch
1,7
4. Hydraulic Filter
5. Hydraulic Hoses and Tubing
ANNUAL
6. Hydraulic Oil Tank
10. Tilt Alarm Switch
11. Placards and Decals
12. Wheel and Tire Assemblies
1,7
1,2
1
8,9
13. Drive Motors
1,5,6
14. Drive Brakes
1,6
15. Drive Torque Hubs
1,3,5,6
16. Steer Cylinder
1
5,6,13
17. Steer Components
1
4,6
18. Wheel Bearings
4
8
8
19. Scissor Arms
1,4
20. Safety Props
1,4
21. Sliding Wear Pads
12
8,12
22. Pivot Pins/Bolts
1,4
23. Switches, Ground Control
1,11
24. Control Tags
1,2
3121166
8
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 DIAGNOSTIC PORT
Installation:
The diagnostic port is located behind the battery cover at
the near the ground control station as shown below. The
MDI (Multifunction Digital Incicator) and the JLG HandHeld 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.
Figure 3-1. Diagnostic Port
2. Locate the Diagnostic Port (1) and Brake Release
Plugs (2).
3.2 MDI (MULTIFUNCTION DIGITAL
INDICATOR) AND BRAKE RELEASE
1. Diagnostic Port
MDI and Brake Release Bracket
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.
NOTE: The brake release plugs have no polarity, therefore,
can be connected to either post on the button.
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– 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)
4. Connect the MDI harness to the Diagnostic Port.
6. Using zip ties, tie back cables and wires to prevent
damage to the cables and wires.
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 preexisting) 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 (pulsewidth modulation; 16kHz). The Duty Cycle (On & Off time)
is varied to control the voltage applied to the Armatures.
When the MOSFET's spend 50% of the period On and
50% Off, approximately ½ of the available Battery Voltage
will be applied to the Armatures. Similarly, the MOSFET
are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the Armatures (as in Driving at Full
Speed).
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 TORQUE HUB
Leak Test
NOTICE
THE PROCEDURES WITHIN THIS SECTION APPLY TO ALL
MACHINES AND TORQUE HUBS. PROCEDURES THAT APPLY TO
SPECIFIC MACHINES AND TORQUE HUBS WILL BE SO NOTED
BY PROPER SERIAL NUMBERS.
NOTE: These instructions will cover how to completely
assemble and disassemble the Torque-Hub unit.
However, if the unit is under warranty you should
contact JLG Industries, Inc. for a replacement unit.
The warranty will no longer be valid if the unit is disassembled by non-JLG personnel.
NOTICE
TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK
TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO
MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE
WORKING PROPERLY.
Torque-Hub units should always be roll and leak tested
before disassembly and after assembly to make sure that
the unit's gears, bearings and seals are working properly.
The following information briefly outlines what to look for
when performing these tests.
The purpose of a leak test is to make sure the unit is air
tight. You can tell if your unit has a leak if the pressure
gauge reading on your leak checking fitting starts to fall
after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings are located. The exact location of
a leak can usually be detected by brushing a soap and
water solution around the main seal and where the o-rings
or gaskets meet on the exterior of the unit, then checking
for air bubbles. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked.
Leak test at 10 psi for 20 minutes.
NOTE: Due to the small air volume inside this Torque-Hub, it
will pressurize to 10 psi very quickly. If the pressure
becomes excessive in the unit the seals will be
destroyed.
Oil Check/Fill Procedure
The torque hub unit is shipped with ISO 68 viscosity oil
(hydraulic fluid). It is designed to utilize the same oil
throughout its service life. However, should it need to be
checked/serviced use the following procedure.
In the event of servicing, fill the unit with ISO grade 68
hydraulic oil.
NOTE: The gearbox capacity is 10 oz of oil.
IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE
ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING
THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR
EVEN DEATH.
1. To check the oil level, rotate the wheel so that the
plugs in the cover are at 12 o-clock and 3 o-clock.
NOTE: The brake must be released before performing the
roll test. This can be accomplished by connecting the
brake release cable and depressing button. The
brake can also be released by following the manual
disengage procedures outlined in this section.
3. If oil begins to come out the oil level is sufficient.
CAUTION
RETURN BRAKE RELEASE CABLE BEFORE RETURNING TO
NORMAL OPERATION.
2. Allow the oil to settle than slowly remove the plug at
3 o-clock.
4. If no oil is noticed at the 3 o-clock plug remove both
plugs.
5. Slowly add oil at the 12 o-clock plug location until oil
begins to seep out at the 3 o-clock plug location.
6. Apply pipe dope or teflon tape to the cover plugs
and reinstall into the cover.
7. TIghten to 6 ft lbs - 8 ft lbs (8.4 Nm to 11.2 Nm).
Roll Test
The purpose of the roll test is to determine if the unit's
gears are rotating freely and properly. You should be able
to rotate the wheel or hub of the gearbox by hand. If you
feel more drag in the gears only at certain points, then the
gears are not rolling freely and should be examined for
improper installation or defects. Some gear packages roll
with more difficulty than others. Do not be concerned if the
gears in your unit seem to roll hard as long as they roll
with consistency.
3121166
– JLG Lift –
3-5
SECTION 3 - CHASSIS & SCISSOR ARMS
Manual Disengage Procedure
1. Brake Cover
3. Brake Cover Bolts
2. Disengage Bolts
Figure 3-5. Disengage Procedure
3. Locate the 2 disengage bolts that are stored in the
motor endcap.
NOTE: Applies only to:
USA machines built prior to S/N 0200118041,
Belgium machines built prior to S/N 1200001487.
4. Remove these bolts and insert them into the two
holes in the brake housing.
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.
5. Tighten down bolts and the brake will disengage.
6. Repeat this procedure for the other wheel drive.
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
3. Cover O-ring Seal
2. Brake Cover
4. Disengage Holes
Figure 3-6. Disengage Procedure
7. After towing is complete, chock wheels and remove
cover bolts from disengage holes.
NOTE: Applies only to:
USA machines built S/N 0200152825 to S/N
020170585,
Belgium machines built S/N 1200008481 to S/N
1200015159.
8. Reinstall cover. Before installation, check the cover
o-ring seal for damage, replace if necessary.
CAUTION
1. Chock wheels or secure machine with tow vehicle.
2. Power machine in ground mode.
3. Remove the two cover bolts, cover, and cover o-ring
seal from the back of drive motor unit.
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.
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.
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– JLG Lift –
3-7
SECTION 3 - CHASSIS & SCISSOR ARMS
Manual Disengage Procedure
1. Brake Cover
3. Disengage Holes
2. Cover Bolts
Figure 3-7. Disengage Procedure
8. Reinstall Brake Cover.
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.
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.
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.
3-8
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor and Brake Disassembly
1. Brake Cover
5. 5. Disc Brake
2. Disengage Bolts
6. Motor
3. Socket Head Screws
7. Thru Bolts
4. Brake Housing
8. 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.
NOTE: Applies only to:
USA machines built prior to S/N 0200118041,
Belgium machines built prior to S/N 1200001487.
7. Remove the brake disc from the motor shaft.
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.
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.
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.
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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
3. Bolt
2. Cable
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
3. Washers
2. Motor Mounting Bolts
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. Spindle Sub-Assembly
5. Cover O-Ring
9. Pipe Plug
2. Spiral Snap Ring
6. Cover Thrust Washer
10. Input Carrier Sub-Assembly
3. Input ring Gear
7. Cover
11. Hub Sub-Assembly
4. Input Sun Gear
8. Cover Snap Ring
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. Remove input sun gear.
4. Remove input carrier sub-assembly.
NOTE: The input ring gear is held in with a press fit on its
outside diameter. Insert jacking screws (1/4-20UNC
grade 8) with at least 1.5 inches of thread length into
each of the three tapped holes to force the ring gear
out. Be sure and alternate between the jacking
screws to keep the ring gear from becoming misaligned in the bore. The screws will push against the
outer race of the main bearing. This bearing will
have to be replaced afterwards.
5. Remove cover o-ring.
7. Using a screwdriver remove spiral snap ring.
6. Remove input ring gear.
8. Pull hub sub-assembly off of the spindle sub-assembly.
3-12
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Disassembly
1. Planet Gears
4. Thrust washer
7. Thrust Plate
2. Output Sun Gears
5. Input Planet Gear
8. Snap Ring
3. Input Carrier
6. Needle Bearings
9. Retaining Ring
Figure 3-12. Input Carrier Disassembly
1. Remove retaining rings from each of the 3 planet
shafts.
9. Remove the three planet shafts from the input carrier.
NOTE: Do not overstress these retaining rings when removing them.
NOTE: The planet pins are held in with a press fit. To avoid
damage to the parts, use an arbor or hydraulic press
to remove the planet pins.
2. Remove thrust plate.
3. Remove a thrust washer from each planet shaft.
4. Slide each input planet gear off the planet shaft.
5. Remove 22 needle bearings from the bore of each
planet gear.
6. Remove the thrust washer from each planet gear.
7. Remove retaining ring from output sun gear.
8. Slide output sun gear out from the center of the
input carrier.
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– JLG Lift –
3-13
SECTION 3 - CHASSIS & SCISSOR ARMS
Hub Disassembly
1. Seal
2. Hub
3. Main Bearing
Figure 3-13. Hub Disassembly
1. Remove main wheel bearing.
2. Remove main lip seal.
NOTE: This part is held in the hub with a press. To remove
have the hub sitting seal side up. Use a plate or rod
with a large enough diameter push in the inner race
of the bearing. Apply force to the push the bearing
out. This bearing will need to be replaced upon reassembly.
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. Spindle Sub-Assembly
5. Thrust Washer
9. O-Ring
2. Main Bushing
6. Output Planet Gear
10. Shaft Seal
3. Shaft Ball Bearing
7. Output Planet Pins
11. Snap Ring
4. Tanged Washer
8. Main Bearing
12. Needle Roller Bearings
Figure 3-14. Spindle DIsassembly
1. Place unit on bench with planet gears facing up.
6. Press out the motor shaft seal from the center bore.
2. Remove 3 output planet shafts.
7. Remove the main bearing from the outside diameter
of the spindle.
NOTE: These planet shafts are held in with a press fit. Use
the tapped hole in the end of the pin in conjunction
with a slide hammer or similar tool to remove them.
NOTE: This bearing is held in with a press fit. You will need
to pry against the spindle to remove it. The bearing
will need to be replaced when this is done.
3. Remove the output planet gear, thrust washer, and
tanged washer out of each gear “window” of the
spindle.
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.
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– JLG Lift –
3-15
SECTION 3 - CHASSIS & SCISSOR ARMS
Spindle Sub-Assembly
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.
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.
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.
6. Line the bore of the output planet gear with 22 needle rollers. Use grease to retain the needle rollers in
the bore.
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
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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.
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3-17
SECTION 3 - CHASSIS & SCISSOR ARMS
Input Carrier Sub-Assembly
1. Planet Gears
4. Thrust washer
7. Thrust Plate
2. Output Sun Gears
5. Input Planet Gear
8. Snap Ring
3. Input Carrier
6. Needle Bearings
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.
visually. Additional grease may help hold everything
together.
6. Place the input planet gear and thrust washers onto
the input planet shaft sticking out from the carrier.
When you slide the input planet shafts into the
bores, the needle bearings will try to push out. If you
have the thrust washers lined up properly they will
contain the needle bearings within the input planetgear.
2. Insert output sun gear into the splined bore of the
input carrier. The gear tooth end of the output sun
gear should protrude in the opposite direction of the
input planet shaft.
3. Using retaining ring pliers. Install the retaining ring
into the groove of the output sun gear. Make sure
that the ring is correctly seated in the groove and
that the output sun gear cannot be pulled out of the
input carrier.
7. Repeat 5 & 6 for the other 2 planet gears.
8. Put the thrust plate onto the three input planet
shafts. Use the 3 holes on the innermost bolt circle.
The other 3 holes are for a different gear ratio.
4. Load 22 needle rollers into the bore of each input
planet gear. Retain the needle bearings in the bore
with a coating of grease.
5. Place a thrust washer on each side of the input
planet gear. Line up the bores as well as you can
3-18
9. Using the appropriate retaining ring pliers put a
retaining ring into the groove of each planet shaft.
NOTE: Do not overstress the snap ring.
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Main Gearbox Assembly
1. Spindle Sub-Assembly
5. Cover O-Ring
9. Pipe Plug
2. Spiral Snap Ring
6. Cover Thrust Washer
10. Input Carrier Sub-Assembly
3. Input ring Gear
7. Cover
11. Hub Sub-Assembly
4. Input Sun Gear
8. Cover Snap Ring
Figure 3-17. Main Gearbox Disassembly
2. Apply a coating of grease to the lip seal of the hub
sub-assembly.
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.
3. Place Spindle Sub-Assembly on table with carrier
side up.
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.
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.
