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1. PLATFORM MOUNTING ARM z z z zz PINS FOR LOAD SENSE ibetidgirtiBgirti B RED HEME EEEE ORANGE BLACK jo d L 9 E ESTOP X048 CHEN zie s z ze 902 1 un so J1 3 62 12 5 5 t z 5 8 z S 5818 2 65 155 MODULE LOCATED ON TOP RED 16 YELLOW J1 4 zo 2 4 41 ARMSTACK UNDER PLATFORM i gS 22 2 lg Ele ges See ge SHIELD 54 82 84 BREAK OUT SPLICED INT imet 1 xq rote 8538095 PLATFORM CABLE f a5 1 E E PROVIDE ACCESSORY X048 lol lal lel ul lu co Ha CANBUS IGNITION AND a9 GROUND CONNECTION lt gt BLACK 5 ETT GREEN 33333333221223322222222222 g 2 CANBUS amp 4 8385883
2. PLATFORM BRAKE CONSOLE DISCONNECT BOX SWITCH LIFT Sg CYLINDER E E VALVE BLOCK d F PLATFORM oo RECEPTACLE o eH p m ROTARY ANGLE SENSOR SENSOR 1 Am i F E o GROUND ORNE CONTROL BOX 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 Bel gium Built Machines S N 1200004293 to S N 1200008265 7 34 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS POTHOLE PROTECTION SECHS INVERTER HB t MB BEACON LIGHT INVERTER POWER SWITCH X m 5 BATTERIES CONTACTOR RELAY O Nai PUMP MOTOR RESERVOIR J POWER MODULE BATTERY CHARGER of a
3. z z z z PLATFORM MOUNTING ARM ERES gt Seer Say lt ate il NT i PINS FOR LOAD SENSE ys 232292 522292932298 jez ss zi i ORANGE 15 Eisd exe S aata fos ree Bm BLACK d ESTOP 02 GREEN SEIS BIE 5 YELLOW 5 12 155 j Els S S S S S 55 818 155 MODULE LOCATED ON TOP RED 16 JI 4 zz2 lzzzzz szzzszihzzzzszzAMSACK UNDER PLATFORM i PASTEUR pF EE SHIELD esses esses BREAK OUT SPLICED INT PLATFORM CABLE TO aS 3 5 PROVIDE ACCESSORY UO coa eo d _ E CANBUS IGNITION AND Ao GROUND CONNECTION i lt gt BLACK 5 a IM 2 CANBUS 84 scs ee Hn 3 POWER 3 YELLOW 5 4 EXTENDER BLACK g 5 2 ORANGE B zx i z 293235285 RED PLATFORM CABLE THAT sa 5 al 5 5 ROUTES UP ARMSTACK SHIELD HAS BREAK OUT por 4 S5 81 hee AFG lem POINT NEAR PLATFORM BLACK WI iaces zl BLK eus lt a al 2 kd 1200 25 WATT WHITE g RESISTOR ASSEMBLED IN CANNON PLUG FOOTSWITCH a d junge tr eut REQUIRES LSS MODULE m E PLATFORM CABLE i YEL RED 2 2 E o YEL RED 2 3 2 Y
4. 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 Bel gium Built Machines S N 1200004293 to S N 1200008265 3121166 JLG Lift 7 35 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 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 2646ES 3246ES USA Built Machines S N 0200151606 to Present Belgium Built Machines S N 11200008265 to Present 7 36 PLATFORM CONSOLE BOX D BRAKE RELEASE SWITCH CS A OR BRAKE DISCONNECT SWITCH PLATFORM RECEPTACLE LIFT CYLINDER VALVE BLOCK 1 17
5. 4 1 8 Critical Stability Weights 1 8 Inspection and 1 1 2 2 2 Cylinder Drift oo us etd ede de I ea bg deb libuit 2 5 Preventive Maintenance and Safety 2 7 Sevcon Power Module 3 38 ZAPI Power Module 7 3 40 Battery Charger Specs iios iL Reed dee aad alee dane oie dea ga S Rt 3 44 Battery Algorithms on EIER ee aa Sa aie Ee 3 47 Battery Charger Inverter 4 3 48 Tilt Sensor Harness 1 3 61 Tilt Sensor Harness for 4000021 3 62 Tilt Sensor Harness for 1001114936 3 62 Joystick Specifications Pha VRE AR os Ae ea 3 66 Connector Chart Lee a e e Ge Mie dene n tei ea Moca awed Aes 3 66 Lift Pressure Settings uu xl ED Rma RR Ren tons Gol ea AG Rn ecd ead 4 3 Cylinder Piston Nut Torque
6. Figure 3 47 Arms and Platform Positioning and Support 3 64 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS 3 19 PLATFORM CONTROL STATION 1 NOTE 3121166 Disconnect the platform control box and remove from the machine Place the platform control box on a suitable work bench Loosen and remove the long through bolts that hold the two side control housings together 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 JLG Lift Loosen and remove the four bolts that hold the bot tom of the control box Disconnect the plug from the printed circuit board Remove the bolts attaching the printed circuit board to the control box Replace board and reassemble control box 3 65 SECTION 3 CHASSIS amp SCISSOR ARMS Joystick Controller ROCKER RIGHI ROCKER LEFI 516 OUTP Figure 3 48 Joystick Table 3 9 Joystick Specifications OFFSET SENSOR AND GAIN CORRECTION Table 3 10 Connector Chart Input Voltage 5 0 1 VDC CONNECTOR PINOUT Current Consumption 10mA 12 VDC Term Color F
7. GROUND CONTROL BOX DRIVE MOTORS Figure 7 34 Electrical Components Sheet 1 of 2 CER DIAGNOSTIC ANALYZER 5 ROTARY ANGLE SENSOR JLG Lift SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS POTHOLE Le PROTECTION SWITCHES LT 0 INVERTER POWER BEACON LIGHT BATTERY CHARGER INVERTER BATTERIES CONTACTOR o PUMP MOTOR RESERVOIR POWER MODULE ce BATTERY CHARGER o oE L 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 Machi
8. 4 13 Wiper Seal Installation RR IH un 4 13 Installation of Head Seal Kit 4 13 Piston Seal Kit Installation l l ee RH n 4 14 Rod Assembly Installation liie 4 14 Lift Cylinder Pump Tank 4 16 Lift Cylinder Assembly RR ERUIT PY EURO LAE RR CR RE odes 4 17 Hand Held Analyzer roseo mto eA UP bec Reg ose et dodge x 5 1 Analyzer Flow Chart Sheet 1 5 22 Analyzer Flow Chart Sheet 2 5 23 Analyzer Flow Chart Sheet 3 5 24 Voltage Measurement 7 2 Resistance 2 7 2 Continuity 1 7 3 Current Measurement 1 7 3 AMP Connectors e Ier en rare hee ETE AH E M pe dtd 7 5 Connector Assembly 1 4 7 6 Connector Assembly 2 of 4
9. a E Em i RED i IV JI 14 12 GROUND i WHITE Im CONTROL BOX SIDE ANGL JI 15 1 SUC SHIELD j ONO TEE decet Bee eee ge 2 5 2 1 SWITCH I MOUNTED UNDER OUTBOARD ARM WELDMENT ON SLIDE TL PONI CLOSED WHEN CHANNEL OPPOSITE GROUND CONTROL BOX i ORN RED 49 1 2 SWITCH FERROUS MATL PROX 1 10 15 PRESENT LH PHP RH PHP APOTHOLE SWITCHES YEL RED 2 5 3 SWITCH oRN RED 49 2 SWITCH ARE CLOSED WHEN GN JI IT pul ORN RED 49 3 MECHANISM IS DEPLOYED PHP 21 18 SUD ANALOG NPUT i YELLOW 9 2 E BLACK 0 1o EET ra STEER RIGHT _ YELLOW 10 2 IT BLACK STEER RIGHT JI 22 LIFT UP 3 2 XY Ww BLACK BRAKE LIFT UP 1 25 TAN 4 2 LIFT DOWN RELEASE MICROPROCESSOR LIFT DOWN 91 26 SWITCH GND 01 21 S EET DIGITAL f A LOCATED ON VEHICLE ae EN TU id 7 is QU a BATTERY DOOR GND JI 30 BLACK OPPOSITE GROUND CONTROL BOX BLACK GND JI 37 T BLU ORN 52 1 5 2 _ GALR 01 28 2 E YEL RED 2 5 10 s 2 i i 8 BLACK 3 due 2 88 2 i BEACON cum n i BRAKE RELEASE IGN i Le uo stet Sees BLK i ORANGE 55 2 Ei us x YEL RED 2 5 8 RED 1 1 2 WHITE a SERE d 2X Mas ts CONNECT HARN
10. 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 2 1 7 32 Electrical Components Sheet 2 2 2 1 7 33 Electrical Components Sheet 1 2 1 7 34 Electrical Components Sheet 2 2 7 35 Electrical Components Sheet 1 2 7 36 Electrical Components Sheet 2 2 7 37 Electrical Components Sheet 1 of 2 Machines with 7 38 Electrical Components Sheet 2 of 2 Machines with 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
11. 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 per sonality 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 5 4 JLG Lift Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION 2 E GROUND ALARM 1 DESCENT X 67 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 set tings 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 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 M
12. 12 7 42 JLG Lift 3121166 TABLE OF CONTENTS TABLE NO 5 2 7 1 7 2 7 3 7 4 7 5 7 6 7 8 7 9 3121166 LIST OF TABLES TITLE PAGE NO Operating 1 1 iw fie meii pies ew Ee etd 1 2 Fluid e b e 1 2 Tite Specificatiohs tenere eto Ae AGE ote rode d 1 3 Travel Speed cci tends Suave been ul ee UU d Rx e ER awa Pene E eed sies RU Rp T 1 4 Lift Speed dux eI Pe ee ente E i e ea qa qe EMEN I QUEE 1 4 Dimensions six Maca oe epee DEPRESS eee es 1 5 Torque Requirement 2 cee pee RES Ed Ree S eR 1 6 Elydraulic Gil Seat eue e dedit metus ed EXE 1 6 L btrication Specificalioris 22s oen ase eR Reo opem ake rana 1 6 Hydraulic Oil Specifications Standard 1 6 JI WI ice METH DN 1 7 High Drive Speed Cutout 1 7 Pr ssure Settings aerial 1 7 Cylinder Specifications 1 8 Major Component
13. 9 21 99149 POWER MODULE FAILURE INTERNAL 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 Eric Error Displayed on MDI The MDI is powered but cannotcommu 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 thatthe platform Check that the machine is tilted If so lower the platform and amp ABOVE ELEVATION is elevated and the vehicle is tilted and reposition the machine to a level surface the machine not configured to cutout 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
14. 6 3 004 DRIVING AT CUTBACK ABOVE ELEVATION ssseeseeeneneneneeeneenneeneee nennen nennen nein etse tnn inneren ennt 6 3 005 DRIVE amp LIFT UP PREVENTED TILTED amp ELEVATED nnne nri 6 4 006 LIFT UP PREVENTED MAX HEIGHT ZONE inne tenen nnns 6 4 007 DRIVING AT CUTBACK POTHOLE STILL ENGAGED esee nnne nnne nri nnne nennen 6 4 008 FUNCTIONS LOCKED OUT SYSTEM POWERED DOWN 6 4 009 DRIVE PREVENTED ELEVATED ABOVE DRIVE CUTOUT HEIGHT 222 6 4 2 1 21 1 POWER CN CLE ue Se aii E et ein os eda ee ee ee ERR 6 4 212 KEYSWITGH FAULTY 5 5 32 Al dl ea eat ice e b Ind A f d P be eee n He ce dt 6 5 2 2 221 FUNCTION PROBLEM HORN PERMANENTLY SELECTED essesseeeeneeeeneee nennen nennen nnne nnne nnns 6 5 222 FUNCTION PROBLEM INDOOR OUTDOOR PERMANENTLY SELECTED eee 6 5 223 FUNCTION PROBLEM DRIVE amp LIFT ACTIVE TOGETHER 0 4 42 0 000 000000 0000000 nennen nnne nennen 6 5 224 FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED eene nennen 6 5 225 FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED eese nennen 6 5 226 ACCELERATOR FAULTY WIPER OUT OF RANGE aa E 6 5 227 8 TEER SWITGHES EAUETY a ueteri eet tim ovate e Er t parete dente 6 6 228 FUNCTION LOCKED O
15. 9 19 9953 POWER MODULE FAILURE INTERNAL 9 19 9954 POWER MODULE FAILURE INTERNAL 9 19 9955 POWER MODULE FAILURE INTERNAL 9 19 9956 POWER MODULE FAILURE INTERNAL 9 20 9957 POWER MODULE FAILURE INTERNAL 9 20 9958 POWER MODULE FAILURE INTERNAL 2 9 20 9960 POWER MODULE FAILURE INTERNAL 9 20 9962 POWER MODULE FAILURE INTERNAL 2 9 20 9963 POWER MODULE FAILURE INTERNAL 9 20 9964 POWER MODULE FAILURE INTERNAL 9 20 9969 POWER MODULE FAILURE INTERNAL 9 20 9970 POWER MODULE FAILURE INTERNAL 9 20 9971 POWER MODULE FAILURE INTERNAL 9 20 99143 POWER MODULE FAILURE INTERNAL 9 20 99144 POWER MODULE FAILURE INTERNAL 9 20 99145 POWER MODULE FAILURE INTERNAL 9 21 99146 POWER MODULE FAILURE INTERNAL 9 21 99147 POWER MODULE FAILURE INTERNAL 9 21 99148 POWER MODULE FAILURE INTERNAL
16. 5 Remove the six bolts at the back of the ground con trol and separate 1 Ground Control Station 6 Pull the pin connectors from the printed circuit 2 Tilt Sensor JLG PN 4000006 board Figure 3 45 Tilt Sensor Location Tilt Sensor Removal NOTE Refer to Figure 3 44 Tilt Sensor Removal for num bers 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 Sen sor 1 from the Ground Control Box 7 Remove the two bolts inside the control box that affix NOTE Follow the above procedures in reverse order when the printed circuit board to the control box installing the tilt sensor assembly After installing be sure to calibrate the tilt sensor refer to Section 5 2 Repl th int ircuit board and semble 8 eplace the printed circuit board and reas Tilt Sensor Calibration the ground control box 3 60 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS Tilt Sensor JLG P N 4000021 and 1001114936 1 Ground Control Station 2 Tilt Sensor JLG P N 4000021 or 1001114936
17. 4 15 Holding Valve Torque Specifications 4 15 Valve Torque Values 32 en ccs ce erg em ee TR P Ro o ack Rn RODA Radix 4 16 Tit Settings iu eere RE a Xe e Y He Aq e e uie ue Rhe cd ms 5 7 Flash God Listing i Shea keh EILEEN PELLI et S 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 iris ini wa Snape cle Fae ae eee ee ace A 7 14 Ground Board JS uu ed REPRE EM beh pe ge end E Medaka 7 14 Platiorm Board J1 eI oe EL ae UI eiue velie ed 7 14 Platform Board J9 o do EROR ab i ESL bea es 7 15 Pla ttorm Board poo Pan EAR RHEINE ERR Fere dee cte ter 7 15 Power Module 1600346 Power Module 7 15 Power Module J1 1001092456 Power Module 7 16 Power Module J2 1001092456 Power Module
18. A gt Kye machines with no MDI 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 Personal ities DRIVE LIFT STEER GROUND Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for selected menus 3121166 SECTION 5 JLG CONTROL SYSTEM while in access level 2 Remember you may always can cel a selected menu item by pressing the ESC key 2 N Changing the Access Level of the Hand Held ILES 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
19. 7 17 JLG Lift vii TABLE OF CONTENTS This page intentionally left blank viii JLG Lift 3121166 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 2 5 Sideslope 2 5 2 2 18 75 ft 20 ft 25 8 ft 26 ft 32 ft Maximum Platform Height 57m 79 79m 98m Maximum Tire Load ANSI 1365 Ib 620 kg 1660 755 1835 Ib 832 kg 207010 939 kg 2070 Ib 939 kg CE 1540 Ib 699 kg 1835 Ib 832 kg 1835 Ib 832kg 23201 1052 0 232010 1052 kg 109 psi 81 psi 90 psi 87 psi 87 psi Ground Bearing Pressure ANSI ngepang Pressure 7 7 kg cm 5 7 kg cm 6 3 kg cm 6 1 kg cm 6 1 kg cm 8 7 kg cm 6 3 kg cm 6 3 kg cm 6 9 kg cm 6 9 kg cm Ground Bearing Pressure CE 123 90 psi 90 psi 98 psi 98 psi 3 mph 3 mph 2 75 mph 2 5 mph 2 5 mph Maximum Dive 51650 4 8 kmh 4 8 kmh 4 4 kmh 4 kmh 4 kmh Maximum Wind Speed 28 mph Depending on model market and 12 5 im indoor outdoor selection Maximum Horizontal Manual Side Force ANSI CSA 100 Ib force 445 120 Ib force 533 N A 150 Ib force 667 N A ANSI CSA Indoor N A N A N A N A N A ANSI CSA O
20. COIL CABLE IN PLATFOM ATTACHED TO RAILS CONNECTS TO TWIN CABLE UNDERNEATH KTS PLATFORM NEAR ARM PIVOT AND TO PLATFORM CONTROL BOX BLACK 2 YEL RED 2 5 9 YEL RED 2 5 8 TWIN CABLE BLACK 1 CONNECTION EET UNDER BLACK PLATFORM RED BLACK SHIELD p CO 123 4 5 6 7 8 5 LSS OPTIONAL dels al al 2 5 IF 155 IS NOT EQUIPPED TWIN CABLE g E CONNECTOR 5 ARE CONNECTED TOGETHER VVVVVV 12 3 4 5 6 7 8 CONNECT TO X22 ON CHASSIS HARNESS IN FRAME NEAR ARM PIVOT ATTACHMENT Figure 7 27 Electrical Schematic Machines with 1001092456 Power Module Sheet 2 of 3 7 28 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 28 1 RIBBON CAPACITY CABLE SWITCH 33 1 o EROWN PURPLE 19 jig LORANGEWHITE 17 LI Lgs ji jg YPITE GREEN 18 OPTIONAL 1230ES ONLY a FOOT SWITCH HORN RIBBON CABLE BUTTON oo 14 1 ONE e OPTIONAL amp HORN SWITCHES ARE MOUNTED IN DIECASTING 119 20 2630 8 AND ATTACHED TO VIA 26 3246ES 1 RIBBON CABLE ONLY FOOT SWITCH PLATFORM CONTROL BOX 1 3LACK e is eu Su A e LSS MODULE LOCATED AT TOP OF ARMSTACK UNDER PLATFORM 19 20 2630 amp 26 3246ES ONLY TO RAILS LOAD
21. REESE GU ERES SERUUM RAE 6 17 9 9 Hardware iue GAA wee RI AD weeny ao hee ae eines d pee desees pets 6 17 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 7 1 General cs us oe E ede or ERU RCRUM ES ERREUR 7 1 7 2 Multimeter Basics ect elie ke eae qu ek er Ene bid eb ni EX 7 1 Grounding ened ace ee RE Se baa OR TORRES TR eae 7 1 ee LAS puro dee t Qe wo on ed d vbt pp 7 1 eei T eR AUR nn RUE ee e CE 7 1 zc obe PT qu uw Gane WE Lee Deeg dade 7 1 Sale ne o scene oath or e eae es edes Dee wen 7 1 Continuity Measurement Over Long Distances 7 4 Requirements Soa te eee eed Ma Sas 7 4 Procedure oy Eu bu b eas 7 4 7 8 Applying Silicone Dielectric Compound To Amp 7 5 Assembly 25 ve Sdn edit sete DR Eo e Rabe du Ride oen esi ie RO cma t pete 7 6 Disassembly d IW Ma MEG RAE ead dos NE Park DEN eda ed ent ne ached 7 7 Wedge Lock Heaps centages Pee oe ee ep ee AE pe 7 8 Service Voltage 0 7 9 7 4 Working With Deutsch 7 10 DI DIP Series Assembly bog re DES oan prb Sb et
22. co e 1eeus uo S SAS x 1631 WALSA NNIWN 3 553 1631 W3LSAS 3121166 SECTION 5 JLG CONTROL SYSTEM MH SS1 SNOISH3A d MS 551 SNOISH3A A GOW H3MOd v 1199 JO JOYS WeYD Jez jeuy p c n dnjas euiuoeyy uo Buipuedep 71 6 S910N SNOISH3A e qejreAe eq uodo siu x 22245 Wd OXXXXX THO SNOISH3A epo A Ul I I je pue uondo siu v MH Wd OS3 ON HIN3 S3A OXXXXX 217130 SNOISH3A 901v1va E ayo7 i po punos MS Wd 3svu3 OMXXXX 1 1199 1 pue uondo siu 5 I x I 2222 NS WO WXX SHA d3QVO 1H3AO 44O NO NHOH SNOISH3A 501VIva WALSAS I x I x amp AdH MH INO WXX 14 SSOYDL1d ALINVWs LX3 L3Y SNOISHHA DOTVIVd avo WALSAS x x x MS W9 WXX SAC AVOT QS10 N3dO 1H dW3l N3dO HO1IMS1004 SNOISH3A DO1VLVG y IWILSAS NO
23. 1 1 1 7 6 Connector Assembly 3 of 4 2 7 7 Connector Assembly 4 of 4 7 7 Connector Disassembly 7 8 Connector 7 9 DT DTP Contact Installation 0 tte 7 10 DT DTP Contact 7 10 HD HDP Contact 2 7 10 HD HDP Locking Contacts Into Position 7 11 HD HDP Contact 7 11 HD HDP Unlocking Contacts 0 7 11 Electrical Schematic 1870164 G Sheet 1 2 7 18 Electrical Schematic 1870164 G 2 0 2 7 19 Electrical Schematic 187205 B Sheet 1 2 7 20 Electrical Schematic 187205 B Sheet 2 2 7 21 Electrical Schematic Sheet 1 of 2 Machines with 7 22 Electrical Schematic Sheet 2 of 2 Machines with 7 23 Battery Inverter Charger
24. 1591 SAS 1591 SAS Y NO QVO TH3AO MS NHOH 3S0 19 1591 SAS 15391 SAS I I NO HOOGLNO u399lH N3dO 1591 SAS 1591 SAS x Y NO HOOQNI 195 LNO NI 3S0 19 1591 SAS 1591 SAS I NO LL 399141 15010 15391 SAS 1591 SAS I I NO 55391514 SAS 195 LNO NI N3dO 1591 SAS 1591 SAS NW OL MOVE THLINO 1 v 11 8 H331S 1H N3dO amp S3NIVA 1531 LSSLWALSAS OS3 ON H1IN3 83A 19531 31VALLOV 1631 SAS 21631 SAS NnH 1631 SAS NnH x x Y XN OL MOVE THLNO vie AMALLVA Hals 1H 35010 NO WHY1V dn Lam 1531 SAS 1631 SAS NnH 1631 SAS NnH 1591 SAS NnH 1631 W31SAS NnH x x Y Y x NIN OL GM4 THLNO 44 z AMALLVA 1109915 N3dO NO NHOH 1417 GND H3als 1 1631 SAS NnH 1631 SAS NnH 1631 SAS NnH 1631 SAS NnH 1631 SAS 1631 WALSAS NnH x x Y Y x x XV OL QMd 1H1NO 7 1 1 AMALIE 4331S 35010 NO QVO1H3AO dn 1417 GND uaais 11 1631 SAS NnH 1931 SAS NnH 631 SAS NnH 1631 SAS NnH 1531 SAS 1631 W31SAS NnH x ALIIdNOO 1631 THLNO dOWd 1931 nay 8 sam 1631 MS d 1831 NHTY 8 GIAO LSAL MS GND 1991 amp S3NVA ISAL OS3 ON HIN3 S3A 1531 SAS NOH 1591 SAS NOY k 1531 SAS NOY 1591 SAS NOY 1531 SAS NOY 1631 SAS NOY 1531 W3LSAS 1931 31VALLOV
25. 3 50 3 14 Pothole Switch Replacement 3 55 Rotary Angle Sensor 3 59 3 15 Ground Control Station eir x eg aes Pha eae thes eee ee 3 59 Printed Circuit Board PCB Replacement 3 59 Tilt Sensor 3 60 3 16 Arms and Platform Positioning and 3 62 3 17 Plattorm Removal eS A Le ern 3 63 3 18 Scissor Arms Removal xd eaae ege ee ae eee ee nade 3 63 3 19 Platform Control Station mr 3 65 Joystick Gontroller ah bal er es REL E ae EUR ee 3 66 SECTION 4 HYDRAULICS 4 1 Cylinders Theory of Operation 4 1 4 2 Valves Theory 4 4 1 Solenoid Control Valves Bang Bang 4 1 Relist Valves cute eae ER abe exo Fe Ro Se ee e eh 4 1 Crossover Relief 4 1 Proportional ValVe bie deed ona t Redes e Ve 4 1 Manual
26. ORN RED 49 4 Figure 7 18 Electrical Schematic 1870164 G Sheet 1 of 2 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PLATFORM i CONTROL BOX ict LBROWN PURPLE 19 212 i DIGITAL INPUT FILTER ANALOG INPUT 1 REDI TE POWER 24 V DIGITAL INPUTS FILTER jea ORANGE ALARM i DISTRIBUTION ACTIVE HIGH 0 TO 5 VOLT WHITE GREEN 18 REGULATION RED 13 PATO A ja ORANGE 9 AREAS Ol LN E SYSTEM MICROPROCESSOR L SRAYS JOYSTICK 1 COMMON RFD 22GA DRIVERS INTERFACE MIA 24 V WIEN ji RO TRIGGER VIOLET 22 G mhm OUTPUT 15 ON PINK 5 Ji 5 5 ROCKER 1 GREEN 24 GA 96 PURPLE 6 T RT Jit 4 ROCKFR RIGHT YELLOW 24 GA i ae er i HORN SWITCH CAPACITY SWITCH 5VDC WHT RED i GROUND WHT RI i4 5 9 SIG OUTPUT BROWN 10 5 VOLT i SWITCHES OUTPUT MOUNTED DIRECTLY ON BOARD ta a i
27. RESERVOIR POWER MODULE 1001092456 BATTERY CHARGER 0 NOTE THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED Figure 7 39 Electrical Components Machines with 1001092456 Power Module Sheet 2 of 2 3121166 JLG Lift 7 41 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 7 8 HYDRAULIC SCHEMATIC A B B NE STEER RELIEF SET AT 1500 51 RPM Em Mi 7 7 E z FTN o 4 NE A ape Em TED LX PES Iu IS rit e e z T 50s a rare 5 fy Z 2 gt s4 E T ps l e o nme 1 S NN pA 52 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
28. 1 4 0 4 1 4 3 Cylinder Checking 4 2 Cylinders Without Counterbalance Valves and Steer 4 2 4 4 Lift Pressure Setting Procedure 4 2 4 5 Hydraulic Oil Fill ic eae oh ede daw edie eae ble ie 4 3 Oil Check Procedure cae RU E be ERREUR DON ERE E Rad eS 4 3 Slide Block Lubrication 1 4 4 4 6 Lift Cylinder Removal 4 4 4 7 gt 6 25 tab tin del nda al utt EVEN htt us 4 6 Pump Motor Electrical 1 4 4 7 Purmp Bertioval 52 2 Enc pi E eee tet Ye EOD uU d ode RT RT eam eae epee 4 8 Motor Removal ister apices ay GU IA IV ee Ee Va pre 4 10 4 8 Cylinder Repair ERREUR DRE EDGE LER ee 4 11 Disassembly repro ade ts dee dl eue 4 11 Steer Cylinder Piston Removal Cyl 1684456 4 12 Cleaning and 2 4 12 ASSOMDIV inc sen es eae ke 4 13 SECTION 5 JLG CONTROL SYSTEM 5 1 Hand Held Analyzer B be Bios diy Ole eee Fred 5 1 To Connect the Hand H
29. 212 ssi SWITCH SWITCH ajajaja 5 lt lt 4189 Sa ays 9x amp 5 5 94 4 zl 5 aux zs Velie 1 zu 3 8 mira B S gt al SW d 33 SRPHRPHP SN 31 PRPH POS RPHP NER PORE AAIR 22_EMS_PLATFORM REDEEM 45 EMS 12 8 BLACK CAN SHIELD 544 CANS 22 15 H POW uk 1 2 6 XX E CHER CANL J2 5 12 23 NOVL 12 22 SGU JI 8 10 LIFT DOWN 8 1 05 Seb T8 EET 41 6 I6 SCH CHOR INTK MS Dee js CHARGER 40 2 ATT REUNY Sep ee 3 BATTERY CHARGER X20 INTERLOCK FOR 1230ES 40 5 BATT RELAY J1 28 INPUT CONNECTOR TOPROX SWICH 23 1_PMC_POS_LCONT CHE 4 HORUM FOR SCISSOR S XK 40 5 BATT RELAY A1 1 NNC NEG LCONT 5 OUTPUT 1 1 40 4 BATT RELAY 18 1 32 WAX PGAL JI 7 CHARGER BBA MAK SEN CGAL JI 3 REMOTE LED 21 34 CONNECTOR 23 2_PMC_POS_LCONT PCT E 540 NRB J1 33 35 8 PRB 41 30 34 T 4 5 POWER CONTROLLER 5 5 543 gpl BtF 2 1833 xS 3 Is 4AWG CABLE alal oo g 1 ELS 51 e 300A t e amp AH23 x e GROUND C ES el ne CBA ALARM eis col 3 ep UO z NES 2 E 1 Hi 30 5 gt E 3 RED z RL3I 5 3 5
30. 7 Horn Switch Active Low Input Vbatt Table 7 7 Power Module 1600346 Power Module ONLY Function Type Range V Ignition Power Input Vbatt Not Used Not Used Not Used Not Used Not Used Not Used Line Contactor High Side Power Output Vbatt Not Used CAN Bus High Input Output Comm CAN Bus Low Input Output Comm Not Used 5 CO N cw P 3121166 JLG Lift 7 15 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 7 8 Power Module J1 1001092456 Power Module ONLY Pin Function Type 1 Primary Elevation Sensor Analog Input 0 5V Analog Input 2 Spare Analog Input Analog Input 3 Control for Ground Alarm PWM Digital Output 4 Positive for Analyzer 12V Power Output 5 Ground Select Logic Supply for Ground Mode Power Input 6 Positive for Tilt Sensor Connect to Power Output 7 Positive for Ground Alarm Connect to BATT Power Output 8 Ground Lift Up Switch High Sensing Digital Input 9 Right Pothole Switch High Sensing Digital Input 10 Ground Lift Down Switch High Sensing Digital Input 11 Left Pothole Switch High Sensing Digital Input 12 Spare Negative Reference Power
31. 3 37 SECTION 3 CHASSIS amp SCISSOR ARMS 3 8 POWER MODULE SEVCON MACHINE FRONT sO amp O Ox a Le 5 SEVCON POWER MODULE Figure 3 32 Sevcon Power Module Location The Sevcon Power Module P N 1600346 was replaced by Use the following instructions when replacing the Power the ZAPI Power Module See Figure 3 33 on macines Module built starting in mid year 2010 a g y 1 Make sure power to the machine is turned off and Table 3 1 Sevcon Power Module Specs the batteries are disconnected Operating Voltage Pin 1 and B 14 5t0 40 VDC NOTE Note the wire terminal locations when removing the old Power Module Maximum Current Limits 2 Disconnect all wires from the old Power Module and ae ps remove from the machine Pump 150A 3 Before bolting the Power Module on using a V notch Standby Current 150 trowel apply a layer of heat transfer grease to the Temperature Range back of the new Power Module Operating 30 C to 40 C 4 Be sure that the ter
32. CAL DATA 6 C L DATA 5 OPTIONAL TWIN CABLE D TOGETHER 1001114879 C 2 Figure 7 28 Electrical Schematic Machines with 1001092456 Power Module Sheet 2 of 3 3121166 JLG Lift SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JINON YAMOd 95720601001 HLIM 351 5 SIHL 3 L0N TOYLNOD ANNOYS 39A 8 405835 1111 SIXv vfq RIEKER vy EY 1001114879_C 3 SS3NUVH 5155 2 NO X 01 Q3123NNO2 40123NNO2 qviH4ing GNNOYS 0 0143 0 GNS QN9 031711 9 gt YAZ HET gt XUL N89 d3T 61 9 gt SERA dau da v1 gt 1VNOI dO gt qN9 1117 NNOUG 4 gt INVI ZI VT gt ANEL 0 gt dN971 071 8 59K 1 8 6 gt DIN JINAH 9 L gt NNOd L41 1 01 9 gt dn 14IT 6 gt hay 1 6 7 S ONUS AIN Z S gt JOIST TE d mgd be UR omi 00000 S ANNOYS _ 48109 gt YILIN IMS OMS 1 40153 g34V348 419 6MS 9 11078272 181 HOLIMS 1311 INTE 945 LMS ey 124 hs HOLINS A 11 Figure 7 29 Electrical Schematic Machines with 1001092456 Power Module Sheet 3 of 3 3
33. 3 32 3 30 Bearing Pressure 4 3 34 3 31 Wire Harness 2 3 35 3 32 Sevcon Power Module 3 38 3 33 ZAPI Power Module 4 3 40 3 94 Battery Fluid Levels eon en Aaa EM ee EID UR ia pA 3 43 3 35 Battery Charger Location 4 3 43 9 36 Battery Charger isco ches pl d aca nee Rb ee b aee ok idle duane ate 3 43 3 37 Battery Charger Inverter 3 48 3 38 Battery Charger Inverter 1 1 5 4 3 48 3 39 Motor Cable Routing 1930 5 3 50 3 40 Motor Cable Routing 2030 5 2630 85 3 50 3 41 Limit Switch Locations 1 0 42 3 53 3 42 Limit Switch Locations 20 2 1 3 54 3 43 Pothole Switch Adjustment 1930ES 2030ES 2630ES 3 55 3 44 Pothole Switch Adjustment 2630 5 3246 8 3 56 3121166 JLG Lif
34. A CAUTION AFTER THE MACHINE IS TOWED THE DISENGAGE BOLTS MUST BE REMOVED FROM THE BRAKE DISENGAGE HOLES THE BRAKES CANNOT BE ENGAGED WITH THE DISENGAGE BOLTS IN THE BRAKE DISENGAGE HOLES THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS Motor and Brake Disassembly NOTE 5 Disc Brake 9 Retention Bolt Motor 10 Washer Thru Bolts Spacers Figure 3 8 Motor amp Brake Disassembly 1 Brake Cover 5 2 Disengage Bolts 6 3 Socket Head Screws 7 4 Brake Housing 8 Applies only to USA machines built prior to S N 0200118041 Belgium machines built prior to S N 1200001487 Drain the oil out of the unit by removing pipe plug Note the condition of the oil 2 Perform the manual disengage procedure outlined in a previous page 3 Disconnect the brake connector not shown 4 Remove the 3 socket head screws in the brake housing NOTE Each screw goes through a spacer when assembled When the screw is removed the spacer will become loose 5 Remove the three spacers and the brake housing 3121166 6 7 Remove the retention bolt and washer from the end of the motor shaft Remove the brake disc from the motor shaft REINSTALL THE RETENTION BOLT AND WASHER INTO THE END OF THE MOTOR SHAFT 8 NOTE JLG Lift Remove the two thru bolts that bolt though the motor housing Gently remove the motor Care
35. Rotate sensor counter clockwise until sensor is upright 3 Rotate the sensor as described in the image above NOTE The sensor is spring loaded DO NOT rotate past its internal stops 4 Install the rotary angle sensor cover and secure to the frame with the two screws 5 Reconnect the batteries 3121166 3 15 GROUND CONTROL STATION 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 SEV CON 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 1 Disconnect the batteries 2 Remove the three bolts at the bottom of the ground control station 2 A D 3 Remove the four bolts where the control cable enters into the control box JLG Lift 3 59 SECTION 3 CHASSIS amp SCISSOR ARMS 4 Remove plug and place control box face down ona Tilt Sensor Replacement suitable work bench Tilt Sensor JLG P N 4000006
36. The inspection and maintenance code numbers are as fol lows 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 Check for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while pump motor is running 12 Check for proper lubrication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 3121166 SECTION 2 GENERAL Table 2 3 Preventive Maintenance and Safety Inspection AREA INTERVAL Daily Weekly 100 Hours 200 Hours 400 Hours 3 Months 6 Months 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 48 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 4 Hydraulic Filter ANNUAL 5 Hydraulic Hoses and Tubing 1 5 6 Hydraulic Oil Tank 5 3 4 8 Lift Cylinde
37. 3121166 Tilt vs Allowed Height Evaluation 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 loca tions and drive the machine to these points If a level sur face can not be found flat shims or plates may be place under the wheels to create a level plane for the wheels In determining the existing tilt angle read the angle on the Analyzer under DIAGNOSTICS SYSTEM Do not place a hand held level on the machine to determine whether the machine is level and lifting to the appropriate height Such a measurement will likely be different than the Ground box tilt sensor angle reading due to manufacturing and mounting tolerances The tilt angle in both directions should read within 0 5 while on a level surface If not then either the machine has a drifting tilt sensor or has been erroneously re calibrated since the original factory calibration Check the service records to determine whether a re cali bration 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 There fore replace the sensor and return to JLG with a detailed troubleshooting description NOTE There is a rare case in which an
38. 4no1no rur H38INnN IION A08 XVIN 96001 0 XVIN NG 2609 0 9682 0 XVIN A3 13 26001 0 XVW 26001 0 WNWIXVW HOLVH3 THOOV x x I 504 HAO ASEZ NIN A3H 09 0 NIN dN 642 0 WNWINIW HOLVH3 THOOV x x x S 0 JONEC YAO 48 WuHvlv AM4 9600L 0 S01 roTagoaa S00L ro13go3a dvol awNnouo5 HOIVH3 T390V Hduls x x x x x 002 0 201 NHOH 22 NIN 926001 0 2115 09 0 19997 5 09 L 0 13097 719929 199318 an x x x x x Qvo1 YOLVHATSOOV uaals 44M SAILIIWNOSYAd 6 5 SAILLIIWNOSYAd M Sal TVNOS Had SAILIIWNOSYAd SSILIIWNOSYAd 00000 3009 1 553020 z 1eeus uo SNOlIVH8ITVO dfiL3S 3NIHOVIN SalLrTvVNOSH3d NNW 13431 SSAD0V 2 3009 UHA31SS399V 3121166 JLG Lift 5 22 SECTION 5 JLG CONTROL SYSTEM JO Z JOYS WeYD JezAjeuy 6 6 e1nDi4 14111234135 1531 SAS 3AIHG 123135 153154 5 NO 1V d MS NHOH N3dO
39. A Wheelbase n 5 i p ein 3121166 JLG Lift SECTION 1 SPECIFICATIONS 1 2 TORQUE REQUIREMENTS Table 1 9 Hydraulic Oil Self locking fasteners such as nylon insert and thread Hydraulic System Operating SAE Viscosity Grade deforming locknuts are not intended to be reinstalled Temperature Range after removal Always use new replacement hardware 0 F to 23 F 10W when installing locking fasteners 18 C to 5 C to 210 F Table 1 8 Torque Requirements 18 C to 99 C 10W 20 10W 30 Description Torque Value Dry Interval Hours 50 F to 210 F d 201 20 30 40 ftIb 10 C to 210 C Rear Wheel Spindle Nut 40 54 Nm Wheel Bolts ds e s 50 142 m Table 1 10 Lubrication Specifications NOTE Anytime a wheel bolt is replaced be sure one of the Key Specifications same length is used Use bolt shown below on Multipurpose Grease having a minimum dripping wheels that use the 1 4 6 4mm ring MPG point of 350 F Excellent water resistance and adhe sive 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 32 36 mm gt Table 1 11 Hydraulic Oil Spec
40. This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal charge cycle to be started 1 Check that none of the battery pack connections between modules are reversed or incorrectly con nected 2 Check that one or more cells in the battery are no shorted 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 Try the charger on a good battery 5 If this fault occurs the battery is likely in poor condi tion 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 appropri ate voltage 6V per 6V battery 12V per 12V string battery JLG Lift 3 45 SECTION 3 CHASSIS amp 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 2 If possible move the machine to a cooler location 3 Confirm that dirt or mud is not blocking the cooling fins of the charger Clean the charger Rinse the charger with a low pressure hose if required Do no u
41. 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 NOTE Refer to Figure 3 46 Tilt Sensor Removal for num Table 3 6 Tilt Sensor Harness Chart bers in parenthesis Wire Color Function Connector Pin 1 Disconnect the batteries Red VCC 1 2 Open the Ground Control Station to gain access to Black Ground 4 the Tilt Sensor Assembly refer to prior mentioned Blue PWMX 2 procedures Yellow PWMY 3 3 Remove the four Screws 3 to remove the Tilt Sen sor 1 and Sensor Mount 2 from the Ground Con trol 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 3121166 JLG Lift 3 61 SECTION 3 CHASSIS amp SCISSOR ARMS 3 4 Tilt Sensor JLG P N 4000021 or 1001114936 Sensor Mount Screw 3 5x0 6x 16 LG 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 Tabl
42. 2 Disconnect the battery plug at the chassis Discon nect platform cable and foot switch cable if applica ble from railing Route the cables out through the hole at the rear of the platform to free platform of any constraints If platform is equipped with an outlet plug disconnect and route cable out of platform 3 Remove the bolts attaching the pins and slide blocks at each corner to the arm stack Carefully remove the four pins attaching the platform to the arm stack 4 Lift the platform from the armstack and set aside NOTE When attaching platform back onto scissor arm assembly follow removal procedures in reverse order 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 18 SCISSOR ARMS REMOVAL 1 Remove platform refer to Section 3 17 Platform Removal Disconnect all wiring and cables attached to scissor arm assembly Remove lift cylinder refer to Section 4 6 Lift Cylin der Removal The scissor arms can be removed as a complete unit or individually Removing scissor arm assembly as a complete unit 1 NOTE Remove the pin attaching the bottom scissor arms to the rear of the frame by removing the bolt 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 bl
43. BATT RELAY i 8 BLACK 5 2 4 TE ORANGE lt m b 2 BROWN BLACK 24 3 BATT NEG amp BLACK 24 1 BATT NEG A E 541 RL32 9 LINE Els ES CONTACTOR 95 S g ae as BLACK 24 6 BAT NEGATIVE 12AWG Ela 5 BIS 2 0 CABLE IT 3 z 8139 E 8 3 8 4 4 aT BR tj nen 6v 2 T Leur ISCONNECT CONNECTOR g Qi p BRUN x27 124 d 34 PLB POS LTBRAKE mE 6v 6v 8738 eure 36 NLB NEG LTBRAKE 212 PA 2 CABLE RED 2 BAT POSITIVE 12AWG Figure 7 25 Electrical Schematic Machines with 1001092456 Power Module Sheet 1 of 3 7 26 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS NOTE ON BOARD DIAGNOSTICS DISPLAY 15 ONLY
