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Service and Maintenance Manual - AL Del

1. RED 9 RIBBON PLATFORM i ALARM 34 DIGITAL E v OUTPUT ene DRIVERS P ANALOG INPUT 24 V WHEN 5 FILTER OUTPUT 15 ON stes 0 TO 5 VOLT JOYSTICK COMMON RED 22GA 1 RED 2 K MICRO zl TRIGGER VIOLET 22 6 2 BLACK Ji PROCESSOR ROMUPURPLE 19 ROCKER LEFT GREEN 24 6A 5 1 DIGITAL INPUT ORANGE WHITE 17 BLUE pur FILTER 24 v Je ARENA A ROCKER RIGHT YELLOW 24 GA 4 BROWN 12 ETAT ELTE GREEN 18 5VDC WHT RED T PINK 5 HIGH 1 1 4 JI p GROUND WHT BLACK 8 PURPLE 6 RIBBON 516 OUTPUT BROWN 9 CAN SS 0 5 VOLT WHITET DISTRIBUTION INTERFACES 7 i OUTPUT AND REGULATION J4 1 e a BLACK TO ALL AREAS HORN 1 OF THE SYSTEM BUTTON BLACK 16 GREEN 4 31 3 1 ESTOP YELLOW a RED 16 1 SHIELD 1 BLACK RED PLATFORM a 7 7 i ji Y 1200 250 WATT BATTERY CABLE 84 GA IN CANNON PLUG OF IM v PLATFORM CABLE BATTERY CABLE 4 GA BEACON RED 1 2 10
2. FOOTSWITCH ACC Y MODULE YEL RED 2 5 14 aH 4 aan MOUNTED IN REAR FRAME PLATFORM BLACK COMPARTMENT NEAR CHARGER CABLE CONNECTOR MM 441 2 GROUND ORN RED 49 8 8 HIGH SENSING WHEN FOOTSWITCH OPTION 15 EIE IERI INSTALLED PLATFORM CABLE amp 5 CONNECTION WILL BE DISCONNECTED AND FOOTSWITCH HARNESS SHOWN ES HSD WILL BE CONNECTED IN LINE EXCLUSIVE S MNT D ON PLATF FLOOR i ele e RED n J2 9 CAN H gt 7 1 ACK FOOT NET BLAC 4 J2 10 CAN L ANALOG ae SWITCH o gt EE K 1234 5 67 8 7 CAN CIRCUITRY TES 1 85 232 uz alela HASSIS HARNESS 81518 CONNECTOR cem Us TEE E m BLUE CONTROL BOX FOOTSWITCH OPTION Ps FL LEFT F2 D NOTOR A2 Al RED BATTERY CABLE 44 GA 2 BATTERY CABLE 4 GA F BRAKE BATTERY CABLE 44 GA BATTERY CABLE e 8 LH PHP SWITCH 44 GA E 2 9
3. 4 3 Wheel and Tire Replacement 4 3 Wheel Installation e c FIR E See ee Re A eiu rue giis 4 3 4 4 REAR WHEEL 4 4 4 5 STEERING LINKAGE ASSEMBLY 4 5 4 6 STEER CYLINDER 2 4 6 Steer Cylinder Disassembly 4 7 Hydraulic Cylinder Component 4 8 Steer Cylinder ccc cette heres 4 8 47 DRIVE MOTOR SPINDLE ASSEMBLY 4 10 4 8 WHEEL DRIVE ASSEMBLY 4 11 Drive Motor Electrical 4 11 Roll And Leak Testing Rede Rx D ERR RC Eas 4 12 Oil Type amp Capacity Peta i be ee 4 12 Drive Motor Power Harness 0 4 12 Wheel Drive Brake Manual Disengage Procedure 4 13 Wheel Drive Motor Assembly Removal From 4 14 Drive Motor 2 tee
4. LLL 6 10 339 STEER RIGHT SHORT 6 10 3310 STEER RIGHT OPEN CIRCUIT 6 10 3311 GROUND ALARM SHORT TO BATTERY 6 10 3312 LEFT BRAKE SHORT TO BATTERY semen tae tula uet 6 10 3313 RIGHT BRAKE SHORT TO BATTERY 222424 4 ttt ttt ttt 6 10 3314 LEFT BRAKE OPEN CIRCUIT 5 c curiae ts 6 11 3315 RIGHT BRAKE OPEN CIRCUIT eS ae D D cu T 6 11 33297 LEFT BRAKE SHORT TO 22202 42 4 6 11 33298 STEER LEFT VALVE SHORT TO GROUND ttes ttt 6 11 33299 LINE CONTACTOR COIL SHORT TO 1 6 11 33302 NEGATIVE SUPPLY SHORT TO BATTERY ttt 6 11 33303 NEGATIVE SUPPLY SHORT TO GROUND 6 11 33304 RIGHT BRAKE SHORT TO eade teret 6 11 33305 STEER RIGHT VALVE SHORT TO 0 ttt 6 11 33406 LIFT UP VALVE SHORT GROUND rco decet eve eden aded e 6 11 33407 LIFT DN VALVE SHORT TO GROUND ttt oosss sss 6 11 4 2 421 POWER MODULE TOO HOT PLEASE ttt ttt ttt tt
5. Figure 5 2 Main Electrical Power Connections 1001092456 ZAPI Power Module oF own Right Side Batteries Left Side Batteries Power Module Main Power Contactor Relay Hydraulic Pump Motor JLG Lift 6 T 8 9 10 Right Drive Motor Left Drive Motor Battery Power Quick Disconnect To Battery Charger To Charger or Inverter Option If Equipped 3121222 SECTION 5 CONTROL COMPONENTS 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 Plattorm 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 resis tance measurement refer to Drive Motor Electrical Evaluation Suspect damaged cabling burned cabling or faulty brake release solenoids Trace the brake release cabling from the Power Module Com partment to the Ground Module Connector J1 24 11 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
6. Pa BATTERIES lt Fy I E 1 1 BATTERY CHARGER mm g BATTERY INVERTER CHARGER POWER INVERTER SWITCH 0 POWER C CONTACTOR 2 RELAY 9 PROXIMITY SENSOR LIFT CYLINDER POWER MODULE 67 e Fi Bj F2 a Figure 9 14 1230ES Overview of Electrical System Components 1600346 Drive Module 3121222 JLG Lift 9 23 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS PLATFORM CONSOLE BOX 9 24 GROUND CONTROL BOX BRAKE DISCONNECT SWITCH PLATFORM RECEPTACLE
7. 14 1 8 SECTION 2 GENERAL SERVICE INFORMATION 2 1 MACHINE PREPARATION INSPECTION AND 2 1 General 2 uc ecd et b dme eser ea f 2 1 Preparation Inspection and Maintenance 2 1 Pre Start Inspection s oS We ed XM ERROR 2 1 Pre Delivery Inspection and Frequent 2 1 Annual Machine 2 1 Preventative 1 2 1 2 2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE 2 2 Maintenance and Inspection Table Codes 2 4 sz ch tee led M Pa arate cR E MIR Cae n 2 4 2 3 SERVICING AND MAINTENANCE 2 e nh 2 5 Generals e GaN aa ad ravi TEE Se UE 2 5 Safety Workmanship 2 5 ned RE beiden Gap Nido wag d 2 5 Components Removal and 1 lt 2 5 Component Disassembly and Reassembly 2 5 Pressure Fit Parts lel biis eR EU EE ue ned esce s
8. Dty of Loctite 212 262 Stress Area ase OR Vibra TITE 111 or TITE 131 140 K 18 K 0 15 et 4 40 0 1120 0 00604 onzo p oost f 6 32 01380 600009 013380 00010015 32 01640 0 01400 y l 36 01640 001444 55 5 10 24 04900 0 01750 1580 60 7 01900 002000 1800 68 8 1 4 20 Esa 25 25 3 8 16 0 3750 0075 700 45 60 40 55 35 50 50 70 0437 0 1187 10700 80 10 70 95 60 80 1 2 13 110 120 155 iro ae ps EE 175 210 285 190 220 240 325 215 245 375 510 340 380 420 570 380 430 um sis 509 0 i 0 5090 45800 670 910 600 815 500 680 875 1015 1310 1475 1855 2055 2430 2760 3225 3625 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS NO 5000059 REV J 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER Figure 1 3 Torque Chart SAE Fasteners Sheet 2 of 7 JLG Lift SECTION 1 MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating Ref 4150701