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.
1. Inspect seal surface of spindle. Remove any debris
that may be present.
a. Stage 1: The hub slides together until the gear
teeth of the hub hit the gear teeth of the 3 output
planets.
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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.
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SECTION 3 - CHASSIS & SCISSOR ARMS
Motor and Brake Assembly
13. Brake Cover
17. 5. Disc Brake
21. Retention Bolt
14. Disengage Bolts
18. Motor
22. Washer
15. Socket Head Screws
19. Thru Bolts
16. Brake Housing
20. Spacers
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.
NOTE: Keep the brake disc clear of any oil or grease.
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.
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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
from the motor end. There may be motor wires in the
way. Push them aside to mount the brake.
7. Fasten with 3 Bolts to a torque of 4 - 5 ft.-lbs.
8. Remove the disengage bolts from the brake housing
and install them into the tapped holes in the motor
end cap for storage.
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SECTION 3 - CHASSIS & SCISSOR ARMS
9. Connect the connector (not shown) from the brake
housing to the connector from the motor.
10. If not already done, remove thru bolts from motor.
11. 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.
12. 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.
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.
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.
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).
3-22
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SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Assembly
1. Motor
3. Bolt
2. Cable
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.
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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).
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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
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SECTION 3 - CHASSIS & SCISSOR ARMS
3.5 ELECTRIC DRIVE MOTOR
5. Remove each of the four brushes from the brush
holder.
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.
6. Inspect each brush, if the brush is equal to or less
than 3/8 in. (9.5 mm), the brush will need replaced.
Replacing Motor Brushes
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.
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.
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.
Disassembly
3. Remove the end cap retaining bolt.
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.
4. Remove the retention bolt and washer from the end
of the armature and remove armature from the
motor shell.
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.
NOTE: The load spring that is behind the motor bearing will
be loose when the armature is removed. Take care
not to lose it.
6. Connect the brush wires to the terminal on the brush
holder using the bolts that were removed earlier.
1. Disassemble the motor from the gearbox.
2. Mark the position of the motor end cap to the motor
shell.
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.
Replacing Motor Bearing
1. Carefully remove the bearing from the armature by
using a bearing puller.
Replacing the Motor Cable
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.
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.
Inspecting Motor Brushes
3. Cut the leads going into each butt splice.
NOTE: Motor brushes should be inspected every 1000
hours.
NOTE: Be sure to cut the leads just below the splice to leave
as much cable as possible.
1. Loosen the strain relief of the cable and push
approximately 1 in. (25 mm) of cable into the motor.
4. Cut off the motor connector that connects to the
brake.
2. Separate the end piece from the motor shell by
approximately 1 in. (25 mm).
5. Remove the motor end cap from the motor shell.
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.
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– JLG Lift –
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.
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SECTION 3 - CHASSIS & SCISSOR ARMS
NOTE: Be sure cut the leads just below the splice to leave
as much cable as possible.
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.
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
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.
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.
11. 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.
12. 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.
13. Connect the armature wires (2 red and 2 black) to
the appropriately marked brush leads using the
large butt splices and shrink tubing.
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.
14. Pull each of the 4 armature slices through the
access holes in the motor end cap.
15. Pull the brake leads (yellow and brown) through the
access hole in the motor end cap.
16. Install the connector for the brake onto the yellow
and brown leads. The leads can go with either of the
connector pins.
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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.
3-27
SECTION 3 - CHASSIS & SCISSOR ARMS
Motor Maintenance
1. Frame and Field Assembly
9. Commutator End Head
2. Armature Assembly
10. Friction Disc
3. Brush and Terminal Assembly
11. Brake Assembly
4. Brush Spring
12. Cover Plate
5. Brush Box Assembly
13. O-Ring
6. Retaining Ring
14. Strain Relief Bushing
7. Bearing
15. Cover
8. Wire Harness
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.
3. Discard the O-ring (13) located inside the cover.
WIRE HARNESS
FIELD CONNECTION
BRAKE CONNECTOR
BLACK WIRES
CAUTION
RED WIRES
EYE PROTECTION SHOULD BE WORN DURING ANY MAINTENANCE OPERATION.
BRAKE ASSEMBLY
MOUNTING SCREWS
COVER PLATE
MOUNTING SCREWS
COVER MOUNTING
SCREWS
THREADED HOLES IN
BRAKE ASSEMBLY
Figure 3-26. Motor Front
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.
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.
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.
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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.
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.
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.
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.
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SECTION 3 - CHASSIS & SCISSOR ARMS
4. Carefully release the brush springs (4) allowing the
brushes to contact the commutator. Make sure
brush shunts do not interfere with spring movement.
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 in-lb.
[10.2-12.4 N-m].
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
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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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
out of the cover and remove the cover from the
motor.
NOTE: Reference Figure 3-29., Drive Motor Components for
part names and locations when servicing the Drive
Motor.
4. Discard the Gasket (12) that was located under the
brake and terminal covers.
Periodic maintenance consisting of inspections of motors,
batteries and wiring circuitry is recommended.
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.
CAUTION
ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE
OPERATION.
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 310.).
Drive Motor Troubleshooting
1. Turn off power to unit and disconnect main battery
power. Disconnect drive motor connections from the
Power Module.
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.
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.
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.
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.
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.
Model
Field Resistance
@ 75°F (24°C)
Armature Resistance
@ 75°F (24°C)
1930ES
0.21 Ohms
0.037 Ohms
10. Use an arbor press or a bearing puller to remove the
armature from the commutator end head assembly.
2030ES/2630ES/
2646ES/3246ES
0.127 Ohms
0.051 Ohms
11. Remove the Snap Ring (7) and Bearing (8) from the
commutator end head. Discard the bearing.
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.
Drive Motor Inspection and Service
NOTE: Refer to Figure 3-29.
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)
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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
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SECTION 3 - CHASSIS & SCISSOR ARMS
physically damaged or brush holders are loose on
the brush plate.
4. Visually inspect the frame and field assembly for
overheating or other signs of damage. Check all wiring to ensure that the insulation is in good condition.
Verify that pole screws are torqued to 250 - 300 in-lb
(28.2 - 33.9 Nm). Verify field resistance using a suitable ohmmeter per the appropriate motor specification. Verify that the field is electrically isolated from
the frame using a dielectric tester. Replace as necessary.
5. Visually inspect the Armature Assembly (3) for signs
of overheating or physical damage. Visually inspect
the seal surface of the shaft for excessive wear.
Check for grounded circuits using a dielectric tester
by applying voltage between the commutator and
the shaft. Visually inspect the commutator for excessive wear and overheating. Replace as necessary.
6. Visually inspect the brake surfaces for excessive
wear. Replace Brake Assembly (11) if necessary.
1.
Press Fixture must press against Outer Race
2.
Bearing
7. Visually inspect the Wire Harness (1) for frayed insulation, loose terminals, or other damage. Replace as
necessary.
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)
Drive Motor Reassembly
NOTE: Refer to Figure 3-29.
Figure 3-30. Bearing Pressure Guidelines
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.
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).
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.
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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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3.7 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 butt-splice
on the two orange wires or use a piercing meter probe.
As with the armature, the field is a very low impedance
and should appear to be a short-circuit for an ordinary
voltmeter. High resistance can signal corrosion,
improper crimps, damaged connectors, damaged
cabling, or an open field winding.
• Resistance > 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 remeasure resistance (isolation).
• 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.
• 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:
• 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.
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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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 selftest since energizing the brakes could pose a hazard. However, it may detect this issue during Drive
(investigate using JLG Analyzer).
tion). 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 self-test 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 short-circuit. If this voltage is
improper (less than 8V), investigate using resistance
measurement (refer to Drive Motor Electrical Evalua-
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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 macines
built starting in mid year 2010.
Use the following instructions when replacing the Power
Module.
1. Make sure power to the machine is turned off and
the batteries are disconnected.
Table 3-1. Sevcon Power Module Specs
Operating Voltage (Pin 1 and B+)
Maximum Current Limits:
Armature
Field
Pump
Standby Current
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.
14.5 to 40 VDC
350 A
40 A
150 A
3. Before bolting the Power Module on, using a V-notch
trowel, apply a layer of heat transfer grease to the
back of the new Power Module.
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
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.
The Power Module is located at the front of the machine
as shown in Figure 3-32., Sevcon Power Module Location.
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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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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/N1001092456).
2. Locate and remove the power module protective
cover from the machine.
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
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.
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
1. Turn machine power off and disconnect the batteries.
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.
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.
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
4. Adjust the lifting device to take the weight of the battery door and remove door from under the machine.
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.
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.).
Figure 3-35. Battery Charger Location
• 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.
1
BATTERY
FILLER CAP
FLUID LEVEL OF FULLY
CHARGED BATTERY
VENT TUBE
1/8 "
2
PLATES
4
3
1. AC Voltage - Input Cable
2. Charger Interlock Cable
3. DC Power Cable to Batteries
4. LED Indicator Cable
Figure 3-34. Battery Fluid Level
Figure 3-36. Battery Charger
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Battery Charger Maintenance
Table 3-3. Battery Charger Specs
BATTERY CHARGER
SPECIFICATION
OUTPUT
Nominal DC Output Voltage
24V
Maximum DC Output Voltage
33.6V
Maximum DC Output Current
25A
Maximum Interlock Current
20A
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.
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]
STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND
REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.
OPERATION
Charging Indicator
Yellow LED
100% Charge Indicator
Green LED
Fault Indicator
Red LED
DANGER
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
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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Battery Charger Troubleshooting
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.
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 Timeout
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.
FAULT LED Flashing
The Fault LED flashes to indicate the microcontroller
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.
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.
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.
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.
[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.
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."
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.
[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.
5. If this problem does not clear after the battery voltage is confirmed to be less than 2.4V per cell, return
the charger for service.
2. Check that one or more cells in the battery are no
shorted.
[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.
– JLG Lift –
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 damanging 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 indicaiton must be
cleared manually by unplugging the AC, waiting 30
seconds and reconnecting the AC power.
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.
2. If possible, move the machine to a cooler location.
1. Confirm that the battery pack is not too small - usually > 50Ah.
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.
2. Confirm that the nominal battery voltage matches
the charger output voltage.
[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. Confirm the correct battery charge algorithm. If the
battery pack is new, the algorthm 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.
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.
3-46
– JLG Lift –
3121166
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 EVGGC6A-A
35
JLG P/N 0400242
23
Douglas Flooded (JLG default)
GES Battery A1055
Trojan T105
US BATT GC-110-WNL
Trojan T105 PLUS
Champion CHGC2 GC2
US BATT EV-145-WNL
8
Concorde 10xAh AGM
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 timeout 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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– JLG Lift –
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
3-47
SECTION 3 - CHASSIS & SCISSOR ARMS
3.12 BATTERY CHARGER/INVERTER (OPTION)
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.
Table 3-5. Battery Charger/Inverter Specs
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
Output Reverse DC Polarity
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
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
3-48
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
Battery Charger/Inverter Troubleshooting
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:
The Fault LED Flash Codes are the same as the Battery
Charger (see Battery Charger Troubleshooting on pages
3-29 and 3-30).
a. 6 pos. terminal 3 to 4 pos. terminal 1
For further specification and troubleshooting information
refer to the manufacturers’ Charger/Inverter Owner’s
Guide shipped with the machine. Publication - RM1024JLG - 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.
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.
No charge voltage:
2. Turn on machine.
1. Disconnect control cable from Inverter/charger.
3. There should be Vbatt present on the Interlock connector socket 1.
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:
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 J119 then goes to harness Interlock connector terminal 1 (Yellow/Red wire), then to switch.
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:
LED(s) suspected to be bad:
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
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.
c. 8 pos. terminal 5 to 6 pos. terminal 4
d. 8 pos. terminal 6 to 6 pos. terminal 6
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1. Disconnect the Inverter/Charger control cable at the
8 position connector and the 2 position Interlock
connector.
– JLG Lift –
3-49
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 3-40. Motor Cable Routing (2030ES/2630ES)
Figure 3-39. Motor Cable Routing (1930ES)
3-50
– JLG Lift –
3121166
SECTION 3 - CHASSIS & SCISSOR ARMS
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
2
1
3. Obtain the Cable Clamp and hardware.
1. Drive Cables
1. Cable Clamp
2. Spacer Plate
3. Capscrew, Washers, and
Nut
2. Cable Clamp
3. Spacer Plate
19. Reconnect battery cable plug. Power up machine
and operate the drive function to ensure drive
motors operate properly.
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3-51
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
3. Cable Clamp
2. Roll Pin
2. Obtain the Cable Clamp and hardware.
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.
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.
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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– 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.
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.
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.
3-56
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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: Reference the chart below for proper pin loading.
NOTE: Omit step 1 following if switches are the outboard of
frame rails design.
PIN-3
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-4
PIN-2
PIN-1
4. With the socket terminals properly installed, re-insert
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 –
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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.