44. Module along scissor arms leading up LSS Module Message Load Cell Message 0x80 not to platform 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 6 6 ACCESSORY CAN COMMUNICATIONLOST A JLG Accessory Module has failed to maintain CANbus Refertodocumentationforthe communications with the ground module JLG Accessory to clear diffi Thecontrolsystem received Accessory Message Control culty 1froman Accessory Module butfailed 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 ACCESSORY FAULT AJLG Accessory Module has encountered a fault condi tion and reported it via the host control system Accessory Message Control 175 Request Accessory Fault flag is set to YES Retained or cleared based on sta tus of flag No motion interlocks Referto documentation forthe JLG Accessory to clear diffi culty Help messages with the 7 7 flash code indicate motor problems N OPEN CIRCUIT DRIVE MOTOR FIELD WIRING The Power Module detected an error in the power wiring F1 amp F2 Terminals for the drive motors The Power Module is reporting a Field Open Circuit Fault Code 16d Ret
45. OR A ORS B j SEN 1 6 zz i 55 i 2 F2 i 82 ORN RED 49 7 Sh ae eee PON pa BATTERY ORN RED 49 6 REMOTE LED S BLACK M DISCONNECT wL CHARGER ORN RED 49 5 LOCATED IN 6C LOCATED ZS RED YELLOW BETWEEN 2 59 MOUNTED IN BLACK 14 f Sn CHASSIS ORANGE WIRE IN LONE DRIVE MOTOR CABLES ORANGE SE US CHARGER INTERLOCK CONNECTED E THER Rie pa eet WITH A BUTT SPLICE d z S OR JUMPER HARNESS C RA BE FI 5 5 ORN RED 49 4 E ED JS 5 i i E i YEL RED 2 5 9 CR al del i E ae eui YELLOW BROWN Figure 7 20 Electrical Schematic 187205 B Sheet 1 of 2 7 20 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PLA
46. c Pins should be inspected to ensure it is free of burrs nicks and scratches which would dam age the bearing during installation and opera tion SECTION 2 GENERAL NOTE This machine requires periodic safety and mainte 2 6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 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 inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM 2 6 JLG Lift nance inspections by a JLG Dealer Notify dealer if inspection is overdue
47. ctt 6 12 423 LIFT UP AT CUTBACK POWER MODULE CURRENT 6 12 4 4 441 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN ttti 6 12 442 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN ttti 6 12 443 LSS BATTERY VOLTAGE TOO HIGH Gas M A LANA tue IE 6 12 444 LSS BATTERY VOLTAGE TOO TOW c e EE 6 12 446 LOGIC SUPPLY VOLTAGE OUT OF RANGE 22 2 6 12 4421 LOGIC SUPPLY VOLTAGE OUT OF RANGE esssssssssssssssssssssssssssssssssssssssssssssssssssstisiiiiitustussissssssssssssssssssssrsssssssssssse 6 12 4422 LOGIC SUPPLY VOLTAGE OUT OF RANGE ens 6 13 6 6 661 CANBUS FAILURE POWER MODULE cti 6 13 662 CANBUS FAILURE PLATFORM MODULE 6 14 663 CANBUS FAILURE LOAD SENSING SYSTEM MODULE 2 1 6 15 664 CANBUS FAILURE ACCESSORY MODULE 6 15 6635 CANBUS FAILURE CHASSIS TILT SENSOR ettet 6 15 6 7 GM ACCESSORY AULT aaa tea eee etc Lc M UE ae 6 15 7 7 771 OPEN CIRCUIT DRIVE MOTOR dai cud 745 772 STALLED TRACTION MOTOR OR POWER WIRING ERROR ctt 7 16 773 CAPACITOR BANK FAULT CHECK POWER CIRCUITS ttt 7 16 774 SHORT C
48. gt MACHINE SETUP gt MARKET configu ration f MARKET is set to CE ensure ANALYZER gt MACHINE SETUP gt TILT CUTOUT parameter is set as desired Backprobing ground board J1 18 should show about 0 volts Backprobing ground board J1 10 should show about 0 volts Check pothole protection switch adjustment Calibrate the elevation sensor see Section 5 5 Calibrate the tilt sensor see Section 5 2 004 DRIVINGAT CUTBACK Theplatformis elevated andthe machine Fully stow the platform ABOVE ELEVATION is driving e 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 gt DIAG NOSTICS gt ELEV SENSOR gt ZEROED should be about OV when stowed and about 0 15V at cutback 005 DRIVE amp LIFT UP PRE Driving is not possible since the platform Check that the machine is tilted If so lower the platform and VENTED TILTED amp ELE is elevated and the chassis is not level reposition the machine to a level surface VATED 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
49. 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 SSSA amma pero PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT Figure 7 7 Connector Assembly 2 of 4 7 6 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Figure 7 8 Connector Assembly 3 of 4 WEDGE LOCK FLUSH WITH 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 3121166 JLG Lift 7 7 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS ls 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 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Service Voltage Reading A CAUTION DO
50. Drive Motor Servicing Guidelines 1 3 35 3 7 Drive Motor Electrical Evaluation 3 36 Servicing Guidelines 3 36 Common Traction System 3 37 ii JLG Lift 3121166 TABLE OF CONTENTS 3 8 Power Module 1 3 38 Power Module Electrical Evaluation 3 39 3 9 Power Mod l ZAPI b v eR ee Oe ee piu ir 3 40 ZAPI Power Module Electrical 3 41 3 10 Battery Removal aped 3 42 Battery Maintenance and Safety 3 43 3 11 Battery Charger c veu tain dag wee aera ee EEUU I QE ES 3 43 Battery Charger 3 44 Battery Charger Troubleshooting 1 3 45 3 12 Battery Charger Inverter 3 48 Battery Charger Inverter 0 3 49 3 13 Drive Motor Cable 0
51. HYDRAULICS 1 Battery Cables 3 Manual Descent 5 Top Cylinder Bolt Torque 41 ft Ib 2 Valves 4 Steer Hoses 6 Bottom Cylinder Bolt Figure 4 2 Cylinder Removal 3121166 JLG Lift 4 5 SECTION 4 HYDRAULICS 4 7 PUMP MOTOR Theory of Operation The Power Module see Figure 3 32 Sevcon Power Mod ule 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 Ter minal of the Power Module which switches current through MOSFET transistors to the Battery Negative Series DC Pump Motor JLG Lift For variable speed pump operation the MOSFET transis tors 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 1 2 of the available Battery Voltage will be applied to the pump motor Simi larly the MOSFET are On continuously 100 Duty Cycle to apply all available Battery Voltage to the pump motor as in Lift Up at full speed When the Control System is energized the voltage at the P Terminal will be approximately 24V referenced to B when the pump is static The P Terminal will be approxi mately at 1V referenced to B when the pump is run ning at full speed Lift Up from Ground Mode Line
52. In Platform Mode the Trigger Digital Input was Energized for 10 000mS AND Drive was In Active AND Lift was In Active Retained until the Trigger Digital Inputis momen tarily De energized Drive Steer amp Lift Prevented Help messages with the 2 3 flash code indicate difficulty with the ground controls 2 3 FUNCTION PROBLEM LIFT PERMANENTLY Lift switch up or down in the ground control box was Release or repair the switch to SELECTED closed during power up clear the message In Ground Mode Lift Up Digital Input is Energized or Lift Down Digital Input is Energized AND Power upis Active Retained until the respective Digital Inputis momentarily De energized Lift Prevented 2 3 GROUND LIFT UP DOWN ACTIVE TOGETHER Inground mode the control system has detected the lift up Check the lift switch and asso and down are active simultaneously ciated wiring in the ground In Ground Mode Ground Lift Up Digital Inputis 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 NODATA FROM TILT SENSOR NOT CON No signal from the tilt sensor mounted inside the ground Check wiring and plug con NECTED OR FAULTY control box nections atthe tilt sensor and Transitions on the Tilt X OR Tilt Y signals notdetectedfor atthe ground control board 2000mS Retained until transitions on both are sensed Vehicle assumed Tilted 20 0 X 20 0
53. JLG Lift 7 27 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS RED 9 PLATFORM E ALARM RAE S RIBBON CAPACITY DRIVERS CABLE SWITCH CONNECTOR LOADING ANALOG INPUT 24 V WHEN 3 7 eO AT JOYSTICK FILTER OUTPUT 15 ON TO 5 VOLT JOYSTICK COMMON RED 2264 1 TUER E zl TRIGGER VIOLET 22 GA 2 BLACK PROCESSOR ji _BROWNZ PURPLE 19 ROCKER LEFT GREEN 24 GA 5 LIFT DRIVE LT ROCKER RIGHT YELLOW 24 6A 4 area fey ME V id R IGITAL giao YHITE GREEN 18 5VDC WHT RED T pms Wiem ri GROUND WHT BLACK 8 PURPLE 6 a 0 5 VOLT 516 OUTPUT BROWN 9 WHITE 7 POWER M AND Reli INTERFACE A s rum ks BLACK TO ALL AREAS RIBBON BLACK 16 i rss n OF THE SYSTEM ja CABLE N oo BLACK g ARE MOUNTED IN DIECASTR o SHIELD AND ATTACHED TO PCB VIA 2 1 RIBBON CABLE E lt gt 1 RED RED 16 1 a a 0 PLATFORM CONTROL BOX mo lo el VE 2 BLACK 5 WHITE ned a 1200 250 WATT RESISTOR 2 5 3 5 a S ee mue 84444442 RIDE VV 19 20 2630 amp 26 3246 ONLY
54. REMOTE LED S 9 PECES i LOCATED IN GO CAN LOW J1 35 Ta ge Se INVERTER X028 i SHIELD J1 36 uas5szzdlqg CHARGER 7 oRNRED497 2zxrxz28 amp Rz 1 CHARGER 6t oo0o0 0 E ORN RED49 6 i INTERLOCK J1 29 gt Pos 2 4 049 5 DIAGNOSTIC a BLACK 14 S X68 q YEURED 2 100 D 6 Y ORN RED 49 91 a YEL RED 2 5 6 1 2 d 2 STBY i ORN RED 49 90 8 3 q ON 1 LS e o i 4 BLACK 78 2 Li 20s 1 INSIDE BATTERY COMPARTMENT GROUND CONTROL BOX SIDE 2 1 OPTIONAL ate INVERTER sot LB Gea SE CONTACTOR amp BAT CABLE a a X058 59 4GA 9 027 X061 8 1 10 1 F1 u 2 BATTERY CABLE 2 0 GA MS POWER en a E 8 CONTROLLI P 5 amp M2ORA MIORS 2 B B 2 Q Q F2 ex 22 BATTERY 8 DISCONNECT X020 ORN RED49 7 X028 X06 LOCATED s ORN RED49 6 REMOTE LED S BLACK THESETWO X019 CHARGER Jornenas s LOCATED IN GC uow 8 BATTERIES EG MOUNTED IN BLACK 14 RED X075 h VEHICLE BROWN E EN CHASSIS x010 ORANGE WIRE 88 5 DRIVE MOTOR CABLES ORANGE CONNECTED EITHER xo98 X092 e xoig CHARGER INTERLOCK WITH A BUTT SPLICE E E OR JUMPER HARNESS E 2 Fi z i ORN RED 49 4 2 ze J E 2 R En g lt a gt VB 8 Tg YEL RED
55. SOLLSONO VIG SOLLSONOVIG SOLLSONOVIG SOLLSONSVIG SOLLSONOVIG SoLLSONSVIG SOLLSONOVIG SOLLSONOVIG SalLrTVNOSH3d 3121166 JLG Lift 5 24 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 DRIVE 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 MINIMUM 0 25 0 0 0 0 0 0 100 100 100 100 100 100 ELEV MAX 0 25 18 16 16 20 20 LIFT ACCEL 0 1 5 0 Sec 0 5 0 5 0 5 0 5 0 5 DECEL 0 1 1 0 Sec 0 1 0 1 0 1 0 1 0 1 UP MIN 0 50 20 20 20 20 20 UP MAX 0 100 100 100 100 100 100 DN MIN 1 60 18 45 42 52 52 DNMAX 1 100 60 85 63 80 80 STEER STATIC 0 100 50 50 50 50 50 DRIVE 0 100 30 30 30 30 30 ACCELERATOR FWD MIN 2 20 2 40V 2 25 2 25 2 25 2 25 2 25 FWD MAX 1 00 1 50V 1 20 1 20 1 20 1 20 1 20 REV MIN 2 60 2 80V 2 75 2 75 2 75 2 75 2 75 REVMAX 3 50 4 00V 3 80 3 80 3 80 3 80 3 80 GROUND HORN 87 107 dB 107 107 107 107 107 ALARM 87 107dB 87 87 87 87 87 LOAD ACCY 0 200Kg 0 0 0 0 0 OVRDBNCE 0 0 5 0 Sec 3 0 3 0 3 0 3 0 3 0 OVRHOLD 0 0 5 0 Sec 5 0 5 0 5 0 5 0 5 0 4150472 H NOTE These settings may change in or
56. 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 105 PLUS Champion CHGC2 GC2 US BATT EV 145 WNL Concorde 10xAh AGM J305 DV DT CP DEKA 8631 Gel Trojan 30 31 5 US Battery USB2200 T105 DV DT CP Trojan T105 tapped P wo OH Trojan T105 JLG Lift 3 47 SECTION 3 CHASSIS amp 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 scis sor arms with arm prop to gain access to the charger Figure 3 37 Battery Charger Inverter Location 4 External DC Fuse Location 5 DC Connection 6 DC Connection 1 AC Output Connector 2 AC Input Connector 3 Remote On Off Switch Cable Figure 3 38 Battery Charger Inverter Table 3 5 Battery Charger Inverter Specs BATTERY CHARGER AC SPECIFICATION INVERTER AC INVERTER SPECS Output Power Continuous 1000W Output Power Surge 3000W AC Output Current 36A AC Output Voltage 115to 125 VAC Output Frequency 60 Hz DC Input Voltage 21 210 29 VDC Remote ON OFF Yes CHARGER SPECS Nominal DC Output Voltage 28 VDC Maximum DC Output Voltage
57. 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 amp 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 amp Terminal Assembly 11 Brake Assembly 6 Brush Box Assembly 12 Gasket Seal Kit Figure 3 29 Drive Motor Components 3 32 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS NOTE Reference Figure 3 29 Drive Motor Components for part names and locations when servicing the Drive Motor Periodic maintenance consisting of inspections of motors batteries and wiring circuitry is recommended A CAUTION ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE OPERATION Drive Motor Troubleshooting 1 Turn off power to unit and disconnect main battery power Disconnect drive motor connections from the Power Module 2 Verify field continuity between the blue and orange wires If available use a 4 wire ohmmeter to verify the field resistance per the applicable motor specifi cation below 3 Verify armature continuity between the red and black wires If available use a 4 wire ohmmeter to verify the field resis
58. Y Drive Stowed Demandlimited as in Worst Case Slope Descent Func tionality 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 setto 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 Demandlimited as in Worst Case Slope Descent Func tionality for both Forward and Reverse Drive will be slow in the forward direction 2 3 FUNCTION PROBLEM BRAKE RELEASE PER The ground control box lift switch was closed up or down Checkifthe lift switch is MANENTLY SELECTED during power up in ground mode obstructed or jammed Check the lift switch signal and wiring to the ground board Replace ground board 5 12 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 2 5 flash code indicate that a function is prevented due to a cutout ELEV ANGLE SENSOR FAULTY NOT MOUNTED OR VOLTAGE OUT OR RANGE The input voltage from the sensor that measures lower arm motionis outside acceptable range This may be caused by improper sensor mounting difficulty with the sensor wiring or afaul
59. amp Lift Prevented The System Module s lift down feedback voltage to the interface INTERNAL ERROR 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 amp Lift Prevented The System Module s VMN feedback voltage to the interface and INTERNAL ERROR power PCB s disagrees Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 99148 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s setpoint request from the interface PCB INTERNAL ERROR 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 amp Lift Prevented The System Module encountered an unexpected software issue INTERNAL ERROR Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 6 20 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 tech nically qualified guidance shoul
60. amp Steer Prevented STEERLEFT OPEN CIRCUIT Current flow to the steer left solenoid was not detected dur ing power up Left Turn INPUT driven High momentarily AND Left Turn STAT detected Low during power up Drive amp Steer Prevented 3121166 JLG Lift 5 15 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing sere 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 amp 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 amp Steer Prevented 3 3 GROUND OVERLOAD LAMP SHORT TOBAT While the load sensing system was enabled voltage was TERY 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 Over load 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 wa
61. 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 1 To check the oil level rotate the wheel so that the plugs in the cover are at 12 o clock and 3 o clock 2 Allow the oil to settle than slowly remove the plug at 3 o clock 3 If oil begins to come out the oil level is sufficient 4 Ifnooil 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 Tighten to 6 ft Ibs 8 ft lbs 8 4 Nm to 11 2 Nm JLG Lift 3 5 SECTION 3 CHASSIS amp SCISSOR ARMS Manual Disengage Procedure 1 Brake Cover 2 Disengage Bolts 3 Brake Cover Bolts Figure 3 5 Disengage Procedure NOTE Applies only to USA machines built prior to S N 0200118041 Belgium machines built prior to S N 1200001487 In the event of a power loss to the Torque Hub the park ing 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 manu ally disengage the parking brakes The following proce dure outlines how this is to be done A WARNING IF THE MACHINE IS ON ANY INCLINE THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANU
62. wards 2 Power up the Control System by turning the lower key to the platform position and pulling both emer gency 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 2 5 MENU HELP PRESS ENTER Sw A HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are as follows HELP DIAGNOSTICS ACCESS LEVEL PERSONALITIES MACHINE SETUP ACTIVATE TESTS CALIBRATION 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 JLG Lift 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 fol lowing display LG ILS HELP log 211 1 STARTUP 2 1 CYCLE
63. 0730 96600 2015 2740 1810 240 1510 2055 13 8 6 1375 1 1550 104000 2385 3245 2145 2915 1785 2430 112 6 1 5000 1 4050 126500 3165 4305 2845 3870 2370 3225 1 12 T 15000 1 5800 142200 3555 4835 3200 4350 2665 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 Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque 10918 dne ion n ae Size PITCH Stress OR Vibra OR Vibra Area TM TM TITE 131 TITE 7111 or 140 ee 8 14 35 o6 295 23 3 4 5 os 1420 618 6 8 1 2010 874 12 19 8 125 3660 159 28 55 97 14 2 154 16 2 241 18 2 5 331 20 2 5 469 22 2 5 639 24 811 27 459 1080 810 970 1130 30 33 561 1320 1530 694 2090 4 2690 45 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO
64. 1 7004275 1 1 2 7004276 YLINDER 2 7002826 Figure 4 6 Rod Seal Installation WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO WIPER SEAL INSTALLA TION 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 gland WIPER SEAL CYLINDER MALLET HEAD Note When installing wiper seal ensure seal is installed properly Install seal so that the flat part is facing into head Figure 4 8 Wiper Seal Installation 3 Place a new O ring and back up seal in the applica ble outside diameter groove of the cylinder head CYLINDER HEAD BACKUP RING Figure 4 9 Installation of Head Seal Kit 4 Install washer ring onto rod carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston spacer on the rod groove NOTE Upper telescope cylinder piston has an o ring PISTON REF Figure 4 7 Poly Pak Piston Seal Installation installed inside the spacer 6 If applicable correctly place new o ring in the inner piston diameter groove The backup ring side fac ing the O ring is grooved 7 f appli
65. 24 Tightening and Torquing Bolts 3 25 Assembly TOOlS 5 Lotes deque ER Eo Rape 3 25 3 5 Electric Drive Motor ins ose ir He ee ee Wb eme De ie ert se e aec a 3 26 Disassembly EVE PEE eR eS 3 26 Replacing Motor 0 3 26 Inspecting Motor 3 26 Replacing Motor Brushes 2 3 26 Replacing the Motor 3 26 Reassembling the 3 27 Motor Maintenance 1 4 3 28 Disassembly merde GN qaa OE RE EE Pen TU Edu Ret wx woe bcd 3 29 Inspection and Service scis s tp dac d e EDU 3 30 Reassembly ue met neni eb e ex Ree Ede ee rp d Ee IUS Aa Aeg 3 30 3 6 Electric Drive Motor piacissi Yee IR URN EVE VR Pe IN e e a rV EN MS 3 32 Drive Motor 0 1 3 33 Drive Motor 4 3 33 Drive Motor Inspection and Service 3 33 Drive Motor 3 34
66. 3440 2370 3225 12 1 5000 1 5800 142200 3020 4105 2845 3870 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3121166 NO 5000059 REV J 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 JLG Lift SECTION 1 SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque TM TM T 94 S Tensile Clamp Load Loctite 242 or 271 Loctite 262 Stress Area Note 4 i OR Vibra TITE 111 or or Vibra TITE 131 m 140 ST Hoa 85 K 0 15 In Sq In LB H 5 a ona oo SS ona 00061 1 SSS 6 32 015 0099 1 101 010 001005 1L 1 8 32 0160 00140 71 61 9449 001474 SSS 39 24 0190 001750 i 0 02000 SSS 0 7500 0 3730 33600 420 i 2 1 Le 1 1250 0 7630 68700 1290 1755 1160 1580 965 12 1250 1
67. 6 10 3311 GROUND ALARM SHORT TO BATTERY ttt ttti 6 10 3312 LEFT BRAKE SHORT TO BATTERY tts 6 10 3313 RIGHT BRAKE SHORT TO 5226 6 10 3314 LEFT BRAKE OPEN CIR CURT at occas tcc D Qu p ND E 6 11 3315 RIGHT BRAKE OPEN CIRCUIT ou ssssssssssscsssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssitisiiustustustisssssssssssssssssssssssssssssse 6 11 33297 LEFT BRAKE SHORT TO 6 11 33298 STEER LEFT VALVE 5 SHORT TO GROUND ota atat cu attulit tod 6 11 33299 LINE CONTACTOR COIL SHORT TO BATTERY sssssssssssssssssssssssssssssssssssssssssssssssssssistitstustusssssssssssssssssssssssssssssse 6 11 33302 NEGATIVE SUPPLY SHORT TO BATTERY ssssssssssssssssssssssssssssssssssssssssssssssesssssisisiititisiustiutusssssssssssssssssssssssssssssss 6 11 33303 NEGATIVE SUPPLY SHORT TO 6 11 33304 RIGHT BRAKE SHORT GROUND duties tpe utc 6 11 33305 STEER RIGHT VALVE SHORT TO 6 11 33406 LIFT UP VALVE SHORT TO GROUND deir cse e tree Peg ted 6 11 33407 LIFT DN VALVE SHORT TO GROUND aah aay M den cto be 6 11 4 2 421 POWER MODULE PLEASE WAIT c cents tbe nats cct t cud 6 12 422 DRIVING AT CUTBACK POWER MODULE CURRENT LIMIT
68. Check the trigger switch signal and wiring to the platform board CLOSED The trigger input 24V is from platform board terminal J1 1 and its output 24V when closed is to platform board terminal J1 8 Replace platform board JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 2 2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK 2210 TRIGGER CLOSED TOO The trigger switch was closed for more Check if the trigger switch is obstructed or jammed LONG WHILE IN NEUTRAL than five seconds while the joystickwas Check the trigger switch signal and wiring to the platform board centered 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 The drive and lift inputs are both de e Check if either function is active if Yes DRIVE amp LIFT BOTH OPEN energized in Platform Mode Repair the wiring or switch to clear the message ZAPI HEALTH Status LED ON A 2 3 Ground Controls DTC FAULT MESSAGE DESCRIPTION CHECK 231 FUNCTION PROBLEM LIFT The ground control box lift switch was Check if the lift switch is obstructed or jammed PERMANENTLY SELECTED or down during power upin Check the lift switch signal and wiring to the ground board The lift ground mode switch input 24V is from ground board termina
69. Connect the brush wires to the terminal on the brush holder using the bolts that were removed earlier 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 the Motor Cable 1 3 NOTE JLG Lift Using a knife remove the shrink tubing from the cable butt splices that stick through a cast hole in the motor cap end Mark the brush leads at each splice according to the color of the cable lead that it is connected to Cut the leads going into each butt splice Be sure to cut the leads just below the splice to leave as much cable as possible Cut off the motor connector that connects to the brake Remove the motor end cap from the motor shell Using a knife remove the shrink tubing that is on the field lead butt splices There should be 2 splices Mark the field leads going into each splice accord ing to the color of the cable lead Cut the leads going into each butt splice 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS NOTE Be sure cut the leads just below the splice to leave 11 12 13 14 15 16 3121166 as much cable as possible Remove the old cable from the motor shell 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 th
70. Contactor Power Module 3121166 SECTION 4 HYDRAULICS Pump Motor Electrical Evaluation Several basic electrical tests can be performed on the Pump Motor Failure of one of these evaluations is signifi cant and may indicate that the device is physically dam aged 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 volt meter other tests can determine if the windings are truly shorted High resistance can signal worn brushes a faulty commutator or open windings Resistance gt 1 MegaOhms between Motor Termi nals 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 C Difficulti The following difficulties can be examined using the JLG Analyzer a voltmeter and simple hand tools Unless oth erwise 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 s
71. 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 9 Remove the three planet shafts from the input car shafts rier NOTE Do not overstress these retaining rings when remov NOTE The planet pins are held in with a press fit To avoid ing them damage to the parts use an arbor or hydraulic press to remove the planet pins Remove thrust plate Remove a thrust washer from each planet shaft Slide each input planet gear off the planet shaft oc d jg Remove 22 needle bearings from the bore of each planet gear o 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 3121166 JLG Lift 3 13 SECTION 3 CHASSIS amp 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 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 dam aged during removal Try not to damage the hub bore NOTE This part is held in the hub with a press To remove have the hub sitting seal side up Use a plate
72. J1 17 and its output 24V when deployed is to ground board termi nal J1 18 257 ELEV PROX PERMANENTLY The elevation proximity switch shows the Verify that an elevation proximity switch is present on the CLOSED CHECK PROXAND platform to be stowed while the elevation machine If not ensure ANALYZER gt MACHINE SETUP gt 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 switchisnotusedoncurrentmachinesso metal this DTC should not occur 258 DRIVE amp LIFT PREVENTED Manualbrake release modeisactivated Push manual brake release switch again or cycle power to clear BRAKES ELECTRICALLY with the switch in the battery boxnearthe manual brake release mode RELEASED FORTOWING groundcontrol box Drive or liftis notpos 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 J1 19 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 was lifting
73. METRIC Fasteners Sheet 5 7 1 13 1 6 Torque Chart METRIC Fasteners Sheet 6 1 14 1 7 Torque Chart METRIC Fasteners Sheet 7 7 1 15 3 1 Diagnostic rp eh an ee aap eae Se ede cae eed 3 1 3 2 MDI 1 4 0 3 2 3 3 Traction Control Circuit Sevcon Power 3 4 3 4 Traction Control Circuit ZAPI Power Module 3 4 3 5 Disengage 2 3 6 3 6 Disengage Proced re ipee ae Se ed SUG eee v See es 3 7 3 7 Disengage 0 3 8 3 8 Motor amp Brake 3 9 3 9 Motor Disassembly 222255052 m RR cet 3 10 3 10 Motor Removal ccu pe EE IU RR I pu ae ee n 3 11 3 11 Main Gearbox Disassembly 4 3 12 3 12 Input Carrier 1 1 3 13 3 13 Hub Disassembly scien ee ae ba eee Cae E E de
74. 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 WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST BOTH BE VISIBLE IN THIS AREA CUTOFF TAB MUST BE VISIBLE SCREWDRIVER SLOT LOCKING LATCH MUST BE TO LIFT LATCH FOR SECURELY FASTENED UNMATING FOR MATING PLUG AND HEADER MUST BE OF IDENTICAL COLOR IN ORDER FOR THEM TO MATE Figure 7 11 Connector Installation 3121166 JLG Lift 7 9 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 wedge lock will snap into place Rectangular wedge
75. 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 Torque Torque TM TM Tensile Clamp Load Torque Goce 204 e ae Loctite 2627 Sike Wat zaba orcas ise fitim Dry K 17 Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 85 4 40 07120 006000 TT 48 0061 6 32 01380 ooo99 y j 40 01380 0 01015 8 32 060 0 01400 141 36 0 1640 0 01474 10 24 0 1900 0 01750 32 0 1900 0 02000 14 20 0250 00318 280 122 14 m Bn T 28 0 2500 0 0364 3280 139 16 131 15 In Sq In LB FT LB N m FT LB N m FT LB N m 5 16 18 0 3125 0 0524 25 25 20 25 24 0 3125 20 25 3 8 16 35 50 24 _ 20 0 4375 0 1187 10700 65 90 60 80 60 80 1 2 9 16 5 8 3 4 78 9 08750 04620 41600 515 700 485 660 455 620 1 8 1000 06060 51500 730 995 68 930 645 875 11 8 11 4 138 6 1 3750 1 1550 104000 2025 2755 1905 2590 1785 2430 12 1 3750 1 3150 118100 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530
76. 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 CHIL DREN 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 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS Battery Charger Troubleshooting No Lights at all No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low It could also indicate an internal failure in the charger 1 Check the connections to AC power Check for AC voltage between 90 and 260 VAC at the charger 2 If the AC voltage is verified to be correct at the con nection to the charger and the charger still displays no lights at all return the charger for service FAULT LED Flashing The Fault LED flashes to indicate
77. SENSE PLATFORM MOUNTING ARM PINS FOR LOAD SENSE ATH WEITE MODULE 5 PLATFORM Saec GB 2 CONNECTS TO B TENCE Um YEL RED 2 5 9 EXCITE 3 3r ExciTe FL JI 12 48 2 CONNECTS TO B te PAIN J1 5 001 HIGH SIDE DIG OUTPUT 31 6 002 HIGH SIDE DIG OUTPUT 5 JI T 013 HIGH SENSING DIG INPUT PETITE 1 8 012 HIGH SENSING DIG INPUT eei JISASUHES UNUSED EXCITE 3 ar excite FR JI 10 GND 2 CONNECTS TO GND YEL RED 2 5 8 EXCITE 4 aveexcite PIN BLACK 1 JI 1 4B PWR SUP FROM HOST CNTL SYS sient ce 31 2 GND GROUND FROM HOST CNTL SYS Gata SHIELD Sek 12 8 CANS 2 CONNECTS TO 1 N SSIOMAL I 1 516 _ RED U J2 7 CANL 2 CONNECTS TO CANL 1 CAL CLOCK 2 21C L CLOCK J2 6 CANH 2 CONNECTS TO CANH 1 EXCITE 3 3i EXciTE RL ant J2 4 1 CANbus INTERFACE HIGH EXCITE 4 aseexcite PIN J2 9 CANL I CANbus INTERFACE LOW e SIGMAL 5 5 SIGNAL SHIELD U J2 5 CANS I SHIELD TERMINATION NOT GND D CAL DATA 6 C L DATA J2 3 1 120 OHM CANbus TERMINATOR SSIMAL I 1 38168AL 12 10 TRP 2 120 OHM CANbus TERMINATOR D CLOCK 2 2xCAL CLOCK i 12 1 PRE REGULATED SUPPLY FOR JLG ANALYZER EXCITE 3 ar excite RR J2 2 TX RS 232 FOR JLG ANALYZER SEXCITE 4 aveexcite PIN 47 11 RX RS 232 FOR JLG ANALYZER SIGMAL 5 5 5IGNAL 12 12 GND GROUND FOR JLG ANALYZER
78. 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 3121166 HEALTH STATUS LED SS P N 1001092456 ZAPI Power Module HEALTH Status LED JLG Lift 3 41 SECTION 3 CHASSIS amp SCISSOR ARMS 3 10 BATTERY REMOVAL JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES 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 A WARNING 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
79. and Electrical Wiring Hydraulic System er epp IEEE L bricatiori oer Eu Rr Ree RS RR P Battety s ccs ue uu acte Ner e ue Ed idu idet e Lubrication and Servicing 2 3 Lubrication and Information Hydraulic 3121166 JLG Lift PAGE NO TABLE OF CONTENTS Hydraulic Oil e Wain ERR es 2 4 Changing Hydraulic Oil 6 IH n 2 4 Lubrication 2 4 2 4 Cylinder Drift L6St i ae coe tars eec SUE 2 5 Platform Drift spit 44 iore Eg heb oem uere re med WEN RH E packed aks 2 5 Cylinder Drift im dece Rx A tr Vas Ted o RUD se a iG Pee EC CR 2 5 2 5 Pins and Composite Bearing Repair Guidelines 2 5 2 6 Preventive Maintenance and Inspection Schedule 2 6 SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 Diagnostic ee ert De iE Pe er esa ges 3 1 3 2 MDI Multifunction Digital Indicator and brake 3 1 3 3 Tracti n System Sica tars debeo e bod A doe Pound 3 3 Theory of Operation eer dna ers 3 3 3 4 T
80. appear asking if you want to overwrite the current software version Click YES 4 After software update is complete disconnect com puter 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 9 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 electri cal systems The first rule for troubleshooting any circuit that is hydraulically operated and electrically controlled is to determine if the cir cuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechani cally 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 t
81. attempted calibra tion 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 trouble shooting 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 Table 5 1 Tilt Settings Model Tilt Setting Tilt Setting Maximum Deck front to back side to side Elevation 1 5 18 75 5 7 m 5 2 14 ft 4 3m 198065 25 11 3 41 3 9ft 2 7 m 1 5 20 ft 6 m 5 2 1511 4 5 20005 3 2 5 12 ft 3 7m 3 10ft 3m 1 5 25 4 ft 7 7 m 2 20 ft 6 m 4 2 89 16 ft 4 9 3 13 ft 4m ps 26ft 7 9 2646ES 3 2 5 22 ft 6 7 m 3 20 ft 6 m 2 31 75 9 7 m 3246 3 2 5 22 ft 6 7 m 3 20 ft 6 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 JLG Lift 5 7 SECTION 5 JLG CON
82. board J1 Armstack passthru pin 5 to ground board socket J1 11 should have conti nuity 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 cir cuit Ground board socket J1 32 to J1 33 should measure open circuit Ensure all connections opened above are reconnected Discon nect 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 CANBUSFAILURE PLAT In platform mode the control system Disconnect platform box connector Open platform box Discon Cont FORM MODULE failed to receive messages from the plat nect platform board connector Platform box socket E to platform Continued form board board J1 3 s
83. board J1 24 and its ground is to ground board J1 30 37 nspect the wiring for physical damage Replace ground board 3314 LEFT BRAKE OPEN CIRCUIT Currentflowtotheleftbrake solenoid was e 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 nspect the wiring for physical damage Replace ground board 3315 RIGHTBRAKEOPENCIR The ground board did notdetectcurrent Check for continuity through this circuit Brake solenoid resis CUIT flow to the right brake during normaloper tance 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 3121166 JLG Lift 6 11 SECTION 6 DIAGNOSTIC TROUBLE CODES 3 3 Ground Output Driver GROUND DTC FAULT MESSAGE DESCRIPTION CHECK 33297 LEFT BRAKE SHORTTO Drive and Steer Prevented Excessive current flow to the Left Brake Solenoid was detected J1 GROUND 34 NLB ZAPI HEALTH Status LED ON 33298 STEERLEFT VALVE SHORT Drive Steer and Lift Up Prevented Excessive current flow to the steer left solenoid detected J2 9 TO GROUND NLV ZAPI HEALTH
84. built S N 1200007882 Belgium built S N 1200007882 2030ES 2630ES USA built S N 0200152825 2030ES 2630ES USA built S N 0200152825 Belgium built S N 1200008481 Belgium built S N 1200008481 Figure 3 43 Pothole Switch Adjustment 1930ES 2030ES 2630ES 1 With the machine in the stowed position and the bat 6 Raise and lower the machine from the ground con tery door open remove the old pothole switch trol several times to ensure that the switch is func tioning properly 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 3 Adjust the switch by inserting an 1 8 shim between back to elevated speed when the pothole is the link and the switch plunger 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 3121166 JLG Lift 3 55 SECTION 3 CHASSIS amp SCISSOR ARMS iia Ke Machines prior to S
85. dance with recommended shop practices See Torque Chart Section 1 3121166 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section 1 JLG Lift 2 3 SECTION 2 GENERAL 2 3 LUBRICATION AND INFORMATION Hydraulic System 1 The primary enemy of a hydraulic system is contam inatio