9. GIAO 1581 258 WEINGSSHA 21631 WALSAS OPO MS 174 1591 MS 1581 41145 SNIHOVIA THAI SSHOOV ISAL WALSAS 7 7 JLG Lift 3121222 SECTION 7 JLG CONTROL SYSTEM Ajuo 9872601001 IdVZ 6679601001 Jo 19945 JezAjeuy 9 SHLLIIVNOS IHd H IDIHHA THAG T SNOILV ISI IVO S0 0 0 S0 0 0 953005 LH JONA YAO 0 qvot 01 8PLOT L8 WATY L8 NOH 00 06 A08 c 09 c AOS 1 007 T m m AJA NIN NOLVUT TOV 94001 001 70 JAINA 70 OLLV IS ATALS 001 09 96001 96001 501 sos I NG 7L NIN 70 XVIN 70 NIN dN THOOV ST 0 96001 96001 501 SO S ag ARTA 70 NAWIXVN 70 WOWININ 0 THOOV SOY TIVA YOSNAS 8 gt 110119
10. 1 2 3 1 3 4 CONTROLS amp SENSORS aua ikea da ie Rep Lb PRA 3 3 Elevation sa Eee eee a Gain ui es we ERE MES 3 3 JOYSTICK c 3 3 i ui dak etra eter e d devi 3 3 3 5 C TRACTION eror epu eto be st se e s 3 3 Metis 3 4 Mes I 3 4 3 6 PUMP EIET MAST 3 5 Personaliti Sio cepe etes m tod a e ae o dg 3 6 InterloCKS eoe ee ees 3 6 Oa eS T a tatu Sl a eade te cotes cum rd cetus addunt tates 3 6 Persornalitles eoe ren Cr ed gest epus de ote heh t e aep 3 6 3 6 SECTION 4 BASE COMPONENTS 4 1 BASE ASSEMBLY e hmm 4 1 42 ERAME COVERS bete UE FA Iu bits d LM eke e 4 2 Base Top Cover Installation 4 2 Step Plate Battery Charger Cover Installation 4 2 Battery Tray Side Door 1 4 2 4 3 WHEELS AND TIRES DRIVE AND 4 3 Tire Wear
11. 2 4 1 4 2 Wheel Lug Nut Tightening 4 4 3 4 3 Drive Motor Power Harness 0 4 12 4 4 Brake Manual Disengage Procedure 4 13 4 5 Drive Motor Disassembly 4 15 4 6 Drive Motor Side 4 16 4 T Drive Motor End View Brake 4 16 4 8 Motor Terminal 1 4 17 4 9 Bearing Replacement 2 4 17 4 10 Main Electrical Power Connections 1600346 SEVCON Power Module 4 30 4 11 Main Electrical Power Connections 1001092456 ZAPI Power 4 31 4 12 Hydraulic Pump Hydraulic Line and Electrical Connections 4 32 4 13 Relief Pressure Setting 2 ren 4 33 5 1 Main Electrical Power Connections 1600346 SEVCON Power Module 5 5 5 2 Main Electrical Power Connections 1001092456 Power 5 6 5 3 Power Module
12. 2 22 4 1 2 1 7 Capacities iden tae e ru Senne n Meadow te on he e da A RU ER EU E E 1 2 1 8 Hydra lic Oil br Pi EQ eMe 1 2 1 9 Lubrication Specifications coiere IER RA be epe e 1 3 1 10 Hydraulic Oil Specifications 2 4 2 1 3 1 11 Cylinder Specifications E er ue RU ex org 1 3 2 1 Maintenance and Inspection Requirements 2 2 2 2 Preventive Maintenance amp Inspection 2 3 4 1 Wheel Torque 1 42 2 2 4 3 4 2 Hydraulic System Pressure Settings 2 4 33 4 3 Hydraulic Pump Selenoid Specifications 4 33 5 1 ZAPI Power Module 5 11 5 2 Module Terminal 5 12 5 3 Tilt Sensor Harness for 1810140 5 15 5 4 Tilt Sensor Harness for 1001114936 5 15 5 5 Battery Algorithms Usu PROS ERR RT Rete Aa Pere dosis Ere Re eds 5 23 7 1 Machine Configuration Progr
13. 20 25 245 1525 io sso 460 24 3 353 2220 1065 960 800 561 2095 1885 1575 694 2855 2570 2140 3665 3300 2750 4s n ewo ses 525 4395 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 7 Torque Chart METRIC Fasteners Sheet 6 of 7 3121222 JLG Lift 1 9 SECTION 1 MACHINE SPECIFICATIONS Magni Coating Ref 4150701 CLASS 12 9 SOCKET HEAD CAP SCREWS M6 AND ABOVE i TM Tensile Dry or Loctite 2427 or 271 Loctite 262 Size PITCH Stress OR Vibra TITE Anda OR Vibra TITE Ae pe or 140 15 678 78 8 78 36 60 12 5 18 0 22 8 36 1 52 5 115 e as mm sen em m 05 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 8 ASSEMBLY USES
14. 11 H 12 65 43 Figure 6 3 Mast Assembly Orientation Top View Front of Machine 7 Hydraulic Cylinder Com Rear of Machine partment Platform Outer Mast 8 Power Trak Compartment Section 9 Cylinder 1 Bleeder Valve 4 Outer Mid Mast Section 10 Cylinder 2 Bleeder Valve 5 Inner Mid Mast Section 11 Cylinder 3 Bleeder Valve 6 Mount Inner Mast Section 12 Corner Slide Pads a Note a Always mount slide pads with the groove oriented to the side of the mast not the front or rear for clearance of the pad mounting rivets during operation The slide pads are available in two thicknesses JLG P N 1001092165 9 7mm thick round notch on ends JLG P N 4700042 8 7mm thick NO round notch on end Figure 6 2 Mast Assembly Components Always use the 1001092165 slide pad unless mast tube Mast shown cutaway for illustrative purposes only clearances prevent installation 1 Platform Outer Mast Section 7 Hydraulic Cylinder 3 2 Outer Mid Mast Section 8 Top External Slide Pads 3 Inner Mid Mast Section 9 Power Trak System 4 Mount Inner Mast Section 10 Power Trak Guide 5 Hydraulic Cylinder 1 11 Power Trak Shield Assy 6 Hydraulic Cylinder 2 12 Bottom
15. Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain 34 93 772 4700 34 93 771 1762 JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 25 46 0 850 659 500 446 0 850 659 534 www jlg com
16. 6 8 6 9 Hydraulic Cylinder Connections 6 8 6 11 Hydraulic Cylinder Top End Bolts 6 8 6 12 Hydraulic Cylinder Removal 0 0 ccc teen eee 6 8 6 14 gt Mast Sections Disassembly 4 6 9 6 13 2 2 7 6 9 6 15 1230 5 Lift Cylinder Internal Components Top 6 12 6 16 1230 5 Lift Cylinder Internal Components Lower 6 13 vi JLG Lift 3121222 TABLE OF CONTENTS 6 17 Valve Block 2 1 0 6 14 6 18 Cylinder 2 and 3 Assembly Removal 6 14 6 19 Cylinder Rod Gland 1 1 0 6 15 6 20 Cylinder Rod Piston 6 15 6 21 Cyl 2 3 to Cylinder Joint 1 6 17 7 1 Analyzer Menu Flow Chart Sevcon vP1 14 Sheet 1 of 2 4170032 15 7 4 7 2 Analyzer Menu Flow Chart Sevcon vP1 14 Sheet 2 4170032 15 7 5 7 3 Analyzer Menu Flow Chart Sheet 1 of 3 1001096495 Mach
17. 6 16 Hydraulic Cylinder Assembly 1 6 16 Hydraulic Cylinder Assembly 0 1 6 17 SECTION 7 JLG CONTROL SYSTEM 7 4 ELECTRONIC CONTROL 5 7 1 To Connect the Hand Held 7 1 Using the Analyzer ea I Eq IAE TUR PSI 7 1 Changing the Access Level of the Hand Held Analyzer 7 2 Machine Setup curru dte EUR c ed m o REY ES 7 8 Diagnostic Trouble Codes DTC 7 8 7 2 MACHINE CONFIGURATION PROGRAMMING INFORMATION 7 9 7 3 MACHINE PERSONALITY ADJUSTMENT 7 11 7 4 TILT SENSOR CALIBRATION 1 7 12 Ground Module Software Version 1 5 7 12 Ground Module Software Version 1 4 7 12 Calibration Fail res c Tim wie tar eager tiered ew e re IE 7 12 7 5 TILT SENSOR ELECTRICAL 7 18 7 6 ELEVATION ANGLE SENSOR ELECTRICAL EVALUATION 7 18 Tilt vs Allowed Height Evaluation 7 13 7