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3-59
SECTION 3 - CHASSIS & SCISSOR ARMS
4. Remove plug and place control box face down on a
suitable work bench.
Tilt Sensor Replacement
Tilt Sensor, JLG P/N 4000006:
.
2
5. Remove the six bolts at the back of the ground control and separate.
1
1. Ground Control Station
6. Pull the pin connectors from the printed circuit
board.
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.
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.
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
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
NOTE: Refer to Figure 3-46., Tilt Sensor Removal for numbers in parenthesis.
1. Disconnect the batteries.
Connector Pin
Red
VCC
1
Black
Ground
4
Blue
PWMX
2
Yellow
PWMY
3
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
3.16 ARMS AND PLATFORM POSITIONING
AND SUPPORT
4
1
CAUTION
3
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:
2
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)
1. Tilt Sensor (JLG P/N 4000021 or
1001114936)
If removal of the platform becomes necessary use the
above procedure to stabilize the platform for pin and platform removal.
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
Table 3-7. Tilt Sensor Harness for 4000021
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
3-62
White
CANH
2
Green
CANL
3
Black
Ground
4
– 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.
1. Remove platform (refer to Section 3.17, Platform
Removal).
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 lift cylinder (refer to Section 4.6, Lift Cylinder Removal).
2. Disconnect all wiring and cables attached to scissor
arm assembly.
4. The scissor arms can be removed as a complete
unit or individually.
Removing scissor arm assembly as a complete unit:
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.
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.
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.
NOTE: Overhead crane and straps must be capable of lifting
at least 1545 lbs (701 kg).
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.
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
4. Loosen and remove the four bolts that hold the bottom of the control box.
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.
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
2.5 (±0.1) VDC
1
RED
HANDLE COM
4 (±0.1) VDC
2
VIOLET
TRIGGER N.O.
3
--
SPARE
4
YELLOW
ROCKER RT
5
GREEN
ROCKER LT
Output: Handle Centered
Output: Full Positive (Reverse) Deflection
Output: Full Negative (Forward) Deflection
3-66
CONNECTOR PINOUT
1 (±0.1) VDC
– JLG Lift –
6
--
SPARE
7
WHITE/RED
+5VDC
8
WHITE/BLACK
GROUND
9
BROWN
SIG OUTPUT
3121166
SECTION 4 - HYDRAULICS
SECTION 4. HYDRAULICS
4.1 CYLINDERS - THEORY OF OPERATION
Relief Valves
Cylinders are of the double acting type. The Lift and Steer
systems incorporate double acting cylinders. A double
acting cylinder is one that requires oil flow to operate the
cylinder rod in both directions. Directing oil (by actuating
the corresponding control valve to the piston side of the
cylinder) forces the piston to travel toward the rod end of
the barrel, extending the cylinder rod (piston attached to
rod). When the oil flow is stopped, movement of the rod
will stop. By directing oil to the rod side of the cylinder, the
piston will be forced in the opposite direction and the cylinder rod will retract.
NOTE: The lift cylinder is a single acting cylinder which
takes hydraulic pressure to extend and gravity to
retract.
A holding valve is used in the 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 springloaded to center position, therefore when the control is
released, the spool automatically returns to neutral, prohibiting any flow through the circuit.
3121166
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 4-1.
4-2
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
CAUTION
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)
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.
10. Torque the large nut to 160 in. lb (16 Nm).
3.
Alternate Lift Pressure Setting Procedure:
4. Slowly remove the fill plug venting any pressure that
may be built up in the reservoir.
1. Increase lift pressure to raise the platform and set
the safety prop.
5. To check the oil level, lower platform so it rests on
the safety porp.
2. Remove plug from port P (3) and install a pressure
gauge.
3. Remove the solenoid from the lift valve.
Wipe all dirt and debris from the filler plug area.
CAUTION
THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK.
4. Set the pressure actuating lift function from the
ground or platform.
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.
5. Remove the pressure gauge from port P (3) and
replace plug.
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.
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
Lube - White Lithium Grease (GREDAG 741)
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.
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 3-47.)
2. Locate the Lower and Upper Slide Pads and wipe/
pressure wash all dirt and debris from the slide
channel area (1, 2).
2. Cut any wire ties that attach any cables or hoses to
the lift cylinder.
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.)
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.
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.
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
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– JLG Lift –
4-5
SECTION 4 - HYDRAULICS
4.7 PUMP/MOTOR
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).
Theory of Operation
The Power Module (see Figure 3-32., Sevcon Power Module Location on page 3-38) is essentially a "low-side"
switch for the pump motor. The positive terminal of the
pump is tied to Battery Positive after the Line Contactor.
The negative terminal of the pump connects to the P Terminal of the Power Module, which switches current
through MOSFET transistors to the Battery Negative.
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 batter 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 deenergize 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 deenergize 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 persist (erratic
PUMP PWM%, PUMP CUR around 150A), examine
the cabling between the Pump Motor and Power
4-7
SECTION 4 - HYDRAULICS
Module compartment for a short-circuit (most likely
near area where cylinder retracts between frame
side sheets or near pot-hole 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 taking
care not to damage internal pickup tube or oring gasket on tank.
c. Place tank on a suitable work bench or work
area.
NOTE: 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 inlb.
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.
11. Remove allen nut on the return/filter line and rotate
large retainer ring to remove return/filter line.
8. Replace plug and torque to 40 ft. lbs (56 Nm).
12. With the return line and the pickup tube removed,
the pump can be removed.
13. Loosen and remove the two hexhead nuts from the
pump and block.
9. To remove the oil pickup line, squeeze retainer and
slide outward.
NOTE: There are two o-rings located in the valve for the
pump outlet.
10. Replace the o-rings if necessary.
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– 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.
14. Check oring on valve block and replace if necessary
before installing the new pump.
2. Pull motor from valve.
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.
4-10
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
4.8 CYLINDER REPAIR
6. Using a spanner wrench, loosen the spanner nut
retainer, and remove spanner nut from cylinder barrel.
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.
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.
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.
8. Attach a suitable pulling device to the cylinder rod
port block end or cylinder rod end, as applicable.
NOTICE
DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE.
RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.
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.
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.
– JLG Lift –
4-11
SECTION 4 - HYDRAULICS
13. Remove the bushing from the piston.
7. Inspect threaded portion of piston for damage.
Dress threads as necessary.
14. Screw the piston CCW, by hand, and remove the
piston from cylinder rod.
8. Inspect seal and o-ring grooves in piston for burrs
and sharp edges. Dress applicable surfaces as necessary.
15. Remove and discard the piston o-rings, seal rings,
and backup rings.
9. Inspect cylinder head inside diameter for scoring or
other damage and for ovality and tapering. Replace
as necessary.
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.
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.
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.
12. Inspect cylinder head outside diameter for scoring
or other damage and ovality and tapering. Replace
as necessary.
2. Insert a flathead screwdriver (or similar tool) into the
cross-drilled retaining ring hole.
13. If applicable, inspect rod and barrel bearings for
signs of correct excessive wear or damage. Replace
as necessary.
3. Using the screwdriver, guide the retaining ring into
the cross-drilled retaining ring hole while turning the
piston.
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.
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.
c. Lubricate inside of steel bushing with WD40
prior to bearing installation.
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.
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
GAR-MAX
BUSHING
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.
ARBOR
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.
4-12
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.
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.
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
Figure 4-9. Installation of Head Seal Kit
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS
ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL
INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND
IMPROPER CYLINDER OPERATION.
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
b. Tap each space once; this means the tapered
bushing is tapped 3 times as there are 3 spaces
between the capscrews.
7. Retorque the capscrews evenly and progressively in
rotation to the specified torque value.
8. Remove the cylinder rod from the holding fixture.
PISTON
9. Place new guide locks and seals in the applicable
outside diameter grooves of the cylinder piston.
(See Figure 4-10.)
BACKUP
RINGS
SPLIT SEAL
10. 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
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
SPLIT
BACKUP
RING
O-RING
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 oring and seal ring are not damaged or dislodged.
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.
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.
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
contact with the bushing in the 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).
– JLG Lift –
3121166
SECTION 4 - HYDRAULICS
Table 4-2. Cylinder Piston Nut Torque Specifications
Description
Nut Torque
Value
Setscrew
torque Value
Lift Cylinder
250-300 ft lb
(339-407 Nm)
N/A
NOTE: Reverse the procedure Steer Cylinder Piston
Removal - Cyl. p/n-1684456 on page 4-12 for installing the steer cylinder piston.
17. Remove the cylinder rod from the holding fixture.
18. Position the cylinder barrel in a suitable holding fixture.
NOTICE
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
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.
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
EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE
CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD
OFF-CENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON
AND CYLINDER BARREL SURFACES.
23. If applicable, install the cartridge-type holding valve
and fittings in the port block using new o-rings as
applicable. Refer to Table 4-3, Holding Valve Torque
Specifications.
– JLG Lift –
4-15
SECTION 4 - HYDRAULICS
TOP VIEW
2
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
13
20
18
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
men u:
HELP:PRESS ENTER
Analyzer Display
Escape Key
Enter Key
To return home or access
previous menu
Stores and selects Top Level, Sub
Level, and item menus
Left & Right Arrow Keys
Up & Down Arrow Keys
Used to move between Top Level,
Sub Level, and item menus
Value Selector
Figure 5-1. Hand Held Analyzer
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:
In platform mode,
HELP: (001)
EVERYTHING OK,
In ground mode,
HELP: (002)
GROUND MODE OK
If ENTER is pressed again, the display moves to the following display:
MENU:
HELP:PRESS ENTER
l og:
HELP:
1:STARTUP ( 2/ 1)
( 211)
or
HELP:
(machines with no MDI)
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
(machines with an MDI)
LOGGED HELP
1: STARTUP (2/1): (Or last recorded fault)
LOG: (211)
1: Power Cycle (Or last recorded fault)
At this point, the analyzer will display the highest priority
active fault, if any are present. You may scroll through the
fault logs to view what the last fifteen faults were. Use the
right and left arrow keys to scroll through the fault logs.
The active faults, are listed before the first POWER
CYCLE. To return to the top menu, press ESC two times.
When a top level menu is selected, a new set of menu
items may be offered; If for example you choose Personalities:
ACCESS LEVEL
PERSONALITIES
MACHINE SETUP
DRIVE
ACTIVATE TESTS
LIFT
STEER
CALIBRATION
GROUND
If you press ENTER, at the HELP:PRESS ENTER display,
and a fault is present, the analyzer display will scroll the
fault across the screen. If more than one fault is present
only the highest priority fault will show. The other active
faults are viewable in Logged Help. If there was no fault
detected, the display will read:
5-2
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
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key.
Changing the Access Level of the Hand Held
Analyzer:
MENU:
ACCESS LEVEL 1
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 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
Once you have gained access to level 1, and a personality
item is selected, press the UP or DOWN arrow keys to
adjust its value, for example:
Machine Setup
When a machine digit item is selected, press the UP or
DOWN arrow keys to adjust its value, for example:
FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION.
PERSONALITIES:
DRIVE ACCEL 0.7s
GROUND ALARM:
1=DESCENT
PERSONALITIES:
DRIVE ACCEL 0.7s
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.
GROUND ALARM:
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.
5-4
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
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.
5.2 TILT SENSOR CALIBRATION
Be sure that the machine is parked and stowed on level
ground.
Ground Module Software Version 1.5
Password 33271 will give you access to level 1,
which will permit you to change all machine personality and/or machine setup settings.
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:
CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE
PERFORMANCE OF YOUR MACHINE.
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.
NOTICE
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSUREWASHING 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.
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.
The flash code is indicated on the face of the platform
control box as shown:
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.
SYSTEM FAULT
Ground Module Software Version 1.4
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.
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
3121166
– JLG Lift –
5-5
SECTION 5 - JLG CONTROL SYSTEM
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.
b. NOT LEVEL - tilt sensor has either developed an
offset or it is too unlevel as mounted on the
machine.
5.3 TILT SENSOR ELECTRICAL EVALUATION
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 or
ground control board failure (observe any
cracks in the box).
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.
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:
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.
• 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.
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).
5-6
– JLG Lift–
3121166
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.
Model
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.
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.
Tilt Setting
Tilt Setting
(front to back) (side to side)
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 UPDATING SOFTWARE
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.
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.
5. Press enter for Yes and the Elevation Sensor will set.
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.
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 Reprogamming 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.
5-8
– JLG Lift–
3121166
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 ALARM SOUNDING--TILTED AND ABOVE ELEVA- Platform is elevated and the chassis is not level.
TION
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.
0
0 DRIVING AT CUTBACK -- ABOVE ELEVATION
0
0 DRIVE & LIFT UP PREVENTED -- TILTED & Driving is not possible since the platform is elevated and
ELEVATED
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.