86. de energized 3 2 LINE CONTACTOR MISWIRED ONOR WELDED The Power Module s Line Contactor Drive Circuitry passed Refer to CANbus documenta power up self tests butthe line contactor did not open tion for Power Module Mes when de energized sage Status The Power Module is reporting a Contactor Welded Fault Code 14d Drive Steer amp Lift Up Prevented JLG Lift 3121166 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing FLASH CODE HELP MESSAGE CAUSE POSSIBLE RESOLVE CONTACTOR DRIVER PERMANENTLY 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 Per manently On Fault Code 23d Refer to CANbus docu mentation for Power Module Message Status Drive Steer amp Lift Up Prevented Refer to CANbus documenta tion for Power Module Mes sage 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 con cerns 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 BRAKE SHORT TO BATTERY Voltage was detected on the brake solenoid when the out put driver was commanded off during powe
87. deployed position adjust the switch bracket assembly down until the plunger clicks Tighten the switch bracket mounting screws until secure NOTE There is a right side and left side mounting plate the plate mounting holes will mount towards the center of the machine on both sides SWITCHES OUTBOARD When pothole bar is in the deployed position depress the plunger fully and release just past the click Tighten the switch mounting screws until secure NOTE Do not push the switch body down in contact with the pothole crank link 6 Mount the new switch assembly to the machine using the supplied 10mm bolts nuts and washers 8 Repeat this procedure on the opposite side pothole Switch 9 Power up machine and operate lift and drive to ensure proper function 3 58 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS Rotary Angle Sensor Replacement 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 This is the position of the sensor at insertion onto the pin
88. elevation angle sensor is securely mounted Check the ANALYZER gt MACHINE SETUP gt MARKET configu ration f MARKET is set to CE ensure ANALYZER gt MACHINE SETUP gt 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 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 0 0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 006 LIFTUPPREVENTED MAX Thevehicle has reachedthe maximum Check that the zone is set appropriately for the platform load HEIGHT ZONE A height and further lift up motion is notpos 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 f there are any elevation sensor faults DTC 251 252 2511 or 2512 troubleshoot those first Check that ANALYZER gt MACHINE SETUP gt MODEL setting is correct Check that ANALYZER gt MACHINE SETUP gt MARKET setting is correct Check ANALYZER gt DIAGNOSTICS gt ELEV SENSOR gt ZEROED is about 1 53V for the 3246 or about 1 22V for the 2630 when at full height If not r
89. felt 13 Pull contact wire assembly out of connector TOOL INSERTED TO TOOL AND CONTACT UNLOCK CONTACT REMOVED Figure 7 17 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 3121166 JLG Lift 7 11 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 Ifthe switch has two terminals a Measure resistance across the terminals b Change the switch position 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
90. 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 3 42 JLG Lift Adjust the lifting device to take the weight of the bat tery door and remove door from under the machine Once the battery door is removed from the machine battery replacement maintenance can begin After any maintenance on the batteries or replace ment of the batteries is complete lift the battery door back onto the machine Make sure the rollers are replaced and tight Reconnect batteries and check for proper operation BATTERY DOOR STOP BATTERY DOOR ROLLER 3121166 SECTION CHASSIS amp SCISSOR ARMS Battery Maintenance and Safety Practices A CAUTION ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARG ING 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 A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABI
91. in the LSS manual load sense system 3124288 992 LSSEEPROMERROR Aproblem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 993 LSSINTERNAL ERROR PIN A problem has been detected withthe Refer to Section 2 3 Troubleshooting in the LSS manual EXCITATION load sense system 3124288 994 LSS INTERNAL ERROR Aproblem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual DRDY MISSING FROMA D load sense system 3124288 995 POWER MODULE FAILURE The power module detected an out of e Record all personality settings in ANALYZER gt PERSONALITIES PERSONALITY RANGE range or corrupt personality setting and ANALYZER gt MACHINE SETUP Reset control system per ERROR sonalities to default settings by selecting a different model than indicated cycle power then select proper model Then enter per sonality settings recorded above 3121166 JLG Lift 6 17 SECTION 6 DIAGNOSTIC TROUBLE CODES 9 9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 996 POWERMODULE FAILURE Drive Steer amp Lift Prevented The System Module s analog to digital converter does not INTERNAL ERROR respond for the power PCB This is an internal failure Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 997 POWERMODULE FAILURE The power module dete
92. 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 gt 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 n
93. layer of grease along the inside and top of the upper slide channel 2 on both sides of the machine Upper Slide Pad Channel JLG Lift removal Always use new replacement hardware when installing locking fasteners 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 Cut any wire ties that attach any cables or hoses to the lift cylinder PULL THE BATTERY DISCONNECT BEFORE REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER ASSEMBLY Remove the valves connectors the two battery cables and the manual decent cable To avoid having to readjust the manual descent remove the large nut located behind the manual descent bracket as shown See Figure 4 2 Ensuring that the deck and scissor arms are prop erly secure remove the top lift cylinder pin and rest the top of the cylinder on the arm cross tube directly below the cylinder Remove the bolt form the lower cylinder pin and have someone assist you in lifting the cylinder from the scissor arms Set the cylinder with pump and motor assembly intact on a clean workbench Remove the 4 bolts that attach the pump motor assembly to the lift cylinder Remove the bolt from the bracket that attaches the hydraulic reservoir to the lift cylinder Separate the cylinder from the pump motor assem bly 3121166 SECTION 4
94. motor type and application to provide the best ser vice Substituting brushes of the wrong grade can cause premature commutator failure and excessive brush wear 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 3 33 SECTION 3 CHASSIS amp SCISSOR ARMS physically damaged or brush holders are loose on the brush plate Visually inspect the frame and field assembly for overheating or other signs of damage Check all wir ing to ensure that the insulation is in good condition Verify that pole screws are torqued to 250 300 in Ib 28 2 33 9 Nm Verify field resistance using a suit able ohmmeter per the appropriate motor specifica tion Verify that the field is electrically isolated from the frame using a dielectric tester Replace as neces sary 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 exces sive wear and overheating Replace as necessary Visually inspect the brake surfaces for excessive wear Replace Brake Assembly 11 if necessary Visually inspect the Wire Harness 1 for frayed insu lation loose terminals or other damage Replace as necessary Drive Motor Rea
95. must be made JLG Lift 4 4 LIFT PRESSURE SETTING PROCEDURE 1 Large Nut 2 Pressure Setting Screw 3 P port Figure 4 1 Lift Pressure Setting Place 12096 of the rated load of the machine on the platform Increase lift pressure to raise the platform and set the safety prop Locate the Large Nut 1 on the underside of the valve block Using a 7 8 in wrench remove the large nut 1 This will expose the Pressure Setting Screw 2 Remove plug from P port 3 and install a pressure gauge Raise the platform and take a pressure reading Adjust the Pressure Setting Screw to reach the proper lift pressure per model as listed in Table 4 1 3121166 SECTION 4 HYDRAULICS Table 4 1 Lift Pressure Settings Model Lift Relief Steer Relief 1800 psi 50 psi 1500 psi 25 124 bar 3 5 bar 103 4 bar 1800 psi 50 psi 1500 psi 208089 124 bar 3 5 bar 103 4 bar 1950 psi 50 psi 1500 psi 20005 134 5 bar 3 5 bar 103 4 bar 2000 psi 50 psi 1500 psi 27065 138 bar 3 5 bar 103 4 bar 2000 psi 50 psi 1500 psi SEED 138 bar 3 5 bar 103 4 bar 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 Ib 16 Nm Alternate Lift
96. of Califormia to cause cancer and reproductive harm WASH HANDS AFTER HANDLING An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 Bj D JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 612 65 811111 61 2 65 810122 A JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 i 55 19 3295 1025 USA 717 485 5161 717 485 6417 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 3121166 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 pla JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 EL 49 0 421 69 350 45 JLG Polska UI Krolewska 00 060 Warsawa Poland FF 48 0 914 320 245 EL 48 0 914 358 200 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 El 852 2639 5797 JLG Industries Scotland Wright Business Centre 1 Lonm
97. oil level should be com pletely full at the top of the fill port with scissor arms resting on the safety prop from the fill port 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 Care should be taken not to introduce any impurities dirt water etc while plug is removed Replace plug and torque to 40 ft Ibs 56 Nm 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 SECTION 4 HYDRAULICS Slide Block Lubrication Lube White Lithium Grease GREDAG 741 NOTE Interval Every 6 months 1 With the platform empty elevate machine and swing safety prop out of it s stowed position 4 6 LIFT CYLINDER REMOVAL 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 Self locking fasteners such as nylon insert and thread deforming locknuts are not intended to be reinstalled A CAUTION after ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED 1 2 Locate the Lower and Upper Slide Pads and wipe pressure wash all dirt and debris from the slide channel area 1 2 3 Apply a layer of grease along the inside and bottom 2 of the lower slide channel 1 on both sides of the machine Lower Slide Pad Channel 4 Apply a
98. otherwise c Ifthe 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 oper ated switches except that the moving object operates the switch These switches can be tested the same way as a stan dard 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 switc
99. per forming 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 recog nized 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 pro cedures are performed in the same manner but at differ ent 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 ser vice 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 Reference the JLG Pre Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the perfor mance of these inspections Reference the appropriate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection JLG recommends that the Annual Machine Inspection be performed by a Factory Certified Service Technician on an a
100. 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 mea surement 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 com pletely 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 Onone 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 a
101. 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 cyl inder head gland can be inserted into the barrel cyl inder 21 If applicable secure the cylinder head retainer using a suitable chain wrench 22 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 23 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable Refer to Table 4 3 Holding Valve Torque Specifications 3121166 JLG Lift 4 15 SECTION 4 HYDRAULICS TOP VIEW Table 4 4 Valve Torque Values Figure 4 12 Lift Cylinder Pump Tank Assembly Item Description Torque 1 Bi directional Relief Valve 33ftlbs 45 Nm 2 Solenoid NA 3 Proportional Valve 15ftlbs 20 Nm 4 Check Valve 33 ftlbs 45 Nm 5 Blocking Valve 15ftlbs 20 Nm 6 4 Way Directional Valve 15ftlbs 20 Nm 7 Extend Port NA 8 Retract Port NA 4 16 JLG Lift 3121166 SECTION 4 HYD
102. the tube and push new filter onto the end of tube 4 Thoroughly clean the tank and clean any debris from the magnet 5 Wipe out tank with clean lint free rag taking care not to introduce debris or dirt 6 Replace the tank Torque mounting bolts to 20 25 in Ib 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 open ing 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 Ibs 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 3121166 JLG Lift 4 9 SECTION 4 HYDRAULICS Motor Removal NOTE Be sure to remove and discard the plastic plug at the oil inlet on the new pump before installing 1 Remove the four bolts attaching the motor to the valve 14 Check oring on valve block and replace if necessary before installing the new pump Pull motor from valve 2 3 Once all maintenance is performed and lift cylinder assembly is reinstalled on the mach
103. to battery terminal and TACTOR close when energized Drive steerandlift 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 OV while contactor should be closing If this happens replace contactor Replace the line contactor 312 CONTACTOR DRIVER PER The power modules line contactor drive Check continuity between contactor connector pin 1 and ground MANENTLY OFF circuitry failed to energize when 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 steer and lift up prevented DTC FAULT MESSAGE DESCRIPTION CHECK 321 LINECONTACTOR MIS Battery voltage was present at the power Check wiring of contactor WIRED ON OR WELDED module B terminal at powerup Drive Check resistance between the studs of the contactor while dis 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
104. up DTC FAULT MESSAGE DESCRIPTION CHECK 259 MODEL CHANGED The model selection has been changed Check ANALYZER gt MACHINE SETUP gt MODEL NUMBER HYDRAULICS SUSPENDED Replace ground board CYCLE EMS 2510 DRIVE PREVENTED While driving ona level surface armature e Ensure vehicle is not stuck on something preventing movement BRAKES NOT RELEASING _ currentwas gt 150A for five seconds e Check repair drive motor wiring brakes or mechanical issues Brakes assumedto notbe releasing prop erly 2511 ELEV ANGLE SENSOR The input voltage from the elevation Check that the elevation angle sensor is securely mounted FAULTY NOT MOUNTED angle sensor indicates the elevation Check that the elevation angle sensor mechanisms are intact angle sensor is not mounted Replace elevation angle sensor 2512 ELEVANGLESENSORNOT Theinput voltage from the elevation Check that the elevation angle sensor is securely mounted DETECTING CHANGE angle sensor did notchange while vehicle Check elevation angle sensor is not jammed or obstructed 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 requested Drive steer and lift up pre vented DTC FAULT MESSAGE DESCRIPTION CHECK 311 OPENCIRCUITLINECON The power modules line contactor did not Check contactor main contact wiring
105. up motions are prevented while vehicle is charg 0 Charger Interlock 1 ing Required for CE 0 NOTINSTALLED Vehicle alarm will function for Arm Guard if enabled Overload if LSS enabled and as a horn 6 1 DESCENT Vehicle alarm will function for Arm Guard if enabled Overload if LSS 2 2 0 2 2 Ground Alarm enabled as a horn and during Lift Down motion 2 MOTION Vehicle alarm will function for Arm Guard if enabled Overload if LSS enabled as a horn and during Drive and Lift motion 0 NOT INSTALLED Load Sensing System LSS is not fitted to the vehicle 1 CUTOUT PLT Load Sensing System LSS is fitted and Platform Controls are pre 7 vented in the event of an Overload Ground Controls remain functional This is the 1 0 0 1 Load default setting for CE machines 2 CUTOUT ALL Load Sensing System LSS is fitted Platform and GRound Controls are prevented inthe eventof an overload 8 0 FLOODED Batteries are conventional lead acid type 0 Battery 1 Batteries are absorbed glass mat type 9 0 NO Vehicle is not fitted with a footswitch 0 0 0 0 1 Footswitch 1 YES Vehicleis fitted with a footswitch 5 28 JLG Lift 1001115626 B 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 6 1 SECTION 6 DIAGNOSTIC TROUBLE CODES INTRODUCTION This section provides a reference for Diagnostic Trouble Codes DTC read from the Multifunction Digital Indicator MDI This section should only
106. up the sun gear splines with the motor shaft splines Install the two motor mounting bolts and washers Torque to 9 11 ft lbs 12 15 Nm JLG Lift Connect the end of the Motor Cable to the Power Module 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 3121166 SECTION CHASSIS amp SCISSOR ARMS Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts extreme care should be taken to ensure that the bolts are not tight ened beyond their specified torque c n 2 360 2 355 The following steps describe how to tighten and torque E 9 1 00 a z 5 bolts or socket head cap screws a bolt circle amp 2 Be a A 1 Tighten but do not torque bolt A until snug 5 2 Go to the opposite side of the bolt circle and tighten E bolt B until equally snug z 8 8 3 Crisscross around the bolt circle and tighten remain ing bolts E eel 3 4 Now use a torque wrench to apply the specified 2 S 5 torque to bolt A M 5 Using the same sequence crisscross around the bolt circle and apply an equal torque to the remain f ing bolts 2 BOLTA Figure 3 22 Assembly Tool 2 E ie see ts el be by ts e
107. which cannot be changed until you enter a pass word to advance to a lower level This ensures that a set ting 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 exam ple MENU ACCESS LEVEL 2 la 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 pass word 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 pass word 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 M E PERSONALITIES DRIVE ACCEL 0 7s Am
108. wise starting with number 1 nearest the notch Terminal 8 is in the center No charge voltage 1 Disconnect control cable from Inverter charger 2 Turn on machine 3 Inverter charger control cable 8 position connector socket 1 should have Vbatt present If it is not check charger interlock connector 2 position socket 1 If voltage is present there replace the Inverter Charger data interface harness If Vbatt is not present at the 2 position connector socket 1 check the circuit through the chassis harness back to Ground Mod ule 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 J1 19 then goes to harness Interlock connector termi nal 1 Yellow Red wire then to switch 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 8 pos terminal 3 to 6 pos terminal 3 8 pos terminal 4 to 6 pos terminal 5 8 pos terminal 5 to 6 pos terminal 4 8 pos terminal 6 to 6 p
109. 121166 JLG Lift 7 30 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 27 NOTES 3121166 JLG Lift 7 31 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PLATFORM BRAKE CONSOLE DISCONNECT Q SEES gt Egi 5 jd LIFT B d CYLINDER BE VALVE PLATFORM BLOCK RECEPTACLE M ROTARY ANGLE SENSOR p SENSOR GROUND CONTROL DRIVE BOX MOTORS 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 120000429
110. 121166 JLG Lift 6 1 SECTION 6 DIAGNOSTIC TROUBLE CODES 2510 DRIVE PREVENTED BRAKES NOT RELEASING n u nnns 6 8 2511 ELEV ANGLE SENSOR FAULTY NOT MOUNTED o ssssssssssssssssssssssssssssssssssssisitistuutussisssssssssssssssssssssssssssssssssssssses 6 8 2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE ttti 6 8 3 1 311 OPEN CIRCUIT LINE CONTACTOR a tai ols Pl Aca dm cen ela 6 8 312 CONTACTOR DRIVER PERMANENTLY OFF sssssssssssssssssssssssssssssssssssssssssssssessssssssisistissssussssssssssssssssssssssssssssssssssssesee 6 8 3 2 321 LINE CONTACTOR MISWIRED ON OR WELDED ttt 6 9 322 CONTACTOR DRIVER PERMANENTLY 6 9 3 3 vincire ms sg una cdidit o ton At d 6 9 332 BRAKE OPEN CIRCUIT in sa de Uus tired 6 9 333 LIFT UP SHORT TO BATTERY s aiti ct as testet tette ttes nt 6 9 334 LIFT UP OPEN CIRCUIT nteger eect cat dooce cece case at raed cA credet id 6 9 335 DN SHORT BATTERY A a ec cL ERU CA m M ND D ME ON 6 9 336 LIFT DN OPEN CIRCUIT acc ge Nt t eei nt 6 10 337 STEER LEFT SHORT TO BATTERY 6 10 338 STEER LEFT OPEN CIRCUIT 6 10 339 STEER RIGHT SHORT BATTERY 2 2 20 222012 6 10 3310 STEER RIGHT OPEN CIRCUIT ti etcetera alae biases Dese e m ea
111. 14 kg Wheel Bolt Torque 105 120 ftlb 142 163 Nm Batteries JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG S AFTERMARKET PARTS DISTRIBUTION CEN TERS OR JLG S AFTERMARKET PROGRAMS FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES THE USE OF NON APPROVED BATTER IES 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 3121166 Motors Drive Motor Type Shunt Wound Sepex 24V DC Power 0 65 Horsepower 3750 rom Hydraulic Pump Electric Motor Assembly All Models Type Series Wound Permanent Magnet 24V DC Power 3kW Battery Charger 20 Amp SCR 110 250 Volts AC 50 60 Hz input 24 Volts DC 20 Amp output w auto timer Japanese Specification 100 200 Volts AC 50 60 Hz input 24 Volts DC 20 Amp output w auto timer JLG Lift 1 8 SECTION 1 SPECIFICATIONS Travel Speed Table 1 5 Travel Speed Model ELEVATED S
112. 2 5 9 F2 F2 Xo21 X096 Xo94 093 097 BLACK YELLOW BROWN Figure 7 22 Electrical Schematic Sheet 1 of 2 Machines with MDI JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PLATFORM X050 097 CONTROL BOX 572 BROWN PURPLEJ1 11 19 7 5 Ji X052 DIGITAL INPUT FILTER ANALOG INPUT ORANGE WHITE J1 9 17 RETS POWER 24 V DIGITAL INPUTS FILTER J1 9 ALARI DISTRIBUTIOI ACTIVE HIGH 0TO 5 VOLT WHITE GREEN Ji 19 18 Yoka REGULATIO 0 RED 19 TO ALL ORANGE J1 12 9 AREAS OF THI GRAY J1 8 8 X049 SYSTEM MICROPROCESSQ J1 8 JOYSTICK DIGITAL 15 OUTPUT PLUEJA 1 CAN DRIVERS BROWN J1 16 12 LA 24V WHEN J1 16 OLET 22GA INTERFAG OUTPUT IS ON PINK J1 5 55 J1 5 os PURPLE J1 7 6 LT RT n7 ROCKER RIGHTYELLOW 24 GA qug WHITE 1 6 7 HORN SWITCH CAPACITY SWITCH Z 5VDC WHT RED Lr GROUNDW
113. 3 7 32 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS POTHOLE INVERTER 4 fe T Ed mm c ALARM O pA g j Q BEACON LIGHT INVERTER POWER SWITCH d BATTERIES CONTACTOR RELAY PUMP MOTOR RESERVOIR POWER MODULE BATTERY or NOTE THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED NI 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 amp SCHEMATICS
114. 32UNC x 50 in long screws hold ing 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 hold ing 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 3121166 JLG Lift BRAKE CONNECTOR 3 Discard the O ring 13 located inside the cover WIRE HARNESS FIELD CONNECTION BLACK WIRES RED WIRES BRAKE ASSEMBLY MOUNTING SCREWS THREADED HOLES IN BRAKE ASSEMBLY Figure 3 26 Motor Front Remove the wire harness 8 from the motor by dis connecting the field connection and brake connec tion 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 Remove the 3 screws holding the brake assembly 11 to the motor Carefully remove the brake assem bly and friction disk 10 from the motor by sliding it off of the shaft 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 Pull back the brush springs 4 in t
115. 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 Charging Indicator Yellow LED 100 Charge Indicator Green LED Fault Indicator Red LED PROTECTION Output Reverse DC Polarity 125 A Replaceable Fuse Electronic Protection Automatic Output AC Short Circuit Reset AC Overload 20 A Internal Slow Blow Charger Fuse DC Overload Voltage Limited Internally Controlled MECHANICAL Operating Temperature ARE Housing Shockand Water Resistant Aluminum 3 48 JLG Lift 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS Battery Charger Inverter Troubleshooting The Fault LED Flash Codes are the same as the Battery Charger see Battery Charger Troubleshooting on pages 3 29 and 3 30 For further specification and troubleshooting information refer to the manufacturers Charger Inverter Owner s Guide shipped with the machine Publication RM1024 JLG Part 3128406 Use the information below to supplement the information in the Inverter Charger manual First go through the trou bleshooting 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 clock
116. 474 1320 4 32 01900 0200 1800 68 58 Z Z ft 0 2500 0 0318 2860 43 16 19 15 28 02500 00364 3280 14 19 148 vr 24 03125 0 0580 5200 25 35 2 5 2 25 38 16 0 3750 0075 700 45 60 40 5 5 50 24 0370 0 0878 7900 50 7 45 60 5 50 716 14 0 4375 0 1063 95 9 6 9 so 70 20 04375 0 1187 1070 9 Ho 0 95 60 80 12 13 0 5000 0 1419 12750 105 15 95 130 80 no 20 05000 0 1599 14400 0 6 0 10 90 120 18 0 5625 0 2030 18250 10 20 15 210 159 175 18 0 6250 0 2560 23000 20 325 215 290 180 24 16 07500 0 3730 33600 420 50 380 55 315 430 78 9 0 8750 04620 41600 605 85 545 740 45 620 14 0 8750 0 5090 45800 670 910 600 815 500 680 1 0000 0 6060 51500 860 1170 770 1045 645 875 i 11 8 2 1 EN xs 8 713759 3590 36 098 12 13750 13150 118100 2705 3680 2435 23310 2030 2760 172 6 1 5000 1 4050 126500 3165 4305 2845 3870 2370 3225 12 15000 1 5800 142200 3555 4835 3200 4350 2665 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS om REV 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED
117. 620 430 646 14 0 8750 0 5090 470 707 i 8 1 0000 0 6060 640 918 12 1 0000 0 6630 700 1000 12 1 1250 0 8560 1193 660 895 925 1258 1 2500 0 9690 1598 6 1 3750 1 1550 1979 1100 1491 1525 2074 12 13780 1 3150 2380 112 6 1 5000 1 4050 2630 1460 1979 2025 2754 T 12 15000 1 5800 2983 1640 2224 2300 3128 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 Stress Area NO 5000059 REV J REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND Vibra TITE 140 High Strength Red Vibra TITE 131 Medium High Strength Red 4 0100019 0100071 Figure 1 1 Torque Chart SAE Fasteners Sheet 1 of 7 0100011 242 Vvibra TITE 121 Medium Strength Blue 2 3121166 JLG Lift 1 9 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Torque Torque orque TM TM Size TPI Bolt Dia Tensile Clamp Load Dry or Loctite 263 Dee 242 oe 271 Loctite xum or Vibra Stress Area K 0 20 OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 n omm ee mi nm me mw ooa 50999 eH 32 0 1380 0 00909 SEHEN 32 0 1640 0 01400 36 0 1640 0 01
118. 8 93888222222222222 8 200651584 YELLOW xo45 4 EXTENDER BLACK E 8 5 2 ORANGE gt Oj r 2 t 2 G 9 a g o 2 g 3 gms BED PLATFORM CABLE TH a of a 6 ROUTES UP ARMSTACK SHIELD HAS BREAK OUT X017 W 2v AN e 7 POINT NEAR PLATFORM PLATFORM BLACK BULKHEAD i n 5 5 rz E BLK 2 a 5 WHITE 3 1200 25 WATT E uw RESISTOR ASSEMBLED IN CANNON PLUG OF FOOTSWITCH 5 REQUIRES LSS MODULE PLATFORM CABLE YEURED 2241175 J2 3 9 gu 3 YEURED 2 3 2 YEURED 2 3 1 4 Ss 2585858 T HOUR METER Se2z293r36 T LIETSWITCH X032 BLUORNS22 Hour ues 5 8 6 83 903 u X081 2 BLACK BLACK 12 5 85 X040 DOWN LAMP 01 2 sit d OVERLOAD X002 4 5 RED YEL 54 1 ovip 129 2 X080 X029 PEN 41 92 7 amp 038 TAN 81 DIGITAL INPUT FILTER i UPG J2 6 POWER 24 V DIGITAL INPUTS PF DISTRIBUTIO ACTIVE HIGH 5 GNDE 42 2 a a BED 2092 KUM RED AS Be ia TOLL gt X036 ESTOP X035 CIR BREAKER AREAS OF THE 501 FOt SYSTEM Y WHT RED57 100 VTLT POWER J3 1 ORNIRED49 100_ rary 43 2 GROUND 8 2 4 ORN RED49 200 WTEAPAG CONTROL u TILTY 13 3 BLACK BOX GND J3 4 BLACK RED 1 1 1 16 4 99 a Dis Fe Be OES A PSO AS eee see CAN HIGH J1 34 958 5 g 55 9
119. A Standby Current 150mA Temperature Range Operating 40 C to 75 C Storage 40 C to 125 C Thermal Limit 75 C to 90 C Switching Frequency 16 kHz The power module is located behind a protective cover at the front of the machine as shown in Figure 3 33 ZAPI Power Module Location Use the following instructions when replacing the power module 3 40 1 JLG Lift Turn machine power off and disconnect the batter ies Locate and remove the power module protective cover from the machine Note the wire terminal locations when removing the old power module Disconnect all wire connectors and cables from the old power module and remove it from the machine When installing the new power module be sure that the terminals are oriented as shown in Figure 3 33 After installing the new power module begin con necting the wire connectors cables to the module Torque all terminal bolts to torque specifications shown on the front of the module After all connections to the power module are made the batteries can be reconnected Reinstall the power module cover then check for normal machine operation 3121166 SECTION CHASSIS amp SCISSOR ARMS ZAPI Power Module Electrical Evaluation INTEGRATED HEALTH INDICATOR The ZAPI Power Module provides a green STATUS LED that shines through the cover to indicate module health status The LED shall be illuminated when the device is powered on
120. ACTION the JLG Analyzer s ARM CUR display Armature Current Reading will exceed 120A The FLD CUR display Field Current Reading will hover around 40A Nei ther wheel will rotate and it will be impossible to rotate either drive wheel by hand The Ground Mod ule cannot detect this fault during power up or self test since energizing the brakes could pose a haz ard However it may detect this issue during Drive investigate using JLG Analyzer 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 sole noid 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 JLG Lift tion Suspect damaged cabling burned cabling or faulty brake release solenoids Trace the brake release cabling from the Power Module Compart ment to the Ground Module Connector J1 24 Open Circuit Brake Release This issue will not allow the vehicle to drive Rapid motor overheating both motors will result Contin ued attempts to drive the vehicle may result in arma ture damage This situation can be detected by elevating the vehi cle s front whe
121. AGE 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 3 Remove the two cover bolts cover and cover o ring seal from the back of drive motor unit 4 Insert the cover bolts into the two disengage holes in the brake housing 5 Tighten down the bolts and the brake on that drive motor will disengage 6 Repeatthis procedure on opposite wheel drive With both drive motor brakes now disengaged the machine can be moved manually 3121166 JLG Lift 3 7 SECTION 3 CHASSIS amp SCISSOR ARMS Manual Disengage Procedure 1 Brake Cover 2 Cover Bolts 3 Disengage Holes Figure 3 7 Disengage Procedure NOTE Applies only to USA machines built S N 0200170585 to Present Belgium machines built S N 1200015159 to Present 1 Chock wheels or secure machine with tow vehicle 2 Ensure battery disconnect switch is in to the OFF position 3 Remove the two Cover Bolts and Brake Cover 4 Insert the Cover Bolts into the two Disengage Holes in the brake housing 5 Tighten down the Cover Bolts and the brake on that drive motor will disengage 6 Repeat this procedure on opposite wheel drive With both drive motor brakes now disengaged the machine can be moved manually 7 After towing is complete chock wheels and remove Cover Bolts from Disengage Holes 8 Reinstall Brake Cover
122. ALLY DISENGAGING THE BRAKES FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH 1 Remove the 3 brake cover bolts from the back end of the motor 2 Remove brake cover 3 6 JLG Lift 3 Locate the 2 disengage bolts that are stored in the motor endcap 4 Remove these bolts and insert them into the two holes in the brake housing Tighten down bolts and the brake will disengage 6 Repeatthis procedure for the other wheel drive A 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 3121166 SECTION CHASSIS amp SCISSOR ARMS Manual Disengage Procedure gt 1 Brake Cover Bolts 3 Cover O ring Seal 2 Brake Cover 4 Disengage Holes Figure 3 6 Disengage Procedure NOTE Applies only to 7 After towing is complete chock wheels and remove USA machines built S N 0200152825 to S N cover bolts from disengage holes 020170909 8 Reinstall cover Before installation check the cover Belgium machines built S N 1200008481 to S N SAU 1200015159 o ring seal for damage replace if necessary 1 Chock wheels or secure machine with tow vehicle A CAUTION AG AFTER THE MACHINE IS TOWED THE DISENGAGE BOLTS MUST 2 Power machine in ground mode BE REMOVED FROM THE BRAKE DISENG
123. ASSIS amp SCISSOR ARMS Motor Assembly NOTE NOTE 3121166 1 Motor 2 Cable 3 Bolt 4 Washer Figure 3 19 Motor Assembly Applies only to USA machines built S N 0200152825 to S N 020170585 Belgium machines built S N 1200008481 to S N 1200015159 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 The motor may need to be rotated to line up the sun gear splines with the motor shaft splines JLG Lift Install the two motor mounting bolts Torque to 9 11 ft lbs 12 15 Nm Connect the end of the cable to the power control module 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 3 23 SECTION 3 CHASSIS amp SCISSOR ARMS Motor Assembly NOTE NOTE 3 24 1 Drive Motor 2 Motor Mounting Bolts 3 Washers 4 Motor Cable Figure 3 20 Drive Motor Assembly Applies only to USA machines built S N 0200170585 to Present Belgium machines built S N 1200015159 to Present 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 The motor may need to be rotated to line
124. An Oshkosh Corporation Company Service amp Maintenance Manual Models 1930ES 2030ES 2630ES 2646ES 3246ES 3121166 June 1 2010 ANSI ALG An Oshkosh Corporation Company INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that maintenance per sonnel pay strict attention to these warnings and precau tions 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 A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION 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 mainte nance 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 suppor
125. C WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING OR SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG NOTE All machines built before mid year 2010 are equipped with the Sevcon 1600346 Power Module in mid year 2010 a new design ZAPI 1001092456 Power Module was introduced for production ES Scissors built in the USA and Belgium may be equipped with either one of two different power modules after mid 2010 All China built machines were equipped the ZAPI 1001092456 Power Module If power module service is required see Section 3 in order to locate and identify which power module your machine is equipped with Original Issue May 27 2003 Revised October 31 2003 Revised March 19 2004 Revised July 8 2004 Revised July 27 2004 Revised October 22 2004 Revised May 4 2005 Revised July 27 2005 Revised May 9 2006 Revised September 6 2006