18. 1 5 9 5 5 POWER MODULE P N 1001092456 1 5 11 ZAPI Power Module Electrical 5 12 5 6 GROUND CONTROL MODULE SERVICE PROCEDURE 5 18 Ground Control Station REA nexa se t bone o eek atn 5 13 Printed Circuit Board PCB Replacement 5 13 5 7 PLATFORM CONTROL STATION SERVICE 5 16 Platform Control Station 5 16 Upper Control Box Component Replacement 5 16 Lower Control Box Component Replacement 5 18 5 8 BATTERY BATTERY 2 5 19 Battery Maintenance and Safety 5 19 Battery Installation der ea tx Ro a gr ede Da d baw dL 5 20 5 9 BATTERY CHARGER e mn 5 20 Battery Charger Troubleshooting 2 5 21 5 10 BATTERY CHARGER INVERTER OPTION 5 24 SECTION 6 MAST COMPONENTS 6 1 MAST COMPONENTS OVERVIEW 1 2 22 6 1 6 2 PLATFORM TOOL TRAY INSTALLATION
19. 5 11 Lo UT HANDHELD ANALYZER CONNECTION PUMP MOTOR TANK BEACON LIGHT POTHOLE PROTECTION DRIVE MOTORS H SWITCHES A Reg Figure 9 15 1230ES Overview of Electrical System Components 1001092456 Drive Module JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS BATTERIES BATTERY CHARGER 0 BATTERY INVERTER CHARGER POWER INVERTER SWITCH TO AC POWER RELAY DRIVE CONTROLLER 5 PROXIMITY SENSOR O LIFT CYLINDER CONTACTOR RELAY Figure 9 15 1230ES Overview of Electrical System Components 1001092456 Drive Module 3121222 JLG Lift 9 25 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
20. AARIG AARIG OST ON TWO WRINGSHA lt 1VO NIN qvoT 4 OST ON L3IdINOO rt TWHINGSHA put MOLLSAOf TVD TVD ISTON tage ee EU gt Wav LAS WAV LAS AUN TIVI YOSNAS 24 3 amp LTTIdINOO gt ld LAST LAS AAT J c 5 AUN UVa 4 L3 1dINOO 4 4 ld ARTA LAC LAS AATA LAET 195 5 OSH ON YOSNAS J 1461 LAS ARTA 1461 195 ARTA 1461 LAS TANTIVA YOSNIS THRLLNGESHA TALI La LALI LAS AAT J 1138 5 OS3 ON AUN VA MOSNAS L3 TdINOO MOIS LAS MOLS LAS Ad TA MOLS LAS B TAAJT LON _ 0 0 0 0 L ILL LL 3121222 Lift 7 8 SECTION 7 JLG CONTROL SYSTEM 7 2 MACHINE CONFIGURATION PROGRAMMING INFORMATION NOTE When configuring an 1230ES machine the machine configuration must be completed before any person ality settings can be changed Changing the person ality settings first and then changing
21. Brush Installation 1 Brush Holder 4 Brush Tension Spring Motor Cover Motor Installation 2 Brush 5 Commutator on Armature 1 Motor Assembly 3 Motor Assembly Screws a 3 Brush Terminal Screw 6 Motor Cover Bearing 2 Motor Cover 4 Disassembly Marks b Installation the same for all four 4 brush assemblies NOTE a When reassembling DO NOT OVERTIGHTEN motor Note Clean the rotor commutator and brushes with a non con assembly screws 3 torque is 8 Nm 70 in Ib ductive electrical cleaner before assembly b Place marks on body to help with reassembly Attach the brush terminal end to the terminal post using the termi alignment nal screw 3 then push the brush 2 down into it s holder 1 slide the tension spring 4 onto the top of the brush Preventative Maintenance Brush Wear Dust Removal Procedure After final assembly of the brushes check that all brush terminal screws are tight and the brush springs are posi Due to a possible build up of dust from brush wear inside tioned properly before installing the motor cover and the pump motor cover around the brushes and armature motor to the pump valve body under heavy usage It is recommended per the Preventa tive Maintenance and Inspection Schedule Section 2 Table 2 2 to perform this dust cleaning task on an NOTICE annual basis DO NOT OVERTIGHTEN THE PUMP MOTOR ASSEMBLY SCREWS INTO THE ALUMINUM VALVE BODY 8 NM OR 70 IN LB Follow th
22. 1 5 7 5 4 Sevcon Power Module 2 1 5 8 5 5 ZAPI Power Module 1 5 11 5 6 Ground Control Station Assembly 5 14 b 45 gt Tilt Sensor EOCatiOn cese ur TR RE esce e do e m 5 15 5 46 Tilt Sensor Removal 4 5 15 5 T Platform Control Station 5 16 5 8 Battery Fluid Level 4 5 Rex gave ea MATO d 5 19 6 1 Mast Components Lec pa ERR RUE Delos eR Ded ee e RA RR ERR ICONE as 6 1 6 2 Mast Assembly 6 3 6 3 Mast Assembly Orientation Ih 6 3 6 4 Extending Mast 0 6 4 6 5 Platform to Mast Installation RII II 6 5 6 6 Mast Installation oii e ete ate eod ils cert tes e tud 6 6 6 7 Mast Base Mounting 1 2 6 7 6 8 Power Trak 1 6 7 6 10 Hydraulic Cylinder Bottom End Bolts
23. 1 6 2 6 3 MAST COVER PLATE 4 6 2 3121222 JLG Lift iii TABLE OF CONTENTS 6 4 PLATFORM AC RECEPTACLE 6 2 6 5 MAST ASSEMBLY 6 3 6 6 PLATFORM ASSEMBLY us eR ERI Euer REV apud 6 4 Platform Extending Mast 6 4 Plattorm Bemowval IM Rp RE uae eo eet D Me YS 6 4 Plattorm Installation i aee eau 6 5 6 7 MAST ASSEMBLY e rp reu MAS 6 6 M st Removal veu t best Excuse wet edhe qa a us 6 7 Mast iDisasSembly EIE e Pb WE E o e ta 6 8 Mast A 6 9 Mast InstallatiOn ntn retener les herd e cb be ot 6 10 Multi Stage Hydraulic Cylinder Cylinder Bleeding Procedure 6 11 Mast Installation 1 1 1 4 6 11 6 8 MULTI STAGE HYDRAULIC CYLINDER SERVICING 6 12 RE eae ii bers 6 12 Hydaulic Cylinder 1 6 14 Hydraulic Cylinder Component
24. 1501004 ISOD Ly 71 NadO 141 NadO 141 1877 HNOZ T a __ 001 9 001 Ly Ly Ly 135012 NHdO La 45010 IMSIOOJUN STIOTTHS AHDVdVO 0 ee NJdO NYOH NOLLSAOf NadO TAS 141 NadO LA WHals 4331 TAS g v 3NOZI N8dO HOLIMS LOO 5010 LNO NI 91 OL I d THH WHINH 9 SS3d d THH 3121222 JLG Lift 7 6 SECTION 7 JLG CONTROL SYSTEM SAA D ON 0 HOLIASLOO INDV I ANALLVE einpoiy 9672601001 IdVZ peddinb3 9699601001 40 19995 JezAjeuy p 7 e1nDi4 TIV LnOL02 C NOLLOIN O SAA 1 ON 0 LAOLAD D LNAQSAC 1 LAOL AARC CHTIVISNI KINO NNOH 0 LON 0 1VOT Wav TV ANC I VINO HADKC 0 1 QOTHALNI YADYVHO INDV I 0 INDV I 110110 0 CATIVISNI LON 0 x1VOT 1 VINO AARIG 0 2 VSZ SAX 1 ON 0 SAX 1 ON 0 LAOLAD CATIVISNI QCINO NYOH 0 So
25. 5191 p apow ase MOJ8q pue 5141 uodn Buipuedap jou SuaaJos ajou suaaJos 2 e qissod smoys jnohey Z 15 SHILITVNOSNHd J48JS aq 14 sazAjeuy ay 1 TSOJON LOOAV I 3121222 JLG Lift 7 4 SECTION 7 JLG CONTROL SYSTEM 2200217 Z 19945 vL Ld uoo eS JazAjeuy 2 2 enBi4 i SST SNOISNSA x DXXNNX T x DXXNXX Z HSISAS 7 5 W3lSAS ONSVIG SOILSONOWIG i 80118089 JLG Lift dnjag uo Burpuedep e qe reAe aq uorjdo 5141