0
0 LIFT UP PREVENTED -- MAX HEIGHT ZONE A
3121166
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.
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
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
While stowed, drive speed is reduced (due to lower ground
clearance) since the control system detected that the pothole 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
pot-hole 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 pothole limit switches, or repair
the wiring to correct the problem.
0
0 DRIVING AT CUTBACK -- POTHOLE STILL
ENGAGED
0
0 FUNCTIONS LOCKED OUT -- SYSTEM POWERD After 2 hours without activity, the control system enters a
DOWN
low-power state to preserve battery charge.
0
0 DRIVE PREVENTED -- ELEVATED AND ABOVE
DRIVE CUTOUT HEIGHT
Check batteries charge, condition, etc. Normal operation
should resume after a power
cycle.
The Drive Cutout functionality is enabled, and the platform Check elevation switches
Check pothole switches.
is elevated above the calibrated cutout height.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is
Greater 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 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.
2
1 KEYSWITCH FAULTY -- PLATFORM & GROUND
ACTIVE TOGETHER
The platform and ground mode inputs from the keyswitch Re-cycle power once the
are active at the same time. The control system will default problem has been resolved to
to ground mode when if this happens. The keyswitch and clear this difficulty.
wiring inside the ground control box should be examined /
repaired.
Platform EMS digital input energized and ground mode
select digital input energized.
Default to ground mode operation and lift up prevented
2
2 FUNCTION PROBLEM -- HORN PERMANENTLY
SELECTED
Horn switch in the platform control box was closed during Release or repair the switch to
power-up.
clear the message.
In platform mode, the Indoor/Outdoor switch digital input is
energized and power-up is active. Retained until either is
momentarily de-energized.
Previously selected Indoor/Outdoor mode maintained.
2
2 FUNCTION PROBLEM -- INDOOR / OUTDOOR
PERMANENTLY SELECTED
Indoor / Outdoor switch in the platform control box was Release or repair the switch to
clear the message.
closed during power-up.
In Platform Mode, the Indoor / Outdoor Switch Digital Input
is Energized and Power-up is Active. Retained until Digital
Input is momentarily De-energized.
Previously selected Indoor / Outdoor Mode maintained
Help messages with the 2-2 flash code indicate difficulty with the platforms controls.
5-10
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
2
2 FUNCTION PROBLEM -- DRIVE & LIFT ACTIVE
TOGETHER
The Drive - Lift selector switch indicates that both functions Repair the wiring or switch to
are selected simultaneously.
clear the message.
In Platform Mode, the Drive and Lift Digital Inputs are Energized at the same time. Retained until either is momentarily
De-energized.
Drive, Steer, & Lift Prevented
2
2 FUNCTION PROBLEM -- STEER LEFT PERMANENTLY SELECTED
Steer left switch in the platform control box was closed dur- Release or repair the switch to
ing power-up.
clear the message.
In Platform Mode, the Left Steer Digital Input Switch is
Energized AND Power-up is Active. Retained until Digital
Input is momentarily De-energized.
Steer & Drive Prevented
2
2 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
Energized and Power-up is Active. Retained until Digital
Input is momentarily De-energized.
Steer & Drive Prevented.
Release or repair the switch to
clear the message.
2
2 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.
The wiper wire being off, the
wiper wire shorted to +B, or
the wiper wire shorted to –B
(ground) could cause this difficulty.
2
2 ACCELERATOR FAULTY – STEER SWITCHES
ACTIVE TOGETHER
Both the steer left and steer right inputs are closed as the
same time.
In Platform Mode, the Steer Left Digital Input is Energized
and the Steer Right Digital Input is Energized. Retained
until either Digital Input is momentarily De-energized.
Drive & Steer Prevented.
A short in the steer switch wiring or a failed steer switch can
cause this difficulty.
2
2 FUNCTION LOCKED OUT – ACCELERATOR NOT Selected function (drive or lift) is not allowed because the
CENTERED
joystick (accelerator) was not centered at power-up.
In Platform Mode, scaled Joystick (accelerator) position
was something other than 0% AND Power-up was Active.
Retained until the Joystick is momentarily centered.
Drive, Steer, & Lift Prevented.
2
2 FUNCTION PROBLEM – TRIGGER PERMANENTLY CLOSED
3121166
Return joystick to center
momentarily and re-initiate.
Trigger switch in the platform control box was closed at
Release switch or repair the
power-up.
switch / wiring to clear the diffiIn Platform Mode, the Trigger Digital Input was Energized culty.
AND Power-up was Active. Retained until the Trigger Digital Input is momentarily De-energized.
Drive, Steer, & Lift Prevented.
– JLG Lift –
5-11
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
2
HELP MESSAGE
2 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL
CAUSE
POSSIBLE RESOLVE
Trigger switch in the platform control box was closed for
Release switch or repair the
more than ten seconds while the joystick (accelerator) was switch / wiring to clear the diffiin the neutral position (centered).
culty.
In Platform Mode, the Trigger Digital Input was Energized
for 10,000mS AND Drive was In-Active AND Lift was InActive. Retained until the Trigger Digital Input is momentarily De-energized.
Drive, Steer, & Lift Prevented.
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 Digital Input is Energized] AND Power-up is Active.
Retained until the respective Digital Input is momentarily
De-energized.
Lift Prevented
2
3 GROUND LIFT UP/DOWN ACTIVE TOGETHER
In ground mode, the control system has detected the lift up Check the lift switch and assoand down are active simultaneously.
ciated wiring in the ground
In Ground Mode, Ground Lift Up Digital Input is Energized control box.
and Ground Lift Down Digital Input is Energized. Retained
until both the Digital Inputs are momentarily De-energized.
Lift Prevented
2
3 NO DATA FROM TILT SENSOR – NOT CONNECTED OR FAULTY
No signal from the tilt sensor mounted inside the ground
Check wiring and plug concontrol box.
nections at the tilt sensor and
Transitions on the Tilt X OR Tilt Y signals not detected for at the ground control board.
2000mS. Retained until transitions on both are sensed.
Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed
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 signa- Calibrate the Tilt Sensor using
ture implanted by the In-Circuit Test Fixture. Retained until the calibration procedure to
Calibration EEPROM is over-written by a valid calibration. clear the message.
Vehicle assumed Tilted (+20.0’ X, +20.0’ Y); Drive Stowed
Demand limited as in Worst-Case Slope Descent Functionality for both Forward and Reverse
Drive will be slow in the forward direction.
2
3 FUNCTION PROBLEM -- BRAKE RELEASE PERMANENTLY SELECTED
The ground control box lift switch was closed up or down,
during power-up in ground mode.
5-12
– JLG Lift–
Release or repair the switch to
clear the message.
Check if the lift switch is
obstructed or jammed. Check
the lift switch signal and wiring
to the ground board. Replace
ground board.
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout.
2
5 ELEV ANGLE SENSOR FAULTY – NOT MOUNTED The input voltage from the sensor that measures lower arm
OR VOLTAGE OUT OR RANGE
motion is outside acceptable range. This may be caused by
improper sensor mounting, difficulty with the sensor wiring,
or a faulty sensor.
The elevation sensor is unhealthy
Platform height assumed to be full elevation.
Check mounting, review sensor wiring against the electrical schematic, or replace the
sensor to clear the message.
2
5 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
Platform is Elevated, but the Elevation Sensor’s Voltage
indicates that the Platform is Stowed. To be conservative,
the control 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.
Calibrate the elevation angle
sensor using the calibration
procedure to clear the message.
2
5 DRIVE PREVENTED – CHARGER CONNECTED
Driving is not possible since the vehicle is charging and it is Disconnect battery charger
configured to only allow lifting.
In Platform Mode, the Battery Charger is Charging AND the
Drive / Lift Select Toggle is set to Lift AND Machine Setup’s
CHARGE INTERLOC is set to 0=DRIVE ONLY.
Drive & Steer Prevented
2
Disconnect battery charger
5 DRIVE & LIFT UP PREVENTED – CHARGER CON- Driving and lifting are not possible since the vehicle is
NECTED
charging and it is configured to prevent all motion.
In Platform Mode, the Battery Charger is Charging AND the
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.
2
5 PLATFORM OVERLOADED
2
5 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.
3121166
Remove excess weight from
While the Load Sensing System is enabled, the platform
load measured by the Load Sensing System is excessive. platform.
Functions from platform control are prevented, and functions from ground control may be prevented, depending on
machine configuration.
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).
– JLG Lift –
Clear the obstacle blocking
the pot-hole protection mechanism, repair the mechanical
problem, re-adjust the pothole 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
CAUSE
POSSIBLE RESOLVE
2
5 ELEV PROX PERMANENTLY CLOSED – CHECK
PROX AND ANGLE ADJUSTMENT
The Elevation Proximity Switch is closed to indicate that the Check elevation switches.
platform is stowed, but the elevation sensor’s voltage indi- Replace if necessary.
cates that the platform is elevated. To be conservative, the
control system will assume that the platform is elevated,
and the drive speed will be restricted to elevated.
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.
2
5 DRIVE & LIFT PREVENTED – BRAKES ELECTRICALLY RELEASED FOR TOWING
The manual brake release has been activated to allow the
vehicle to be towed.
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 Check elevation switches
is elevated above the calibrated cutout height.
Check pothole switches.
Drive Cutout is set to 1=YES AND the Elevation Sensor is
“Healthy” AND the Elevation Sensor’s Zeroed Voltage is
Greater Than the Calibrated Drive Cutout Voltage.
Refer to Drive Cutout Functionality.
2
5 MODEL CHANGED -- HYDRAULICS SUSPENDED The model selection has been changed.
- CYCLE EMS
2
5 DRIVE PREVENTED -- BRAKES NOT RELEASING While driving on a level surface, armature current was >
Ensure vehicle is not stuck on
150A for five seconds. Brakes assumed to not be releasing something preventing moveproperly.
ment. Check/repair drive
motor wiring, brakes or
mechanical issues.
Disengage the manual brake
release.
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 OPEN CIRCUIT LINE CONTACTOR
The Power Module’s line contactor drive circuitry passed Refer to CANbus documentapower-up self-tests, but the line contactor did not close
tion for Power Module Meswhen energized.
sage - Status.
The Power Module is reporting a “Contactor Did Not Close”
Fault Code (15d).
Drive, Steer, & Lift Up Prevented.
3
1 CONTACTOR DRIVER PERMANENTLY OFF
The Power Module’s Line Contactor drive circuitry failed to Refer to CANbus documentaenergize during power-up self-tests.
tion for Power Module MesThe Power Module is reporting a “Contactor Driver 1 Per- sage - Status.
manently Off” Fault Code (22d).
Drive, Steer, & Lift Up Prevented.
3
2 LINE CONTACTOR MISWIRED ON OR WELDED
Help messages with the 3-2 flash code indicate that a contactor did not open when de-energized.
5-14
The Power Module’s Line Contactor Drive Circuitry passed Refer to CANbus documentapower-up self-tests, but the line contactor did not open
tion for Power Module Meswhen de-energized.
sage - Status.
The Power Module is reporting a “Contactor Welded” Fault
Code (14d).
Drive, Steer, & Lift Up Prevented.
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
3
HELP MESSAGE
2 CONTACTOR DRIVER PERMANENTLY ON
CAUSE
The Power Module’s Line Contactor Drive Circuitry failed
to de-energize during power-up self-tests.
The Power Module is reporting a “Contactor Driver 1 Permanently On” Fault Code (23d). Refer to CANbus documentation for Power Module Message – Status.
Drive, Steer, & Lift Up Prevented.
POSSIBLE RESOLVE
Refer to CANbus documentation for Power Module Message - Status.
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 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.
3
3 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
3
3 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.
3
3 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.
3
3 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.
3
3 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.
3
3 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.
3
3 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.
3121166
– JLG Lift –
5-15
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
3
3 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.
3
3 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.
3
3 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.
3
3 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.
3
3 GROUND ALARM SHORT TO BATTERY
While enabled, voltage was detected on the ground alarm
when the output driver was commanded off during powerup.
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.
3
3 LEFT BRAKE SHORT TO BATTERY
The ground board detected voltage while the left brake was Check for continuity through
commanded off.
this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3
3 LEFT BRAKE OPEN CIRCUIT
Current flow to the left brake solenoid was not detected dur- Check for continuity through
ing normal left brake operation.
this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3
3 RIGHT BRAKE SHORT TO BATTERY
Voltage was detected on the right brake solenoid when the Check for continuity through
ground board output was commanded off during power-up. this circuit. Inspect the wiring
for physical damage.
Replace ground board.
3
3 RIGHT BRAKE OPEN CIRCUIT
The ground board did not detect current flow to the right
brake during normal operation.
5-16
– 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
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
Help messages with the 4-2 flash code indicate a thermal problem.
4
2 POWER MODULE TOO HOT – PLEASE WAIT
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.