126. 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 wo 42 w Figure 1 5 Torque Chart METRIC Fasteners Sheet 5 of 7 3121166 JLG Lift 1 13 SECTION 1 SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 10 9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12 9 SOCKET HEAD CAP SCREWS M5 Torque Eu Torque Lub OR Loctite amp Torque ensie Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress TM i TM Area Load 263 Vibra TITE 111 or Vibra TITE 131 K 0 20 140 K 0 15 K 0 18 e Beep 3 5 0 6 6 78 4 22 4 oz ave se 5 os 1420 0 0 0 e NENNEN 5 125 seco 228 365 8 24 24 3 2220 14065 90 33 3 5 694 432 5 2855 2570 2140 36 4 817 509 0 3665 3300 2750 42 4 5 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 ASSEMB
127. CTIVE taneously in platform mode Check switch continuity There should only be continuity from the TOGETHER center post to one of the outer posts at atime Otherwise replace the switch Check drive lift switch signal and wiring to the platform board Its input OV is from platform board terminal J1 11 Lift selection output OV when selected is to platform board terminal J1 9 Drive selection output OV when closed is to platform board ter minal J1 10 Replace platform board 224 FUNCTION PROBLEM The steer left switch was closed during Check if the steer left switch is obstructed or jammed STEERLEFT PERMA power up in platform mode Check steer left switch and its wiring The steer left switch input NENTLY SELECTED 24V is from platform board terminal J1 1 and its output 24V when closed is to platform board terminal J1 15 Replace platform board 225 FUNCTION PROBLEM The steer right switch was closed during Check if the steer right switch is obstructed or jammed STEER RIGHT PERMA power up in platform mode Check steer right switch and its wiring to the platform board The NENTLY SELECTED Steer right switch input 24V is from platform board terminal J1 1 and its output 24V when closed is to platform board terminal J1 16 Replace platform board 226 ACCELERATORFAULTY Thejoysticksignalisoutsidetheaccept Center joystick and check to see if a power cycle will clear DTC WIPER OUT OF RANGE ab
128. ED 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 amp SCHEMATICS NOTE THIS ILLUSTRATION USED WITH 1001092456 POWER MODULE BRAKE RELEASE SWITCH OR BRAKE DISCONNECT SWITCH LIFT CYLINDER VALVE BLOCK PLATFORM CONSOLE BOX PLATFORM RECEPTACLE cH al DIAGNOSTIC ANALYZER C6 ROTARY ANGLE FER SENSOR QO MDI HOUR METER GROUND CONTROL BOX adf P 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 amp SCHEMATICS NOTE THIS ILLUSTRATION USED WITH 1001092456 POWER MODULE PROTECTION SWITCHES ru POTHOLE 1 BATTERY DISCONNECT INVERTER i POWER SWITCH BEACON LIGHT BATTERY CHARGER INVERTER CONTACTOR POWER RELAY
129. EL RED 2 3 1 guys 20 4 S ES 5 II HOUR METER Bus ieee i 1 SWITCH BLU ORN 52 2 hour 2 8 Sep SS LIFT LIFT BLACK BLACK up 32 5 285 i DOWN LAMP 01 9 mE 3 OVERLOAD E RED YEL 54 1 QE z OVLD J2 9 BOS 7 15 5 ATN TAN 4 1 png 2 0 3 1 DIGITAL INPUT FILTER UPG J2 6 POWER 24 V DIGITAL INPUTS 25 DISTRIBUTION ACTIVE HIGH YEL RED 2 1 1 4 2 Mee REGULATION oa RED 1 2 RED I I Ig 2 1 TO ALL DI ESTOP CIR BREAKER AREAS OF THE EN 01 Fol SYSTEM MICROPROCESSOR i VTLT POWER 3 1 i ORN RED 49 100 5 TILTK 33 2 GROUND 2 ORN RED 49 200 CONTROL 3 TILTY 03 3 INTERFACE BOX BLACK 43 4 usc Spee Pee Seer ces Se i BLACK 1 B JI 40 i RED 1 1 1 16 gy gig CAN HIGH J1 34 a te i Som m CAN LOW 41 35 ae 1 a bes T 5 je SHIELD J1 36 EU E tS eee CHARGER LN Sees 45225 i INTERLOCK J1 29 e EET EEE FO EE R A YEL RED 2 100 ANALYZER as 3 ORURED 49 91 YEL RED 2 5 6 CONNECTOR LOCATED piis 22 8 INSIDE BATTERY 2 ORN RED 48 90 aj 2 COMPARTMENT GROUND Z8 a 5 CONTROL BOX SIDE S BLACK 18 5 gr S BATTERY CABLE 2 0 GA A BAT CABLE S 3 BIN di 4 6A SE ee a 2 i 5 i 8 10 i glu FI i POWER a E t YEL RED 1 CONTROLLER P S a
130. ERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121166 Table 7 9 Power Module J2 1001092456 Power Module ONLY Pin Function Type 1 Spare Connect to BATT Power Output 2 Positive Lift Down Valve High Side Driver Power Output 3 Spare Digital Input High Sensing Digital Input 4 Spare Digital Input High Sensing Digital Input 5 CANbus Low Serial 0 6 CANbus High Serial VO 7 Spare Positive Analog Reference 5 Power Output 8 Platform EMS Logic Supply for Plattorm Mode Power Input 9 Negative Steer Left Solenoid Valve Low Side Driver Digital Output 10 Switch Manual Brake Release High Sensing Digital Input 11 Spare Digital Input High Sensing Digital Input 12 Spare Digital Input High Sensing Digital Input 13 Spare Digital Input High Sensing Digital Input 14 Spare Negative Analog Reference Connectto B Power Output 15 CANbus Shield Connectto B Power Output 16 Negative Lift Down Valve Low Side Driver Power Output 17 Negative Lift Up Solenoid Valve Low Side Driver Digital Output 18 Negative Steer Right Solenoid Valve Low Side Driver Digital Output 19 Spare Analog Input 0 5V Analog Input 20 Spare Digital Output Low Side Driver Digital Output 21 Spare Digital Output Low Side Driver Digital Output 22 Negative for Overload Lamp Low Side Driver Digital Output 23 Negative for Hourmeter Low S
131. ESS TO l ELECTRICALLY RELEASE YEL RED 2 5 6 BRAKES TO ALLOW TOWING BLACK LOCATED ON CYLINDER BLACK BATTERY CABLE owe 4 GA BATTERY CABLE 4 GA YELLOW BROWN POWER MODULE amp CONTACTOR ARE MOUNTED IN FRONT COMPARTMENT OF CHASSIS BETWEEN DRIVE MOTORS COMPARTMENT IS COVERED DRIVE MOTOR CABLES ENTER COMPARTMENT 1930ES USA Built Machines Prior to S N 0200150266 1930ES Belgium Built Machines Prior to S N 1200007882 2030ES 2630ES USA Built Machines Prior to S N 0200152825 2030ES 2630ES Belgium Built Machines Prior to S N 1200008481 2646ES 3246ES USA Built Machines Prior to S N 0200151606 2646ES 3246ES Belgium Built Machines Prior to S N 1200008265 1870164 G Figure 7 19 Electrical Schematic 1870164 G Sheet 2 of 2 3121166 JLG Lift 7 19 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
132. F 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 maxi mum 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 mount ing bracket NOTE The brake release plugs have no polarity therefore can be connected to either post on the button 3121166 JLG Lift 3 1 SECTION 3 CHASSIS amp SCISSOR ARMS 4 Connect the MDI harness to the Diagnostic Port 1 MDI Connected 2 Brake Release Connected Using a 5 32 allen wrench mount the MDI and Brake Release Bracket onto the wall of the battery compartment appropriate mounting holes are pre existing Apply Loctite 242 to the screws and torque to 3 6 ft lb 5 Nm Refer to Figure 3 2 1 MDI amp Brake Release Bracket 2 Screw 5 x 16 3 Washer 5mm Figure 3 2 MDI Installation Removal 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 Er
133. HP Switch Input Vbatt 19 Ignition Power Output Vbatt 20 Brake Release Swtich Input Vbatt 21 Steer Left Coil Output Vbatt 22 Steer Right Coil Output Vbatt 23 Left Brake Release Output Vbatt 24 Right Brake Release Output Vbatt 25 LiftUp Coil Output Vbatt 26 LiftDown Coil Output PWM 27 Ground Power Output 0 28 Ground Alarm Output PWM 29 Charger Interlock Input Vbatt 30 Ground Power Output 0 31 CAN Bus High Input Output Comm JLG Lift 7 13 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 7 14 Table 7 1 Ground Board J1 1600346 Power Module ONLY Pin Function Type Range V 32 CAN Bus Low Input Output Comm 33 CAN Bus Shield Output 0 34 CAN Bus High Input Output Comm 35 CAN Bus Low Input Output Comm 36 CAN Bus Shield Output 0 37 Ground Power Output 0 38 Ground Enable Power Output 0 39 Master Ignition Connection Power Input Vbatt 40 Master Ground Connection Power Input 0 Table 7 2 Ground Board J2 Pin Function Type Range V 1 Ignition Power Output Vbatt 2 GroundEMS Power Input Vbatt 3 Platform EMS Source Power Input Vbatt 4 Ground Mode Select Input Vbatt 5 Ground Power Output 0 6 Ground Lift Up Input Vbatt 7 Ground Lift Down Input Vbatt 8 Hour Meter Output Vbatt 9 Ground Overload Lamp Ou
134. HT BLACK m SIG QUTPUT BROWN 0 5 VOLT DP MEMBRANE SWITCHES OUTPUT MOUNTED DIRECTLY ON BOARD T MOUNTED ON RED 2 015 mommy BOTTOM ARM PIVOT APWR J1 14 GROUND WHITE CONTROL BOX SIDE ANGL J1 15 3 X001 BLACK SHIELD GND J1 16 YEURED 2 5 3 SWITCH POTHOLE SWITCHES IGN J1 9 ARE CLOSED WHEN PHP ORN RED49 1 X023 MECHANISM IS DEPLOYED LH PHP J1 10 RH PHP VELRED 2 52 SWITCH BULKHEAD CONNECTION AT ARM PIVOT IGN 01 17 IN HARNESS GND WIRE FOR STEER amp ORNIREDAS S ali LIFT UP COILS ARE SPLICED TOGETHER RH PHP J1 18 a ANALOG INPUT YELLOW9 2 CO WT BLACK 7 FILTER STEER LEFT J1 21 52 VALVE 0TO 5 VOLT STEER RIGHT YELLOW10 2 BLACK6 STEER RIGHT J1 22 Se LIFT UP LIFT UP 1 28 TAN 3 2 rt BLACKS BBARE TANA X043 LIFT DOWN RELEASE MICROPROCESSOR LIFT DOWN J1 26 A SWITCH BLACK 26 Xot GND J1 27 DIGITAL ORANGE 55 141 OPTIONAL ACC Y OUTPUT RH BRAKE J1 24 A LOCATED ON VEHICLE DRIVERS CHASSIS COILED ORANGE 55 2 RS232 L N 24 V WHEN LH BRAKE J1 23 UP HANGING ON OUTPUT IS ON BAS HOOK INSIDE GND J1 30 BATTERY DOOR OPPOSITE GROUND GND J1 37 CONTROL BOX BLU ORN 52 1 s GALR J1 28 x X022 2 2 E d YEURED 2 5 10 1 E E amp BLACK 9 5 PS X014 BLACK 15 9 YEL RED 2 5 8 9 4 a BRAKE RELEASE 5 IGN ORANGE 55 2 BLK BRAKE RELEA POWER BATTERY CABLE YEURED 2 5 11 WHITE Pum 4GA BULKHEAD CON
135. 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 dis assembled by non JLG personnel 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 A WARNING 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 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 A CAUTION RETURN BRAKE RELEASE CABLE BEFORE RETURNING TO NORMAL OPERATION Roll Test The purpose of the roll test is to determine if the unit s gears are rotating freely and properly You shou
136. IELD 2 2 292828225 ET BREAK OUT SPLICED INT ma S ats poc PLATFORM CABLE TO i A AA PROVIDE ACCESSORY a lul fol 5222 CANBUS IGNITION AND 7777777777 H ao GROUND CONNECTION i o EL CRAT BLACK ig SHIELD e 2 CANBUS amp 4 GREEN ue ee 2 3 POWER YELLOW E 4 EXTENDER SLACK a 5 2 ORANGE d 2 ay goa S Ta g va saz ge S ae PLATFORM CABLE THAT a S a s E ROUTES UP ARMSTACK ab Hejs SHIELD HAS BREAK OUT ED Wah ee eae eee 7 S S BACK POINT NEAR PLATFORM ST ST T zT zT zl m BULKHEAD uS 9 ga BLK a al a a az a Sa e 1200 25 WATT d a S RESISTOR ASSEMBLED IN CANNON PLUG OF 801234802 FOOTSWITCH a REQUIRES LSS MODULE PLATFORM CABLE YEL RED 2 2 Ipis 32 37 RENE YEL RED 2 3 2 YEL RED 2 3 1 eps jos m i LIFT SWITCH 77007 BLU ORN 52 2 gy weteR 2 05 E 9 2 s amp a i 503 CREME i LIFT LIFT BLACK BLACK GND 0 5 288 i up DOWN LAMP 01 es ENT 3 OVERLOAD 2 2 18 O RED YEL 54 1 vip 32 9 pi P TAN 4 1 5 Lr png 2 1 be TAN 3 1 DIGITAL INPUT FILTER i UPG J2 6 POWER 24 V DIGITAL INPUTS DISTRIBUTION ACTIVE HIGH rad YEL RED 2 1 1 32 2 AND 8 REGULATION NE ura gi 32 0 TO ALL 47 ESTOP CIR BREAKER AREAS OF THE 501 FoI SYSTEM MICROPROCESSOR i WHT RED 57 100 VTLT PO
137. ILOVHL qNHOJ1V Td Y x Y x I Y SNOISH3A Solvivd avol QS19 N3d0 VX XX uno qu 0 MOILSAOP SOLLSONOVIG SOLLSONOVIG SOILSONOVIG WALSAS NOLLOVHLL uWNHOAl1Vld x I I Q3SO 10 N3dO 96001 0 WMd NadO H355IlHL I31SAS NOLLOVHL WHOS d x I I S3 T3u AS SS LIOA G14 N3dO NHOH WALSAS NOLLOVHL WHOL d x I I 44O NO WHY N3dO 8 INOZ HOSN3S A313 WALSAS SOlLSONSVIQ Y x Y Y Q3MOLS d33dS Sdd XX LL 96001 0 INMd WHY NadO LNO NI HOSN3S A313 A31SAS NOLLOVHL WHOL 1d I x I I 00 0 1511 Q3MOLS WHOSLW 1d AA XX LL AX XX LIOA WHY N3dO 1 SATA HOSN3S A373 248168 NOLLOVHL WHOS d Y Y x Y Y NO 33O df L417 N3dO MS AX XX VX XXX HNO dNNd AYA NadO 11 4331S ISIJAVA HOSN3S AN1A WALSAS NOLLOVHL WHOS 1d I I x I I I NO 34O LY 4331S AXX X 2 AMALIE 36001 0 WMd 9001 0 d33dS 1511 N3dO 13S 1511 SJAA HOSN3S WALSAS NOLLOVHL aNnou5 WHOS d Y Y x Y Y x Y 3193NNOO LON NO 4JO 17 4331S HSNS STONY IOW WHLNAN WHLNAN IQON 141 13S IS3ATVA HOSN3S Add W31SAS NOILOVHL aNnous INHO41V ld x I I x I I x I H39HVHO S3NWA HOSN3S A313 W3lSAS NOLOVHL WHOSLVW1d
138. IRCUIT FIELD WIRING carece ae tee ae EE 7 16 6 2 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 8 2 9 9 775 OPEN CIRCUIT FIELD WIRING fics ae a cr ee rr t ee ci d te i aie es 7 16 776 STALLED PUMP MOTOR OR POWER WIRING 02 7 16 777 OPEN CIRCUIT PUMP MOTOR 7 16 778 TRACTION T HIGH CHECK POWER 7 16 779 TRACTION T LOW CHECK POWER 5 2 7 16 7710 PUMP P HIGH CHECK POWER 5 7 16 7711 PUMP P LOW CHECK POWER CIRCUITS piirsi 7 16 7741 ARMATURE BRAKING CURRENT 7 16 7742 FIE D VOLTAGE IMPROPER mineira pt tees te gir tm be dite e tet 7 17 811 TILT SENSOR NOT CALIBRATED ee biete eden videre e a den Rete Eee T e e 6 17 812 NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY 6 17 821 LSS CELL TERROR cu snnt eite i eve et ad ee NE EIE n 6 17 822 ESS CELL 2 ERROR s set ota eire tht eden dei dte enda t Pd and die oce 6 17 823 LSS CELL 43 ERROR te re Riese ii erede 6 17 9824 LSS CELE F amp ERROR eb Heat re e dee E e p eid dee edet 6 17 825 188 HAS NOT BEEN CALIBRATED
139. L 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 set tings can be changed Changing the personality settings first and then changing the model number of the machine con figuration 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 Configuration o Market Default Setting Digit Setting Description 0 1 2 3 1 B 1 1930ES 1 E 2 E Setto your applicable ES Model Model 4 2646ES 1 through 5 5 3246ES 0 ANSI USA 1 ANSI EXPORT 2 2 CSA 0 ANSI USA Market 3 CE your applicable market 4 AUSTRALIA 5 JAPAN 3 0 NO Drive and lift up not prevented while tilted Ground and Platform Mode 1 1 1 0 1 1 Tilt Cutout 1 YES Drive and lift up prevented while tilted Ground and Platform Mode 4 0 No Drive and lift up not prevented while elevated 0 Drive Cutout 1 Yes Drive and lift up prevented while elevated 5 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 0 0 0 0 0 0 Charger Interlock Required for CE 0
140. LG Lift 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 A 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 DRIVING AT CUTBACK POWER MODULE CUR RENTLIMIT The drive portion ofthe Power Module has reached ther mal limit Allow to cool by waiting for temperature to fall The Power Module is reporting a I T Drive Current Limit faultcode LIFT UP AT CUTBACK POWER MODULE CUR RENTLIMIT The lift up portion of the power module has reached ther mal limit Allow to cool by waiting for temperature to fall The POwer Module is reporting PPump Current Limit fault code Help messages with the 4 4 flash code indicate a battery supply problem BATTERY VOLTAGE TOOLOW SYSTEM SHUT DOWN Battery Voltage momentarily dropped below 14 5V With a low battery charge this can occur during heavy current demand due to drive steer or lift up The Power Module is reporting a Low Battery Fault Code 7d Drive Steer amp Lift Up Prevented Recharge batteries or check for damaged batteries BATTERY VOLTAGE TOO HIGH SYSTEM SHUT DOWN The Power Module momentarily measured excessively high
141. LIFT DOWN RELEASE MICROPROCESSOR LIFT DOWN J1 26 VALVE SWITCH GND 1 27 BLACK 26 DIGITAL HE 0PTIONAL ACC Y OUTPUT RH BRAKE J1 24 5 ORANGES AA LOCATED ON VEHICLE DRIVERS CHASSIS COILED RS232 24 V WHEN LH BRAKE JI 23 UP HANGING ON OUTPUT IS ON HOOK INSIDE GND 01 30 BLAK BATTERY DOOR OPPOSITE GROUND GND 01 37 BLACK 18 CONTROL BOX BLU ORN 52 1 A GALR J1 28 3 2 E YEL RED 2 5 10 BEACON RACKS Z BLACK 15 S YEL RED 2 5 8 gt BRAKE RELEASE E ORANGE 55 2 EN site BRAKE RELEASE POWER BATTERY CABLE YEL RED 2 5 11 WHITE 4 GA ewe N BULKHEAD CONNECTION AT ARM LOCATED ON PUSH BUTTON SWITCH PIVOT FOR PUMP CABLES INSIDE BATTERY DOOR BATTERTSCABEE UA 161 NEAR GOUND CONTROL BOX 5 BLACK 10 BLACK II 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 Figure 7 21 Electrical Schematic 187205 B Sheet 2 of 2 3121166 JLG Lift 7 21 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 7 22
142. LITY SUCH AS BATTERIES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICA TION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Check the electrolyte level of the batteries often adding only distilled water when required When fully charged battery fluid level should be 1 8 below vent tubes See Figure 3 34 DO NOT fill to bottom of vent tubes DO NOT allow fluid level to go below the top of the plates when charging or operating BATTERY FILLER CAP a FLUID LEVEL OF FULLY CHARGED BATTERY VENT TUBE Figure 3 34 Battery Fluid Level 3121166 3 11 BATTERY CHARGER 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 Figure 3 35 Battery Charger Location 1 AC Voltage Input Cable 2 Charger Interlock Cable 3 DC Power Cable to Batteries 4 LED Indicator Cable Figure 3 36 Battery Charger JLG Lift 3 43 SECTION 3 CHASSIS amp SCISSOR ARMS Table 3 3 Battery Charger Specs BATTERY CHARGER SPECIFICATION OUTPUT Nominal DC Output Voltage 24V Maximum DC Output Voltage 33 6V Maxim
143. LY 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 JLG Lift 3121166 SECTION 1 SPECIFICATIONS 3121166 Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE Torque Tensile Dry or Loctite 242 or 2717 Loctite 2627 Size PITCH Stress OR Vibra TITE OR Vibra TITE pos or Pi i K 15 CT L 6 a ee e p ono po 19 a 125 z28 54 95 150 255 325 20 2 5 245 460 22 2 5 303 625 24 3 353 790 27 3 459 1160 1875 33 2140 2750 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 Fa
144. N s 3 56 2630ES 3246ES USA built S N 0200151610 Belgium built S N 1200008265 __ Pothole Switch Machines from S N s to present 2630ES 3246ES USA built S N 0200151610 Belgium built S N 1200008265 Figure 3 44 Pothole Switch Adjustment 2630ES 3246ES With the machine in the stowed position and the battery door open remove the old pothole switch Mount the new limit switch and harness to crank with the washer placed behind the switch Adjust the switch by inserting an 1 8 shim between the link and the switch plunger Push the switch to fully depress the plunger and tighten the switch screws Repeat this procedure on the opposite side Raise and lower the machine from the ground con trol several times to ensure that the switch is func tioning properly JLG Lift 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 3121166 SECTION CHASSIS amp SCISSOR ARMS Pothole Switch Replacement Service Kit 1001109345 NOTE Omit
145. NECTION AT ARM RO x012 PUSH BUTTON SWITCH PIVOT FOR PUMP CABLES SIDER TERROR BATTERY CABLES GA NEAR GOUND CONTROL BOX X024 BLACK 10 A025 BLACK 11 POWER MODULE amp CONTACTOR ARE MOUNTED IN FRONT COMPARTMENT OF CHASSIS BETWEEN DRIVE MOTORS COMPARTMENT IS COVERED DRIVE MOTOR CABLES ENTER COMPARTMENT OPTIONAL EQUIPMENT CONNECTION 3121166 1870205 B Figure 7 23 Electrical Schematic Sheet 2 of 2 Machines with MDI JLG Lift 7 23 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121166 880X 120 2 z 318vO 10H1NOO 2 o o8 6 on 2 E e o e 9 8 4 6 SISSVHO 93N og s ex 28 8 99 NI 9 6 NI GSLNNOW RE o SOd 5 S 6r13H NHO Y og 2 lt 8 o 8z0x vixovig e H3OHVHO 51 o 0LOX 020 S H31H3ANI 2 9 doc gt L x og 5 Dc RBS d N 80 S a 4S0X 9S0X AE Q o 2 9 62 17 6 800X SINGOW gt 2 61 10 6 5 2 Q3u 13A 980X 810X 390 IH31NI H3OHVHO 7 24 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS JES NO
146. NOT INSTALLED Vehicle alarm will function for Arm Guard if enabled Overload if LSS enabled and as a horn 6 1 DESCENT Vehicle alarm will function for Arm Guard if enabled Overload if LSS 2 2 2 0 2 2 Ground Alarm enabled as a horn and during Lift Down motion 2 MOTION Vehicle alarm will function for Arm Guard if enabled Overload if LSS enabled as a horn and during Drive and Lift motion 0 NOT INSTALLED Load Sensing System LSS is not fitted to the vehicle 1 CUTOUT PLT Load Sensing System LSS is fitted and Platform Controls are pre 7 vented in the event of an Overload Ground Controls remain functional This is the 0 1 0 0 1 Load default setting for CE machines 2 CUTOUT ALL Load Sensing System LSS is fitted Plattorm and GRound Controls are prevented inthe eventof an overload 8 0 PEERLESS Vehicle is fitted with Peerless drive motors 1 Drive Motors 1 ADVANCED DC Vehicleis fitted with ADvanced DC drive motors 0 NOT INSTALLED Vehicle is not fitted with an Elevation Prox Sensor Vehicle has 9 Leftand Right Brake Release Outputs and Maintained Brake Release functionality ElevP 1 INSTALLED Vehicle is fitted with an Elevation Prox Sensor original ES Series 0 Elev Prox Vehicle has a single Brake Release Output and Momentary Brake Release function ality 10 0 FLOODED Batteries are conventional lead acid type 0 Battery 1 AGM Batteries are absorbed glass mattype 11 0 NO Vehicle is not fitted with
147. Output 13 Positive Main Line Contactor Connect to GNDS diode OR d with EMS Power Output 14 Spare Digital Input High Sensing Digital Input 15 Spare Digital Input High Sensing Digital Input 16 Positive Rotary Sensor Reference 5V Power Output 17 Negative for Rotary Sensor Power Output 18 Positive Left Pothole Switch Reference Connectto BATT Power Output 19 Positive Right Pothole Switch Reference Connect to BATT Power Output 20 RS 232 Receive Serial Input 21 RS 232 Transmit Serial Output 22 Negative for Analyzer Connectto B Power Output 23 Spare Negative Reference Connectto B Power Output 24 Spare Digital Input High Sensing Digital Input 25 Elevation Proximity Switch High Sensing 1230ES only Digital Input 26 Charger Interlock High Sensing Digital Input 27 Foot Switch High Sensing 1230ES only Digital Input 28 Battery Supply from External Relay Power Input 29 Positive Left Brake Release Connect to BATT Power Output 30 Positive Right Brake Release Connect to BATT Power Output 31 Positive Manual Brake Release Connect to BATT Power Output 32 Negative Main Line Contactor Low Side Driver Digital Output 33 Negative Right Brake Solenoid Low Side Driver Digital Output 34 Negative Left Brake Solenoid Low Side Driver Digital Output 35 Spare Digital Output Low Side Driver Digital Input High Sensing Digital Output 7 16 JLG Lift 3121166 SECTION 7 GEN
148. PEED MAXIMUM SPEED Unit of Measure Mph Sec 25 ft Kph Sec 7 6m Mph Sec 25 ft Kph Sec 7 6m 1930ES 0 5 28 37 0 8 25 30 3 5 5 6 2 4 8 5 5 6 2 2030 5 0 5 28 37 0 8 25 30 2 75 6 18 6 6 4 8 6 18 6 6 2630 5 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 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 1 4 JLG Lift 3121166 SECTION 1 SPECIFICATIONS Model Dimensions Table 1 7 Dimensions MODEL 1930ES 2030ES 2630ES 2646ES 3246ES Platform Height Elevated i P en 2 2 re 2 Platform Height Stowed i i 1 pu 1 p 1 2n ogee 9m Overall Stowed Machine Height Rails Up on os 24 93 i i id Overall Stowed Machine Height Rails Collapsed N A 1 p i x jt Rail Height From platform floor 1 i d i t Overall Machine Width me 9 2 2 n Overall Machine Length Deck Retracted put 94 us he A Overall Machine Length Deck Extended ni om um Platform Size Length 3 n a ne n 22 i Platform Size Width 11 uf 6d n a 3 jj im Platform Extension Length con ri
149. PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING 3 52 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 prevent the clamp from turning 4 5 6 1 Bolt Washers and Nut 2 Cable Clamp JLG Lift 3 Cable Clamp Drive Cable Roll Pin When bolting the green clamp onto the frame place the larger washer against the clamp on the outside of the clamp Connect the drive motor cables to the power mod ule Tuck all wires into the power module compartment and install cover Reconnect battery cable plug Power up machine and operate the drive function to ensure drive motors operate properly 3121166 SECTION CHASSIS amp SCISSOR ARMS NOTE 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 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 Po
150. Pressure Setting Procedure 1 6 4 5 Increase lift pressure to raise the platform and set the safety prop Remove plug from port P 3 and install a pressure gauge Remove the solenoid from the lift valve Set the pressure actuating lift function from the ground or platform Remove the pressure gauge from port P 3 and replace plug Replace the solenoid on the lift valve 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 Oil Check Procedure 1 3121166 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 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 A CAUTION ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED NOTE The 2630ES 2646ES 3246ES platforms will have to be raised higher than the 1930ES and 2030ES in order to access the oil plug Wipe all dirt and debris from the filler plug area Slowly remove the fill plug venting any pressure that may be built up in the reservoir To check the oil level lower platform so it rests on the safety porp A CAUTION THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK 6 NOTE JLG Lift With the plug removed the
151. R 123065 ONLY AVAILABLE ON 19 20 2630 amp 26 3246ES MACHINE S NSING MAST ues p s 43 ELEVAT ION PROX ON 19 20 2630 8 26 3246ES ONLY iB CAND Gea ox ROTARY ANGLE SENSOR ROTARY RELEASE BUTTON WICH b 40 S BATT RELAY PED RUNE CEN LOCATED OW GROUND CONNECTOR STATION SIDE OF MACHINE 1 OF MACHINE IN BATTERY COMPARTMENT i i 8 c TT o we i i REL SW N26 25 5 9 P 1 2 2 E LH PHP i NOTE BRAKE 8 m RELEASE BUTTON ON LISH SWITCH 1230 5 MACHINE 15 a 9 4 2 AT REAR OF FRAME FINI S a ss 8 gt 2 2 alsz a ges a als a a E sam cn 33_SRPH_RPHP_SW TRE d PRPH POS RPHP EIN 2 FSW JI 21 VV VV X24 22 ENS PLATFORM SO DIAGNOSTIC BLACK CAN SHIELD HAT ET CONNECTOR N H_POW_MOD PROT JI 16 as ee EN CAN L PON NOD CANH J2 6 19 AROTP ELEV SEN L POW AROTP J1 1 CANL 32 5 21 NROT N ELEV SEN HRNTR_NEG 32 23 JI 17 SIRs 1 0L GND 38 SMB SW MAN BRK 9 LIFT UP 132522 IA 39 PMB POS MAN BRK SGU JI 8 PMB JI 31 aman ara 10 LIFT DOWN SUO 29 NANA NEG ANLYZR 8 PTLT POS TLT MMC 28 D PILT 01 6 28 TX ANALYZE 1 m GNDS JI 5 1 20 21 RX ANALYZER 8 SCH CHGR INTK SCH J1 26 27_PANA_POSANLYZR 40 2_BATT_RELAY J1 4 23 1 PMC POS LCONT AIT Een mm uc m m 01 13 NRV 02 18 102_NRV_NEG_STEE
152. RAULICS OPPOSITE SIDE OF CYLINDER PORT BLOCK 1 Proportional Valve 7 Spring 13 Locknut 19 Wear Ring 25 Check Valve 2 Emergency Release Assy 8 Jam Nut 14 Piston 20 Spacer 26 Dowel Pin 3 Coil 9 Bushing 15 O ring 21 Wiper 27 Directional Control Valve 4 Relief Valve 10 Barrel 16 Seal 22 O ring 28 Coil 5 Pump 11 Wear Ring 17 Head 23 Bushing 29 Directional Control Valve 6 Filter 12 Seal 18 O ring 24 Cylinder Rod Figure 4 13 Lift Cylinder Assembly 3121166 JLG Lift 4 17 SECTION 4 HYDRAULICS JS NOTES 4 18 JLG Lift 3121166 SECTION 5 JLG CONTROL SYSTEM SECTION 5 JLG CONTROL SYSTEM 5 1 HAND HELD ANALYZER menu Analyzer Display gt HELP PRESS ENTER Escape Key Enter Key To return home or access Stores and selects Top Level Sub Level and item menus gt A previous menu Up amp Down Arrow Keys Left amp Right Arrow Keys Value Selector lt Used to move between Top Level Sub Level and item menus 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 back
153. R_RT 2 gt 102_NRV_NEG_STR_RT NMC_NEG_ 01 32 02 9 NLV_NEG_STEER_LT gt 101 NLV NEG STR LT PGAL 1 7 rosmoow CASE BATT RELAT S 104 PULRV LFT STR CGAL J1 3 103_NUV_NEG_LIFT UP 103_NUV_NEG_LIFT_UP MEOS Mv 2 11 Tos ppv LFT_DN f x PLB J1 29 PDV 22 2 IT 5 gt 5 5 106_NDV_NEG_LFT_DN NRB 21 33 NDV J2 16 6 6 SE PRB 41 30 o gt POWER CONTROLLER HANG CYLGHARNESS 2828 1813 BHF I B F2 Y ez js 4AWG CABLE E 1 COO TS GE 4 ANG IE EM Ex e 300A Eher Ss B PUMP CABLE S Eid Ex T CONNECTION 3 38 5 lt Q sLOCATED AT ARM PIVOT zz col ie BLUE ATTACHMENT ON EE i deaf ww ME 28 No xu ZN Coo js Ls exo EE 5 LIFT STEER RED UP VALVE LEFT VALVE a BLACK STEER RIGHT VALVE ORANGE t gt lt X43 X42 Zi BROWN LIFT ES al 8 DOWN VALVE LOCATED ON EM ae CYL PORT BLOCK 9 NE z z els se E m 5 8 2 2 amp amp V3 23 es E E HANG LE 55 5 BLUE HANG 28 e RT BR a eter BROWN 5 NOTES 212 Fl d E ALL WIRES ARE 18 AWG UNLESS OTHERWISE NOTED 5 34_PLB_POS_LTBRAKE g 2 ALL WIRES ARE WHITE IN COLOR UNLESS OTHERWISE 36 NLB NEG LTBRAKE gt 2 NOTED OR LARGER THAN 18 AWG 32 ANG CABLE 1001114879 C 1 3121166 Figure 7 26 Electrical Schematic Machines with 1001092456 Power Module Sheet 1 of 3
154. 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 Lift 3121166 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A Generals anki eet Lad rs A B Hydraulic System A C Mainteriance oes ect aes ae SECTION 1 SPECIFICATIONS 1 1 Specifications ice tie aw EUR ed Cle T ERN dus Gapacitios cuve heen SEA aed he Fluid Capacities pep ue cm pce eU ere eee Batteries eene UTI ek I DP NE I quA EM WA MOTOTS eL et wert aa rer oe due o Ee Battery Charger aun de ids Travel Speed Lift Speed No Load in Model 1 2 Torque 1 3 L Dricatioi needa IIR RECESSU a eae ee Hydraulic Oll ya oo keep herd 1 4 TIEA ae dott Saad eae EE B
155. Status LED ON 33299 LINE CONTACTOR COIL Drive Lift and Steer Prevented Voltage from an external source was detected on the Negative SHORT TO BATTERY Main Line Contactor e ZAPI HEALTH Status LED ON 33302 NEGATIVE SUPPLY SHORT Drive Lift and Steer Prevented At power up the system module detected an external short on TO BATTERY 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 e ZAPI HEALTH Status LED ON 33303 NEGATIVE SUPPLY SHORT Drive Liftand Steer Prevented At power up the System Module detected an external short on TO GROUND J1 12 J1 17 J2 14 or J2 15 Normally these pins are grounded by the System Module Since the external ground may compro mise integrity all functions will be prevented ZAPI HEALTH Status LED ON 33304 RIGHTBRAKE SHORTTO Drive and Steer Prevented Excessive current flow to the Right Brake solenoid was detected GROUND J1 33 NRB ZAPI HEALTH Status LED ON 33305 STEER RIGHT VALVE Drive Steer and Lift Up Prevented Excessive current flow to the Steer Right Solenoid was detected SHORT TO GROUND 12 18 e ZAPI HEALTH Status LED ON 33406 LIFTUPVALVE SHORTTO Drive Steer and Lift Up Prevented Excessive current flow to the Lift Up Solenlid was detected at J2 GROUND 2 PDV or J2 16 NDV e ZAPI HEALTH Status LED ON 33407 LIFTDNVALVE SHORTTO LiftU
156. TERNAL ERROR 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 amp Lift Prevented The System Module s MC EB valve activation pin is shorted This INTERNAL ERROR is an internal fault Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 99143 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s power and interface PCB digital inputs do INTERNAL ERROR not agree Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 99144 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s MC feedback from the interface PCB dis INTERNAL ERROR agrees with the feedback from the power PCB Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 3121166 JLG Lift 6 19 SECTION 6 DIAGNOSTIC TROUBLE CODES 9 9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 99145 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s enable for the power PCB requested a drive INTERNAL ERROR motor or valve activation when not expected Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 99146 POWER MODULE FAILURE Drive Steer
157. TES 3121166 JLG Lift 7 25 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS X3 GROUND CONTROL 3 BOX CONNECTOR X22 PLATFORM ELEVATION PROX SENSOR 1230ES ONLY CABLE CONNECTOR LOCATED ON FRAME SENSING MAST SEE SHEET 3 SEE SHEET 2 SWITCH T cu 43 ELEVATION PROX CLOSED PROXIMITY b D Y FERROUS MATL SWITCH 40 5 BATT RELAY 10542 15 PRESENT CONNECTOR N lt SS P P VASP SOT ORM xreouooor Oe PAS ABO zs lE m t gt ag IRE 15 ONLY LOADED 5426 5025 ig 34145 ON 230 5 MACHINE RH PHP LH PHP al gleja
158. TFORM EOD CONTROL BOX i L BROWN PURPLE Ji 11 19 21 DIGITAL INPUT FILTER ANALOG NPUT die R POWER 24 V DIGITAL INPUTS FILTER gigy ORANGE MME ITE 012817 ALARM DISTRIBUTION ACTIVE HIGH 0 TO 5 VOLT i REGULATION ae RED 13 ei al jig ORANGE Ji 12 9 MICROPROCESSOR jpg RES i OUIPUT fei COMMON RED 22GA JOYSTICK DRIVERS ge 24 V WHEN Jj jas Issa 2 TRIGGER VIOLET 22 GA mh OUTPUT 15 ON BENE i JI 5 5 ROCKE FFT GRFEN 24 GA PURPLE JI T 6 LT RT JT 4 ROCKF GHT YF W 24 GA 6 1 PEERERERPRERERE 5 HORN SWITCH CAPACITY SWITCH 5VDC WHT RE i i GROUND WHT BLAC i 9 SIG OUTPUT BROWN 10 5 VOLT MEMBRANE SWITCHES OUTPUT MOUNTED DIRECTLY ON BOARD cmm eee 2 i APWR JI 14 ED 2 pm PIN GROUND CONTROL BOX SIDE ANGL JI 15 suu GND 41 16 BLACK YELIRED 2 5 3 SWITCH POTHOLE SWITCHES IGN o e6 30 ARE CLOSED WHEN PHP 1 ORN RED 49 1 MECHANISM I DEPLOYED SITE BULKHEAD CONNECTION ARM PIVOT ELRES 2520 UTEM IN HARNESS GND WIRE FOR STEER amp ORRE ASS i LIFT UP COILS ARE SPLICED TOGETHER RH PHP JI 18 i ANALOG INPUT i STEER LEFT a FILTER STEER LEFT H 92 DEAS T rs STEER RIGHT STEER RIGHT JI 22 JELEON 10 2 at BLACKS 1 LIFT UP LIFT UP 01 25 TAS 2 BENCHES BRAKE TAN 4 2
159. TROL SYSTEM 5 5 ELEVATION SENSOR CALIBRATION 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 CALI BRATION 4 Under Calibrations go to SET ELEV SENSOR 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 5 6 UPDATING SOFTWARE 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 set tings to verify they are the same after software update is complete NOTE Software update must be done with the machine powered in Ground Mode 1 Disconnect analyzer from diagnostic port 2 Using the laptop connector cable connect the lap top 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
160. The DRDY Interrupt from the Load Sensing System Mod This may indicate Load Sens A D ule s A D Converter is missing ing System Module hardware 9 9 Flash Code difficulty LSS Module Message Status Message 0x81 is report ing INTERNAL ERROR DRDY INTERRUPT FROM A D AND Machine Setup s LOAD is setto 1 CUTOUT PLT OR2 CUTOUT ALL Retained until power is re cycled Vehicle assumed to be Overloaded 9 9 POWER MODULE FAILURE PERSONALITY The Power Module detected an out of range or corrupt Reset control system Person RANGE ERROR personality setting alities to default settings to 9 9 Flash Code clear difficulty The Power Module is reporting a Configuration Range Fault Code 11d OR a Configuration 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 Re cycle power to clear diffi 9 9 Flash Code culty The Power Module is reporting a Two Direction Fault Code 4d OR a Sequence Fault Code 5d OR a CAN bus Input Fault Code 6d OR a 12V Supply Detection Fault Code 18d OR a System Monitor Activated Fault Code 24d Retained until power is re cycled 9 9 POWER MODULE FAILURE CHECK POWER The Power Module detected an error in the Power Wiring Check wiring and motors or CIRCUITS OR MOSFET SHORT CIRCUIT for the Drive or Pump Alternately the Power Modulehas repl