26. 3477 6 5 47 68 OPTIONAL CAN Low CAN High X108 PLATFORM BOARD X105 1 Ignition 2 Ground J2 g CAN High 10 CAN Low X106 107 MODULE OPTIONAL POWER MODULE B Vbatt X027 1 Ignition 1200 11 CAN Low 10 High CAN Shield CAN Low CAN High Ignition CAN High CAN Low X108 12 34765 1 2 3 4 7 6 5 lt p X017 Vbatt 24 Vbatt Battery CANLO 3 2 Figure 3 1 Shield Ground Ignition PLT EMS PLT EMS Source B B Ground board PLT EMS Source Ground Mode Select JLG Lift CIRCUIT BREAKER C E STOP X035 X036 X034 X033 PLATFORM KEY SW A038 X040 e X039 GROUND Basic Electronic Module Connections 3121222 SECTION 3 THEORY OF OPERATION 1230ES 3 4 CONTROLS amp SENSORS Elevation The elevation sensor is an inductive proximity switch It must be powered to operate There is a 1 3k Ohm resistor where it connects to the ground module to produce the proper signal for the ground module See electrical sche matic in Section 9 for details If Ferrous material is present i e the mast is fully retracted it will close The sensor is calibrated mechanically The
27. An Oshkosh Corporation Company Service and Maintenance Manual Model s 1230ES P N 3121222 February 22 2012 JG LB NOTES INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A GENERAL C MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial A WARNING platform It is of utmost importance that maintenance per FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN sonnel pay strict attention to these warnings and precau THIS SECTION COULD RESULT IN MACHINE DAMAGE PERSON tions to avoid possible injury to themselves or others or NEL INJURY OR DEATH AND IS A SAFETY VIOLATION damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during machine maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of ot
28. ttt 9 20 9962 POWER MODULE FAILURE INTERNAL ERROR ttt ttti 9 20 9963 POWER MODULE FAILURE INTERNAL ERROR ttt ttt 9 20 9964 POWER MODULE FAILURE INTERNAL ERROR ttt ttt 9 20 9969 POWER MODULE FAILURE INTERNAL ERROR ttt ttt 9 20 9970 POWER MODULE FAILURE INTERNAL ERROR 9 20 3121222 JLG Lift 8 3 SECTION 8 DIAGNOSTIC TROUBLE CODES 8 4 9971 POWER MODULE FAILURE INTERNAL 9 20 99143 POWER MODULE FAILURE INTERNAL 9 20 99144 POWER MODULE FAILURE INTERNAL 4 9 20 99145 POWER MODULE FAILURE INTERNAL 2 9 21 99146 POWER MODULE FAILURE INTERNAL 4 9 21 99147 POWER MODULE FAILURE INTERNAL 9 21 99148 POWER MODULE FAILURE INTERNAL 9 21 99149 POWER MODULE FAILURE INTERNAL 9 21 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 8 4 DTC CHECK TABLES 0 0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 001 EVERYTHINGOK 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
29. 6 7 257 ELEV PROX PERMANENTLY CLOSED CHECK PROX AND ANGLE ADJUSTMENT 6 8 258 DRIVE 8 LIFT PREVENTED BRAKES ELECTRICALLY RELEASED FOR TOWING 6 8 259 MODEL CHANGED HYDRAULICS SUSPENDED CYCLE EMS 6 8 2510 DRIVE PREVENTED BRAKES NOT RELEASING 6 8 2511 ELEV ANGLE SENSOR FAULTY NOT MOUNTED 6 8 2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE 11 10011111 tetto ttt 6 8 3 1 311 OPEN CIRCUIT EINE CONTACTOR ra Dea _______6_6_6_ _6_6__ 6 8 312 CONTACTOR DRIVER PERMANENTLY OFF letta ih ER E ete to dettes 6 8 3 2 321 LINE CONTACTOR MISWIRED ON OR WELDED ttd 6 9 322 CONTACTOR DRIVER PERMANENTLY ON sssssssssssssssssssssssssssssssssssssssssssssssssstssssstuussssssssssssssssssssssssssssssssssssssesssnssseeee 6 9 3 3 331 BRAKE SHORT BATTERY oA PM A 6 9 332 BRAKE OPEN CIRCUIT oM te de ELLE tal 6 9 333 LIFT UP SHORT TO BATTERY 2 2 tack RR macte sce oat iq 6 9 334 LFT UP OPEN CIRCUIT S E ME DR M d E 6 9 335 DN SHORT TO BATTERY cime tid Id ID CM ELLE E e 6 9 336 unix ctc re POL S a LE 6 10 337 STEER LEFT SHORE TO BATTERY Dese Lco 6 10 336 STEER LER OPEN CIHGUIT
30. 8 1 SECTION 8 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 be used for machines equipped with a SEVCON Power Module ground board software version P1 13 or higher or ZAPI Power Module ground board software version P1 0 or higher For more information on any sensors or indi cators refer to the appropriate section for the machine area Many of the checks below require configuring and using a mul timeter 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 con trol system Some procedures below refer to this nominal voltage VMN as 24V Actual voltage measurements may differ based on the charge of the batteries If a correction is made during a check conclude the check by cycling the machine power using the emergency stop switch It may also be helpful to run a system test ANALYZER gt SYSTEM TEST for inter mittent or difficult problems 8 2 X CONNECTOR REFERENCES Throughout the following DTC troubleshooting procedures electrical connectors are given a three digit identifier number p
31. JLG Lift 9 17 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 18 Table 9 2 X Connector ID Index ID Description 110 End2ID X030 Overload X031 Hourmeter X032 Hourmeter X033 Circuitbreaker Out X034 Circuitbreaker In X035 Gnd E Stop In X036 Gnd E Stop Out X037 Lift Switch E06P X038 Key Common X039 Key Ground X040 Key Platform X041 Lift Down Valve DTO2P X042 Steer Right Valve DTO2P X043 Lift Up Valve DTO2P X044 Steer Left Valve DTO02P X046 Platform Box DHD14P DHD14R X047 Platform E Stop Out X048 Platform E Stop In X049 Joystick 09 050 Platform Module J1 MMF16P X051 Platform Lift Drive Switch X052 Platform Alarm 4 X053 Platform Alarm X054 Platform Horn Switch X056 Inverter Switch Out X057 Inverter Switch In X058 Contactor Supply X059 Contactor Out X060 Power Module B X061 Power Module F1 X062 Power Module F2 X063 Left Motor Power Mod M1 X064 Power Module P X065 Power Module from Contactor X066 Left Motor Power Mod M2 X069 Pump Motor X070 Pump Motor X071 Battery 1 to Contactor X072 Battery 1 X073 Battery 2 X074 Battery 2 X075 Battery Disconnect X076 Battery 3 X077 Battery 3 X078 Battery 4 X079 Battery 4 to Power Mod X080 Right Motor Field Cross JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 3121222 Table 9 2 X Connector ID Index ID
32. cceettttttttttt ttt ttt ttt ttt 6 17 994 LSS INTERNAL ERROR DRDY MISSING FROM A D 6 17 995 POWER MODULE FAILURE PERSONALITY RANGE ERROR 6 17 996 POWER MODULE FAILURE INTERNAL ERROR ttt ttti 6 18 997 POWER MODULE FAILURE CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT 6 18 998 EEPROM FAILURE CHECK ALL SETTINGS 6 18 999 FUNCTION LOCKED OUT POWER MODULE SOFTWARE VERSION IMPROPER 6 18 9910 FUNCTION LOCKED OUT PLATFORM MODULE SOFTWARE VERSION IMPROPER 6 18 9911 FUNCTION LOCKED OUT LSS MODULE SOFTWARE VERSION IMPROPER 6 18 9912 POWER MODULE FAILURE SYSTEM MONITOR ttt ttti 6 18 9924 FUNCTIONS LOCKED OUT MACHINE NOT CONFIGURED 6 18 9950 POWER MODULE FAILURE INTERNAL ERROR 9 19 9951 POWER MODULE FAILURE INTERNAL ERROR ttt ttt ttti 9 19 9952 POWER MODULE FAILURE INTERNAL ERROR ttt 9 19 9953 POWER MODULE FAILURE INTERNAL ERROR tttt ttti 9 19 9954 POWER MODULE FAILURE INTERNAL ERROR ttti 9 19 9955 POWER MODULE FAILURE INTERNAL ERROR ttt ttt ttt 9 19 9956 POWER MODULE FAILURE INTERNAL ERROR ttti 9 20 9957 POWER MODULE FAILURE INTERNAL ERROR ttt ttc 9 20 9958 POWER MODULE FAILURE INTERNAL ERROR ttt ttt ttti 9 20 9960 POWER MODULE FAILURE INTERNAL ERROR