4
2 DRIVING AT CUTBACK -- POWER MODULE CUR- The drive portion of the Power Module has reached therRENT LIMIT
mal limit. Allow to cool by waiting for temperature to fall.
The Power Module is reporting a "I2T Drive Current LImit"
fault code.
4
2 LIFT UP AT CUTBACK -- POWER MODULE CURRENT LIMIT
The lift up portion of the power module has reached thermal 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 BATTERY VOLTAGE TOO LOW – SYSTEM SHUT- Battery Voltage momentarily dropped below 14.5V. With a Recharge batteries or check
DOWN
low battery charge, this can occur during heavy current
for damaged batteries.
demand due to drive, steer, or lift up.
The Power Module is reporting a “Low Battery” Fault Code
(7d).
Drive, Steer, & Lift Up Prevented
4
4 BATTERY VOLTAGE TOO HIGH – SYSTEM SHUT- The Power Module momentarily measured excessively
This may be due to improper
DOWN
high battery voltage (>37.0v) and the ground module de- battery charging or incorrect
energized the ignition relay to protect system devices.
voltage batteries being used.
The Power Module is reporting a “High Battery” Fault Code
(8d) OR a “High Battery without Line” Fault Code (10d). In
response, the Ground Module shall de-energize the Ignition Relay and suppress all Help Messages caused by the
lack of Ignition Signal. This fault is latched until the next
power-cycle.
Drive, Steer, & Lift Prevented.
4
4 LSS BATTERY VOLTAGE TOO HIGH
While the Load Sensing System is enabled, the Load Sens- This may be due to improper
ing System module measured battery voltage >34.0Vdc, battery charging or incorrect
voltage batteries being used.
which may compromise ability to predict weight.
LSS Module Message – Status Message (0x81) is reporting “BATT TOO HIGH” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Vehicle
assumed to be Overloaded.
4
4 LSS BATTERY VOLTAGE TOO LOW
While the Load Sensing System is enabled, the Load Sens- Recharge batteries or check
for damaged batteries.
ing 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.
LSS Module Message – Status Message (0x81) is reporting “BATT TOO LOW” AND [Machine Setup’s LOAD is set
to 1=CUTOUT PLT OR 2=CUTOUT ALL].
Vehicle assumed to be Overloaded.
3121166
– 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 CANBUS FAILURE: POWER MODULE
The control system failed to receive messages from the
Power Module.
Power Module Message – Status (0x24) not received for
1000mS or Power Module is reported a “CANbus Bus Difficulty” Fault Code (0x09).
Drive, Steer, & Lift Up Prevented.
Check wiring at the ground
control box and power module. Recycle power to clear
difficulty.
6
6 CANBUS FAILURE: PLATFORM MODULE
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.
6
6 CANBUS FAILURE: LOAD SENSING SYSTEM
MODULE
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.
6
6 ACCESSORY CAN COMMUNICATION LOST
A JLG Accessory Module has failed to maintain CANbus
Refer to documentation for the
communications with the ground module.
JLG Accessory to clear diffiThe control system received Accessory Message – Control culty.
1 from an Accessory Module, but failed to receive another
within 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 ACCESSORY FAULT
A JLG Accessory Module has encountered a fault condition and reported it via the host control system.
Accessory Message – Control 1’s Request Accessory
Fault flag is set to YES. Retained or cleared based on status of flag.
No motion interlocks.
7
7 OPEN-CIRCUIT DRIVE MOTOR FIELD WIRING
Refer to documentation for the
JLG Accessory to clear difficulty.
Help messages with the 7-7 flash code indicate motor problems.
5-18
The Power Module detected an error in the power wiring
Check power wiring and re(F1 & F2 Terminals) for the drive motors.
cycle power to clear difficulty.
The Power Module is reporting a “Field Open Circuit” Fault
Code (16d). Retained until power is re-cycled.
Drive & Steer Prevented
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
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 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.
This situation indicates that
the sensor is unplugged, or
the sensor is damaged.
8
2 LSS CELL #2 ERROR
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.
This situation indicates that
the sensor is unplugged, or
the sensor is damaged.
8
3 LSS CELL #3 ERROR
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.
8
4 LSS CELL #4 ERROR
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
LSS Module Message – Status Message (0x81) is reporting “WATCHDOG RST” AND [Machine Setup’s LOAD is
set to 1=CUTOUT PLT OR 2=CUTOUT ALL]. Retained
until power is re-cycled.
No motion interlocks.
9
2 LSS EEPROM ERROR
Memory used to retain settings on Load Sensing System After resolution, re-cycle
Module has been corrupted and must be reset by verifying power to clear difficulty.
all entries / re-calibrating.
9-2 Flash Code
LSS Module Message – Status Message (0x81) is reporting “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
3121166
– JLG Lift –
Re-cycle power to clear difficulty
5-19
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
9
3 LSS HAS NOT BEEN CALIBRATED
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-Circuit Test Fixture) AND [Machine
Setup’s LOAD is set to 1=CUTOUT PLT OR 2=CUTOUT
ALL]. Retained until Calibration EEPROM is over-written
by a valid calibration.
Vehicle assumed to be Overloaded.
Calibrate the Load Sensing
System using the calibration
procedure to clear the message.
9
9 LSS INTERNAL ERROR – PIN EXCITATION
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.
9
9 LSS INTERNAL ERROR – DRDY MISSING FROM
A/D
The DRDY Interrupt from the Load Sensing System Module’s A/D Converter is missing.
9-9 Flash Code
LSS Module Message – Status Message (0x81) is reporting “INTERNAL ERROR – DRDY INTERRUPT FROM A/
D” 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.
This may indicate Load Sensing System Module hardware
difficulty.
9
9 POWER MODULE FAILURE: PERSONALITY
RANGE ERROR
Reset control system PersonThe Power Module detected an out-of-range or corrupt
alities to default settings to
personality setting.
clear difficulty.
9-9 Flash Code
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 re-cycled.
9
9 POWER MODULE FAILURE: INTERNAL ERROR
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.
Re-cycle power to clear difficulty.
9
9 POWER MODULE FAILURE: CHECK POWER
CIRCUITS OR MOSFET SHORT CIRCUIT
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
The Power Module is reporting an “Armature MOSFET
Short Circuit” Fault Code (17d) OR an “Armature MOSFET’s Off” Fault 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 recycled.
Check wiring and motors or
replace the Power Module.
Re-cycle power to clear difficulty.
5-20
– JLG Lift–
3121166
SECTION 5 - JLG CONTROL SYSTEM
Table 5-2. Flash Code Listing
FLASH
CODE
HELP MESSAGE
CAUSE
POSSIBLE RESOLVE
9
9 POWER MODULE FAILURE: SYSTEM MONITOR The ground board detected armature, field, or pump current while function was not commanded.
9
9 EEPROM FAILURE – CHECK ALL SETTINGS
The control system detected an EEPROM failure. Person- Check / correct all settings and
alities and Machine Setup settings may be reset to default re-cycle power to clear diffivalues.
culty.
9-9 Flash Code
The control system’s EEPROM checksum indicates corruption. Retained until EEPROM settings are corrected
and power is re-cycled.
9
9 FUNCTIONS LOCKED OUT – MACHINE NOT
CONFIGURED
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.
9
9 FUNCTIONS LOCKED OUT – PLATFORM MODULE SOFTWARE VERSION IMPROPER
The control system will not function because the Platform Re-program or replace with a
Module Software Version is not compatible with the rest of Version 1.xx module.
the system.
9-9 Flash Code
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.
9
9 FUNCTIONS LOCKED OUT – POWER MODULE
SOFTWARE VERSION IMPROPER
The control system will not function because the Power
Re-program or replace with a
Module Software Version is not compatible with the rest of Version 1.xx module.
the system.
9-9 Flash Code
The Power Module reported a Software Major Version that
was not equal to “1”. The control system may resume operation once the difficulty has been corrected.
9
9 FUNCTIONS LOCKED OUT – LSS MODULE
SOFTWARE VERSION IMPROPER
The control system will not function because the LSS Mod- Re-program or replace with a
ule Software Version is not compatible with the rest of the Version 7.xx module.
system.
9-9 Flash Code
Machine Setup’s LOAD=1 or 2 AND the LSS Module
reported a Software Major Version that was not equal to “7”.
The control system may resume operation once the difficulty has been corrected.
3121166
– JLG Lift –
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.
Use the JLG Analyzer to
adjust all Machine Setup and
Personality settings and recycle power to clear difficulty.
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
*
SET ELEV SENSOR:
0.10 - 1.20V X.XXV
*
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 - Sheet 1 of 3
*
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:
SYS DISTRESS ON
RUN SYS TEST:
TILT LAMP ON
RUN SYS TEST:
OPEN IN/OUT SEL
RUN SYS TEST:
CLOSE TRIGGER
RUN SYS TEST:
OVERLOAD ON
RUN SYS TEST:
PLAT ALARM ON
RUN SYS TEST:
CLOSE HORN SW
RUN SYS TEST:
OPEN HORN SW
RUN SYS TEST:
SELECT LIFT
RUN SYS TEST:
SELECT DRIVE
RUN SYS TEST:
OUTDOOR ON
RUN SYS TEST:
OPEN TRIGGER
RUN SYS TEST:
INDOOR ON
RUN SYS TEST:
CNTRL BACK TO MN
RUN SYS TEST:
BATTERY 4 (FULL)
RUN SYS TEST:
OPEN RT STEER
RUN SYS TEST:
CLOSE IN/OUT SEL
RUN SYS TEST:
CNTRL BACK TO MX
RUN SYS TEST:
BATTERY 3 (3/4)
RUN SYS TEST:
CLOSE RT STEER
RUN SYS TEST:
CNTRL FWD TO MIN
RUN SYS TEST:
CNTRL FWD TO MAX
RUN SYS TEST:
BATTERY 1 (1/4)
RUN SYS TEST:
BATTERY 2 (½)
RUN SYS TEST: (4)
TEST PROP CNTRL?
RUN SYS TEST: (4)
TEST LEDS & ALRM?
RUN SYS TEST:
OPEN STEER LT
RUN SYS TEST:
CLOSE STEER LT
RUN SYS TEST:
OVERLOAD ON
RUN SYS TEST:
HORN ON
RUN SYS TEST: (4)
TEST PLT SW?
RUN SYS TEST: (3)
TEST OVLD & ALRM?
Figure 5-3. Analyzer Flow Chart - 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
* = 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
*
*
*
DATALOG:
ERASE RENTAL?
DATALOG:
YES:ENTR, NO:ESC
*
LOAD:
CELL 1 XXXXKG
*
LOAD:
CELL 2 XXXXKG
Figure 5-4. Analyzer Flow Chart - Sheet 3 of 3
*
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
DATALOG:
DRIVE XXH XXM
*
SYSTEM:
PHP RET/EXT/FAULTY
DIAGNOSTICS:
DATALOG
*
LOAD:
PLT LOAD XXXXKG
*
*
SYSTEM:
RT PHP OPEN/CLSD
*
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
DIAGNOSTICS:
LOAD
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
*
SYSTEM:
LT PHP OPEN/CLSD
*
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
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
LIFT
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
STEER
ACCELERATOR
FWD MIN
2.20 - 2.40 V
2.25
2.25
2.25
2.25
2.25
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
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
GROUND
LOAD
4150472-H
NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.
3121166
– JLG Lift –
5-25
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
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
LIFT
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%
85
85
85
85
85
STATIC
0 - 100%
70
70
70
70
70
DRIVE
0 - 100%
30
30
30
30
30
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
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
STEER
ACCELERATOR
FWD MIN
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
LOAD
5.0
1001115627-B
NOTE: These settings may change in order to achieve optimal performance on a machine by machine basis.
5-26
– JLG Lift–
3121166
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
(Load)
0
1
2
8
(Drive Motors)
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
0
0
9
(Elev Prox)
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
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.
4
0
0
0
4150473-F
3121166
– JLG Lift –
5-27
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
(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
0
1
7
(Load)
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
1
1
2
3
1
4
5
0
1
1
0
0
0
0
2
2
0
2
2
1
0
1
0
1
0
0
1
0
0
0
0
0
1001115626-B
5-28
– 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
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
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
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
775 OPEN CIRCUIT FIELD WIRING................................................................................................................................... 7-16
776 STALLED PUMP MOTOR OR POWER WIRING ERROR ............................................................................................ 7-16
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
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 commu- • Check the MDI connector.
nicate with the control system.
• Check the diagnostic connector.
• Check continuity between MDI connector socket 6 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.
003
ALARM SOUNDING - TILTED Control system senses that the platform
& ABOVE ELEVATION
is elevated and the vehicle is tilted, and
the machine not configured to cutout.
004
DRIVING AT CUTBACK ABOVE ELEVATION
The platform is elevated and the machine • Fully stow the platform.
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.