161. The control system s EEPROM flag indicates that the vehi cycle power to clear difficulty cle has not been configured new control system compo nents Retained until EEPROM flag is cleared and power is re cycled 9 9 FUNCTIONSLOCKED OUT PLATFORM MOD The control system will not function because the Platform Re program or replace with a ULE SOFTWARE VERSION IMPROPER Module Software Version is not compatible with the restof 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 FUNCTIONSLOCKED OUT POWERMODULE Thecontrol system will not function because the Power Re program or replace with a SOFTWARE VERSION IMPROPER Module Software Version is not compatible with the restof 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 oper ation once the difficulty has been corrected 9 9 FUNCTIONS LOCKED OUT LSS MODULE The control system will not function because the LSS Mod Re program or replace with a SOFTWARE VERSION IMPROPER ule Software Version is not compatible with therestofthe 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 thatwas notequalto 7 The control system may resume operation o
162. The cylinder oil must be at ambient temper ature and temperature stabilized The cylinder must have the normal load which is the nor mal platform load applied If the cylinder passes this test it is acceptable NOTE 3121166 This information is based on 6 drops per minute cyl inder leakage 2 5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES Filament wound bearings 1 JLG Lift Pinned joints should be disassembled and inspected if the following occurs a Excessive sloppiness in joints b Noise originating from the joint during operation Filament wound bearings should be replaced if any of the following is observed a Frayed or separated fibers on the liner surface b Cracked or damaged liner backing c Bearings that have moved or spun in their hous ing d Debris embedded in liner surface Pins should be replaced if any of the following is observed pin should be properly cleaned prior to inspection a Detectable wear in the bearing area b Flaking pealing scoring or scratches on the pin surface c Rusting of the pin in the bearing area 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 lubri cated
163. UT ACCELERATOR NOT CENTERED eene rennen nnne nnne nnns 6 6 229 FUNCTION PROBLEM TRIGGER PERMANENTLY CLOSED 1 ennemis 6 6 2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL seen nennen 6 6 2232 FUNCTION PROBLEM DRIVE amp LIFT BOTH OPEN esent enr etnr innen ennt enne 6 6 2 3 231 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED essent nnne nennen 6 6 232 GROUND LIFT UP DOWN ACTIVE TOGETHER 2 nnne nne nnne innere inneren 6 6 233 FUNCTION PROBLEM BRAKE RELEASE PERMANENTLY SELECTED eene 6 6 2 5 251 ELEV ANGLE SENSOR FAULTY VOLTAGE OUT OF RANGE enne nnne 6 7 252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED nnne nennen nnne nne nnne nnne nnns 6 7 253 DRIVE PREVENTED CHARGER CONNECTED eeseseeeeeeeneennee nennen enne nenne tnnt enne rris 6 7 254 DRIVE amp LIFT UP PREVENTED CHARGER CONNECTED 6 7 255 PLATEORM OVERLOADED ses sce iiti o e pP ou ep terio bd die habia dba tees 6 7 256 DRIVE PREVENTED POTHOLE NOT ENGAGED essen 6 7 257 ELEV PROX PERMANENTLY CLOSED CHECK PROX AND ANGLE ADJUSTMENT 6 8 258 DRIVE amp LIFT PREVENTED BRAKES ELECTRICALLY RELEASED FOR 2 6 8 259 MODEL CHANGED HYDRAULICS SUSPENDED CYCLE EMS eene 6 8 3
164. VEHICLE screen 2 Choose the right arrow key to view the raw uncali brated 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 read ing 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 accept able remove and open the Ground Control box carefully Observe whether the tilt sensor is prop erly seated in its grooves c Tilt sensor has developed an offset shift Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected Level one axis of the tilt sensor and observe the raw read ing should be within 2 0 Do the same for the other axis If either axis is greater than 2 0 replace the tilt sensor Ground Module Software Version 1 4 1 Enter Access Level 1 and go to the CALIBRATION TILT SENSOR LEVEL VEHICLE screen 2 Choose the right arrow key to view the raw uncali brated 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 t
165. WER 13 1 ORN RED 49 100 GROUND TILTX 33 2 M CONTROL z E ORN RED 487200 ring 43 3 BOX BLACK fein 43 4 MERC RR E AET E OE BLACK 8 Ji 40 i O RED 1 1 1 16 gy gi 3 sum CAN HIGH 21 34 93 22234 i 2577 4 Sse 5 i CAN LOW JI 35 858 1 SHIELD JI 36 280585568 D EH E YEL RED 2 1 3 T CANBUS amp ANALYZER 2 CONNECTOR S LOCATED ES E INSIDE BATTERY SS gu QS COMPARTMENT GROUND Z2 E 565 CONTROL BOX SIDE zs al NELIRED 2 5 6 RED crm 8 5 lt 5 BLACK ee SHIELD SHIELD BATTERY CABLE CABLE z BATTERY CABLE 2 0 GA TWTY SIR 3 CONTACTOR pees EA cr pee peneecetm te E YEL RED 2 5 7 1017 3 POWER i Ls 1 CONTROLLER iii i e pon i wi ORA ORS UT sg tO op Oo nm 2 amp 35 ORN RED 49 1 i 05 BATTERY SAS REMOTE LED S i f DISCONNECT a CHARGER ORN RED 49 5 LOCATED IN 6 i LOCATE Dro e MOUNTED IN a aa a ae BETWEEN THESE TWO VEHICLE RED BATTERIES CHASSTS km mener 1 85 gt CHARGER INTERLOCK ORANGE F2 quor Fl SI LEFT F2 S E 5 MOTOR MOTOR o e 5 42 m YEL RED 2 5 9 i Cay i 4 BRAKE 6 BRAKE g ELO 8 7 J YELLOW BROWN
166. X029 X030 X035 X036 Z ROTARY ANGLE SENSOR X081 X080 Lee X037 DRIVE MOTORS xogo X092 X094 Figure 7 36 Electrical Components Sheet 1 of 2 Machines with MDI JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS POTHOLE PROTECTION SWITCHES ae 27 RR amp xm X023 fL X020 X082 X074 4 4 Q 076 X073 X077 ALARM X22 X018 mmn 5 056_ v X072 X078 X014 INVERTER m ot x POWER Iv SWITCH xos BEACON LIGHT BATTERY X008 XOR CHARGER X071 O INVERTER T X088 BATTERIES CONTACTOR RELAY Em X06 q X070 6 X058 E X059 PUMP MOTOR RESERVOIR X019 X069 POWER MODULE X060 LE E xo68 X018 N X020 M X8 Fay X061 2 Q B x X083 X064 La CHARGER Q o X063 7 E X027 X067 x12 oe gt J X085 X066 NOTE THIS CONNECTION US
167. a footswitch 0 0 0 0 0 1 Footswitch 1 YES Vehicleis fitted with a footswitch 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 set tings can be changed Changing the personality settings first and then changing the model number of the machine con figuration 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 Configuration m Market Default Setting Digit Setting Description 1 2 3 3 5 1930ES 1 2 a Setto your applicable ES Model Model 3 1 through 5 4 2646ES 5 3246ES 0 ANSIUSA 1 ANSI EXPORT 2 2 CSA 0 ANSI USA Market 3 CE Setto your applicable market 4 AUSTRALIA 5 JAPAN 3 0 NO Drive and lift up not prevented while tilted Ground and Platform Mode 1 1 1 0 1 1 Tilt Cutout 1 YES Drive and lift up prevented while tilted Ground and Platform Mode 4 0 NO Drive and lift up not prevented while elevated 0 Drive Cutout 1 YES Drive and lift up prevented while elevated 5 0 DRIVE ONLY Drive motion prevented while vehicle is charging DRIVE AND LIFT UP Drive and lift
168. ace the Power Module failed a self test Re cycle power to clear diffi 9 9 Flash Code culty The Power Module is reporting an Armature MOSFET Short Circuit Fault Code 17d OR an Armature MOS FET s Off Fault Code 19d OR an Armature MOSFET s Fault Code 20d OR an Armature Pullup MOSFET Short Circuit Fault Code 21d Retained until power is re cycled 5 20 JLG Lift 3121166 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing fas HELP MESSAGE CAUSE POSSIBLE RESOLVE 9 9 POWER MODULE FAILURE SYSTEM MONITOR The ground board detected armature field or pump cur Refer to Drive Motor Electrical rent while function was not commanded Evaluation in Section 3 7 Refer to Pump Motor Electri cal Evaluation in Section 4 7 Referto Power Module Elec trical Evaluation in Section 3 8 9 9 EEPROM FAILURE CHECK ALL SETTINGS The control system detected an EEPROM failure Person Check correctallsettings and alities and Machine Setup settings may be resetto default re cycle power to clear diffi values culty 9 9 Flash Code The control system s EEPROM checksum indicates cor ruption Retained until EEPROM settings are corrected and poweris re cycled 9 9 FUNCTIONS LOCKED OUT MACHINE NOT The control system has not been configured for the first Use the JLG Analyzer to CONFIGURED time adjust all Machine Setup and 9 9 Flash Code Personality settings and re
169. achine Configuration Pro gramming Information Machines with Sevcon 1600346 Power Module Only for the default set tings Password 33271 will give you access to level 1 which will permit you to change all machine person ality and or machine setup settings A WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS 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 The flash code is indicated on the face of the platform control box as shown SYSTEM FAULT Diagnostic Trouble Codes are indicated on the MDI for those machines that are equipped with an MDI refer to Section 3 2 NOTE Flash codes and DTC s are also displayed on the handheld analyzer For descriptions see Table 5 2 Flash Code Listing 3121166 5 2 TILT SENSOR CALIBRATION Be sure that the machine is parked and stowed on level ground Ground Module Software Version 1 5 1 Enter Access Level 1 and go to the CALIBRATION TILT SENSOR LEVEL
170. acities Table 1 2 Capacities NOTE All platform extension capacities are 250 Ibs 120 kg AUSTRALIAN AUSTRALIAN MODEL ANSI CSA CE INDOOR CE OUTDOOR INDOOR OUTDOOR Max Max Max Max Max Max Max Max Max Max Capacity Persons Capacity Persons Capacity Persons Capacity Persons Capacity Persons 500 Ibs 1930ES 227 kg 2 230 kg 2 120 kg 1 230 kg 2 120 kg 1 800 Ibs 2030ES 363 kg 2 360 kg 2 160 kg 1 360 kg 2 160 kg 1 2630ES 500 Ibs single cap 227 kg 2 230 kg 2 N A NA 230 kg 2 N A N A 2630ES 800 Ibs dualcapto20ft 363kg 2 360 kg 2 N A NA 360 kg 2 N A N A 2630ES 500 Ibs dualcapto26ft 227kg 2 230 kg 2 N A NA 230 kg 2 N A N A 1000 Ibs 2646ES 454 kg 2 450 kg 2 230 kg 2 450 kg 2 230 kg 2 1000 Ibs 3246ESto026ft 454kg 2 450kg 2 320 kg 1 450 kg 2 320 kg 1 Zone A 700 Ibs 3246ESt032ft 317kg 2 320kg 2 320 kg 1 320 kg 2 320 kg 1 Zone B Fluid Capacities Table 1 3 Fluid Capacities Description 1930ES 2030ES 2630ES 2646ES 3246ES 2 2 Gal 2 Gal 3 Gal Hydraulic Tank 7 61 7 61 1131 2 2 Gal 2 8 Gal 5 3 Gal Hydraulic System Including Tank 8 31 1061 19 91 1 2 JLG Lift 3121166 SECTION 1 SPECIFICATIONS Tires Table 1 4 Tire Specifications Description 1930ES 2030ES 2630ES 2646ES 3246ES Size 323mm x 100mm 406 mm x 125 mm Max Tire Load 2500 Ibs 1134 kg 4000 Ibs 18
171. ained until power is re cycled Drive amp Steer Prevented Check power wiring and re cycle power to clear difficulty 5 18 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 zx LSS CELL 1 ERROR Cell 1 s Bridge 2Vdc gt 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 report ing CELL 1 ERROR AND Machine Setup s LOAD is set to 12 CUTOUT PLT OR 2 CUTOUT ALL Vehicle assumed to be Overloaded This situation indicates that the sensoris unplugged or the sensor is damaged 8 2 LSSCELL 42 ERROR Cell 2 s Bridge 2Vdc 3Vdc or could the LSS Module This situation indicates that could not read Cell 42 s Internal Memory the sensoris unplugged or 8 2 Flash Code the sensor is damaged LSS Module Message Status Message 0x81 is report ing CELL 2 ERROR AND Machine Setup s LOAD is set to 12 CUTOUT PLT OR 2 CUTOUT ALL Vehicle assumed to be Overloaded 8 3 LSS CELL 3 ERROR Cell 43 s Bridge 2Vdc 3Vdc or could the LSS Module This situation indicates that could not read Cell 3 s Internal Memory the sensor is un
172. al battery voltage is the same as the charger volt age 3 This fault will clear automatically when the low bat tery voltage problem is rectified 3121166 4 lf this problem does not clear after the battery volt age is confirmed to be higher than 1 0V per cell and all connections are good return the charger for ser vice 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 ambi ent temperature It can also occur if the battery is dam aged old or in poor condition 1 Check the battery for damage such as shorted cells and insufficient water Try the charger on a good bat tery 2 Ifthe same fault occurs on a good battery check the connections on the battery and connection to AC and the AC voltage itself 3 Confirm that the nominal battery pack voltage is the same as the battery charger voltage 4 This fault must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 5 Ifa 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 occur ring as the pack recovers 4 Flashes Check Battery
173. amaged 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 prob lems 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 Press Fixture must press against Outer Race Bearing End Head held stationary Armature Assembly Assembled End Head Bearing and Retaining Ring Press Fixture must press against Inner Race held sta tionary Figure 3 27 Bearing Pressure Guidelines Press the armature 2 commutator end into the commutator end head and bearing assembly care fully supporting the inner race of the bearing See Figure 3 3121166 SECTION CHASSIS amp 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 Assemble the commutator end head to the frame and field assembly 1 and tighten the screws to 120 140 in Ib 13 6 15 8 N m Make sure to align the field connection with the notch in the commuta tor end head Seal wires where they exit from com mutator end head with a small amount of RTV Silicone Sealant Align wires from brake assembly 11 into notch in friction disc 10 Install both items onto shaft of motor aligning wir
174. anner the system provides effective traction control with no added complexity It is essential that the same amount of field current is sup plied to both drive motors or one wheel will pull the vehi cle 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 ener gizes 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 amp SCISSOR ARMS Line Contactor Right Field Winding Field Switches Armature Switch Left Field Winding Power Module Figure 3 3 Traction Control Circuit Sevcon Power Module Line Contactor 24V Right Field Winding Left Right Armature Armature Armature MOSFET Field Shunt MOSFETS Left Field Winding Power Module Figure 3 4 Traction Control Circuit ZAPI Power Module 3 4 JLG Lift 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS 3 4 TORQUE HUB THE PROCEDURES WITHIN THIS SECTION APPLY TO ALL MACHINES AND TORQUE
175. at elevated speed DRIVE amp LIFT UP PREVENTED TILTED amp ELEVATED Drivingis not possible since the platform is elevated and the chassis is notlevel In Platform Mode Platform Position Sensor PPS eleva tion status is elevated and the vehicle is tilted and machine setup s TILT CUTOUT is 1 YES Drive prevented LIFT UP PREVENTED MAX HEIGHT ZONE Applicable to 3246ES configured for the Zone A B Capac ity Selection and operating on Zone A The vehicle has reached the maximum height and further lift up motionis 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 3121166 JLG Lift SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing eset HELP MESSAGE CAUSE POSSIBLE RESOLVE 0 0 DRIVING AT CUTBACK POTHOLE STILL While stowed drive speed is reduced due to lower ground Clear the obstacle blocking ENGAGED clearance since the control system detected that the pot the pot hole protection mech hole protection mechanismis deployed failedto retraced anism repair the mechanical In platform mode with a healthy elevation sensor elevation problem re adjust the pot sensor less than 0 15V and the elevation proxclosedand hole limit switches or repair pot hole protection s PHP switches detect down the wiring to correct the prob In pl
176. at the orange and blue wires are facing the field coils Push the cable in so that the outer jacket is flush with the bottom of the strain relief Reassemble the strain relief to clamp the cable in place Using small butt splices and small shrink tubing connect the field wires orange and blue with the appropriate marked wires coming from the field coils Connect the armature wires 2 red and 2 black to the appropriately marked brush leads using the large butt splices and shrink tubing Pull each of the 4 armature slices through the access holes in the motor end cap Pull the brake leads yellow and brown through the access hole in the motor end cap Install the connector for the brake onto the yellow and brown leads The leads can go with either of the connector pins Reassembling the Motor 1 JLG Lift Install the armature through the motor shell and into the separated end cap Retain the armature in the end cap with the retention bolt 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 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 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 th
177. ate the tilt sensor see Section 5 2 BRATED performed Replace then calibrate tilt sensor see Section 5 2 812 NODATAFROMTILTSEN Nosignalfrom tilt sensor Check tilt sensor connections and wiring in ground control box SOR NOT CONNECTED OR Calibrate the tilt sensor see Section 5 2 FAULTY Replace then calibrate tilt sensor see Section 5 2 8 2 Platform Load Sense DTC FAULT MESSAGE DESCRIPTION CHECK 821 LSSCELL 1 ERROR A problem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 822 155 2 ERROR A problem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 823 155 ERROR A problem has been detected withthe e Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 824 LSSCELL 4 ERROR A problem has been detected withthe e Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 825 LSSHASNOTBEENCALI Theloadsensing system module has not e Empty platform Calibrate LSS see Section 2 2 Calibration in the BRATED 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 LSSWATCHDOG RESET A problem has been detected withthe e Refer to Section 2 3 Troubleshooting
178. atform mode with an unhealthy elevation sensor the lem elevation proxis closed AND pot hole protection s PHP switches detect down 0 0 FUNCTIONS LOCKED OUT SYSTEM POWERD After 2 hours without activity the control system entersa Check batteries charge con DOWN low power state to preserve battery charge dition etc Normal operation should resume after a power cycle 0 0 DRIVE PREVENTED ELEVATED AND ABOVE The Drive Cutout functionality is enabled and the platform Check elevation switches DRIVE CUTOUT HEIGHT is elevated above the calibrated cutout height Check pothole switches Drive Cutoutis 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 Referto 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 amp GROUND The platform and ground mode inputs from the keyswitch Re cycle power once the ACTIVE TOGETHER are active atthe 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
179. ay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 amp 44 0 141 773 1907 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 EL 39 029 359 5845 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 EL 34 93 771 1762 0 www jlg com JLG Europe B V Polaris Avenue 63 2132 JH Hoofddorp The Netherlands 31 0 23 565 5665 amp 31 0 23 557 2493 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 pla
180. battery voltage gt 37 0v and the ground module de energized the ignition relay to protect system devices The Power Moduleis reporting a High Battery Fault Code 8d OR a High Battery without Line Fault Code 109 In response the Ground Module shall de energize the Igni tion Relay and suppress all Help Messages caused by the lack of Ignition Signal This faultis latched until the next power cycle Drive Steer amp Lift Prevented This may be due to improper battery charging or incorrect voltage batteries being used LSS BATTERY VOLTAGE TOO HIGH While the Load Sensing Systemis enabled the Load Sens ing System module measured battery voltage 34 0Vdc which may compromise ability to predict weight LSS Module Message Status Message 0x81 is report ing BATT TOO HIGH AND Machine Setup s LOAD is set to 1 CUTOUT PLT OR 2 CUTOUT ALL Vehicle assumed to be Overloaded This may be due to improper battery charging or incorrect voltage batteries being used LSS BATTERY VOLTAGE TOO LOW While the Load Sensing Systemis enabled the Load Sens ing System module measured battery voltage 9 0vdc which may compromise ability to predict weight With alow battery charge this can occur during heavy current demand due to drive steer or lift up LSS Module Message Status Message 0x81 is report ing BATT TOO LOW AND Machine Setup s LOAD is set to 1 CUTOUT PLT OR 2 CUTOUT ALL Vehicle ass
181. be examined repaired Platform EMS digital input energized and ground mode select digital input energized Defaultto ground mode operation and lift up prevented Help messages with the 2 2 flash code indicate difficulty with the platforms controls 2 2 FUNCTION PROBLEM HORN PERMANENTLY Horn switch in the platform control box was closed during Release or repair the switch to SELECTED power up clearthe message In platform mode the Indoor Outdoor switch digital inputis energized and power upis active Retained until either is momentarily de energized Previously selected Indoor Outdoor mode maintained 2 2 FUNCTION PROBLEM INDOOR OUTDOOR Indoor Outdoor switch in the platform control box was Release or repair the switch to PERMANENTLY SELECTED closed during power up clear the message In Platform Mode the Indoor Outdoor Switch Digital Input is Energized and Power up is Active Retained until Digital Inputis momentarily De energized Previously selected Indoor Outdoor Mode maintained 5 10 JLG Lift 3121166 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing fo HELP MESSAGE CAUSE POSSIBLE RESOLVE 2 2 FUNCTION PROBLEM DRIVE amp LIFT ACTIVE The Drive Liftselector switch indicates that both functions Repair the wiring or switch to TOGETHER are selected simultaneously clearthe message In Platform Mode the Drive and Lift Digital Inputs are Ener gized atthe same t
182. be used for machines equipped with a MDI and SEVCON Power Module ground board soft ware version P1 13 or higher or ZAPI Power Module ground board software version P1 0 or higher For more informa tion 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 amp 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 volt age 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 gt SYSTEM TEST for intermittent or difficult problems 6 2 DTC INDEX Error Error Displayed on MDI nti cac i ant ei t Se e Lob a 6 3 0 0 00T EVERYTHING OK v cities esta cor o ib uS eene See cit Se tied est ui cot QUE A comcs aN ea 6 3 002 GHOUNDB MODE teet eco eura iege Pes 6 3 003 ALARM SOUNDING TILTED amp ABOVE ELEVATION 222
183. c Oil 1 NOTE 2 4 Refer to Section 1 for recommendations for viscosity ranges JLG recommends DTE11 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 Start up of hydraulic system with oil temperatures below 15 F 26 C is not recommended If it is nec essary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density electrical heater to a minimum temperature of 15 F 26 C Changing Hydraulic Oil 1 NOTE 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 specifica tions appearing in this manual If unable to obtain the same type of oil supplied with the machine con sult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends chang ing the hydraulic oil annually 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 contami nants from the service container Always replace the filter and clean magnet any time the system oil is changed While the unit is shut down a good preventive main tenance measure is t
184. cable 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 pis ton is recommended to install the solid seal NOTE The backup rings for the solid seal have a radius on 3121166 JLG Lift one side This side faces the solid seal See magni fied 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 4 13 SECTION 4 HYDRAULICS PISTON BACKUP SPLIT SEAL SPLIT BACKUP RING Figure 4 10 Piston Seal Kit Installation 1 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible 2 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged 3 Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing NOTE When installing the tapered bushing piston and mat ing end of rod must be free of oil 4 Assemble the tapered bushing loosely into the pis ton and insert JLG capscrews not vendor cap screws 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 shaf
185. 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 14 15 16 17 Remove the bushing from the piston Screw the piston CCW by hand and remove the piston from cylinder rod Remove and discard the piston o rings seal rings and backup rings If applicable remove the piston spacer from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer plate if applica ble Discard the o rings back up rings rod seals and wiper seals Steer Cylinder Piston Removal Cyl p n 1684456 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 Insert a flathead screwdriver or similar tool into the cross drilled retaining ring hole Using the screwdriver guide the retaining ring into the cross drilled retaining ring hole while turning the piston 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 Lift up on the retaining ring so that the hook on the start of the retaining ring releases from the hole in the rod Pull the retraining ring all the way out of the cross drilled retraining ring hole Slide the piston over the rod i
186. ch 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 mea sure the voltage at both power terminals with respect to battery ground The difference between those two measure ments is the voltage applied to the load 7 6 CIRCUIT BOARDS INPUTS AND OUTPUTS 3121166 Table 7 1 Ground Board J1 1600346 Power Module ONLY Pin Function Type Range V 1 Ground Power Output 0 2 Analyzer Power Power Output 12 3 RS 232 Receive Input Output Comm 4 RS 232 Transmit Input Output Comm 5 Platform EMS Input Vbatt 6 Ground Power Output 0 7 Ignition Power Output Vbatt 8 Platform EMS Source Power Output Vbatt 9 Ignition Power Output Vbatt 10 Left PHP Switch Input Vbatt 11 CAN Bus high Input Output Comm 12 CAN Bus Low Input Output Comm 13 CAN Bus Shield Power Output 0 14 Analog Power Power Output 5 15 Elevation Angle Sensor Input 5 16 Ground Power Output 0 17 Ignition Power Output Vbatt 18 Right P
187. cted voltage while Check for continuity through this circuit Steer left solenoid resis TERY 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 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 3 3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK 338 STEER LEFT OPENCIRCUIT The ground board did not detect current Check for continuity through this circuit Steer left solenoid resis flow to the steer left solenoid during nor tance should measure about 30 Ohms The steer left solenoid is mal operation powered with 24V from ground board J1 21 and its ground is to ground board J1 30 37 Inspect the wiring for physical damage Replace ground board 339 STEERRIGHTSHORTTO The ground board detected voltage while Check for continuity through this circuit Steer right solenoid BATTERY the steer right solenoid was commanded resistance should measure about 30 Ohms The steer right sole off noid is powered with 24V from ground board J1 22 and its ground is to ground board J1 30 37 e Inspect the wiring for physical damage e Replace ground board 3310 STEERRIGHTOPENCIR The ground board did notdetectcurrent Check for continuity thro
188. ctedanerrorin Refer to Drive Motor Electrical Evaluation in Section 3 5 CHECKPOWER CIRCUITS thepower wiring for the drive or pump Refer to Pump Motor Electrical Evaluation in Section 4 8 ORMOSFET SHORT CIR Referto Power Module Electrical Evaluation in Section 3 6 CUIT 998 EEPROM FAILURE CHECK The control system detected an Replace ground board ALL SETTINGS EEPROM failure 999 FUNCTIONLOCKEDOUT The power module software versionisnot Replace power module to clear fault POWER MODULE SOFT compatible with the rest of the system WARE VERSION IMPROPER 9910 FUNCTIONLOCKED OUT The platform board software versionis Reprogram platform board PLATFORM MODULE SOFT notcompatible with the restofthe system WARE VERSION IMPROPER 9911 FUNCTIONLOCKED OUT Theloadsensing system modulesoft Replace LSS module to clear fault LSS MODULE SOFTWARE ware versionis not compatible with the VERSION IMPROPER restofthe system 9912 POWERMODULE FAILURE The ground board detected armature Referto Drive Motor Electrical Evaluation in Section 3 5 SYSTEM MONITOR field or pump current whilefunctionwas Refer to Pump Motor Electrical Evaluation in Section 4 8 not commanded Referto Power Module Electrical Evaluation in Section 3 6 9924 FUNCTIONS LOCKED OUT The control system s memoryindicates Use the JLG analyzer to adjust all machine setup and personality MACHINE NOT CONFIG thatthe vehicle has not been configured sett
189. d 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 796 is recommended for the measurements in these procedures This section shows dia grams 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 connec tor such that the test also checks both terminals of the connection It is possible to inspect a connection within a closed con nector by backprobing both sides of a connector terminal and measuring resistance Do this after giving each wire a gentle pull to ensure the wires ar
190. der 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 DRIVE 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 MINIMUM 0 25 0 0 0 0 0 MAXIMUM 0 100 100 100 100 100 100 ELEV MAX 0 25 25 25 25 25 25 LIFT ACCEL 0 1 5 0 Sec 0 5 0 5 0 5 0 5 0 5 DECEL 0 1 1 0 Sec 0 1 0 1 0 1 0 1 0 1 UP MIN 0 50 20 20 20 20 20 UP MAX 0 100 100 100 100 100 100 DNMIN 1 60 45 45 45 45 45 DN MAX 1 100 85 85 85 85 85 STEER STATIC 0 100 70 70 70 70 70 DRIVE 0 100 30 30 30 30 30 ACCELERATOR FWD MIN 2 20 2 40V 2 23 2 23 2 23 2 23 2 23 FWD MAX 1 00 1 50V 1 19 1 19 1 19 1 19 1 19 REVMIN 2 60 2 80V 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 GROUND HORN 87 107 dB 107 107 107 107 107 ALARM 87 107 dB 87 87 87 87 87 LOAD ACCY 0 200 Kg 0 0 0 0 0 OVRDBNCE 0 0 5 0 Sec 3 0 3 0 3 0 3 0 3 0 OVRHOLD 0 0 5 0 Sec 5 0 5 0 5 0 5 0 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 CONTRO
191. e If not examine the cable between the termi nal and the Power Module compartment P Termi nal Inspect crimps for corrosion and ensure that bolted connections are tight Ensure that the cable is not crushed where it passes between the frame side sheets and the cylinder assembly 3 Open Circuit Pump Motor This issue will allow the vehicle to drive but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate Under DIAGNOSTICS PUMP the JLG Analyzer will show PUMP PWM 100 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode Pull the Main Battery Disconnect to completely de energize the Control System Next detach the cable from Pump Motor Positive Terminal Using a voltme ter 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 bro ken terminals After examination re connect the Pump Motor Positive Terminal and the Main Battery Disconnect 4 Short Circuit between Pump Motor Positive and Negative Terminals This issue will allow the vehicle to drive but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate Under DIAGNOSTICS PUMP the JLG Analyzer will show an erratic reading for PUMP PWM and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode Pull the Main Battery Disconnect to completely de energ
192. e 3 8 Tilt Sensor Harness for 1001114936 Wire Color Function Connector Pin Red VCC 1 White CANH 2 Green CANL 3 Black Ground 4 3 62 JLG Lift 3 16 ARMS AND PLATFORM POSITIONING AND SUPPORT A CAUTION PLATFORM IS HEAVY AND PRESENTS A CRUSHING HAZARD TAKE GREAT CARE WHEN REMOVING PLATFORM OR SCISSOR ARM ASSEMBLY The arm stack can be supported by using an overhead crane See Figure 3 47 If an overhead crane is not avail able the stack may also be lifted by using a forktruck using the following instructions 1 With the forks on the forktruck slid close together enter from the front of the machine and place the forks on the cross tube of the second arm weldment below the platform 2 Slowly lift the arm stack with the forktruck while the manual descent valve is being engaged this allows the oil to drain back into the tank 3 Place machine on safety prop and leave the fork truck in place 4 At this point the lift cylinder removal may begin Refer to Section 4 6 Lift Cylinder Removal If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and plat form removal 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS 3 17 PLATFORM REMOVAL 1 Support the platform using an overhead crane with straps capable of lifting at least 250 Ibs 114 kg See Figure 3 47 Refer to Section 3 16 Arms and Platform Positioning and Support
193. e 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 Check ANALYZER gt CYCLE EMS MACHINE SETUP gt MODEL NUMBER Replace ground board 2 5 DRIVE PREVENTED BRAKES NOT RELEASING While driving on a level surface armature currentwas gt Ensure vehicle is not stuck on 150A for five seconds Brakes assumed to not be releasing something preventing move properly ment Check repair drive motor wiring brakes or mechanical issues 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 Referto CANbus documenta power up self tests butthe line contactor did not close tion for Power Module Mes when energized sage Status The Power Module is reporting a Contactor Did Not Close Fault Code 15d Drive Steer amp Lift Up Prevented 3 1 CONTACTOR DRIVER PERMANENTLY OFF The Power Module s Line Contactor drive circuitry failed to Refer to CANbus documenta energize during power up self tests tion for Power Module Mes The Power Module is reporting a Contactor Driver 1 Per sage Status manently Off Fault Code 22d Drive Steer amp Lift Up Prevented Help messages with the 3 2 flash code indicate that acontactor did not open when
194. e ZAPI HEALTH Status LED FLASHING 9955 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s field power circuitry is driven without for INTERNAL ERROR ward selection from the power PCB for 100mS Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 6 18 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 9 9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 9956 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s field current control or MOSFET s are mal INTERNAL ERROR functioning Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 9957 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s hardware that generates an interrupt at 36V INTERNAL ERROR 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 amp Lift Prevented The System Module s pump current measurement or MOSFET are INTERNAL ERROR malfunctioning Pump current measurement gt 2 74V or lt 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 amp Lift P