33. 9 20 9 13 1230ES Location of Component X Connectors on Ground Control Module 9 21 9 14 1230 5 Overview of Electrical System Components 1600346 Drive Module 9 22 9 15 1230 5 Overview of Electrical System Components 1001092456 Drive Module 9 24 9 16 Electrical Schematic Machines with 1600346 Drive 9 26 9 17 Electrical Schematic Machines with 1001092546 Drive 9 28 9 18 Electrical Schematic Machines with 1001092546 Drive 9 30 9 19 Electrical Schematic Ground Control Module Machines with 1001092546 Drive Module 9 32 9 20 Battery Charger Inverter Electrical Connection Schematic 9 37 9 21 Hydraulic Diagram 2792708 9 42 3121222 JLG Lift vii TABLE OF CONTENTS LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Operating 1 1 1 1 2 gt ae ee ata aye ea Ry 1 2 1 3 DIMENSIONS 1 2 1 4 Specifications RP Leer ems RE M eem 1 2 1 5 Battery Specifications wict o uu ee hea ee bed Lit eel ee 1 2 1 6 Critical Stability
34. cost wen SONTACTOR YEL RED 2 5 7 BLACK S JuMPER RH PHP PHP 15 P WIRE 5 YEL RED 2 5 9 SNITCH DEPLOYED YEL RED 2 5 4 YEL RED 2 5 6 BLACK II s p BRAKE YEL RED 2 5 5 OR 5 RED BLACK 10 Wr D A2 Al BLACK FL RIGHT F2 Pos SHIELD ELE or BLUE CONTROLLER PM BRAKE UM CONNECTOR BLACK 11 Brown Y ORANGE 55 2 YELLOW BATTERY CABLE BLACK 9 44 GA ORN RED 49 2 BLACK 10 BROWN ORN RED 49 3 ORANGE 55 1 YELLOW ELEVATION SENSOR LOCATED ON FRAME YEL RED 2 5 2 T Switch 1s Proxim y CLOSED WHEN ORN RED 49 1 ORN RED 49 1 2 Switch FERROUS MATL 15 PRESENT p 7 BRAKE RELEASE AND GROUND ALARM YELIREI 25 11 BRAKE eet MOUNTED IN REAR EL RED 2 5 12 Lo OF MACHINE UNLESS OTHERWISE SPECIFIED ALL ORANGE 55 3 DASE TOE DB SWITCH DIMENSIONS ARE IN MILLIMETERS ORN RED 52 1 BLACK 9 YEL RED 2 5 10 THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES INC TAN 4 2 AND CONTAINS PROPRIETARY AND CONFIDENTIAL LIFT LOCATED GROUND INFORMATION OF JLG IT MAY NOT BE COPIED OR BLACK 26 tt ALARM DISCLOSED TO ANY THIRD PARTY WITHOUT JLG S L1 VALVE PORT BLOCK WRITTEN CONSENT AND S PROVIDED FOR THE RED LIMITED PURPOSE OF REVIEW AND EVALUATION BLACK SHIELD ORANGE 55 2 ORANGE 55 1 YEL RED 2 100 BREAK OUT LOCATED ORN RED 49 300 55 NEAR CONTACTOR RELAY 5 ORN RED 49 400 E BLACK 2 4 Figure 9 16 Electrical Schematic Machines with 1600
35. 00000 HOUR METER J2 8 DIGITAL INPUT FILTER ANALOG INPUT RED a BLACK POWER 24 V DIGITAL INPUTS FILTER CAN HIGH JI 31 2 GND J2 5 DISTRIBUTION ACTIVE HIGH 0 TO 5 VOLT BLACK AND CAN LOW 1 32 4 3 OVERLOAD KA REGULATION SHIELD 24 S LAMP AREAS SHIELD 41 33 ES gt 8 O RED YEL 54 1 oyip 2 9 SYSTEM RIGHT BRAKE ORANGE 552 _ LEFT BRAKE 1 24 ORANGES TAN 1 DIGITAL YEL RED 2 100 ei TAN 3 1 CAN OUTPUT ANLP i a 4 UPG 22 6 INTERFACE EN viel ORN RED 49 300 YEL RED 2 1 1 2 2 RS232 2 125 7 e d 1 ORN RED 49 400 di E 2 1 BLACK 2 RED 1 24 2 10 ei 4 ESTOP CIR BREAKER RED 51 100 VILT POWER 3 1 T ORN RED 49 100 32 ORN RED 49 200 4 M TILTY 03 3 p BAK GROUND CONTROL BOX Figure 9 16 Electrical Schematic Machines with 1600346 Drive Module 9 26 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
36. B battery terminal 6 F2 motor field terminal F1 motor field terminal 7 M1 motor armature terminal B battery terminal 8 M2 motor armature terminal P pump terminal 9 DTC Flash Code LED Indicator Mini Fit Jr B Connector 10 Unused 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 Make all measurements with a voltmeter set to resistance scale Ohms Refer to Section 9 Figure 9 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 read ings otherwise 5 8 JLG Lift RESISTANCE gt 100 OHMS ALL TERMINALS HOUSING Ensure that there is an open circuit between all ter minals of the Power Module and the module s alumi num housing The device is fully potted and all electronics are insulted from the housing Place the Black meter lead on the housing and use the Red meter lead to probe all terminals RESISTANCE lt 2 OHMS BETWEEN AND 1 Ensure that there is a short circuit between the and M1 Terminals Interna
37. Emergency Stop Shut Down Switch Installation 1 Switch Base 4 Barrel Release Lever 2 Switch Button Barrel 5 Switch 3 Base Release Screw 1 Loosen the release screw then spin the switch base if necessary to access the barrel release lever Lower Control Box Cover Installation 1 Lower Control Box Cover 2 Attach Screws 2 Pull the barrel release lever straight out with the blade of a screwdriver and pull barrel out of the 1 Remove the four 4 attach screws and remove the switch base from the front of the control box cover from the other half 3 Reverse steps to install NOTE Note wiring connections and routing when taking apart 8r 4 Joystick Control Installation 1 Joystick Assembly 3 Lower Control Box 2 Attach Screws 5 18 JLG Lift 3121222 SECTION 5 CONTROL COMPONENTS 5 8 BATTERY BATTERY CHARGER NOTICE JLG MACHINES EQUIPPED WITH DELTA BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC TORY APPROVED BATTERIES APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG 5 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
38. I ces 32 SLPH LPHP SW 30 PLPH POS LPHP a 33_SRPH_RPHP_SW 31 PRPH_POS_RPHP SIME 22_EMS_PLATFORM 45 I EMS 12 8 m BLACK CAN SHIELD cue co YELLOW CAN H_POW MOD GREEN CAN L_POW MOD EAMDEM Sainte 2 5 EYE NHRM 12 23 42 22 SGU J1 8 10_LIFT_DOWN 8 1_PTLT_POS_TLT PILT 1 6 CHARGER 40 2 Ser VERD 3 BATTERY CHARGER X20 INTERLOCK FOR 123055 40 5 BATT RELAY A 1 28 INPUT CONNECTOR SEE ZONE H 5 23 PNC POS LCONT rp 4 85 265VAC FoR scissor s SZ 49 S BATT RELAY _ 41 NNC NEG LCONT 5 12A RMS 0108 40 4 BATT RELAY SEE ZONE E 3 J1 32 OUTPUT Lo nu PGAL JI 7 BOA MAR ING CGAL JI 3 NLB 21 34 2 23 2 POS LCONT CHARGER 4 REMOTE LED 40 1 33 CONNECTOR 85 HE PRB 01 30 X34 MS al POWER CONTROLLER 543 B F E o i 1833 3 5 5 34AWG CABLE 2181 s 28 1 Ela g 5 2 GROUND C 6 2 ne CBA ALARM NET UO Pe e E 5 E x 1 a4 5 i x amp o E 2 8 RED 2 110 1 8 5 RL3I 2 8 BATT RELAY 5 8 BLACK 2 8 lt 5 gt ORANGE 3 2 BROWN BLACK 24 3 BATT_NEG 6