005
DRIVE & LIFT UP PREVENTED - TILTED & ELEVATED
Driving is not possible since the platform • Check that the machine is tilted. If so, lower the platform and
is elevated and the chassis is not level.
reposition the machine to a level surface.
• Fully stow the platform.
• 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.
6-4
• Check that the machine is tilted. If so, lower the platform and
reposition the machine to a level surface.
• Fully stow the platform.
• The tilt sensor is 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.
• 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.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
0-0 Help Comments
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
The vehicle has reached the maximum • Check that the zone is set appropriately for the platform load.
height and further lift up motion is not pos- • Check that the platform height is at the rated maximum height
sible. Applicable to 2630ES or 3246ES.
specification (20’ for 2630 or 26’ for the 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.
006
LIFT UP PREVENTED - MAX
HEIGHT ZONE A
007
DRIVING AT CUTBACK - POT- While stowed, drive speed is reduced
• Check for obstructions around the pot-hole protection mechaHOLE STILL ENGAGED
since the control system detected that the
nisms.
pot-hole protection mechanism failed to • Check that the PHP switches are securely mounted.
retract.
• Check PHP switches wiring from the ground board and for proper
operation. The left PHP input (24V) is from J1-9 and its output
(24V when deployed) is to J1-10. The right PHP input (24V) is
from J1-17 and its output (24V when deployed) is to J1-18.
008
FUNCTIONS LOCKED OUT - After 2 hours without activity, the control
SYSTEM POWERED DOWN system enters a low-power state to preserve battery charge.
• Normal operation should resume after a power cycle.
• Check batteries charge, condition, etc.
009
DRIVE PREVENTED - ELEVATED 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.
The platform is elevated above the calibrated cutout height.
2-1 Power-Up
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
211
POWER CYCLE
This help message is issued at each
power cycle. Displays on the analyzer
only.
Normal operation. No check necessary.
212
KEYSWITCH FAULTY
Both platform and ground modes are
selected simultaneously. Defaults to
ground mode.
• Check key switch function.
• Backprobe J2-3 with the keyswitch in the ground 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 J2-4 and to
emergency stop switch.
• Replace ground board.
2-2 Platform Controls
DTC
FAULT MESSAGE
221
FUNCTION PROBLEM HORN PERMANENTLY
SELECTED
3121166
DESCRIPTION
CHECK
The horn switch was closed during
power-up in platform mode.
• Check if the horn switch is damaged, obstructed or 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.
– JLG Lift –
6-5
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-2 Platform Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• Check if the indoor/outdoor (zone A / zone B) capacity switch is
damaged, obstructed or jammed.
• Replace platform board.
222
FUNCTION PROBLEM INDOOR / OUTDOOR PERMANENTLY SELECTED
The indoor / outdoor (zone A / zone B)
switch was closed during power-up in
platform mode.
223
FUNCTION PROBLEM DRIVE & LIFT ACTIVE
TOGETHER
The drive and lift inputs are closed simul- • Check drive/lift switch for visible damage.
taneously in platform mode.
• 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.
224
FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED
The steer left switch was closed during
power-up in platform mode.
225
FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED
The steer right switch was closed during • Check if the steer right switch is obstructed or jammed.
power-up in platform mode.
• Check steer right switch and its wiring to the platform board. The
steer right switch input (24V) is from platform board terminal J11, and its output (24V when closed) is to platform board terminal
J1-16.
• Replace platform board.
226
ACCELERATOR FAULTY WIPER OUT OF RANGE
The joystick signal is outside the accept- • Center joystick and check to see if a power cycle will clear DTC.
able range of 0.50V - 4.5V, or is unstable. • 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.
227
STEER SWITCHES FAULTY
The steer left and steer right inputs were • Check if the steer switches are damaged, obstructed or jammed.
closed simultaneously.
• 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.
228
FUNCTION LOCKED OUT ACCELERATOR NOT CENTERED
The joystick was not centered at powerup.
• Release joystick and allow to center.
• 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.
• 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.
6-6
• Check if the steer left switch is obstructed or jammed.
• Check steer left switch and its wiring. The steer left switch input
(24V) is from platform board terminal J1-1, and its output (24V
when closed) is to platform board terminal J1-15.
• Replace platform board.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-2 Platform Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
2210 TRIGGER CLOSED TOO
LONG WHILE IN NEUTRAL
The trigger switch was closed for more
than five seconds while the joystick was
centered.
• 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.
2232 FUNCTION PROBLEM DRIVE & LIFT BOTH OPEN
The drive and lift inputs are both deenergized in Platform Mode.
• Check if either function is active, if Yes;
• Repair the wiring or switch to clear the message.
• ZAPI - HEALTH (Status LED) - ON
2-3 Ground Controls
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• 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.
231
FUNCTION PROBLEM - LIFT The ground control box lift switch was
PERMANENTLY SELECTED closed up or down, during power-up in
ground mode.
232
GROUND LIFT UP / DOWN
ACTIVE TOGETHER
The lift up / down inputs are closed simul- • Check if the lift switch is obstructed or jammed.
taneously.
• 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 BRAKE RELEASE PERMANENTLY SELECTED
The manual brake release switch was
closed during power-up.
• Check if the brake release switch is obstructed or jammed.
• Check the brake release switch signal and wiring to the ground
board. The brake release switch input (24V) is from ground board
terminal J1-19, and its output (24V when closed) is to ground
board terminal J1-20.
• 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
DESCRIPTION
CHECK
251
ELEV ANGLE SENSOR
FAULTY - VOLTAGE OUT OF
RANGE
The elevation angle sensor input voltage • Check that the platform elevation sensor is securely mounted and
is outside the acceptable range of 0.10V undamaged.
4.50V.
• 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 J1-16.
• Replace the ground board.
252
ELEV ANGLE SENSOR HAS
NOT BEEN CALIBRATED
The elevation angle sensor has not been • Calibrate the elevation angle sensor to clear fault. See Section 5.5.
calibrated.
3121166
– JLG Lift –
6-7
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-5 Function Prevented
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
253
DRIVE PREVENTED CHARGER CONNECTED
Driving is not possible while the vehicle is • Check if the charger is connected to off board power source and
charging.
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 the vehi- • Check if the charger is connected to off board power source and
cle is charging AND is configured to predisconnect if desired.
vent all motion.
• Check ANALYZER -> MACHINE SETUP -> CHARGER INTERLOC
is set as desired. (Must be in ACCESS LEVEL 1 to change.)
• Check that charger's red (positive) battery wire connector terminal is receiving power (24V) from batteries.
• Check signal from charger interlock connector terminal 2 to
ground board terminal J1-29, where 0VDC indicates charging in
process.
255
PLATFORM OVERLOADED
The load sensing system measured plat- • Remove excess weight from the platform.
form 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 elevated
since the pot-hole protection system
failed to deploy.
257
ELEV PROX PERMANENTLY The elevation proximity switch shows the • Verify that an elevation proximity switch is present on the
CLOSED - CHECK PROX AND platform to be stowed, while the elevation
machine. If not, ensure ANALYZER -> MACHINE SETUP ->
ANGLE ADJUSTMENT
angle sensor shows the platform to be
ELEV PROX is set to NOT INSTALLED. If the switch is present, set
raised. The elevation proximity switch is
ELEV PROX to INSTALLED and check switch continuity. The
only found on certain older lifts. This
switch should close when placed in close proximity to ferrous
switch is not used on current machines so
metal.
this DTC should not occur.
258
DRIVE & LIFT PREVENTED BRAKES ELECTRICALLY
RELEASED FOR TOWING
6-8
• Check for obstructions or mechanical problems around the pothole protection mechanisms.
• Check that the PHP switches are securely mounted.
• 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.
Manual brake release mode is activated • Push manual brake release switch again or cycle power to clear
with the switch in the battery box near the
manual brake release mode.
ground control box. Drive or lift is not pos- • Check if the brake release switch is obstructed or jammed.
sible.
• Check the brake release switch signal and wiring to the ground
board. The switch input (24V) is from ground board terminal J119, and its output (24V when closed) is to ground board terminal
J1-20.
• Replace ground board.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
2-5 Function Prevented
DTC
259
FAULT MESSAGE
DESCRIPTION
CHECK
MODEL CHANGED The model selection has been changed. • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER.
HYDRAULICS SUSPENDED • Replace ground board.
CYCLE EMS
2510 DRIVE PREVENTED BRAKES NOT RELEASING
While driving on a level surface, armature • Ensure vehicle is not stuck on something preventing movement.
current was > 150A for five seconds.
• Check / repair drive motor wiring, brakes or mechanical issues.
Brakes assumed to not be releasing properly.
2511
The input voltage from the elevation
angle sensor indicates the elevation
angle sensor is not mounted.
ELEV ANGLE SENSOR
FAULTY - NOT MOUNTED
2512 ELEV ANGLE SENSOR NOT
DETECTING CHANGE
• Check that the elevation angle sensor is securely mounted.
• Check that the elevation angle sensor mechanisms are intact.
• Replace elevation angle sensor.
The input voltage from the elevation
• Check that the elevation angle sensor is securely mounted.
angle sensor did not change while vehicle • Check elevation angle sensor is not jammed or obstructed.
was lifting 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
The power modules line contactor did not • Check contactor main contact wiring to battery (+) terminal and
close when energized. Drive, steer and lift
power controller terminal B+.
up prevented.
• Contactor solenoid resistance should measure about 52 Ohms.
• 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.
311
OPEN CIRCUIT LINE CONTACTOR
312
CONTACTOR DRIVER PER- The power modules line contactor drive
MANENTLY OFF
circuitry failed to energize when
requested. Drive, steer and lift up prevented.
• Check continuity between contactor connector pin 1 and ground
board socket J1-19.
• Contactor solenoid resistance should measure about 52 Ohms.
• Check continuity between contactor connector pin 2 and power
module connector socket 8.
• Replace power module.
3-2 Line Contactor Short Circuit
DTC
FAULT MESSAGE
321
LINE CONTACTOR MISWIRED ON OR WELDED
3121166
DESCRIPTION
CHECK
Battery voltage was present at the power • Check wiring of contactor.
module B+ terminal at power up. Drive, • Check resistance between the studs of the contactor while dissteer and lift up prevented.
connected from the machine.
• Check contactor main contact wiring to battery (+) terminal and
power module terminal B+.
• Check continuity between contactor connector pin 1 and ground
board socket J1-19.
• 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.
– JLG Lift –
6-9
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-2 Line Contactor Short Circuit
DTC
322
FAULT MESSAGE
DESCRIPTION
CHECK
CONTACTOR DRIVER PER- The power modules line contactor drive
MANENTLY ON
circuitry failed to de-energize when
requested. Drive, steer and lift up prevented.
• 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.
• Replace power module.
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
331
BRAKE SHORT TO BATTERY The ground board detected voltage while • Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is set to
the brake solenoid was commanded off.
NOT INSTALLED.
332
BRAKE OPEN CIRCUIT
333
LIFT UP SHORT TO BATTERY The ground board detected voltage while • Check for continuity through this circuit. The lift up solenoid resisthe lift up solenoid was commanded off at
tance should measure about 30 Ohms. The lift up solenoid is
power up.
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.
334
LIFT UP OPEN CIRCUIT
335
LIFT DN SHORT TO BATTERY The ground board detected voltage while • Check ANALYZER -> MACHINE SETUP -> ELEV PROX is set to
NOT INSTALLED
the lift down solenoid was commanded
• Check for continuity through this circuit. The lift down solenoid
off.
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
337
STEER LEFT SHORT TO BAT- The ground board detected voltage while • Check for continuity through this circuit. Steer left solenoid resisTERY
the steer left solenoid was commanded
tance should measure about 30 Ohms. The steer left solenoid is
off at power up.
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.
6-10
The ground board did not detect current • Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is set to
flow to the brake solenoid during normal
NOT INSTALLED.
operation.
The ground board did not detect current
flow to the lift up solenoid during power
up.
The ground board did not detect current
flow to the lift down solenoid during normal operation.
• 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.
• 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.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
3-3 Ground Output Driver
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
• 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.
338
STEER LEFT OPEN CIRCUIT The ground board did not detect current
flow to the steer left solenoid during normal operation.
339
STEER RIGHT SHORT TO
BATTERY
The ground board detected voltage while • Check for continuity through this circuit. Steer right solenoid
the steer right solenoid was commanded
resistance should measure about 30 Ohms. The steer right soleoff.
noid 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 CIRCUIT
The ground board did not detect current • Check for continuity through this circuit. Steer right solenoid
flow to the steer right solenoid during norresistance should measure about 30 Ohms. The steer right solemal operation.
noid 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 The ground board detected voltage while • Check for continuity through this circuit. The ground alarm soleBATTERY
the ground alarm was commanded off.
noid is powered with 24V from ground board J1-19, its PWM signal is from ground board J1-28, 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.