195. e 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 bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Self locking fasteners such as nylon insert and thread deforming locknuts are not intended to be reinstalled after removal Always use new replace ment 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 accor
196. e still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters 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 cor rectly 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 micro Displayed Number 1 000 000 Example 1 2 1200 Q Example 50 mA 0 05A 3121166 JLG Lift 7 1 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 First test meter and leads by touching leads together See multimeter s operation manual Resistance should read a short circuit very low resis Use firm contac
197. e strain relief to get the parts assembled Reassemble the strain relief onto the cable Reassemble the motor to the gearbox per assembly instructions shown in the motor and brake disas sembly in this section 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 amp SCISSOR ARMS Motor Maintenance 1 Frame and Field Assembly 2 3 4 5 6 T 8 Armature Assembly Brush and Terminal Assembly Brush Spring Brush Box Assembly Retaining Ring Bearing Wire Harness 10 11 12 13 14 15 Commutator End Head Friction Disc Brake Assembly Cover Plate O Ring Strain Relief Bushing Cover Figure 3 24 Drive Motor 3 28 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS NOTE A well planned maintenance program will save many hours of future down time and expense on a piece of equipment Periodic maintenance consisting of inspections of motors batteries and wiring circuitry is recommend CAUTION EYE PROTECTION SHOULD BE WORN DURING MAINTE NANCE OPERATION COVER MOUNTING SCREWS COVER PLATE l MOUNTING SCREWS Figure 3 25 Motor Side Disassembly 1 Remove the 2 8
198. ead 20 0 then a sensor wiring connector fault exists If the readings intermit tently 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 cor rosion on the tilt sensor and control board connec tions 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 by a few degrees flat doesn t imply level park 5 4 ELEVATION ANGLE SENSOR ELECTRICAL ing lots are often not level b The tilt sensor has failed one or both of the EVALUATION channels X axis and Y axis These basic checks using the JLG Analyzer can be used c Tilt sensor has moisture intrusion that has to test the Elevation Angle Sensor If the problem is still shifted its output occurring perform the Tilt vs Allowed Height Evaluation described below 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 e The Ground Control Box as mounted on the machine does not allow the tilt sensor to be level For the following troubleshooting steps a bubble level smaller is better will be needed and the machine must be on a level surface 5 6 1 On the Analyzer go to the Diagnostics System and
199. ed are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents 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 preventi
200. ee peice anes eae a DUCES High Drive Speed Cutout Pressure Settings 22 25 ioi kee eee ease rhea des 1 5 Cylinder Specifications 1 6 Major Component Weights 1 7 Critical Stability Weights 1 8 Torque Chants e recedere ie dg SECTION 2 GENERAL 2 1 Machine Preparation Inspection and Maintenance General oe ei a Ee VIRA Preparation Inspection and Pre Start Pre Delivery Inspection and Frequent Inspection Annual Machine Preventative 2 2 Service and eee eC OPE RES RU Ra eu ee Qut DR RR dunia Safety and Workmanship Cleanliness tense tc LAU bak Ps Components Removal and Component Disassembly and Reassembly Press re FIit P lts ret d E Der Aa Bearings o rte Hee ee beta ee oig ed GASKCIS x scien PEPPER Bolt Usage and Torque Application Hydraulic Lines
201. eire E ei i le e RR DRE e erbe eel 6 17 991 LSS WATCHDOG RESET ersten iiid nete peii Eg e pec ip 6 17 992 LSS EEPROM ERROR i etu eeu etes ede ter des etic eec nter ep er tee c deae pe det dew 6 17 993 LSS INTERNAL ERROR PIN 6 17 994 LSS INTERNAL ERROR DRDY MISSING FROM A D cece cee 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 5 00 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 6 18 9924 FUNCTIONS LOCKED OUT MACHINE NOT CONFIGURED essent 6 18 9950 POWER MODULE FAILURE INTERNAL 9 19 9951 POWER MODULE FAILURE INTERNAL 9 19 9952 POWER MODULE FAILURE INTERNAL
202. el and Tire Assembly each 22 lbs 9 8 kg 42 lbs 19 kg Wheel Tire and Drive Assembly each 117 Ibs 53 kg 162 105 73 4 kg Lift Cylinder 1761bs 80 kg 205105 93 kg 263 Ibs 119 kg 283 Ibs 128 kg Batteries each 220 Amp 220 Amp used with Inverter Charger 245 Amp 60 Ibs 27 kg 66 Ibs 30 kg N A 60 Ibs 27 kg 66 Ibs 30 kg 70 Ibs 32 kg 1 8 JLG Lift 3121166 SECTION 1 SPECIFICATIONS 1 8 TORQUE CHARTS Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Torque 4 Tensile Torque Torque Loctite 242 or 271 Lubricated OR Vibra TITE 111 or Torque Loctite 262 or Vibra TITE 131 n Sam tB mB Nm mB Nm Nm Nm 0 1120 0 00604 s 09 e oz 1411 48 0 1120 0 00661 o8 6 32 0 1380 0 00909 40 0 1380 0 01015 8 32 0 1640 0 01400 36 0 1640 0 01474 0 1900 0 01750 32 0 1900 0 02000 0 2500 0 0318 28 0 2500 0 0364 EET Sq In 0 3125 0 0524 PEEH 0 3125 0 0580 3 8 16 0 3750 0 0775 24 03750 0 0878 0 4375 0 1063 120 04375 0 1187 0 5000 0 1419 75 20 0 5000 0 1599 90 0 5625 0 1820 10 149 108 120 18 0 5625 0 2030 120 13 90 122 135 0 6250 0 2260 150 224 3 4 10 0 7500 0 3340 260 353 200 271 285 388 16 0 7500 0 3730 300 449 7 8 9 0 8750 0 4
203. eld Analyzer 5 1 Using the Analyzer cose le Se lue rei oh y Ee ER ERE dees 5 2 Changing the Access Level of the Hand Held Analyzer 5 3 Adjusting Parameters Using the Hand Held Analyzer 5 4 Machiine Setu p ien REIR DERI RE dre ee A ae ee eae 5 4 5 2 Tilt Serisor Calibration PERLE UE USE Pet v 5 5 Ground Module Software Version 1 5 5 5 3121166 JLG Lift TABLE OF CONTENTS Ground Module Software Version 1 4 5 5 Failure Troubleshooting for The 5 6 5 3 Tilt Sensor Electrical 2 2 5 6 5 4 Elevation Angle Sensor Electrical 5 6 Tilt vs Allowed Height 1 5 7 5 5 Elevation Sensor n 5 8 5 6 Updating PE dee ee Eua eed po epe 5 8 5 7 Tro bleshooting A erras etur E Pe eder Ye oi e PAGE Nue ERE 5 9 5 8 Machine Model Adjustment SEVCON 1600346 Power 5 25 5 9 Machine Model Adjustment ZAPI 1001092456 Power Module 5 26 5 10 Mac
204. els 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 cir cuit Listen for the brake release solenoid when acti vating 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 alter native 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
205. epair or replace the elevation angle sensor 007 DRIVINGATCUTBACK POT While stowed drive speed is reduced Check for obstructions around the pot hole protection mecha HOLE STILL ENGAGED since the control system detectedthatthe nisms pot hole protection mechanism failedto 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 FUNCTIONSLOCKED OUT After 2 hours without activity the contro Normal operation should resume after a power cycle SYSTEM POWERED DOWN system enters a low power state to pre Check batteries charge condition etc serve battery charge 009 DRIVEPREVENTED ELE The platform is elevated above the cali Check that the elevation angle sensor is securely mounted VATED ABOVE DRIVE CUT brated cutout height Check the ANALYZER gt MACHINE SETUP gt MARKET configu OUT HEIGHT ration e f MARKET is set to Japan ensure ANALYZER gt MACHINE SETUP gt DRIVE CUTOUT parameter is set as desired 2 1 Power Up DTC FAULT MESSAGE DESCRIPTION CHECK 211 POWERCYCLE This help message is issued at each Normal operation No check necessary power cycle Displays on the analyzer only 212 FAULTY Both platform and ground modes are C
206. equirements or Strong Sulphur Rotten Egg Smell These symptoms indicate over charging or high battery temperature These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack The most likely cause for this problem is incorrect charge algorithm setting and or high ambient temperatures 1 Confirm that the battery pack is not too small usu ally gt 50Ah 2 Confirm that the nominal battery voltage matches the charger output voltage 3 Confirm the correct battery charge algorithm If the battery pack is new the 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 sec tion 4 Ifthe 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 num ber and charge algorithm setting available when calling 3121166 SECTION CHASSIS amp SCISSOR ARMS 3121166 Checking Changing the Battery Charge Algo rithm 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
207. er lead to probe all terminals Resistance lt 2 Ohms between B and M1 Ensure that there is a short circuit between the B and M1 Ter minals Internally there is a low impedance current measurement shunt for the Armature portion of Trac tion Place the Red meter lead on B and the Black meter lead on M1 Resistance 1 MegaOhms between F1 and B F2 and B Ensure that there is an open circuit between the two Field Terminals F1 amp 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 gt 1 MegaOhms between F1 and B F2 and B Ensure that there is an open circuit between the two Field Terminals F1 amp 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 3121166 JLG Lift Resistance gt 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 imped ance 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 Resista
208. er source and VENTED CHARGERCON cleischarging ANDis configuredto pre disconnect if desired NECTED ventall motion Check ANALYZER gt MACHINE SETUP gt CHARGER INTERLOC is set as desired Must be in ACCESS LEVEL 1 to change Check that charger s red positive battery wire connector termi nal is receiving power 24V from batteries Check signal from charger interlock connector terminal 2 to ground board terminal J1 29 where OVDC indicates charging in process 255 PLATFORMOVERLOADED Theloadsensing 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 f any CAN bus faults are active troubleshoot those first Refer to Section 2 3 Troubleshooting in the LSS manual 3124288 256 DRIVEPREVENTED POT Drivingis not possible while elevated Check for obstructions or mechanical problems around the pot HOLE NOT ENGAGED sincethe pot hole protection system hole protection mechanisms failed to deploy e Check that the PHP switches are securely mounted Adjust pot hole protection switches e 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
209. es not 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 Anaccessory module is reporting a fault CHECK See accessory module documentation for troubleshooting 7 1 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 771 OPENCIRCUIT DRIVE The power module detected a problem Refer to Drive Motor Electrical Evaluation in Section 3 5 MOTOR WIRING the drive motors powercircuitwiring Refer to Power Module Electrical Evaluation in Section 3 6 772 STALLED TRACTION MOTOR Drive Steer and Lift Prevented The System Module detected armature current feedback gt 4 5V OR POWER WIRING ERROR 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 _ Drive Steer and Lift Prevented There is an internal or external fault that prevents the System CHECK POWER CIRCUITS Module s capacitor bank from charging The System Module detected that the VMN of the pump and trac tion has not increased more than 1 3V in 1000mS Alternately the VMN o
210. es with groove in commutator end head Secure brake assembly to commutator end head using 3 bolts and apply small bead of RTV Sili cone sealant around wires between friction disc and commutator end head and in notch in friction disc MOTOR CABLE SECURING NUT STUD TERMINAL SECURING NUT 10 CABLE LUG TERMINAL E FLAT WASHER SECURE NUT WHILE a APPLYING TORQUE INSULATING WASHER MOTOR HOUSING 3121166 Figure 3 28 Terminal Tightening JLG Lift Install wire harness 8 to motor by connecting the field and brake connectors and securing the arma ture 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 Ib 10 2 12 4 N m Remove manual release screws from brake assem bly 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 Assemble strain relief bushing 14 around jacket of wire harness and slide into slot in cover Align cover plate 12 with groove in frame and field and affix using 2 screws 3 31 SECTION 3 CHASSIS amp SCISSOR ARMS 3 6 ELECTRIC DRIVE MOTOR NOTE Applies only to
211. f the pump or traction is less than 2096 of battery volt age f 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 The field wiring passed System Module power up diagnostics ING 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 3121166 JLG Lift 6 15 SECTION 6 DIAGNOSTIC TROUBLE CODES 7 1 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 775 OPEN CIRCUIT FIELD WIR ING 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 POWER WIRING ERROR Drive Steer and Lift Prevented The System Module measured improper pump current feedback gt 4 5V or lt 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 indi cates there
212. from ground board J1 25 and its ground is to ground board J1 30 37 nspect the wiring for physical damage Replace ground board 334 LIFT UP OPEN CIRCUIT The ground board did notdetectcurrent Check for continuity through this circuit The lift up solenoid resis flow to the lift up solenoid during power tance should measure about 30 Ohms The lift up solenoid is 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 335 LIFT DN SHORT TOBATTERY The ground board detected voltage while e Check ANALYZER gt MACHINE SETUP gt ELEV PROX is set to the lift down solenoid was commanded NOT INSTALLED off e Check for continuity through this circuit The lift down solenoid resistance should measure about 20 Ohms The lift down sole noid is powered PWM by ground board J1 26 and its ground is to ground board J1 27 e Inspect the wiring for physical damage e Replace ground board 336 LIFT DN OPEN CIRCUIT The ground board did notdetectcurrent Check for continuity through this circuit The lift down solenoid flow to the lift down solenoid during nor resistance should measure about 20 Ohms The lift down sole mal operation noid 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 337 STEERLEFT SHORT TOBAT The ground board dete
213. gainst Inner Race held sta tionary Figure 3 30 Bearing Pressure Guidelines Assemble the commutator end head to the Frame amp Field Assembly 2 and tighten the screws to 120 140 in Ib 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 commuta tor end head with the Grommet 10 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 com mutator end head Secure brake assembly to com mutator end head using three bolts Install Wire Harness 1 to motor by connecting the brake connectors and securing the armature termi nals 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 Ib 10 2 12 4 Nm 3121166 SECTION CHASSIS amp SCISSOR ARMS Attach to Brake Connector Crimp Blue Wires Together Crimp Red Wire to the Orange Wire Connect Red Wire to This Terminal Connect Black Wire to This Terminal Figure 3 31 Wire Harness Connections 8 Remove manual release screws from brake assem Drive Motor Servicing Guidelines bly Apply new Gasket 12 and affix brake cover to motor using the 2 manual release screws Because the operating en
214. h 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 ener gized 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 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for exam ple 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 swit
215. he 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 Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly Remove the snap ring 6 and bearing 7 from the commutator end head Discard the bearing 3 29 SECTION 3 CHASSIS amp SCISSOR ARMS Inspection and Service 1 3 30 Carefully blow out any accumulated carbon dust and dirt from the end head and the frame assembly using clean oil free compressed air 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 Make sure the brush box assembly 5 is tight on the commutator end head Replace brush box assem blies in the commutator end head if they are physi cally damaged or brush holders are loose on the brush plate Visually inspect the frame and field assembly 1 for overheating or other signs of damage Check all wir ing to insure that the insulation is in good condition Verify that pole screws are t
216. he 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 read ing 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 accept able remove and open the Ground Control box JLG Lift 5 5 SECTION 5 JLG CONTROL SYSTEM carefully Observe whether the tilt sensor is prop erly seated c Tilt sensor has developed an offset shift b NOT LEVEL tilt sensor has either developed an offset or it is too unlevel as mounted on the machine Remove the tilt sensor from the Ground Control 5 3 TILT SENSOR ELECTRICAL EVALUATION box but keep both the tilt sensor and Ground Control box electrically connected Level one This basic check using the JLG Analyzer can be used to axis of the tilt sensor and observe the raw read test the Tilt Sensor ing should be within 2 0 Do the same for the other axis If either axis is greater than 2 0 replace the tilt sensor 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 cali brate are a The surface the machine is sitting on is off level If angle measurements r
217. heck key switch function selected simultaneously Defaults to ground mode 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 Volt age 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 DESCRIPTION CHECK 221 FUNCTION PROBLEM The horn switch was closed during e Check if the horn switch is damaged obstructed or jammed HORN PERMANENTLY power up in platform mode Disconnect the horn switch ribbon cable on the platform board If SELECTED DTC still present replace the platform board If DTC 221 is no longer present replace the horn switch or platform board 3121166 JLG Lift SECTION 6 DIAGNOSTIC TROUBLE CODES 2 2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK 222 FUNCTION PROBLEM Theindoor outdoor zone A zoneB Check if the indoor outdoor zone A zone B capacity switch is INDOOR OUTDOORPER switch was closed during power up in damaged obstructed or jammed MANENTLY SELECTED platform mode Replace platform board 223 FUNCTION PROBLEM The drive andliftinputs are closed simul e Check drive lift switch for visible damage DRIVE amp LIFT A
218. hine Configuration Programming Information SEVCON 1600346 5 27 5 11 Machine Configuration Programming Information ZAPI 1001092456 5 28 SECTION 6 DIAGNOSTIC TROUBLE CODES 6 1 LE 6 1 6 2 eti A ee ee a ee ae re aea 6 1 6 3 DTC Cheek Tables eh ehh TA Ae ak daha t ed tee hy 6 4 0 0 Help Comment 22 20 eee waite te Rp tee eee te ied aes 6 4 2 1 Power Up oim Ree eh Ie e VEU RACK Ux EORR RR TR eR ER 6 5 2 2 Platform GControls LIA Det NDW pele QD OE 6 5 2 3 Ground Controls e erac ERE E ee eh athe a 6 7 2 5 Functiori Prevented 2 zou uius deep PUES Ep ed dunt ai Aad 6 7 3 1 Line Contactor Open 6 9 3 2 Line Contactor Short Circuit 0 0 teens 6 9 3 3 Ground Output Driver 1 6 10 4 2 Thermal Limit SQA gt 22222 e dn eee 6 12 4 4 Battery SUPPLY scene bed Der E deed ed ee we Se 6 13 6 6 COMMUNICATION et e a i ee e ok b dg 6 13 6 7 ACCeSSOL Dicas e ep orani cu Patet 6 15 7 7 Electric MOtOE uere e Ee ut esa MUR OA nace ae erar cd 6 15 8 T TilESerisor o TI em REN ede od NO NT eta EEUU VORNE Y 6 17 8 2 Platform Load Sense
219. hine in platform mode If DTC 662 is present trouble shoot that DTC before continuing 3121166 JLG Lift 6 13 SECTION 6 DIAGNOSTIC TROUBLE CODES A 6 6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK 662 CANBUSFAILURE PLAT In platform mode the control system Turn on machine in ground mode If DTC 661 is not present check FORM MODULE failed to receive messages from the plat for 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 plat form box connector socket D to ground board connector socket J1 7 If DTC 661 was present in the previous check disconnect arm stack passthru connector located near the ladder on the left Turn on in ground mode If DTC 661 is not present then there is a prob lem 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 596 Arm stack 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
220. hould have continuity Platform box socket F to plat form 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 6 14 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 6 6 Communication TILT SENSOR received for 1000 mS while B is present on J1 28 DTC FAULT MESSAGE DESCRIPTION CHECK 663 CANBUSFAILURE LOAD With load sensing system enabled the Check ANALYZER gt MACHINE SETUP gt MODEL NUMBER is SENSING SYSTEM MODULE control system failed to receive mes correct sages from the load sensing system mod Check ANALYZER gt MACHINE SETUP gt MARKET is correct ule Check ANALYZER gt MACHINE SETUP gt LOAD is correct e Check for 24V between load sense system module connector J1 1 and J1 2 Turn on machine in platform mode If DTC 662 is present trouble shoot that DTC before continuing e Refer to Section 2 3 Troubleshooting in the LSS manual 3124288 664 CANBUS FAILURE ACCES Anaccessory module has stopped com Turn on machine in platform mode If DTC 662 is present trouble SORY MODULE munication shoot that DTC before continuing See accessory module documentation for troubleshooting 6635 CANBUS FAILURE CHASSIS Chassis Tilt Sensor messag
221. ide Driver Digital Output JLG Lift 7 17 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 7 1 ELECTRICAL SCHEMATICS AND LAYOUTS 7 18 z z z PLATFORM MOUNTING ARM ek HP Y Arca ee oe eee E PINS FOR LOAD SENSE RED esters sees se se ees vd ORANGE 15 ii BLACK ji 7 d d Ji 2 Cia ES p GREEN ls Elze S S S ls le S 5 i Sz2s522z225222s2222z E 155 MODULE LOCATED ON TOP JI4 Ex Wes sow melee 27 lt ARMSTACK UNDER PLATFORM Pam ME FEES Bee SH
222. ifications Standard M12 1 5 X 32 36 SPECIFICATION MOBIL DTE 11M NOTE After tightening the spindle nut to the proper torque ENVIRONSYN 32 loosen completely until you can turn by hand Finger n 432 tighten nut by hand without rotating hub Install cotter Grade FR by backing nut off if necessary in order line up Gravity API 31 9 m Slot Pour Point Max 40 F 40 C 59 F 51 C When maintenance becomes necessary or fas Flash Point Min 330 F 166 C 514 F 268 C tener has loosened refer to Section 1 8 Torque ChartS to determine proper torque value VISCOSITY SPECIFICATIONS at 40 C 15 cSt 33 1 cSt 1 3 LUBRICATION 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 at 210 F 43 SUS to API Service Classification GL 3 and sufficient cp at 30 F 3 200 chemical stability for mobile hydraulic system ser vice JLG Industries recommends DTE 11M hyarau Viscosity Index 140 147 lic oil Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than DTE 11M is desired contact JLG Industries for proper recommendations JLG Lift 3121166 SECTION 1 SPECIFICATIONS 1 4 LIMIT SWITCHES Tilt Alarm Il
223. ime Retained until eitheris momentarily De energized Drive Steer amp Lift Prevented 2 2 FUNCTION PROBLEM STEER LEFT PERMA Steer left switch the platform control box was closed dur Release or repair the switch to NENTLY SELECTED 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 Inputis momentarily De energized Steer amp Drive Prevented 2 2 FUNCTION PROBLEM STEER RIGHT PERMA Steer right switch in the platform control box was closed Release or repair the switch to NENTLY SELECTED during power up clear the message In Platform Mode the Right Steer Digital Input Switch is Energized and Power up is Active Retained until Digital Inputis momentarily De energized Steer amp Drive Prevented 2 2 ACCELERATOR FAULTY WIPER OUT OF The joystick accelerator wiper signal inputis outside the The wiper wire being off the RANGE acceptable voltage range wiper wire shorted to B or In Platform Mode the Joystick accelerator Analog Input the wiper wire shorted to B Switch is gt 4 50V OR 0 50V Retained until Analog Input ground could cause this diffi is measured within proper range culty Drive Steer amp Lift Prevented 2 2 ACCELERATOR FAULTY STEER SWITCHES Both the steer left and steer rightinputsare closedasthe A shortin the steer switch wir ACTIVE TOGETHER same time ing or a failed steer switch can In P
224. ine 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 Ibs 4 10 JLG Lift 3121166 SECTION 4 HYDRAULICS 4 8 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Disassembly 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 A WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture BARREL CLAMP PROTECTED ROD CLAMP SUPPORT TABLE Figure 4 3 Cylinder Barrel Support 5 Mark cylinder head and barrel with a center punch for easy realignment Loosen the cylinder head set Screw NOTE Steps 6 and 7 apply only to the steer cylinder 3121166 6 Using a spanner wrench loosen
225. ings refer to 5 7 Machine Configuration Programming Infor URED new control system components mation 9950 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s armature power circuitry is driven without INTERNAL ERROR PWM command for 100mS Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 9951 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s pump power circuitry is driven without INTERNAL ERROR enable from the interface PCB for 100mS Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 9952 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s pump power circuitry is driven without INTERNAL ERROR PWM command for 100mS Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 9953 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s field power circuitry is driven without INTERNAL ERROR enable from the interface PCB for 100mS Cycle machine if error still exists replace System Module e ZAPI HEALTH Status LED FLASHING 9954 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s field power circuitry is driven without INTERNAL ERROR reverse direction from the power PCB for 100mS Cycle machine if error still exists replace System Module
226. is 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 vehi cle 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 Nei ther 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 Bat tery Disconnect and disconnect the Armature Wiring heavy red and black conductors from the sus pected 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 Short Circuit Brake Release This issue will not allow the vehicle to drive Rapid motor overheating both motors will result Contin ued attempts to drive the vehicle may result in arma ture damage This situation can be detected by elevating the vehi cle s front wheels and engaging drive platform stowed Under DIAGNOSTICS TR
227. ize the Control System Next detach both Pump Motor Terminals and insulate them indepen dently 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 Pump Removal 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 clamp on ammeter set for 200A DC 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 work bench NOTE Drain the hyaraulic oil by carefully removing the oil fill plug located on the left side of the hydraulic reser voir 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 o ring gasket on tank c Place tank on a suitable work bench or work area NOTE The filter and bypass are located on the pickup tube inside the tank The filter should be changed once a year JLG Lift 3121166 SECTION 4 HYDRAULICS 3 If replacing filter pull old filter off the end of
228. l J2 4 and its outputs 24V when closed are to ground board terminals J2 6 J2 7 up and down Replace ground board 232 GROUNDLIFTUP DOWN _ Theliftup downinputs are closed simul Check if the lift switch is obstructed or jammed ACTIVE TOGETHER 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 The manual brake release switch was Check if the brake release switch is obstructed or jammed BRAKE RELEASE PERMA closed during power up Check the brake release switch signal and wiring to the ground NENTLY SELECTED 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 251 FAULT MESSAGE ELEV ANGLE SENSOR FAULTY VOLTAGE OUT OF RANGE DESCRIPTION The elevation angle sensor input voltage is outside the acceptable range of 0 10V 4 50V CHECK Check that the platform elevation sensor is securely mounted and undamaged Check voltage as displayed on ANALYZER gt DIAGNOSTICS gt ELEV SENSOR gt ANGLE SNSR Backprobe ground board J1 15 If this v
229. l es 7 10 DT DTP Series 1 7 10 HD30 HDP20 Series 7 10 HD30 HDP20 Series 1 7 11 7 5 SWITCHES cte eer tht i RES hee PU b loon woh adios bac aa 7 12 Basic ehieck ou E Reese ede Uo em EUR E ERE Ads 7 12 JLG Lift 3121166 TABLE OF CONTENTS Limit SwiteheS ure RR C Ye oe RE nee 7 12 Automatic Switches sei eaa avesse dea he CUR FU S CRI dan Banco asa RO eh 7 12 Switch Wiring Low Side High 7 13 7 6 Circuit Boards Inputs and 7 13 7 7 Electrical Schematics and 7 18 7 8 Hydraulic Schematic DR us te Rao e a ea PEDE Ree ee tees eas 7 42 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Torque Chart SAE Fasteners Sheet 1 7 1 9 1 2 Torque Chart SAE Fasteners Sheet 2 7 1 10 1 3 Torque Chart SAE Fasteners Sheet 3 7 1 11 1 4 Torque Chart SAE Fasteners Sheet 4 7 1 12 1 5 Torque Chart
230. l side 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 down onto the spindle This installation should be a slip fit and takes place in 3 stages a Stage 1 The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 output planets 3121166 JLG Lift 3 19 SECTION 3 CHASSIS amp SCISSOR ARMS 6 NOTE NOTE 3 20 Using an appropriate pressing tool press the Input Ring gear recessed side down into the hub sub assembly Do not use excessive pressing force because it will be reacted by the main wheel bearings 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 Install the input sun gear into the area between the 3 input planet gears Apply a coating of grease to the cover o ring and install it into the o ring groove of the hub It may be helpful to stretch the o ring out prior to assembly to avoid pinching or shearing when the cover is assembled 10 11 NOTE 12 JLG Lift 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 d
231. latform Mode the Steer Left Digital Inputis Energized cause this difficulty and the Steer Right Digital Inputis Energized Retained until either Digital Inputis momentarily De energized Drive amp Steer Prevented 2 2 FUNCTION LOCKED OUT ACCELERATOR NOT Selected function drive or lift is notallowed because the Return joystick to center CENTERED joystick accelerator was not centered at power up momentarily and re initiate 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 amp Lift Prevented 2 2 FUNCTION PROBLEM TRIGGER PERMA Trigger switch inthe platform control box was closed at Release switch or repair the NENTLY CLOSED power up switch wiring to clear the diffi In Platform Mode the Trigger Digital Inputwas Energized culty AND Power up was Active Retained until the Trigger Digi tal Inputis momentarily De energized Drive Steer amp Lift Prevented 3121166 JLG Lift 5 11 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing ae HELP MESSAGE CAUSE POSSIBLE RESOLVE 2 2 TRIGGER CLOSED TOOLONG WHILE IN NEU Trigger switch in the platform control boxwasclosedfor Release switch or repair the TRAL more than ten seconds while the joystick accelerator was switch wiring to clear the diffi inthe neutral position centered culty
232. lation of any holding valve or valves 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 3121166 SECTION 4 HYDRAULICS Table 4 2 Cylinder Piston Nut Torque Specifications Description Nut Torque Setscrew Value torque Value i 250 300 ft Ib Lift Cylinder 339 407 Nm N A 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 he m Integrated Proportional Valve Integrated Blocking Valve hs Relief 5 un Coil Nuts Hand Tighten A WARNING 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 SPECIFI CATIONS NOTE Reverse the procedure Steer Cylinder Piston Removal Cyl p n 1684456 on page 4 12 for install ing the steer cylinder piston 17 Remove the cylinder rod from the holding fixture 18 Position the cylinder barrel in a suitable holding fix ture 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 19 With barrel clamped securely and while adequately supporting
233. ld 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 Leak Test 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 equal ize 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 gas ket 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
234. le range of 0 50V 4 5V oris unstable e Check the joystick signal and its wiring The joystick input 5V is from the platform board terminal J1 5 its output 2 5V with joy Stick 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 leftand steer rightinputswere 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 FUNCTIONLOCKED OUT Thejoystickwas notcenteredatpower e Release joystick and allow to center ACCELERATORNOTCEN up e Check if the joystick is obstructed or jammed TERED Check the joystick signal and its wiring The joystick input 5V is from the platform board terminal J1 5 its output 2 5V with joy stick at center to the platform board terminal J1 6 and its ground OV is to the platform board terminal J1 7 Observe output signal while slowly operating joystick Replace platform board 229 FUNCTION PROBLEM Thetrigger switch was closed during e Check if the trigger switch is obstructed or jammed TRIGGER PERMANENTLY platform mode
235. lide the input planet shafts into the bores the needle bearings will try to push out If you have the thrust washers lined up properly they will contain the needle bearings within the input planet gear Repeat 5 amp 6 for the other 2 planet gears Put the thrust plate onto the three input planet shafts Use the 3 holes on the innermost bolt circle The other 3 holes are for a different gear ratio Using the appropriate retaining ring pliers put a retaining ring into the groove of each planet shaft NOTE Do not overstress the snap ring 3121166 SECTION CHASSIS amp 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 1 Inspect seal surface of spindle Remove any debris b Stage 2 Find the planet gear that is tight and that may be present turn it until you feel it go into mesh with the hub gear teeth apply slight downward pressure to 2 Apply a coating of grease to the lip seal of the hub the hub and then find the next gear that is tight sub assembly and do the same c Stage 3 Once all the planet gears are in mesh 3 Place Spindle Sub Assembly on table with carrier apply pressure to the hub it should go on the side up rest of the way 4 Carefully install the hub sub assembly sea