39. POWER MODULE FAILURE INTERNAL ERROR 9 9 a The Power Module detected an internal error via self test b May indicate that the Line Contactor Coil is Open Circuit in Power Module s prior to V1 10 a Power Wiring Issue or a faulty Power Module 11 Flashes on Power Module POWER MODULE FAILURE CHECK POWER CIRCUITS OR MOSFET SHORT CIRCUIT 9 9 a The Power Module detected an error in the Power Wiring for the Drive or Pump Alternately the Power Module has failed a self test b 3 Flashes on Power Module may indicate a Short Circuit in the Armature Wiring or a faulty Power Module c No Flashes on Power Module may indicate a faulty Power Module 3121222 SECTION 5 CONTROL COMPONENTS 5 5 POWER MODULE 1001092456 ZAPI POWER MODULE P N 1001092456 Figure 5 5 ZAPI Power Module Location 1230ES SCISSORS BUILT STARTING IN MID YEAR 2010 REPLACED THE SEVCON POWER MODULE P N 1600473 WITH THE ZAPI POWER MODULE P N 1001092456 Table 5 1 ZAPI Power Module Specs Operating Voltage B 14 540 40 VDC Maximum Current Limits Armature 300A Field 40A Pump 180A 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 Turn machine power
40. Torque Torque Si TPI Bolt Di Tensile Clamp Load Torque gocmen Loctite 262 07778 Stress Area See Note 4 Dy K 17 ORVibra TITE 111 or or Vibra TITE 131 140 OR Precoat 859 0 01120 00064 1 111 48 J T T T 1 e 32 01380 00099 T T T 8 32 0 1640 0 01400 10 24 0 1900 0 01750 32 01900 oo00 T T 5S 1646 20 0 2500 0 0318 2860 122 14 1 T 28 02050 0 0364 3280 139 16 131 75 T 5 16 18 0 3125 0 0524 4720 20 25 20 25 20 25 24 0 3125 0 0580 5220 3 8 16 0 3750 0 0775 7000 50 35 50 35 50 7716 1 2 9 16 5 8 34 78 9 08750 0 4620 41600 515 70 485 660 45 620 1 1000 0 6060 5150 70 95 685 90 645 875 11 8 12 114 7 12 13 8 6 2300 3130 2165 2945 2030 2760 11 2 6 1 5000 1 4050 126500 2690 3660 2530 3440 2370 3225 NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS REV 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 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 3 of 7 JLG Lif
41. Viscosity Index 140 153 Oil Check Procedure Lube Point s Hydraulic Reservoir Reservoir Capacity 0 80 Gal 3 L Lube Hydraulic Oil NOTE Figure 1 1 Hydraulic Oil Check Procedure Recommended lubricating intervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubrication frequencies must be increased accord ingly 1 3 CYLINDER SPECIFICATIONS NOTE All dimensions are given in inches in with the met ric equivalent centimeters cm given in parenthe Ses Table 1 11 Cylinder Specifications Interv NOTE 3121222 al Check Daily Be certain the hydraulic oil has warmed to operat ing temperature before checking the oil level in the reservoir From either side of the machine open the side access door on the base frame 1 Locate the hydraulic oil reservoir 2 on the pump unit 3 Check the oil level in the hydraulic reservoir by look ing at the markings on the side of the tank The res ervoir is marked with MIN minimum and MAX maximum markings 4 The oil level must be within these markings to operate properly If additional oil is required wipe all dirt and debris from the filler breather cap 5 area add proper grade of oil by using a funnel with a flexible spout or a plastic squeeze bottle Fill until oil level is between the MIN and MAX markings
42. 1001092456 ZAPI Power Module 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 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 Personalities Traction system Personality settings can be changed via ANALYZER gt PERSONALITIES gt DRIVE ACCEL Time to ramp from 096 to 10096 of command DECEL Time to ramp from 096 to 10096 of command MINIMUM Minimum drive speed Creep MAXIMUM Maximum drive speed when platform is stowed ELEV MAX Maximum drive speed when platform is elevated 3 4 JLG Lift Interlocks As the machine travels down an incline the drive power output will be reduced proportionally to avoid overspeed ing the vehicle A bad tilt sensor will force the control sys tem to assume maximum incline and reduce drive power accordingly Creep mode reduced drive speed will be active if the control system determines th
43. 7 16 775 OPEN CIRCUIT FIELD WIRING ccrte linac btu Boc Den adus t 7 16 776 STALLED PUMP MOTOR OR POWER WIRING ERROR 04222 7 16 777 OPEN CIRCUIT PUMP MOTOR 21412 7 16 778 TRACTION T HIGH CHECK POWER CIRCUITS ttt ttti 7 16 779 TRACTION T LOW POWER CIRCUITS iiir ttti 7 16 7710 PUMP P HIGH CHECK POWER CIRCUITS 7 16 7711 PUMP P LOW CHECK POWER tct ect 7 16 7741 ARMATURE BRAKING CURRENT TOO HIGH 7 16 7742 FIELD VOLTAGE IMPROPER 747 8 1 811 TILT SENSOR NOT t buta pea esu ody s 6 17 812 NO DATA FROM TILT SENSOR NOT CONNECTED OR FAULTY 6 17 8 2 8214 LSS CELL 1 ERROR E 6 17 Ben ta N 6 17 823 LSS CELL 3 ERROR an aut tpe ate doa tti ux reek Me Caf 6 17 624 CE DING A ERROR Sca eo tacendo tute 6 17 825 LSS HAS BEEN CALIBRATED Lp ose tte boe diera ut 6 17 9 9 991 LSS WATCHDOG toe 6 17 992 LSS EEPROM ERROR ttt nnan 6 17 993 LSS INTERNAL ERROR PIN EXCITATION
44. 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 The trigger switch was closed during Check if the trigger switch is obstructed or jammed TRIGGER PERMANENTLY power upin platform mode 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 3121222 JLG Lift SECTION 8 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 jammed LONGWHILEINNEUTRAL _ thanfivesecondswhile 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 Check if either function i