3312 LEFT BRAKE SHORT TO BAT- The ground board detected voltage while • Check for continuity through this circuit. The left brake is powered
TERY
the left brake was commanded off.
with 24V from ground board J1-23, and its ground is to ground
board J1-30, 37. Brake solenoid resistance should measure
about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
3313 RIGHT BRAKE SHORT TO
BATTERY
Voltage was detected on the right brake
solenoid when the ground board output
was commanded off during power-up.
• Check for continuity through this circuit. Brake solenoid resistance should measure about 20 Ohms. The right brake is powered
with 24V from ground board J1-24, and its ground is to ground
board J1-30, 37.
• Inspect the wiring for physical damage.
• Replace ground board.
3314 LEFT BRAKE OPEN CIRCUIT Current flow to the left brake solenoid was • Check for continuity through this circuit. The left brake is powered
not detected during normal left brake
with 24V from ground board J1-23, and its ground is to ground
operation.
board J1-30, 37. Brake solenoid resistance should measure
about 20 Ohms.
• Inspect the wiring for physical damage.
• Replace ground board.
3315 RIGHT BRAKE OPEN CIRCUIT
3121166
The ground board did not detect current • Check for continuity through this circuit. Brake solenoid resisflow to the right brake during normal opertance should measure about 20 Ohms. The right brake is powered
ation.
with 24V from ground board J1-24, 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
33297 LEFT BRAKE - SHORT TO
GROUND
DESCRIPTION
CHECK
Drive and Steer Prevented
• Excessive current flow to the Left Brake Solenoid was detected (J134 NLB).
• ZAPI - HEALTH (Status LED) - ON
33298 STEER LEFT VALVE - SHORT Drive, Steer and Lift Up Prevented
TO GROUND
• Excessive current flow to the steer left solenoid detected (J2-9
NLV).
• ZAPI - HEALTH (Status LED) - ON
33299 LINE CONTACTOR COIL SHORT TO BATTERY
Drive, Lift and Steer Prevented
• Voltage from an external source was detected on the Negative
Main Line Contactor.
• ZAPI - HEALTH (Status LED) - ON
33302 NEGATIVE SUPPLY - SHORT Drive, Lift, and Steer Prevented
TO BATTERY
• 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 Drive, Lift and Steer Prevented
TO GROUND
• 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
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 (J22 PDV or J2-16 NDV).
• ZAPI - HEALTH (Status LED) - ON
33407 LIFT DN VALVE - SHORT TO
GROUND
Lift Up and Down Prevented
• 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 - The power module has reached thermal • Power down and allow to cool.
PLEASE WAIT
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 The drive portion of the power module
POWER MODULE CURRENT has reached thermal limit.
LIMIT
6-12
• 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.
– JLG Lift –
3121166
SECTION 6 - DIAGNOSTIC TROUBLE CODES
4-2 Thermal Limit (SOA)
DTC
423
FAULT MESSAGE
DESCRIPTION
CHECK
LIFT UP AT CUTBACK The lift up portion of the power module
POWER MODULE CURRENT has reached thermal limit.
LIMIT
• Check for jammed or obstructed arm stack or pivot bushing.
• Check for excessively high current consumption in the pump,
ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP CUR over 130
Amps with an empty deck.
• Refer to Pump Motor Electrical Evaluation in Section 4.8.
4-4 Battery Supply
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
441
BATTERY VOLTAGE TOO
The power module momentarily mea• Recharge batteries or check for damaged batteries.
LOW - SYSTEM SHUTDOWN sured battery voltage under 14.5V
• Check battery charger function.
between ground board J1-39 and ground
board J1-40.
442
BATTERY VOLTAGE TOO
The power module momentarily meaHIGH - SYSTEM SHUTDOWN sured battery voltage > 37.0V.
443
LSS BATTERY VOLTAGE
TOO HIGH
The load sensing system module
• May be due to improper battery charging or incorrect voltage batmomentarily measured battery voltage >
teries being used.
34.0V.
• Refer to Section 2.3: Troubleshooting in the LSS manual,
3124288.
444
LSS BATTERY VOLTAGE
TOO LOW
The load sensing system module
• Recharge batteries or check for damaged batteries.
momentarily measured battery voltage < • Refer to Section 2.3: Troubleshooting in the LSS manual,
9V.
3124288.
446
LOGIC SUPPLY VOLTAGE
OUT OF RANGE
The system module logic supply voltage • This may be caused by a loose battery terminal, severely diswas measured to be out of normal operatcharged batteries, damaged battery, or an improper wire harness
ing range by the interface PCB (<11V).
connection.
• Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON
4421 LOGIC SUPPLY VOLTAGE
OUT OF RANGE
The system module logic supply voltage • This may be caused by a loose battery terminal, severely discharged batteries, damaged battery, or an improper wire harness
was measured by the power PCB to be
connection.
more than 34V for 10uS.
• Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON
4422 LOGIC SUPPLY VOLTAGE
OUT OF RANGE
The system module logic supply voltage • This may be caused by a loose battery terminal, severely diswas measured by the power PCB to be
charged batteries, damaged battery, or an improper wire harness
less than 11V for 10uS.
connection.
• Drive, Steer, and Lift Prevented
• ZAPI - HEALTH (Status LED) - ON
• May be due to improper battery charging or incorrect voltage batteries being used.
6-6 Communication
DTC
661
FAULT MESSAGE
DESCRIPTION
CHECK
CANBUS FAILURE - POWER The control system failed to receive mes- • Check for 24V between power module 12 position connector terMODULE
sages from the power module.
minal 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.
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
6-6 Communication
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
CANBUS FAILURE - PLATFORM MODULE
In platform mode, the control system
• Turn on machine in ground mode. If DTC 661 is not present check
failed to receive messages from the platfor 24V between platform box connector terminals D and A. If not
form board.
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
662 CANBUS FAILURE - PLAT(Cont.) FORM MODULE
(Continued)
In platform mode, the control system
• Disconnect platform box connector. Open platform box. Disconfailed to receive messages from the platnect platform board connector. Platform box socket E to platform
form board.
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.
662
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
6-6 Communication
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
663
CANBUS FAILURE - LOAD
With load sensing system enabled, the • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER is
SENSING SYSTEM MODULE control system failed to receive mescorrect.
sages from the load sensing system mod- • Check ANALYZER -> MACHINE SETUP -> MARKET is correct.
ule.
• Check ANALYZER -> MACHINE SETUP -> LOAD is correct.
• Check for 24V between load sense system module connector J11 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 - ACCES- An accessory module has stopped com- • Turn on machine in platform mode. If DTC 662 is present, troubleSORY MODULE
munication.
shoot that DTC before continuing.
• See accessory module documentation for troubleshooting.
6635 CANBUS FAILURE - CHASSIS Chassis Tilt Sensor messages not
TILT SENSOR
received for 1000 mS while B+ is
present on J1-28
• The control system failed to receive messages from the Chassis
Tilt Sensor located inside the Ground Control Box.
• 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
671
FAULT MESSAGE
ACCESSORY FAULT
DESCRIPTION
CHECK
An accessory module is reporting a fault. • See accessory module documentation for troubleshooting.
7-7 Electric Motor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
The power module detected a problem in • Refer to Drive Motor Electrical Evaluation in Section 3.5.
the drive motors' power circuit wiring.
• Refer to Power Module Electrical Evaluation in Section 3.6.
771
OPEN CIRCUIT DRIVE
MOTOR WIRING
772
STALLED TRACTION MOTOR Drive, Steer, and Lift Prevented
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
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 WIR- Drive, Steer, and Lift Prevented
ING
• 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
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
7-7 Electric Motor
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
775
OPEN CIRCUIT FIELD WIRING
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 OR Drive, Steer, and Lift Prevented
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
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 CUR- Drive, Steer, and Lift Prevented
RENT TOO HIGH
• 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
6-16
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
7-7 Electric Motor
DTC
FAULT MESSAGE
7742 FIELD VOLTAGE IMPROPER
DESCRIPTION
CHECK
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 short-circuit in the field wiring or motor.
Disconnect the field and motor wiring from the System Module
and connect F1 / F2 with a short wire. If the situation persists
after a power cycle, it may be an internal issue.
• ZAPI - HEALTH (Status LED) - ON
8-1 Tilt Sensor
DTC
FAULT MESSAGE
DESCRIPTION
811
TILT SENSOR NOT CALIBRATED
812
NO DATA FROM TILT SEN- No signal from tilt sensor.
SOR - NOT CONNECTED OR
FAULTY
CHECK
The tilt sensor calibration has not been
performed.
• 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.
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.
824
LSS CELL #4 ERROR
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 CALIBRATED
The load sensing system module has not • Empty platform. Calibrate LSS, see Section 2.2: Calibration in the
been calibrated
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 A problem has been detected with the
EXCITATION
load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual,
3124288.
994
LSS INTERNAL ERROR DRDY MISSING FROM A/D
A problem has been detected with the
load sense system.
• Refer to Section 2.3: Troubleshooting in the LSS manual,
3124288.
995
POWER MODULE FAILURE - The power module detected an out-ofPERSONALITY RANGE
range or corrupt personality setting
ERROR
• Record all personality settings in ANALYZER -> PERSONALITIES
and ANALYZER -> MACHINE SETUP. Reset control system personalities to default settings by selecting a different model than
indicated, cycle power then select proper model. Then, enter personality settings recorded above.
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
996
POWER MODULE FAILURE - Drive, Steer, & Lift Prevented
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 - The power module detected an error in
CHECK POWER CIRCUITS the power wiring for the drive or pump.
OR MOSFET SHORT CIRCUIT
• Refer to Drive Motor Electrical Evaluation in Section 3.5.
• Refer to Pump Motor Electrical Evaluation in Section 4.8.
• Refer to Power Module Electrical Evaluation in Section 3.6.
998
EEPROM FAILURE - CHECK The control system detected an
ALL SETTINGS
EEPROM failure.
• Replace ground board.
999
FUNCTION LOCKED OUT - The power module software version is not • Replace power module to clear fault.
POWER MODULE SOFTcompatible with the rest of the system.
WARE VERSION IMPROPER
9910 FUNCTION LOCKED OUT - The platform board software version is • Reprogram platform board.
PLATFORM MODULE SOFT- not compatible with the rest of the system.
WARE VERSION IMPROPER
9911
FUNCTION LOCKED OUT LSS MODULE SOFTWARE
VERSION IMPROPER
The load sensing system module software version is not compatible with the
rest of the system.
• Replace LSS module to clear fault.
• Refer to Drive Motor Electrical Evaluation in Section 3.5.
9912 POWER MODULE FAILURE - The ground board detected armature,
SYSTEM MONITOR
field, or pump current while function was • Refer to Pump Motor Electrical Evaluation in Section 4.8.
not commanded.
• Refer to Power Module Electrical Evaluation in Section 3.6.
9924 FUNCTIONS LOCKED OUT - The control system' s memory indicates • Use the JLG analyzer to adjust all machine setup and personality
MACHINE NOT CONFIGthat the vehicle has not been configured
settings, refer to 5.7 Machine Configuration Programming InforURED
(new control system components).
mation.
9950 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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
6-18
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
9956 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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
9970 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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
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SECTION 6 - DIAGNOSTIC TROUBLE CODES
9-9 Hardware
DTC
FAULT MESSAGE
DESCRIPTION
CHECK
99145 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
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 FAILURE - Drive, Steer, & Lift Prevented
INTERNAL ERROR
• The System Module encountered an unexpected software issue.
• Cycle machine, if error still exists, replace System Module.
• ZAPI - HEALTH (Status LED) - FLASHING
6-20
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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.
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 k = 1200 
Example: 50 mA = 0.05 A
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Voltage Measurement
Resistance Measurement
Figure 7-1. Voltage Measurement (DC)
Figure 7-2. Resistance Measurement
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• First test meter and leads by touching leads together.
Resistance should read a short circuit (very low resistance)
• Use firm contact with meter leads
• Circuit power must be turned OFF before testing
resistance
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multimeter’s operation manual)
• Use firm contact with meter leads
7-2
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3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Continuity Measurement
Current Measurement
Figure 7-3. Continuity Measurement
Figure 7-4. Current Measurement (DC)
• Some meters require a separate button press to
enable audible continuity testing
• Circuit power must be turned OFF before testing continuity
• Set up the meter for the expected current range
• Be sure to connect the meter leads to the correct
jacks for the current range you have selected
• Disconnect component from circuit before testing
• If meter is not auto ranging, set it to the correct range
(See multi meter’s operation manual)
• Use firm contact with meter leads
• Use firm contact with meter leads
• First test meter and leads by touching leads together.
Meter should produce an audible alarm, indicating
continuity
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Continuity Measurement Over Long Distances
When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to
perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a
particular wire in the harness.
Requirements:
• Harness with at least three separate wires including the wire under test.
• These wires must be able to be isolated from other wires, etc.
• Jumper or method to connect contacts on one side of harness.