236. luminates 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 specifica tions Table 1 12 Tilt Settings Model Tilt Setting Tilt Setting Maximum Deck front to back side to side Elevation 1 5 18 75 ft 5 7 m 2 14 ft 4 3m 193083 2 5 11ft 3 4m 3 9ft 2 7 m 1 5 20 ft 6 m 2 1511 4 5 203063 3 2 5 12 3 7 m 3 10ft 3m 15 25 4 ft 7 7 m 2 20 ft 6 2630 25 16ft 4 9m 3 13 ft 4m 2 26 ft 7 9m 2646ES 3 2 5 22 ft 6 7 m 3 20 ft 6 m 2 31 75ft 9 7 m 3246ES 3 2 5 22 ft 6 7 m 3 20 ft 6 High Drive Speed Cutout High drive speed is cut out when the platform is raised above the preset height per model as follows NOTE These figures are given with a tolerance of 6 in 0 15 m Table 1 13 High Drive Speed Cutout Height Model High Drive Speed Cutout 1930ES 54 in 1 4 m 2030ES 66 in 1 7 m 2630ES 1 9 2646 5 1 9 3246 5 1 9 Pressure Settings Table 1 14 Pressure Settings Model Lift Relief Steer Relief ones o 95 LIE T JN 9855 840 3121166 JLG Lift 1 7 SECTION 1 SPECIFICATIONS 1 5 CYLINDER SPECIFICATIONS Table 1 15 Cylinder Specifica
237. ly damaged if not installed with care It is a good idea to start the seal into the bore with a rubber mallet before pressing 3121166 JLG Lift 3 17 SECTION 3 CHASSIS amp SCISSOR ARMS Input Carrier Sub Assembly 3 18 1 Planet Gears 2 Output Sun Gears 5 Input Planet Gear 3 Input Carrier 4 Thrust washer 6 Needle Bearings 7 Thrust Plate 8 Snap Ring 9 Retaining Ring Figure 3 16 Input Carrier Disassembly 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 car rier hole 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 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 Load 22 needle rollers into the bore of each input planet gear Retain the needle bearings in the bore with a coating of grease Place a thrust washer on each side of the input planet gear Line up the bores as well as you can JLG Lift visually Additional grease may help hold everything together Place the input planet gear and thrust washers onto the input planet shaft sticking out from the carrier When you s
238. minals are oriented as shown ae Limit 5 After installing the new Power Module begin con Switching F T necting the wires back to the controller witching Frequency 2 6 Torque the M6 terminal bolts to 5 ft lb 7 Nm Torque the M8 terminal bolts to 7 ft lb 10Nm The Power Module is located at the front of the machine as shown in Figure 3 32 Sevcon Power Module Location 7 After all connections to the Power Module are made the battery can be reconnected 3 38 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS Power Module Electrical Evaluation Several basic electrical tests can be performed on the Power Module Failure of one of these evaluations is sig nificant 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 gt 100kOhms all Terminals to Housing Ensure that there is an open circuit between all termi nals 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 met
239. mproper wire harness ing range by the interface PCB 11V connection Drive Steer and Lift Prevented ZAPI HEALTH Status LED ON 4421 LOGIC SUPPLY VOLTAGE The system module logic supply voltage This may be caused by a loose battery terminal severely dis OUT OF RANGE was measured by the power PCB to be charged batteries damaged battery or an improper wire harness more than 34V for 10uS connection Drive Steer and Lift Prevented ZAPI HEALTH Status LED ON 4422 LOGIC SUPPLY VOLTAGE The system module logic supply voltage This may be caused by a loose battery terminal severely dis OUT OF RANGE was measured by the power PCB to be charged batteries damaged battery or an improper wire harness less than 11V for 1005 connection Drive Steer and Lift Prevented ZAPI HEALTH Status LED ON 6 6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK 661 CANBUS FAILURE POWER The control system failed to receive mes Check for 24V between power module 12 position connector ter MODULE 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 mac
240. n 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 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 opera tion 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 speci fied intervals required in the Lubrication Chart in Section 1 Always examine filters for evidence of metal particles Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 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 oper ating are recommended for use Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydrauli
241. n 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 PLUG AND HEADER ASSEMBLY COLORS ARE MECHANICALLY KEYED TO MATE ONLY WITH IDENTICAL COLORS MATING SEAL PLUG ASSEMBLY RETENTION LEG WEDGE LOCK HOUSING Figure 7 5 AMP Connector 3121166 JLG Lift 7 5 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 Pro ceed as follows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION 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 Ibs to be sure the retention fingers are holding the contact See Fig ure 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 lock ing latches by squeezing them inward See Figure 7 8 Connector Assembly
242. n the use and application of servicing and maintenance proce dures contained in this book Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support 2 is provided Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for 3 2 2 eign materials out of the vital components Precau tions 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 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter Clean and inspect all parts during servicing or main tenance 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 contain ers until they are ready to be used Components Removal and Ins
243. n the direction of the spanner holes to remove Cleaning and Inspection 1 4 12 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary 10 11 12 13 NOTE Inspect threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct exce
244. nce gt 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 imped ance 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 amp 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 3 39 SECTION 3 CHASSIS amp SCISSOR ARMS 3 9 POWER MODULE ZAPI ZAPI POWER MODULE 5 8184 i S 22 ELELELELELEL 2 Figure 3 33 ZAPI Power Module Location ES Scissors built starting in mid year 2010 replaced the Sevcon Power Module with the ZAPI Power Module P N 1001092456 Table 3 2 ZAPI Power Module Specs Operating Voltage B 14 5 to 40 VDC Maximum Current Limits Armature 300A Field 40A Pump 180
245. nce the diffi culty has been corrected 3121166 JLG Lift 5 21 SECTION 5 JLG CONTROL SYSTEM JO Jays JezAjeuy 2 6 eJnDi4 NOZCL 0L0 XXX HOSN3S A313 13S danvoNn x I OSF ON HLNF SJA OS3 ON HINX S2A OSA ON 53 08 HINJ S3A O1 HOSN3S A313 136 310IH3A T3A31 x I x I 1noino3AMQ HOSN3S aJa aS HOSN3S LLL SNOLvuarivo SNOLLVHgIivo Nvdvr S SJA 1 GATIVISNI 1 LEVIN HOLIMSLOOS AMALLVE x x x x VIWWELSNV v 52245 ON 0 4 0 GATIVLSNI LON 0 LEVIN HEIN TICON HOLIMSLOOS Ad3llvg A313 x 30 6 519092 LEWIN H38INnN IION x I Tv LNOLNO z NOILOW Z VSO z 820692 qvo1 Waviv aNnouo sevi HIANNN IION I I Jd LNOLNO 1N30S3d dn 14178 ANG 1 S3A 1 S3A 1 1HOdX3 ISNV 1 ANNOYS qvo1 WHT 0OTHINI H3OUHO LNOLNO 4noino rur H38INnN IION x x x x SSd1H33d 0 _ GSTIWLSNILON 0 _ GaTIvISNILON 0 ON 0 ON 0 vSnISNV 0 530861 SHO1ON qvo1 ANNOYS 71 OOTHLNI u39uHO 1no1no
246. nd measurement setup Redo measure ment 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 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 Whe
247. nected 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 measure ment it will be necessary to disconnect the butt splice on the two orange wires or use a piercing meter probe As with the armature the field is a very low impedance and should appear to be a short circuit for an ordinary voltmeter High resistance can signal corrosion improper crimps damaged connectors damaged cabling or an open field winding Resistance 15 25 Ohms Yellow to Brown Brake Wires The yellow and brown wires are connected to the integral brake Improper resistance can signal cor rosion improper crimps damaged cabling or a faulty solenoid Resistance 1 MegaOhms Red Armature Wire to Motor Housing The armature winding should be elec trically 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 3 36 JLG Lift Resistance 1 MegaOhms Blue Field Wire to Motor Housing The field winding sh
248. nes 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 amp SCHEMATICS PLATFORM po X051 CONSOLE BRAKE X042 Jv Ol BOX RELEASE X050 a SWITCH ch OR 1 S mA d Gd LIFT B E BRAKE CYLINDER E i DISCONNECT VALVE SWITCH xo12 DD Xxo13 BLOCK i PLATFORM oop 4 RECEPTACLE J oe X041 X048 Gli p X043 9 L LJ X046 016 X103 X102 4 IF X011 X045 OR E 7 38 rom f GROUND CONTROL BOX X034 saf X028 DIAGNOSTIC ANALYZER MDI X025 Doni X010 X024 TES X031 X032 X033
249. ng rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit 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 pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual 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
250. nnual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Indus tries Inc recognizes a Factory Certified Service Techni cian 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 perfor mance 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 man ual 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 mainte nance 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 train ing 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 a
251. 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 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 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 dis played 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 sec onds The algorithm is now in the permanent mem ory Remove the AC power from the charger and recon nect the charger s positive connector to the battery It is recommended to check a newly changed algo rithm by repeating the above steps 1 and 3
252. nt the drive cables going back towards the rear of the machine as shown below 2 Loop the cables forward towards the front of the machine then up and back so that the clamping rings on the cables are aligned together 3 Obtain the Cable Clamp and hardware 1 Cable Clamp 3 Capscrew Washers and Nut 2 Spacer Plate 3121166 15 Place the Green Clamp on the clamping rings as shown below 16 17 18 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 Connect the drive motor cables to the power mod ule Tuck all wires into the power module compartment and install cover 19 JLG Lift er Lt M X DNI 1 Drive Cables 2 Cable Clamp 3 Spacer Plate Reconnect battery cable plug Power up machine and operate the drive function to ensure drive motors operate properly 3 51 SECTION 3 CHASSIS amp SCISSOR ARMS USA Built Machines S N 0200170585 to Present amp 3 Belgium Built Machines S N 1200015159 to Present 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 NOTE The below procedures apply to 2030ES 2630ES 2646ES 3246ES only CAUTION BE SURE PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING
253. o do the following for intermittent or difficult problems run a system test ANALYZER SYSTEM TEST check the machine personalities ANALYZER gt PERSONALITIES refer to Table 5 3 Machine Model ment 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 Indica tor 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 occ ur during normal operation and explain various vehicle interlocks ALARM SOUNDING TILTED AND ABOVE ELEVA TION Platform is elevated and the chassis is not level Platform Position Sensor PPS elevation status is ele vated and the vehicle is tilted and machine setup s TILT CUTOUT is 0 YES No motion restrictions DRIVING AT CUTBACK ABOVE ELEVATION Platform is elevated and the machine is in the drive mode of operation In platform mode Platform Position Sensor PPS eleva tion status is elevated and the vehicle is driving and the drive speedis drive elevated Driving
254. o 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 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 evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart JLG Lift 3121166 SECTION 2 GENERAL 2 4 CYLINDER DRIFT TEST Maximum acceptable cylinder drift is to be measured using the following methods Platform Drift Measure the drift of the platform to the ground Fully ele vate the platform Maximum allowable drift is 2 inches 5 cm in 10 minutes If the machine does not pass this test proceed with the following Cylinder Drift Table 2 2 Cylinder Drift Max Acceptable Drift Cylinder Bore Diameter in 10 Aa inches mm inches mm 3 76 2 0 026 0 66 3 5 89 0 019 0 48 4 101 6 0 015 0 38 5 127 0 009 0 22 6 152 4 0 006 0 15 7 177 8 0 005 0 13 Drift is to be measured at the cylinder rod with a calibrated dial indicator
255. ocks at front of machine slide out the front of the slide channel on the frame Overhead crane and straps must be capable of lifting at least 1545 Ibs 701 kg 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 2 6 NOTE Start with the top arms closest to platform Secure each arm section being removed using an overhead crane with suitable lifting straps Remove the bolts securing the connecting pins in place Remove the pins from the arms Remove the arm section from the machine using the overhead crane Repeat previous steps for remaining arm sections 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 3121166 JLG Lift 3 63 SECTION 3 CHASSIS amp SCISSOR ARMS 4 WARNING NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS BLOCKING OR OVERHEAD SLING STRAP
256. oltage will be applied to the Armatures Similarly the MOSFET are On continuously 10096 Duty Cycle to apply all avail able 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 magne tism 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 The Field Windings also provide direction reversal for trac tion 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 m
257. oltage 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 OV Check the elevation angle sensor signal and wiring to the ground board The elevation angle sensor input is from ground board ter minal 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 ELEVANGLE SENSORHAS NOT BEEN CALIBRATED The elevation angle sensor has notbeen e calibrated Calibrate the elevation angle sensor to clear fault See Section 5 5 3121166 JLG Lift SECTION 6 DIAGNOSTIC TROUBLE CODES 2 5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 253 DRIVEPREVENTED Driving is not possible while the vehicleis Check if the charger is connected to off board power source and CHARGER CONNECTED charging disconnect if desired Check ANALYZER gt MACHINE SETUP gt CHARGER INTERLOC is set as desired Check that charger s red positive battery wire connector termi nal is receiving power 24V from batteries Check signal from charger interlock connector terminal 2 to ground board terminal J1 29 where OVDC indicates charging in process 254 DRIVE amp LIFT UP PRE Drive or liftis not possible while the vehi Check if the charger is connected to off board pow
258. 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 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 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 Activate pump motor and extend cylinder 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 With cylinder fully retracted shut down machine power and carefully disconnect hydraulic hose from cylinder extend port Activate pump motor and retract cylinder Check extend port for leakage 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
259. 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 reas sembly 3 14 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS Spindle Disassembly NOTE NOTE 3121166 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 Place unit on bench with planet gears facing up Remove 3 output planet shafts 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 Remove the output planet gear thrust washer and tanged washer out of each gear window of the spindle The output planet gears are a very similar size to the input planet gears tag or label the planet gears to avoid confusion Using a screwdriver remove the shaft bearing snap ring Remove the shaft ball bearing from the center bore NOTE JLG Lift Press out the motor shaft seal from the center bore Remove the main bearing from the outside diameter of the spindle 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 Pre
260. orgus oT 3 5 Roll Test 455a ie ieee a Segue 3 5 Leak Testi soi xi ELE ELE SE e eei 3 5 Oil Check Fill Procedure 1 II Hn 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 Res eek E Ree n une done ae ae ee 3 10 Drive Motor Removal 2 2 3 11 Main Gearbox Disassembly 1 3 12 Input Carrier Disassembly 3 13 H b Disassembly mI S eR bas at eed Rea ETAT AERIS e Mta e 3 14 Spindle Disassembly 4 254 Reb ad p nd eost Mete CREE 3 15 Spindle Sub Assembly 3 16 H b Sub ASSemlbly 7 ues donde edo te FR e AH Re sce nU od 3 17 Input Carrier Sub Assembly 3 18 Main Gearbox Assembly 1 3 19 Motor and Brake Assembly 2 3 21 Motor Assembly oes Rabb ORDER RO 3 23 Motor Assembly iieri bac eru eae erre rex ev eene pa 3
261. orqued to 250 300 in Ib 28 2 33 9 N m Verify field resistance using a suit able ohmmeter per the appropriate motor specifica tion Verify that the field is electrically isolated from the frame using a dielectric tester Replace as neces sary 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 exces sive wear and overheating Replace as necessary 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 neces sary Visually inspect the wire harness 8 for frayed insu lation loose terminals or other damage Replace as necessary Reassembly 1 JLG Lift oa fF DN After inspection and servicing reassemble the wir ing 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 unre stricted in the holders Motor terminals must be assembled as shown Figure 4 Torque bottom termi nal nut to 110 140 in Ib 12 4 15 8 Nm After the motor has been disassembled it is recom mended that new bearings be installed because bearings may have been d
262. os terminal 6 3121166 2 Disconnect Inverter Charger control cable at the 6 position connector and the chassis harness at the 4 position connector at the Ground Box There should be continuity between the following a 6 pos terminal 3 to 4 pos terminal 1 b 6 pos terminal 4 to 4 pos terminal 3 6 pos terminal 5 to 4 pos terminal 2 d 6 pos terminal 6 to 4 pos terminal 4 3 If wiring is found to be good the LED printed circuit card is likely to be bad Interlock Cable suspected to be bad or vehicle thinks charging is in progress but it is not 1 Disconnect Interlock 2 position connector on the Inverter Charger control cable 2 Turn on machine 3 There should be Vbatt present on the Interlock con nector socket 1 4 Turn off machine 5 Disconnect Inverter Charger control cable at the charger 6 Inverter Charger connector 8 position pin 6 should have continuity to Interlock connector pin 2 and then to ground module socket J1 29 Ground Module powered while key is off or similar behavior This condition can be caused by various ground module outputs getting shorted to battery If not done already cycle power and check for fault codes If no fault codes perform the following 1 Disconnect the Inverter Charger control cable at the 8 position connector and the 2 position Interlock connector 2 Set digital multimeter to diode check or continuity check to check diode in Inverter Charger con
263. ot 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 RENT TOO HIGH Drive Steer and Lift Prevented The System Module detected excessive braking current for more than 5000mS This can be caused by transporting an excessive load on a steep grade Alternately this may indicate an internal fault ZAPI HEALTH Status LED ON 6 16 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 7 1 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 7742 FIELD VOLTAGE IMPROPER Drive Steer and Lift Prevented The System Module voltage at the F1 and F2 terminals was improper at power up expected to be 1 2 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 CHECK 811 TILTSENSOR NOT CALI Thetiltsensorcalibrationhasnotbeen Calibr
264. ould also be elec trically 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 discon necting the drive motor cable from the motor and re measure 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 a Dusty or dirty locations like cement plants lum ber and flour mills coal mining stone quarries etc b High temperature areas like steel mills found ries etc c Environments with sudden temperature change such as in refrigeration plant etc 3121166 SECTION CHASSIS amp SCISSOR ARMS Common Traction System Difficulties 1 3121166 Short Circuit Motor Armature Th
265. oving the cover plug Note the condition of the oil replace if neces sary 3121166 JLG Lift 3 11 SECTION 3 CHASSIS amp SCISSOR ARMS Main Gearbox Disassembly 1 Spindle Sub Assembly 5 Cover O Ring 2 Spiral Snap Ring 6 Cover Thrust Washer 3 Input ring Gear 7 Cover 4 Input Sun Gear 8 Cover Snap Ring 9 Pipe Plug 10 Input Carrier Sub Assembly 11 Hub Sub Assembly Figure 3 11 Main Gearbox Disassembly 1 Using a screwdriver pry off the cover snap ring NOTE The input ring gear is held in with a press fit on its 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 5 Remove cover o ring 6 Remove input ring gear 3 12 JLG Lift outside diameter Insert jacking screws 1 4 20UNC grade 8 with at least 1 5 inches of thread length into each of the three tapped holes to force the ring gear out Be sure and alternate between the jacking screws to keep the ring gear from becoming mis aligned in the bore The screws will push against the outer race of the main bearing This bearing will have to be replaced afterwards Using a screwdriver remove spiral snap ring Pull hub sub assembly off of the spindle sub assem bly 3121166 SECTION CHASSIS amp SCISSOR ARMS Input Carrier
266. p 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 POWERMODULE TOOHOT PLEASE WAIT The power module has reached thermal cutout Power down and allow to cool 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 gt DIAGNOSTICS gt PUMP gt PUMP CUR over 130 Amps with an empty deck Check for excessively high traction current consumption ANA LYZER gt DIAGNOSTICS gt TRACTION gt ARM CUR over 120 Amps while driving on the level 422 DRIVING AT CUTBACK POWER MODULE CURRENT LIMIT The drive portion ofthe power module has reached thermal limit Check for jammed or obstructed drive motors Check for excessively high traction current consumption ANA LYZER gt DIAGNOSTICS gt TRACTION gt ARM CUR over 120 Amps while driving on the level 6 12 JLG Lift 3121166 SECTION 6 DIAGNOSTIC TROUBLE CODES 4 2 Thermal Limit SOA DTC FAULT MESSAGE DESCRIPTION CHECK 423 LIFTUP AT CUTBACK The lift up portion ofthe power module Check for jammed or obstructed arm stack or pivot bushing POWER MODULE CURRENT ha
267. plugged or 8 3 Flash Code the sensor is damaged LSS Module Message Status Message 0x81 is report ing CELL 3 ERROR AND Machine Setup s LOAD is set to 12 CUTOUT PLT OR 2 CUTOUT ALL Vehicle assumed to be Overloaded 8 4 LSSCELL 4 ERROR Cell 4 s Bridge 2Vdc 3Vdc or could the LSS Module This situation indicates that could not read Cell 44 s Internal Memory 8 4 Flash Code LSS Module Message Status Message 0x81 is report ing CELL 4 ERROR AND Machine Setup s LOAD is set to 12 CUTOUT PLT OR 2 CUTOUT ALL Vehicle assumed to be Overloaded the sensoris 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 addi tional information about the difficulty k 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 report ing 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 Re cycle power to clear diffi culty LSS EEPROM ERROR Memory used to retain settings on Load Sensing System Module has been corrupted and mustbe reset by verifying all entries re calibrating 9 2 Flash Code LSS Mod
268. 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 3121166 JLG Lift SECTION 6 DIAGNOSTIC TROUBLE CODES 3 2 Line Contactor Short Circuit DTC FAULT MESSAGE DESCRIPTION CHECK 322 CONTACTORDRIVERPER The power modules line contactor drive Check continuity between contactor connector pin 1 and ground MANENTLY ON circuitry failed to de energize when board socket J1 19 requested Drive steerandliftuppre Check continuity between contactor connector pin 2 and power vented 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 e Ensure ANALYZER gt MACHINE SETUP gt ELEV PROX is set to the brake solenoid was commanded off NOT INSTALLED 332 BRAKE OPEN CIRCUIT The ground board did notdetectcurrent Ensure ANALYZER gt MACHINE SETUP gt ELEV PROX is set to flowtothe brake solenoid during normal NOT INSTALLED operation 333 LIFT UP SHORT TOBATTERY The ground board detected voltage while Check for continuity through this circuit The lift up solenoid resis the lift solenoid was commandedoffat tance should measure about 30 Ohms The lift up solenoid is power up powered with 24V
269. r 1 12 5 6 13 4 9 Limit Switch 1 7 10 Tilt Alarm Switch 1 7 11 Placards and Decals 1 2 12 Wheel and Tire Assemblies 1 8 9 13 Drive Motors 1 5 6 14 Drive Brakes 1 6 8 15 Drive Torque Hubs 1 3 5 6 16 Steer Cylinder 1 5 6 13 4 17 Steer Components 1 4 6 8 18 Wheel Bearings 8 12 19 Scissor Arms 14 20 Safety Props 1 4 21 Sliding Wear Pads 8 12 22 Pivot Pins Bolts 1 4 7 8 23 Switches Ground Control 1 1 24 Control Tags 1 2 3121166 JLG Lift 2 7 SECTION 2 GENERAL JS NOTES 2 8 JLG Lift 3121166 SECTION 3 CHASSIS amp SCISSOR ARMS SECTION 3 CHASSIS amp SCISSOR ARMS 3 1 DIAGNOSTIC PORT Installation The diagnostic port is located behind the battery cover at NOTE order for the MDI to be functional the machine the near the ground control station as shown below The must be equipped with either the Sevcon Power MDI Multifunction Digital Incicator and the JLG Hand Module with Ground Module Software Version P1 13 Held Analyzer Gan Dee annee osa nis pons 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 ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE PUSHED IN TO THE OF
270. r up Brake INPUT driven Low AND Brake STAT detected Low during power up Drive Steer amp Lift Prevented BRAKE OPEN CIRCUIT Current flow to the brake solenoid was not detected during normal brake operation Brake INPUT driven High normal operation AND Brake STAT detected Low Drive amp Steer Prevented LIFT UP SHORT TO BATTERY Voltage was detected on the lift up solenoid when the out put driver was commanded off during power up Lift Up INPUT driven Low AND Lift Up STAT detected Low during power up Drive Steer amp Lift Up Prevented LIFT UP OPEN CIRCUIT Currentflow to the lift up solenoid was not detected during power up Lift Up INPUT driven High momentarily AND Lift Up STAT detected Low during power up No motion interlocks LIFT DN SHORT TO BATTERY Voltage was detected on the lift down solenoid when the output driver was commanded off during power up Lift Down INPUT driven Low AND Lift Down STAT detected Low during power up No motion interlocks LIFT DN OPEN CIRCUIT Current flow to the lift down solenoid was not detected dur ing normal lift down motion Lift Down INPUT driven High normal operation AND Lift Down STAT detected Low Lift Up Prevented STEERLEFT 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
271. 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 b Disconnect the sensor and clean any corrosion off of the tilt sensor and control board connec tions c Reassemble and test If fault persists replace tilt sensor 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 fre quency is out of range replace sensor JLG Lift On a level surface with the Analyzer under DIAG NOSTICS ELEV SENSOR verify that the elevation angle sensor voltage increases ranges from 0 2V 0 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 mount ing and operability by placing metal in front of the prox sensor face 3121166 SECTION 5 JLG CONTROL SYSTEM
272. reas 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 3121166 JLG Lift 2 1 SECTION 2 GENERAL Table 2 1 Inspection and Maintenance Primary Service Type Responsibility Qualification inferne User or Operator User or Operator Operator and Safety Manual Inspection At each Operator change Pre Delivery Prior to each sale lease or Qualified JLG Senco ane Owner Dealer or User Manualand applicable JLG nspection rental delivery Mechanic inspection form In service for 3 months or 150 hours which ever comes first or Qualified JLG Service and Maintenance ne Out of service for a period of more than 3 Owner Dealer or User Manual and applicable JLG nspection Mechanic months or inspection form Purchased used Annual Machine Annually no later than 13 months from the Pace ined Service ang yaimtenange s Owner Dealer or User Service Technician Manual and applicable JLG nspection date of the prior inspection c recommended inspection form Preventative Atintervals as specified in the Service and Qualified JLG Service and Maintenance Owner Dealer or User f Maintenance Maintenance Manual Mechanic Manual 2 2 SERVICE AND GUIDELINES General The following information is provided to assist you i
273. revented The System Module detected an issue with the traction current INTERNAL ERROR measurement or the MOSFET s Armature current feedback gt 2 74V or lt 2 26V while idle Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 9962 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module s temperature feedback is gt 4 9V or lt 0 1V INTERNAL ERROR Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 9963 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module detected a mismatch in the redundant RAM INTERNAL ERROR 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 amp Lift Prevented The System Module s analog to digital converter does not INTERNAL ERROR 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 amp Lift Prevented The System Module s MC EB EV DV Enable is always on This is INTERNAL ERROR internal fault Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 9970 POWER MODULE FAILURE Drive Steer amp Lift Prevented The System Module detected a mismatch in the redundant RAM IN
274. ror will display on the LCD If a fault exists the trouble code will display on the LCD Refer to Section 6 Diagnostic Trouble Codes 6 Using zip ties tie back cables and wires to prevent damage to the cables and wires Removal 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 electri cal harnesses 3 Remove Bracket JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS 3121166 3 3 TRACTION SYSTEM Theory of Operation The Armatures rotating windings of the separately excited drive motors are wired in parallel to the Power Module s M1 and M2 terminals Sevcon and T and B terminals ZAPI The M1 B Terminal is always at the same voltage as the B Battery Voltage when the Line Contactor is closed and allows the module to measure current with the internal shunt extremely low impedance The M2 T Terminal is pulled to Ground by the Armature Switch MOSFET s connected to B Terminal To provide variable speed control the Armature MOSFET transistors switch On and Off at high frequencies pulse width modulation 16kHz The Duty Cycle On amp 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 1 2 of the available Battery V
275. s N 5199 2 vIQ 5 BOLT B E rt 2909 1 i a o Assembly Tools 3 8 5 fe os 5 8 i 222 3 s 3 Figure 3 23 Assembly Tool 3 ONL 214 4 000 Figure 3 21 Assembly Tool 1 3121166 JLG Lift 3 25 SECTION 3 CHASSIS amp SCISSOR ARMS 3 5 ELECTRIC DRIVE MOTOR NOTE The information contained within this section applies to the following machines USA machines built S N 0200152825 to S N 020170585 Belgium machines built S N 1200008481 to S N 1200015159 A WARNING DISCONNECT THE BATTERY AND ALLOW THE MOTOR TO COOL DOWN BEFORE PERFORMING ANY MAINTENANCE THE SUR FACE TEMPERATURE OF THE MOTOR FRAME MAY CAUSE INJURY TO PERSONNEL Disassembly 1 2 NOTE Disassemble the motor from the gearbox Mark the position of the motor end cap to the motor shell Remove the end cap retaining bolt Remove the retention bolt and washer from the end of the armature and remove armature from the motor shell The load spring that is behind the motor bearing will be loose when the armature is removed Take care not to lose it Replacing Motor Bearing 1 Carefully remove the bearing from the armature by using a bearing puller 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 racewa
276. s 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 1 3 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 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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 LOCKING FINGERS CONTACT CONTACT INSERTION cm UNLOCKED POSITION CONTACT LOCKED IN POSITION 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 zT Figure 7 16 HD HDP Contact Removal With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 11 12 Slide tool along into the insert cavity until it engages contact and resistance is
277. s 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 power up Ground Alarm INPUT driven Low AND Ground Alarm STAT detected Low during power up AND Machine Setup s GROUND ALARM setto 1 DECENT OR 2 MOTION No motion interlocks 3 3 LEFT BRAKE SHORT TO BATTERY The ground board detected voltage while the leftbrakewas 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 Check for continuity through brake during normal operation this circuit Inspectthe wiring for physical damage Replace ground board 5 16 J