45. Ex T Et 5 4 3 2 1 DTM12BP Deutsch 12 position DT E06P 9 16 Eaton Toggle Switch Ay 2 OE 5 6 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 9 1 Connector Loading Diagrams Continued ID Description Diagram Molex 3 position plug Cis 3 2 4 mm MMF12P Molex Mini Fit 12 posi tion plug 1 T i 5 6 MMF16P Molex Mini Fit 16 posi 12 13 tion plug 91011 11415 16 9 8 X CONNECTOR ID INDEX 3121222 Table 9 2 X Connector ID Index ID Description 110 End2ID X001 Ground Module J1 DRC40P X002 Ground Module J2 9 X003 Ground Module J3 4 X008 Battery X009 RH Pothole Switch X010 Ground Passthru 4 AMPO4R X011 Diagnostic Port AMPO4R X012 Brake Release Power X013 Brake Release Ign X014 Beacon DTO2R X017 Arm Stack Passthru DTO8AR DTO8AP X018 Charger Interlock 2 AMP02R X019 Charger Plug X020 Charger DTO6R X021 Battery X022 Ground Alarm 023 LH Pothole Switch X024 Left Brake DTO2R DTO2P X025 Right Brake DTO2R DTO2P X026 Contactor DT02R X027 Power Module MMF12P X028 LED Display AMPO4R X029 Overload
46. JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 2 2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK 222 FUNCTION PROBLEM Theindoor outdoor zoneA 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 Check drive lift switch for visible damage DRIVE 8 LIFT ACTIVE 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 boar
47. cle s front wheels and engaging drive platform stowed Under DIAGNOSTICS TRACTION the JLG Analyzer s ARM CUR display Armature Current Reading will hover around 350A The FLD CUR dis play Field Current Reading will hover around 40A It is possible that one wheel may rotate or neither may rotate depending on the location of the open circuit Listen for the brake release solenoid when activating drive The Ground Module cannot detect this fault during power up or self test since energiz ing 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 vehi
48. tion disk 10 from the motor by sliding off of the shaft See Figure 4 7 7 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 8 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 9 Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly 10 Remove the snap ring 6 and bearing 7 from the commutator end head Discard the bearing 3121222 JLG Lift 4 15 SECTION 4 BASE COMPONENTS COVER PLATE MOUNTING SCREWS v COVER MOUNTING SCREWS WIRE HARNESS FIELD CONNECTION j BRAKE RED WIRES p WIRES _ BRAKE ASSEMBLY gt MOUNTING SCREWS MW Sx BS THREADED HOLES j IN BRAKE ASSEMBLY Figure 4 6 Drive Motor Side View Drive Motor Inspection and Servicing Reference Figure 4 5 Drive Motor Disassembly Illustra tion 1 Carefully blow out any accumulated carbon dust and dirt from the end head and the frame and field assembly using clean oil free compressed air 2 Replac
49. 2 Positive Pump Connection Right Positive Armature X7 B Controll to Negative Battery T Leftand Right Negative Armature X8 P Negative Pump Connection Fi To Motor Fields Wired in Series X9 F2 LT MFR Field Wires X10 JLG Lift HEALTH STATUS LED P N 1001092456 ZAPI Power Module HEALTH Status LED 3121222 SECTION 5 CONTROL COMPONENTS 5 6 GROUND CONTROL MODULE SERVICE PROCEDURE NOTE The Ground Control Station supplied with the ZAPI Power Module P N 1001092456 production start mid year 2010 does not require use of the printed circuit board inside the ground control module 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 Ground Control Station See Figure 5 6 Ground Control Station Assembly NOTICE DO NOT ATTEMPT TO DISASSEMBLE THE GROUND CONTROL MODULE IF MACHINE IS STILL UNDER WARRANTY OPENING THE GROUND CONTROL MODULE WHILE THE MACHINE IS UNDER WARRANTY WILL VOID THE WARRANTY IF UNDER WARRANTY REQUEST A REPLACEMENT MODULE FROM THE FACTORY The Ground Control Module allows for field replacement of components internal to the module Printed Circuit Board PCB Replacement NOTE Anytime the ground control b
50. 4 Description Bore Stroke Rod Dia in cm in cm in cm Lift Cylinder 1 57 4 124 315 1 18 3 Steer Cylinder 1 97 5 4 21 10 7 0 98 2 5 1 4 TORQUE REQUIREMENTS When maintenance becomes necessary or a fastener has loosened refer to the applicable Torque Chart in this sec tion of the manual to determine proper torque values for various size fasteners 1 5 SERIAL NUMBER LOCATIONS For machine identification a metal serial number plate is affixed to the machine The plate is mounted behind the left rear wheel on the side of the base frame The machine serial number can also be found on a bar code label placed on the platform control station mounting plate in the platform JLG Lift SECTION 1 MACHINE SPECIFICATIONS Size Tensile Stress Area Clamp Load Torque Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 5 BOLTS amp GRADE 2 NUTS Lubricated Torque Loctite amp 242 or 271 OR Vibra TITE 111 or Torque Loctite amp 262 or Vibra TITE 131 4 Bolt Dia o 0 00661 In IN LB N m IN LB i IN LB N m IN LB N m 0 1120 0 00604 380 B 6 0 1380 0 01015 610 18 0160 ooroo 90 50 7 16 10 48 35 55 3 4 EE 2500 0 0364 2320 120 13 5 86 10 135 15 sem Nm
51. 45 Pound Force 200 Newtons Maximum Hydraulic System Pressure Setting 1600 psi 110 bar Lift 1250 psi 86 bar Steer Electrical System Voltage DC 24V JLG Lift 1 1 SECTION 1 MACHINE SPECIFICATIONS 1 1 OPERATING SPECIFICATIONS Critical Stability Weights Platform Capacities A WARNING Table 1 2 Capacities DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS M BATTERIES OR SOLID TIRES WITH ITEMS OF DIFFERENT CE AUST WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY Model ANSI CSA Indoor Only TO AFFECT STABILITY Max Max Max Max m 5 Capacity Persons Capacity Persons Table 1 6 Critical Stability Weights 1230ES 50015 2 230 kg 1 Component Model 1230 ES Wheeland Tire Assembly each 15 7kg Dimensional Data Wheel Tire and Drive Assembly each 93 lb 42kg Table 1 3 Dimensions Batteries Standard each 6210 28kg Batteries Standard Combined 248 b 112kg Description Model 1230ES Platform Height Elevated 12 ft 3 66m 1 2 LUBRICATION Platform base to ground T hr Lubrication Capacities Platform Height Stowed 22 in 56cm m Platform base to ground Table 1 7 Capacities Working Height 181 5 48m Component 1230ES Overall Stowed Machine Height 65 25in 16