• Meter that can measure resistance or continuity.
Procedure
Test multimeter leads resistance. Subtract this value from the measured resistance of the wires to get a more accurate measurement.
Consult the circuit schematic to determine which wires to use in addition to wire under test, here called wire #1 and wire #2,
and how to isolate these wires. These wires should appear in the same connectors as the wire under test or are within reach
of the jumper.
1. Disconnect all connections associated with the wire under test and the two additional wires. If harness is not completely isolated disconnect battery terminals also, as a precaution.
2. Measure continuity between all three wires, the wire under test, wire #1 and wire #2. These should be open. If not,
repair the shorted wires or replace the harness.
3. On one side, jumper from contact of wire #1 and wire #2.
4. Measure continuity between wire #1 and wire #2. If there is continuity, both wires are good and can be used for this
test. If there is not continuity, either wire could be bad. Check connections and measurement setup. Redo measurement. If still no continuity, repair wires or consult schematic for other wires to use for test.
5. Jumper from wire under test to wire #1.
6. Measure continuity. If there is continuity, the wire under test is good. Resistance of a wire increases as the length
increases and as the diameter decreases.
One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the
third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure.
7-4
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS
Silicone Dielectric Compound must be used on the AMP connections for the following reasons:
• To prevent oxidation at the mechanical joint between male and female pins.
• To prevent electrical malfunction caused by low level conductivity between pins when wet.
Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors.
1. To prevent oxidation and low level conductivity, silicone dielectric grease must be packed completely around male and
female pins on the inside of the connector after the mating of the housing to the header. This is easily achieved by
using a syringe to fill the header with silicone dielectric compound, to a point just above the top of the male pins inside
the header. When assembling the housing to the header, it is possible that the housing will become air locked, thus
preventing the housing latch from engaging.
2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape.
3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it.
Figure 7-5. AMP Connector
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7-5
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Assembly
Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-6. Connector Assembly (1 of 4)). Proceed as follows:
Figure 7-6. Connector Assembly (1 of 4)
1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Figure 7-7. Connector
Assembly (2 of 4)).
2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Figure 7-7. Connector Assembly (2 of 4)).
3. After all required contacts have been inserted, the wedge lock must be closed to its locked position. Release the locking latches by squeezing them inward (See Figure 7-8. Connector Assembly (3 of 4)).
4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9. Connector Assembly (4 of 4)).
Figure 7-7. Connector Assembly (2 of 4)
7-6
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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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7-7
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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7-9
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.
7-10
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly
locked in place.
Figure 7-15. HD/HDP Locking Contacts Into Position
NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing
HD30/HDP20 Series Disassembly
Figure 7-16. HD/HDP Contact Removal
11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
12. Slide tool along into the insert cavity until it engages contact and resistance is felt.
13. Pull contact-wire assembly out of connector.
Figure 7-17. HD/HDP Unlocking Contacts
NOTE: Do Not twist or insert tool at an angle.
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7-11
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.5 SWITCHES
Basic check
The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch
is functioning properly when there is continuity between the correct terminals or contacts only when selected.
1. De-energize the circuit.
2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings.
3. Access the terminals to the switch.
4. If the switch has two terminals:
a. Measure resistance across the terminals.
b. Change the switch position.
c. Measure resistance again with the leads in the same positions. If the meter was reading short, it should read an
open. If the meter was reading open it should read short.
5. If the switch has more than two terminals, consult the schematic or switch diagram to determine what terminals will
be connected. The test is similar to testing a switch with two terminals.
a. Place one meter lead on the common contact and the other on a different contact in the same circuit.
b. Cycle through all positions of the switch. The meter should read short only when the switch connects the two
terminals and open otherwise.
c. If the switch has more than one common contact repeat the process for that circuit.
Limit Switches
Limit switches are used to control movement or indicate position. Mechanical limit switches are just like manually operated switches except that the moving object operates the switch. These switches can be tested the same way as a standard switch by manually operating the sensing arm.
Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive
proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do
not require contact, and must be energized to actuate. These types of switches can be used to detect boom or platform
position, for example. These switches have a sensing face where the switch can detect ferrous metal close to it. To find
the sensing face, take note how the switch is mounted and how the mechanisms meet the switch. Test this type of switch
as follows:
1. Remove prox switch from its mount.
2. Reconnect harness if it was disconnected for step a, and turn on machine.
3. Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer. See
vehicle or control system documentation on how to do this.
4. Place sensing face of switch on the object to be sensed by the switch. If that is not available, use a piece of ferrous
metal physically similar to it. The switch state in the control system diagnostics should change.
5. When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the
switch and object sensed.
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.
7-12
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
3. Operate system such that the switch actuates. This could be going over a certain pressure or temperature, for example. The state indicated in the control system should change.
Switch Wiring - Low Side, High Side
When controlling a load, a switch can be wired between the positive side of the power source and the load. This switch is
called a "high side" switch. The switch supplies the power to the load. When a switch is wired between the negative side
of the power source and the load, it is a "low side" switch. The switch provides the ground to the load.
A low side switch will allow voltage to be present on the load. No power is applied because the switch is stopping current
flow. This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery
negative side or grounded to the vehicle. What is actually being measured is the voltage drop across the switch. This
could mislead a technician into thinking the load is receiving power but not operating. To produce an accurate picture of
power or voltage applied to the load, measure voltage across the load’s power terminals. Also, the technician can measure the voltage at both power terminals with respect to battery ground. The difference between those two measurements is the voltage applied to the load.
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
3121166
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
– JLG Lift –
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
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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
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
– 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
Range (V)
Vbatt
0
Comm
Comm
5
5
0
Vbatt
Vbatt
Vbatt
0
Vbatt
Vbatt
Vbatt
Vbatt
Vbatt
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
Pin
1
2
3
4
5
6
7
Pin
1
2
3
4
5
6
7
8
9
10
11
12
3121166
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
Range (V)
0
0
----Vbatt
Range (V)
0
0
----Vbatt
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
--
– JLG Lift –
Vbatt
------Vbatt
-Comm
Comm
--
7-15
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
7-16
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)
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 (High-Sensing)
– JLG Lift –
Analog
Analog
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Power
Power
Digital
Digital
Power
Power
Power
Power
Serial
Serial
Power
Power
Digital
Digital
Digital
Digital
Power
Power
Power
Power
Digital
Digital
Digital
Digital
Input
Input
Output
Output
Input
Output
Output
Input
Input
Input
Input
Output
Output
Input
Input
Output
Output
Output
Output
Input
Output
Output
Output
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
Output
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SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
3121166
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
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7-19
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Electrical Schematic - 1870205B - Sheet 1 of 2
Figure 7-20. Electrical Schematic - 187205 B - Sheet 1 of 2
7-20
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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
1870205 B
Figure 7-21. Electrical Schematic - 187205 B - Sheet 2 of 2
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7-21
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
RED 6
TILT
SENSOR
X034
RED 1-1
1
CIR_BREAKER
F01
WHT/RED57-100
3
ORN/RED49-100
4
ORN/RED49-200
BLACK
2
RED 1-1-1 (16)
G
F
E
GREEN
SHIELD
BLACK
SHIELD (J1-13)
CAN LOW (J1-12)
CAN HIGH (J1-11)
RED
BLACK 3
YEL/RED
DIGITAL INPUT FILTER
(24 V DIGITAL INPUTS)
POWER
(ACTIVE HIGH)
DISTRIBUTION
AND
REGULATION
(TO ALL
AREAS OF THE
SYSTEM)
UPG (J2-6)
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
NC
4
3
3
SHIELD (J1-36)
4
ORN/RED49-6
CHARGER
INTERLOCK (J1-29)
2
ORN/RED49-5
3
BLACK 14
1
MDI
X101
X010
7
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
GNDE (J1-38)
CAN HIGH (J1-34)
REMOTE LED'S
(LOCATED IN GC)
X028
SHIELD (J1-33)
X033
RED 1-2
X036 ESTOP X035
S01
DNG (J2-7)
2
ORN/RED 49-90
4
BLACK 78
SHIELD
YEL/RED 2-1-1
OVLD (J2-9)
CAN LOW (J1-32)
TAN 3-1
GND (J1-6)
PLTS (J2-3)
120 /.25 WATT
RESISTOR ASSEMBLED
IN CANNON PLUG OF
PLATFORM CABLE
BLACK
RED/YEL 54-1
X029
TAN 4-1
BLACK 1
INVERTER/
CHARGER
J1-4
SHIELD
YELLOW
7
CAN HIGH (J1-31)
X030
A
BLACK
6
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
X038
D
ORANGE
5
IGN (J1-7)
YEL/RED 2-2-1
GROUND
C
BLUE
4
2-5-1
RED
3
YEL/RED 2-3-1
YEL/RED 2-3-2
YEL/RED 2-1-2
2
YEL/RED 2-4
FOOTSWITCH
(REQUIRES LSS MODULE)
PLATFORM
1
X017
PLATFORM
BULKHEAD
BLK
GROUND
CONTROL
BOX
J1-3
X045
WHITE
B
B
GREEN
YELLOW
BLACK
ORANGE
YEL/RED 2-2-2
BLACK
LIFT
UP
X039
J1-2
SHIELD
PLTE (J1-5)
YEL/RED 2-30
X046
PLATFORM CABLE THAT
ROUTES UP ARMSTACK;
HAS BREAK-OUT
POINT NEAR PLATFORM
RED
3
GREEN
YELLOW
PLTS (J1-8)
4:+EXCITE
6:CAL DATA
5
1
2 CANBUS & 4
3 POWER 3
EXTENDER
1
4
2
5
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
3:-EXCITE
5:-SIGNAL
GREY 5
+EXCITE-4
BLUE 3
GREEN 4
-EXCITE-3
RED 14-1
X047
J8
RED 6
WHITE 2
+SIGNAL-1
CAL DATA-6
CAL CLOCK-2
BROWN1
1:+SIGNAL
2:CAL CLOCK
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
X027
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
X008
B-
B+
F2
BLACK 14
BLACK
3
YELLOW
RED
BLUE
X062
X028
REMOTE LED'S
(LOCATED IN GC)
2
1
X010
CHARGER INTERLOCK
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
3
4
2
X018
4
ORN/RED49-6
ORN/RED49-5
BRAKE
MOUNTED IN
VEHICLE
CHASSIS
1
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
J1-9
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
ANALOG INPUT
FILTER
0 TO 5 VOLT
DRIVE
BROWN/PURPLEJ1-11-19
J1-11
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
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)
MOUNTED ON
BOTTOM ARM PIVOT
PIN, GROUND
CONTROL BOX SIDE.
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
YELLOW9-2
BLACK 7
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
POWER MODULE & CONTACTOR ARE
MOUNTED IN FRONT COMPARTMENT
OF CHASSIS BETWEEN DRIVE
MOTORS; COMPARTMENT IS
COVERED, DRIVE MOTOR CABLES
ENTER COMPARTMENT;
1870205 B
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
TO S42
CONNECTOR
TO PROX. SWTCH.
TO X18 CONN.
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
TO S42
CONNECTOR
TO S42 CONN.
1001114879_C-1
Figure 7-26. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3
3121166
– JLG Lift –
7-27
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
Figure 7-27. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3
7-28
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001114879_C-2
Figure 7-28. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3
3121166
– JLG Lift –
7-29
NOTE: THIS SCHEMATIC USED WITH 1001092456 POWER MODULE
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
1001114879_C-3
Figure 7-29. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 3 of 3
7-30
– JLG Lift –
3121166
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
NOTES:
3121166
– JLG Lift –
7-31
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)
7-32
– JLG Lift –
3121166
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)
3121166
– JLG Lift –
7-33
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
7-34
– JLG Lift –
3121166
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
3121166
– JLG Lift –
7-35
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
7-36
– JLG Lift –
3121166
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
3121166
– JLG Lift –
7-37
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)
7-38
– JLG Lift –
3121166
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)
3121166
– JLG Lift –
7-39
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
7-40
– JLG Lift –
3121166
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
3121166
– JLG Lift –
7-41
SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS
7.8 HYDRAULIC SCHEMATIC
Hydraulic Schematic - 2792599C
2792599-D
Figure 7-40. Hydraulic Schematic - 2792599-D
7-42
– JLG Lift –
3121166
CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of Califormia
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
3121166
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+55 19 3295 0407
+61 2 65 811111
+55 19 3295 1025
+61 2 65 810122
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0)161 654 1000
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
+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
JLG Europe B.V.
Polaris Avenue 63
2132 JH Hoofddorp
The Netherlands
+31 (0)23 565 5665
+31 (0)23 557 2493
(852) 2639 5797
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
+48 (0)914 320 245
+48 (0)914 358 200
JLG Industries (Scotland)
Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland
+44 (0)141 781 6700
+44 (0)141 773 1907
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762
www.jlg.com
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534
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