278. s reached thermal limit Check for excessively high current consumption in the pump LIMIT ANALYZER gt DIAGNOSTICS gt PUMP gt 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 mea May be due to improper battery charging or incorrect voltage bat HIGH SYSTEM SHUTDOWN sured battery voltage gt 37 0V teries being used 443 155 BATTERY VOLTAGE The load sensing system module May be due to improper battery charging or incorrect voltage bat TOO HIGH momentarily measured battery voltage teries being used 34 0V Refer to Section 2 3 Troubleshooting in the LSS manual 3124288 444 LSSBATTERY VOLTAGE Theload sensing system module Recharge batteries or check for damaged batteries TOOLOW momentarily measured battery voltage lt Refer to Section 2 3 Troubleshooting in the LSS manual 9V 3124288 446 LOGIC SUPPLY VOLTAGE The system module logic supply voltage This may be caused by a loose battery terminal severely dis OUT OF RANGE was measured to be outofnormaloperat charged batteries damaged battery or an i
279. se high pressure Do not us a pressure washer 6 Flashes Over Load Over Temperature This fault indicates that the batteries will not accept charge current or an internal fault has been detected in the charger This fault will nearly always be set within the first 30 seconds of operation If it occurs after the charger has started charging normally be sure to make a note of it 1 Remove excessive AC loads from inverter if installed 2 Try to clear the fault by unplugging the AC waiting 30 seconds and reconnecting the ac power 3 Check all battery connections Look for a high resis tance connection The most likely reason for this fault is a fault in the battery such as a bad battery con nection 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 Excessive Battery Watering R
280. 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 bot tom of the motor housing with a rubber mallet The motor should slip out 3 9 SECTION 3 CHASSIS amp SCISSOR ARMS Motor Disassembly 1 Motor 3 Bolt 2 Cable 4 Washer Figure 3 9 Motor Disassembly NOTE Applies only to 3 Drain the oil out of the unit by removing the pipe USA machines built S N 0200152825 to S N plug note the condition of the oil 0501 0989 4 Remove the 2 motor mounting bolts and washers Belgium machines built S N 1200008481 to S N 1200015159 5 Gently remove the motor 1 Make sure the E stop button is pushed in 2 Disconnect the cable from the power control mod ule 3 10 JLG Lift 3121166 SECTION CHASSIS amp 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 3 Remove the two motor mounting bolts and washers USA machines built S N 0200170585 to Present 4 Genti the Belgium machines built S N 1200015159 to Present Aen remove the drive metodo A 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 rem
281. ss out the main bushings at the top of the spindle neck Remove the motor O ring from the groove on side opposite from the carrier side 3 15 SECTION 3 CHASSIS amp SCISSOR ARMS Spindle Sub Assembly 1 3 16 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 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 Using the appropriate pressing tool press on main bearing until it is fully seated 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 Retain the bearing with the spiral retaining ring Line the bore of the output planet gear with 22 nee dle rollers Use grease to retain the needle rollers in the bore 10 11 12 13 14 15 16 Place tanged thrust washer into each planet win dow of the spindle Make sure the tang sits in the cast groove on the inside of the window Place a thrust washer onto the plane gear Line up the bores as best as
282. ssembly NOTE Refer to Figure 3 29 1 3 34 After inspection and servicing reassemble the wir ing 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 unre stricted in the holders Motor terminals must be assembled as shown Figure 3 31 Torque bottom terminal nut to 110 140 in Ib 12 4 15 8 Nm After the motor has been disassembled it is recom mended 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 prob lems 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 Press the Armature 3 commutator end into the commutator end head and bearing assembly care fully supporting the inner race of the bearing See Figure 3 27 Carefully release the Brush Springs 4 allowing the Brushes 5 to contact the commutator Make sure brush shunts do not interfere with spring movement JLG Lift oa Press Fixture must press against Outer Race Bearing End Head held stationary Armature Assembly Assembled End Head Bearing and Retaining Ring Press Fixture must press a
283. ssive wear or damage Replace as necessary a Thoroughly clean hole steel bushing of burrs dirt etc to facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod barrel must be replaced c Lubricate inside of steel bushing with WD40 prior to bearing installation d Using an arbor of the correct size carefully press the bearing into steel bushing Install pin into the Gar Max bearing dry Lubrication is not required with nickel plated pins and bearings STEEL BUSHING GAR MAX BUSHING 429 20 Figure 4 5 Gar Max Bearing Installation 14 15 16 JLG Lift Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 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 SEAL TOOL
284. steners Sheet 7 of 7 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 comprehen sive 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 fur ther 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 per form a Pre Start Inspection of the machine prior to use daily or at each change of operator Reference the Opera tor 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
285. step 1 following if switches are the outboard of frame rails design 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 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 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 de EE 4 With the socket terminals properly installed re insert the wedge lock orange back into the socket to lock the socket terminals in place EXISTING SWITCH NEW SWITCH TELEMECHANIQUE HONEYWELL TELEMECHANIQUE IF EXISTING SWITCH IS 13814 3 amp 4 NEW CONNECTOR SHOULD 184 WIRED TO PINS 21822 182 BELOADED TO PINS 283 3121166 JLG Lift 3 57 SECTION 3 CHASSIS amp SCISSOR ARMS 5 Before connecting the wire harness to the new 7 Adjust the switch assembly switch mount assembly apply the supplied dielec tric grease to both the connector end and the switch SWITCHES INBOARD SHOWN BELOW socket pin areas When pothole bar is in the
286. t TABLE OF CONTENTS vi 3 45 3 44 3 45 3 46 3 47 3 48 4 1 4 3 4 4 4 5 4 7 4 8 4 9 4 10 4 11 4 12 4 13 5 1 5 3 5 4 7 1 7 3 7 4 7 5 7 6 7 8 7 9 7 10 7 11 7 12 7 18 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 Tilt Sensor Location rroi coe eh pet ay se Sk a es 3 60 Tilt Sensor Removal Pays aie oes 3 61 Tilt Sensor Location Revue E our EA bei qe ERE 3 61 Tilt Sensor Removal eerie EHI Rev ER epu Ris eeu ed Mere 3 62 Arms and Platform Positioning and 3 64 JOYSTICK eol eod A e AR DR er ES aye Sue entes 3 66 Lift Pressure Setting e g hace AE She oa ded EA ARE SP E 4 2 ean Os one 4 5 Cylinder Barrel 1 4 11 Gylinder Rod SUppott 2 osea HR m Rex ba ER RM REA RP es eae CR ROS d 4 11 Gar Max Bearing Installation 0 0 0 0 ccc e n 4 12 Rod Seal Installati n enn uis tated chad eee teed e EROS 4 13 Poly Pak Piston Seal
287. t 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 b Tap each space once this means the tapered bushing is tapped 3 times as there are 3 spaces between the capscrews Retorque the capscrews evenly and progressively in rotation to the specified torque value Remove the cylinder rod from the holding fixture Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston See Figure 4 10 Position the cylinder barrel in a suitable holding fix ture 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 JLG Lift CYLINDER BARREL With the barrel clamped securely and while ade quately 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 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder Secure the cylinder head gland using the washer ring and socket head bolts SPACER HEAD ASSY PISTON ASSY o Figure 4 11 Rod Assembly Installation After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstal
288. t is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pres sures 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 discon nected with minimal fluid loss 3121166 A C MAINTENANCE A WARNING 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 NO SMOKING IS MANDATORY NEVER REFUEL DUR ING 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 CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ET
289. t the pot hole limit switches or repair the wiring to correct the prob lem 3121166 JLG Lift 5 13 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing 5 14 DE HELP MESSAGE CAUSE POSSIBLE RESOLVE 2 5 ELEV PROX PERMANENTLY CLOSED CHECK The Elevation Proximity Switch is closed toindicate thatthe Check elevation switches PROXAND ANGLE ADJUSTMENT 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 gt 0 15V AND the Elevation Prox Switch is Closed for 2000mS Retained until situation changes Refer to Platform Position Sensor Functionality 2 5 DRIVE amp LIFT PREVENTED BRAKES ELECTRI The manual brake release has been activated to allowthe Disengage the manual brake CALLY RELEASED FOR TOWING vehicle to be towed release Brake release digital inputis energized Drive and Lift Prevented 2 5 DRIVE PREVENTED ELEVATED ABOVE DRIVE The Drive Cutout functionality is enabled andthe platform Check elevation switches CUTOUT HEIGHT is elevated above the calibrated cutout height Check pothole switches Drive Cutoutis set to 1 YES AND the Elevation Sensor is Healthy AND th
290. t with meter leads tance 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 JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement 2 17 7 Figure 7 3 Continuity Measurement Some meters require a separate button press to enable audible continuity testing Circuit power must be turned OFF before testing con tinuity Disconnect component from circuit before testing Use firm contact with meter leads First test meter and leads by touching leads together Meter should produce an audible alarm indicating continuity Figure 7 4 Current Measurement DC Set up the meter for the expected current range Be sure to connect the meter leads to the correct jacks for the current range you have selected If meter is not auto ranging set it to the correct range See multi meter s operation manual Use firm contact with meter leads JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp 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
291. tallation 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 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 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 com plete 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 When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers ar
292. tance per the applicable motor specifi cation below Model Field Resistance Armature Resistance 75 F 24 C 75 F 24 C 1930ES 0 21 Ohms 0 037 Ohms 2030 5 2630 5 2646ES 3246ES 0 127 Ohms 0 051 Ohms 4 Using a dielectric tester verify that there are no shorts between the following items a Field connector pins and the case of the motor b Armature terminals and the case of the motor c Field connector pins to the armature terminals 5 Verify continuity in 2 pin brake connector yellow and brown wires Measure the brake resistance and verify that it is between 18 and 22 Ohms Drive Motor Disassembly NOTE Refer to Figure 3 29 1 3121166 Remove the two Cover Plate Mounting Screws 14 holding the Cover Plate 13 in place and remove the cover plate from the motor 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 Remove the two Terminal Cover Mounting Screws 16 Slide the strain relief of the Wire Harness 1 10 11 out of the cover and remove the cover from the motor Discard the Gasket 12 that was located under the brake and terminal covers Remove the wire harness from the motor by discon necting the brake connection and armature connec tions Cut the field connection close to the crimp connection on the motor side Install the two Brake Cover Mounting Screws 15 in
293. 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 With any battery system the most common problem will be a faulty battery connection Because of the high likeli hood of a battery connection problem it is always worth while to confirm that all connections are good before checking for any other problems 1 Flash High Battery Voltage 1 Indicates a high battery voltage Check that the bat tery charger voltage is consistent with the battery pack voltage The first two digits of the four digit model name indicate the battery voltage the charger supports 2 Check for wiring errors 3 This fault will automatically clear and the charger will restart charging when this problem is removed 4 High battery voltage could also occur if there is another source charging the battery Disconnect any other sources during charging 5 If this problem does not clear after the battery volt age is confirmed to be less than 2 4V per cell return the charger for service 2 Flashes Low Battery Voltage 1 Indicates either a battery failure no battery con nected or a lower than expected battery voltage Check the battery and battery connections 2 Check the nominal battery voltage The first two dig its of the four digit model name indicate the battery voltage the charger supports Confirm that a nomi n
294. the spanner nut retainer and remove spanner nut from cylinder bar rel 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 8 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER 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 ROD SUPPORT SUPPORT 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 Oylin der Piston Removal Cyl p n 1684456 on page 4 12 following 11 Loosen and remove the cap screw s if applicable which attach the tapered bushing to the piston 12 Insert the
295. the vehicle is charging and itis configured to prevent all motion In Platform Mode the Battery Charger is Charging AND the Drive Lift Select Toggleis setto Lift AND Machine Setup s CHARGE INTERLOC is setto 1 DRV amp LIFT UP Drive amp Lift Up Prevented Disconnect battery charger PLATFORM OVERLOADED Whilethe Load Sensing Systemis enabled the platform load measured by the Load Sensing Systemis excessive Functions from platform control are prevented and func tions from ground control may be prevented depending on machine configuration TheLoadSensing System Functionality s Overloadis True AND Machine Setup s LOAD is setto 1 CUTOUT PLT OR 2 CUTOUT ALL Drive Steer amp Lift Prevented except 3246ES CE Indoor Mode Height gt 24 Ft and lt 26Ft Lift Dn allowed Remove excess weight from platform DRIVE PREVENTED POTHOLE NOT ENGAGED While elevated drivingis not possible since the control sys tem detected thatthe pot hole protection mechanism failed to deploy In Platform Mode with a Healthy Elevation Sensor the Ele vation Sensor Voltage gt 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 amp Steer Prevented Clear the obstacle blocking the pot hole protection mech anism repair the mechanical problem re adjus
296. thole Switch Typical on opposite side of machine 2 Proximity Switch 3 Rotary Angle Switch Figure 3 41 Limit Switch Locations 1 of 2 3121166 JLG Lift 3 53 SECTION 3 CHASSIS amp SCISSOR ARMS 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 CHASSIS amp SCISSOR ARMS 3 14 POTHOLE SWITCH REPLACEMENT Pothole Pothole Switch Switch Machines prior to S N s Machines from S N s to present 1930ES USA built S N 0200150266 1930ES USA built S N 0200151266 Belgium
297. tions Description 1930ES 2030ES 2630ES 2646ES 3246ES DE 2 8in 3 1in 3 1in 3 9in 3 9in Lift Cylinder Bore 7 1 cm 7 9 cm 7 9 cm 9 9 cm 9 9 PEE 43 2in 48 in 48in 44 9in 56 8in Lift Cylinder Stroke 108 cm 122 cm 122 cm 114 cm 144 cm b 1 1 8in 2 1in 2 1in 24in 24in Lift Cylinder Rod Diameter 45cm 5 5 cm 55cm 6 3in 6 3in 6 3in 6 1 in 6 1in Steer Cylinder Stroke 16cm 16cm 16cm 15 6cm 15 6cm 1 6 MAJOR COMPONENT WEIGHTS Table 1 16 Major Component Weights Component 1930ES 2030ES 2630ES 2646ES 3246ES Platform 100 Ibs 133 lbs 176 lbs 45 kg 61 kg 80 kg 45 lbs Manual Platform Extension 20kg er 620 lbs 939 lbs 1 213 lbs 1 645 lbs Arm Assembly Includes Lift Cylinder 281 kg 426 kg 550 kg 746kg 7 3 1 067 lbs 1 764 1 554 Ibs Chassis w Wheel Tire and Drive Assembly 484kg 800 ko 705kg 1 7 CRITICAL STABILITY WEIGHTS A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS BATTERIES OR SOLID TIRES WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 1 17 Critical Stability Weights Component 1930 ES 2030ES 2630ES 2646ES 3246ES 582 lbs 721 Ibs 1592 lbs 1956 lbs Counterweight s CE AUS 264kg 327kg 722kg 887 ko 1 721 Ibs 589165 Counterweight ANSI CSA JPN N A N A 327 kg 267 kg Whe
298. 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 Ibs 8 Remove the disengage bolts from the brake housing and install them into the tapped holes in the motor end cap for storage JLG Lift 3 21 SECTION 3 CHASSIS amp SCISSOR ARMS 9 Connect the connector not shown from the brake housing to the connector from the motor 10 13 If not already done remove thru bolts from motor 14 11 Grease the motor O ring 31 and install in the groove of the gearbox assembly Also apply grease NOTE to the lip of the motor shaft seal 17 in the gearbox 15 16 12 Lift motor and line up the thru bolt holes with the tapped holes of the gearbox so that the motor ori ents with the strain relief behind the neck of the spin dle 3 22 JLG Lift Lower motor into the bore of the spindle Motor may need to be tapped with a rubber mallet to get by the O ring Install the thru bolts Tighten to 9 11 ft Ibs 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 Reinstall the back sealing cover onto the motor end Fill the gearbox with ISO grade 68 oil or oil of a simi lar viscosity 80W gear oil or 20W engine oil 3121166 SECTION CH
299. to the threaded holes in the brake assembly and tighten to manually release the brake see Figure 3 10 Remove the three screws holding the brake assem bly to the motor Carefully remove the brake assem bly brake disc and reaction disc from the motor by sliding off of the shaft Remove the screws holding the Commutator End Head 9 in place and remove the commutator end head from the frame and field assembly The Arma ture 2 will be attached to the commutator end head 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 Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly Remove the Snap Ring 7 and Bearing 8 from the commutator end head Discard the bearing Drive Motor Inspection and Service NOTE Refer to Figure 3 29 1 JLG Lift Carefully blow out any accumulated carbon dust and dirt from the Commutator End Head 9 and the Frame amp Field Assembly 2 using clean oil free compressed air 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 discol ored 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
300. tput Vbatt Table 7 3 Ground Board J3 Pin Function Type Range V 1 Tilt Sensor Power Power Output 12 2 Tilt Sensor X Axis PWM Input 12 3 Tilt Sensor Y Axis PWM Input 12 4 Ground Power Output 0 Table 7 4 Platform Board J1 Pin Function Type Range V 1 Master Ignition Power Input Vbatt 2 Master Ground Power Input 0 3 CAN Bus High Input Output Comm 4 CANBus Low Input Output Comm 5 Joystick Power Supply Power Output 5 6 Joystick Signal Input 5 7 Ground Power Output 0 8 Trigger Switch Input Vbatt 9 Lift Select Switch Active Low Input Vbatt 10 Drive Select Switch Active Low Input Vbatt 11 Ground Power Output 0 12 Platform Alarm Active Low Output Vbatt 13 Indoor Outdoor Select Swtich Power Output Vbatt 14 Horn Switch Power Output Vbatt 15 Steer Left Switch Input Vbatt 16 Steer Right Switch Input Vbatt JLG Lift 3121166 SECTION 7 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 7 5 Platform Board J3 Pin Function Type Range V 1 Ground Power Output 0 2 Swtich Shield Grounded Output 0 3 NotUsed 4 NotUsed 5 NotUsed 6 NotUsed 7 Indoor Outdoor Select Switch Active Low Input Vbatt Table 7 6 Platform Board J4 Pin Function Type Range V 1 Ground Power Output 0 2 Switch Shield Ground Power Output 0 3 NotUsed 4 NotUsed 5 NotUsed 6 NotUsed
301. trol 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 JLG Lift 3 49 SECTION 3 CHASSIS amp SCISSOR ARMS 3 13 DRIVE MOTOR CABLE ROUTING USA Built Machines Prior to S N 0200170585 amp Belgium Built Machines Prior to S N 1200015159 A CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING DRIVE MOTOR CABLES _ DRIVE MOTOR CABLES SHOULD SHOULD NOT EXTEND wi NOT EXTEND MORE THAN 4 PAST CROSS BRACE PAST CROSS BRACE 5 2 lt Ld CABLES CROSS EACH OTHER BEFORE ENTERING SEVCON COMPARTMENT CABLES SHOULD BE P CLAMPED 8 24 FROM STRAIN RELIEF Figure 3 39 Motor Cable Routing 1930ES Figure 3 40 Motor Cable Routing 2030ES 2630ES 3 50 JLG Lift 3121166 SECTION CHASSIS amp SCISSOR ARMS USA Built Machines S N 0200170585 to Present amp Belgium Built Machines S N 1200015159 to Present NOTE The below procedures 1 19 apply to 1930ES only A CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING 1 Orie
302. ty sensor The elevation sensor is unhealthy Platform height assumed to be full elevation Check mounting review sen sor wiring against the electri cal schematic or replace the sensor to clear the message ELEV ANGLE SENSOR HAS NOT BEEN CALI BRATED The Elevation Sensor s Calibration EEPROM is setto the signatureimplanted by the In Circuit Test Fixture Retained until Calibration EEPROM is over written by a valid calibra tion Platform Height assumedto be Full Elevation The Elevation Proximity Switch is Open to indicate that the Platformis Elevated butthe Elevation Sensor s Voltage indicates thatthe Platform is Stowed To be conservative the control system will assume that the Platform is Ele vated Elevation Sensor is Healthy AND the Elevation Sensor s Zeroed Voltage is lt 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 mes sage DRIVE PREVENTED CHARGER CONNECTED Drivingis not possible since the vehicle is charging and itis 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 setto 0 DRIVE ONLY Drive amp Steer Prevented Disconnect battery charger DRIVE amp LIFT UP PREVENTED CHARGER CON NECTED Driving and lifting are not possible since
303. ugh this circuit Steer right solenoid CUIT flow to the steer right solenoid during nor resistance should measure about 30 Ohms The steer right sole mal 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 e Check for continuity through this circuit The ground alarm sole BATTERY the ground alarm was commanded off noid is powered with 24V from ground board J1 19 its PWM sig nal 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 nspect the wiring for physical damage Replace ground board 3312 LEFT BRAKE SHORT TOBAT 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 nspect the wiring for physical damage Replace ground board 3313 RIGHTBRAKESHORTTO Voltage was detected ontherightbrake Check for continuity through this circuit Brake solenoid resis BATTERY solenoid when the ground board output tance should measure about 20 Ohms The right brake is powered was commanded off during power up with 24V from ground
304. ule Message Status Message 0x81 is report ing 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 After resolution re cycle power to clear difficulty 5 19 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing DE HELP MESSAGE CAUSE POSSIBLE RESOLVE 9 3 LSS HAS NOT BEEN CALIBRATED 9 3 Flash Code Calibrate the Load Sensing The Load Sensing System s Calibration EEPROM for System using the calibration Empty Platform Loadis set to Never Set signature procedure to clear the mes implanted by the In Circuit Test Fixture AND Machine sage 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 9 9 LSS INTERNAL ERROR PIN EXCITATION The Excitation Voltage for the Load Sensors lt 4 25V The sensors may be exces 9 9 Flash Code sively loading the Excitation LSS Module Message Status Message 0x81 is report Supply due to wiring damage ing INTERNAL ERROR PIN EXCITATION lt 4 25V AND or the Load Sensing System Machine Setup s LOAD is setto 1 CUTOUT PLT OR Module may have hardware 2 CUTOUT ALL Retained until power is re cycled difficulty Vehicle assumed to be Overloaded 9 9 LSS INTERNAL ERROR DRDY MISSING FROM
305. um DC Output Current 25 Maximum Interlock Current 20 INPUT AC Input Voltage 85 265VAC Nominal AC Input Voltage 120VAC 230VAC RMS AC Input Frequency 45 65 HZ Maximum AC Input Current 12ARMS 108VAC OPERATION Charging Indicator Yellow LED 100 Charge Indicator Green LED Fault Indicator Red LED PROTECTION Output Reverse Polarity 4 Protection Automatic SN Electronic Protection Automatic Output Short Circuit Raset AC Overload Current Limited DC Overload Current Limited MECHANICAL Operating Temperature Housing Shock and Water Resistant Aluminum 3 44 JLG Lift Battery Charger Maintenance A WARNING USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGO RITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDRO GEN GAS DURING NORMAL OPERATION KEEP SPARKS FLAMES AND SMOKING MATERIALS AWAY FROM BATTERIES PROVIDE ADEQUATE VENTILATION DURING CHARGING NEVER CHARGE A FROZEN BATTERY STUDY ALL BATTERY MANUFACTURERS SPECIFIC PRECAU TIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING A DANGER RISK OF ELECTRIC SHOCK CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK DO NOT USE GROUND ADAPTERS OR MODIFY
306. umed to be Overloaded Recharge batteries or check for damaged batteries 3121166 JLG Lift 5 17 SECTION 5 JLG CONTROL SYSTEM Table 5 2 Flash Code Listing ese HELP MESSAGE CAUSE POSSIBLE RESOLVE Help messages with the 6 6 flash code indicate vehicle communication CANbus problems These faults shall not be latched Nor mal operation shall resume if difficulty is resolved 6 6 CANBUS FAILURE POWER MODULE The control system failed to receive messages from the Check wiring at the ground Power Module control box and power mod Power Module Message Status 0x24 notreceivedfor ule Recycle power to clear 1000mS or Power Module is reported a CANbus Bus Diffi difficulty culty Fault Code 0x09 Drive Steer amp Lift Up Prevented 6 6 CANBUS FAILURE PLATFORM MODULE In Platform Mode the control system failed to receive mes Check wiring at the platform sages from the platform module and ground control boxes Digital Input Message Motion 0x00 not received for Check wiring along scissor 1000mS AND Platform Mode selected Retained until arms leading up to Platform poweris re cycled All Platform functions Prevented Normal operation from Ground Mode 6 6 CANBUS FAILURE LOAD SENSING SYSTEM With the Load Sensing System enabled the controlsystem Check wiring atthe Load MODULE failed to receive messages from the Load Sensing System Sensing System Module and
307. unction Output Handle Centered 2 5 0 1 VDC 1 RED HANDLE COM Output Full Positive Reverse Deflection 4 0 1 VDC 2 VIOLET TRIGGER 0 Output Full Negative Forward Deflection 1 0 1 VDC 3 E SPARE 4 YELLOW ROCKER RT 5 GREEN ROCKER LT 6 SPARE 7 WHITE RED 5VDC 8 WHITE BLACK GROUND 9 BROWN SIG OUTPUT 3 66 JLG Lift 3121166 SECTION 4 HYDRAULICS 3121166 SECTION 4 HYDRAULICS 4 1 CYLINDERS THEORY OF OPERATION Cylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the cyl inder 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 retrac tion 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 us
308. urface 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 exam ine 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 2 Open Circuit between Pump Motor Negative Ter minal and P Terminal This issue will allow the vehicle to drive but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate Under DIAGNOSTICS PUMP the JLG Analyzer will show PUMP PWM 100 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode After ensuring there is not an Open Circuit between the B Terminal and Pump Motor Positive Terminal check that the voltage measured between the Pump Motor Negative Terminal and Ground Reference is 24V If not examine the issues within Open Circuit Pump Motor This voltage should ramp to approxi mately OV when Lift Up is operated from Ground Mod
309. uring assembly Center the cover in the hub bore so that the ULG logo is up Push it into the bore 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 Install the cover retaining ring into the hub groove 3121166 SECTION CHASSIS amp SCISSOR ARMS Motor and Brake Assembly 13 Brake Cover 17 14 Disengage Bolts 18 15 Socket Head Screws 19 16 Brake Housing 20 NOTE Applies only to 5 Disc Brake 21 Retention Bolt Motor 22 Washer Thru Bolts Spacers Figure 3 18 Motor amp Brake Disassembly USA machines built prior to S N 0200118041 Belgium machines built prior to S N 1200001487 1 Remove back sealing cover from motor if it is not already removed 2 Remove retention bolt and washer from the motor shaft end Do not let the armature shaft fall out of the open end of the motor 3 Open up Brake Kit It should have a brake housing brake disc and three spacers 4 Install Brake disc onto splined end of motor shaft 3121166 NOTE Keep the brake disc clear of any oil or grease 5 Reinstall the retention bolt and washer into the shaft end to keep the armature in the motor 6 Install the brake housing onto motor end cap use the included spacers
310. us RES 3 14 3 14 Spindle 3 15 3 15 Hub Disassembly ex ue RNPENI IR oe dnd aioe EAR eee ee 3 17 3 16 Input Carrier 3 18 3 17 Main Gearbox Disassembly 1 3 19 3 18 Motor amp Brake 3 21 3 19 Motor Assernbly ark ee seb ttle oe pene ag ele eg 3 23 3 20 Drive 4 2 4 E 3 24 3 21 Assembly TOON 1 eet Dee eI tL RU Qi E b B Ha eee hg Sosa RT RBS 3 25 3 22 Assembly Tool 2i occu noeh PER pene pepe qu 3 25 3 23 Assemibly TO0L3 265 ente IRIS ciet nae qnte 3 25 39 24 Drive Motor i co SC aee ker etek Se ER e TA Ep AR TRIN 3 28 3 25 Motor Side ey EARN EHE P eig E AIR en CR 3 29 3 26 Motor Fronts uu EL Go TROLLEY nS an E eR cete cU ee ex tend eod e AUS 3 29 3 27 Bearing Pressure 3 30 3 28 Terminal 3 31 3 29 Drive Motor Components
311. utdoor N A N A N A N A N A ANSI CSA Zone A N A N A 120 Ib force 533 N A 150 Ib force 667 ANSI CSA Zone B N A N A 100 1b force 445 N A 105 Ib force 467 CE Indoor 90 Ib force 400 901 10 400N 90Ibforce 400 N 9010 force 400N 9010 force 400 CE Outdoor 45 b force 200 45 lb force 200 N A 90 Ib force 400 4510 force 200 AUS Indoor 90 Ib force 400 901b force 400 N A 90 Ib force 400 N A AUS Indoor Zone A N A N A 90 Ib force 400 N A 901b force 400 N AUS Indoor Zone B N A N A 90 Ib force 400 N A 901b force 400 N AUS Outdoor 45 b force 200 45Ibforce 200 N A 90 Ib force 400 N A AUS Outdoor Zone A N A N A N A N A N A AUS Outdoor Zone B N A N A N A N A 45 Ib force 200 1700 psi single Maximum Hydraulic Pressure 1800psi 1800 psi 2000 psi 2000 psi 1850 psi dual Inside Steer Angle 90 90 90 90 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 Ibs 3830 Ibs 4815 Ibs 4945 Ibs 4945 Ibs Approximate Gross Machine Weight CE Australia 1495 kg 2063 8 kg 2197 7 kg 2705 7 kg 2871 2 kg Ground Clearance with pothole protection system up 3 91 59 em Ground Clearance with pot hole protection system down 1 in 2 5 cm 0 75 in 1 9 cm 3121166 JLG Lift 1 1 SECTION 1 SPECIFICATIONS Cap
312. vironment of industrial equip ment varies widely the following are suggested for peri 9 Attach terminal cover to the commutator end head odic maintenance inspection intervals using two terminal cover screws Normal Service Perform routine inspection outlined 10 Slide the strain relief of the wire harness into the slot in the Drive Motor Inspection and Service portion of of the terminal cover Align cover plate with groove in this section every 1 000 hours of drive time frame and field and affix using two cover plate screws 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 lum ber and flour mills coal mining stone quarries etc b High temperature areas like steel mills found ries etc c Environments with sudden temperature change such as in refrigeration plant etc 3121166 JLG Lift 3 35 SECTION 3 CHASSIS amp SCISSOR ARMS 3 7 DRIVE MOTOR ELECTRICAL EVALUATION Several basic electrical tests can be performed on the Drive Motors Failure of one of these evaluations is signifi cant and may indicate that the device is physically dam aged 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 con
313. y Inspecting Motor Brushes NOTE 3 26 Motor brushes should be inspected every 1000 hours Loosen the strain relief of the cable and push approximately 1 in 25 mm of cable into the motor Separate the end piece from the motor shell by approximately 1 in 25 mm Using compressed air clean the brush housing area of any accumulated carbon dust Remove the screw in each of the brush holders that connects the brush wires Remove each of the four brushes from the brush holder 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 Remove any copper chips that may have settled between the commutator bars Measure the diameter of the commutator If the diameter is less than 2 8 in 70 5 mm the commuta tor can no longer be used Measure the depth of the commutator mica com mutator 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 arma ture of any loose mica Install the new brushes into the brush holders Make sure the brush is in the correct orientation to make smooth contact on the commutator
314. you can Use grease to hold the thrust washer in place Slide the planet gear into the window with the tanged washer until the bores line up 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 Before pressing the planet pin into the spindle make sure the gear spins freely 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 Repeat Steps 6 12 for the other two output planet gears Turn the spindle over so that the carrier is down 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 Grease and install the motor O ring into the groove A WARNING CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING CONTACT WITH THE BRAKE DISCS IF THIS OCCURS IT WILL DEGRADE THE BRAKES PERFORMANCE JLG Lift 3121166 SECTION CHASSIS amp 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 3 Flip the hub over Gown 4 Using an appropriate pressing tool press the main 2 Using a flat plate in conjunction with a pressing tool bearing into the bore until it bottoms out press in the seal so it is flush with the edge of the hub NOTE The seal has a thin outer shell that can be easi

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