52. INDOOR OUTDOOR PERMANENTLY SELECTED essen 6 5 223 FUNCTION PROBLEM DRIVE 8 LIFT ACTIVE TOGETHER 0 6 5 224 FUNCTION PROBLEM STEER LEFT PERMANENTLY SELECTED 6 5 225 FUNCTION PROBLEM STEER RIGHT PERMANENTLY SELECTED 6 5 226 ACCELERATOR FAULTY WIPER OUT OF RANGE 6 5 227 STEER SWITCHES FAULTY ier cr te t e A e dont IR re ee 6 6 228 FUNCTION LOCKED OUT ACCELERATOR NOT CENTERED 6 6 229 FUNCTION PROBLEM TRIGGER PERMANENTLY 6 6 2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL 2 6 6 2232 FUNCTION PROBLEM DRIVE amp LIFT BOTH retinere innen 6 6 231 FUNCTION PROBLEM LIFT PERMANENTLY SELECTED 6 6 3121222 JLG Lift 8 1 SECTION 8 DIAGNOSTIC TROUBLE CODES 232 GROUND LIFT UP DOWN ACTIVE TOGETHER ttt 6 6 233 FUNCTION PROBLEM BRAKE RELEASE PERMANENTLY SELECTED 6 6 2 5 251 ELEV ANGLE SENSOR FAULTY VOLTAGE OUT OF RANGE 6 7 252 ELEV ANGLE SENSOR HAS NOT BEEN CALIBRATED 6 7 253 DRIVE PREVENTED CHARGER CONNECTED ttt ttt ttt ttti Dos 6 7 254 DRIVE amp LIFT UP PREVENTED CHARGER CONNECTED 6 7 255 PLATFORM OVERLOADED cede iot ec 6 7 256 DRIVE PREVENTED POTHOLE NOT ENGAGED
53. 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 The 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 loca tion of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o rings or gaskets meet on the exterior of the unit then checking for air bubbles If a leak is detected in a seal o ring or gasket the part must be replaced and the unit rechecked Leak test at 10 psi for 20 minutes NOTE Due to the small air volume inside this Torque Hub it will pressurize to 10 psi very quickly If the pressure becomes excessive in the unit the seals will be destroyed 4 12 JLG Lift Oil Type amp Capacity This 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 serviced the oil will need to be drained a
54. Internal Slide Pads 3121222 JLG Lift 6 3 SECTION 6 MAST COMPONENTS 6 6 PLATFORM ASSEMBLY Platform Extending Mast Unpowered NOTICE IF LIFT IS DISABLED AND THE MAST CANNOT BE EXTENDED UNDER THE MACHINE S OWN POWER THE PLATFORM MUST BE HOISTED OR LIFTED BY OTHER MEANS LIFT PER ILLUSTRA TION BELOW BEFORE EXTENDING THE MAST PRESS AND HOLD THE MANUAL DESCENT VALVE BUTTON ON THE FRONT OF THE MACHINE WHEN DESIRED PLATFORM HEIGHT IS REACHED RELEASE THE MANUAL DESCENT VALVE Figure 6 4 Extending Mast Unpowered This procedure shows the platform assembly only removal installation to the mast assembly The platform and outer mast section are a one piece manufactured weldment Platform Removal 1 1 Sling Position 1 3 Lifting Ring Hook 2 Sling Position 2 4 Manual Descent Valve Location 6 4 JLG Lift Extend the mast and raise the platform far enough out of the base assembly to allow access to the slide pads on the bottom corners of the outer mast sec tion but not to high that you cannot easily get to the top of the mast to work on it Support platform for later liting with either an over head crane or a fork truck attaching a lifting strap to remove the platform once the following steps are completed See Figure 6 5 Disconnect machine power at the right side battery tray using the quick disconnect
55. It is the primary control station for the vehicle At power up indicators applicable to the vehicle configuration illumi nate for a lamp check Battery Discharge Indicator Sys tem Distress Indicator and Tilt Indicator 3 3 CAN COMMUNICATIONS CAN Controller Area Network is the type of two wire dif ferential serial communication link used between the plat form board ground board and the power module for control of the vehicle This type of network has matured since its invention in 1986 and is used extensively in many kinds of machines Two Wire Differential The signal meaning is derived from the difference in voltage between two wires usually twisted together in a common jacket This jacket can also contain a shield surrounding the wires inside for noise protection Any noise that does penetrate the shield will affect both wires the same However the difference in voltage stays the same therefore signal meaning is not corrupted This differs from one wire signals in that one wire signals derive the signal meaning from the difference between the signal wire and system ground wire The sys tem ground is the ground for many signals as well as power Any noise on either wire will change the signal and may corrupt it Serial Communication Link Modules on the link send messages digitally bit by bit along the wires where differ ent voltage levels represent a 1 or a 0 The 175 and 05 are assembled by the receiver according
56. amp SCHEMATICS RED 9 PLATFORM ALARM REDE Iss DIGITAL RIBBON CAPACITY Li P CONNECTOR LOADING ANALOG INPUT 24 V WHEN AT JOYSTICK FILTER OUTPUT IS ON 0 TO 5 VOLT JI 12 JOYSTICK COMMON RED 2264 1 RED 14 2 TRIGGER VIOLET 22 GA 2 flack gt DICRO i BROWN PURPLE 19 ROCKER LEFT GREEN 24 GA 5 DIGITAL INPUT LIFT ORIVE cre RIGHT YELLOW 24 6 4 arc BROWN 12 JI 18 INPUTS JI 10 WHITE GREEN 18 5VDC WHT RED 7 rine 5 LUACTIVE Hen pos GROUND WHT BLACK 8 PURPLE 6 0 5 VOLT 516 OUTPUT BROWN 9 vis NER on Ls OUTPUT AND REGULATION INTERFACE Jal SWITCH BLACK ATO ACL AREAS RIBBON ME BLACK 16 5 GREEN CABLE CAPACITY amp HORN SWITCHES 8 EE SHIELD SUE V RIBBON CABLE RED RED 16 1 A AAA A PLATFORM CONTROL BOX BLACK WHITE rd E d 1200 250 WATT RESISTOR ol s Z ASSEMBLED IN CIRCULAR PLUG 2 S 2 2 2 VVVVVV 19 20 2630 4 26 3246ES ONLY 1 gt 3 4 s e y al COIL CABLE IN PLATFOM ATTACHED TO RAILS CONNECTS TO TWIN CABLE UNDERNEATH
57. 1130 30 1530 33 36 42 5 4 817 355 5 2560 1920 2690 5 42 4 1120 487 0 4090 3070 4290 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 3 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 6 Torque Chart METRIC Fasteners Sheet 5 of 7 JLG Lift 3121222 SECTION 1 MACHINE 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 em Torque Lub OR Loctite amp Torque Dry or Loctite 242 or 271 OR Loctite 262 OR Size PITCH Stress TM INGA 263 Vibra TITE 111 or Vibra TITE 131 K 0 20 140 0 15 0 18 3 os sos s13 oz ez sea 0 8 25 2 22 7 18 9 1 25 36 5 32 8 DC DN Xr jr rm mer x e 2 wm ze 200 150 e 2 157 98
58. 3 5 x 0 6 x 10 LG Figure 5 46 Tilt Sensor Removal Table 5 3 Tilt Sensor Harness for 1810140 Wire Color Function Connector Pin Red VCC 1 Green PWMX 2 White PWMY 3 Black Ground 4 Table 5 4 Tilt Sensor Harness for 1001114936 Wire Color Function Connector Pin Red VCC 1 White CANH 2 Green CANL 3 Black Ground 4 JLG Lift 5 15 SECTION 5 CONTROL COMPONENTS 5 7 PLATFORM CONTROL STATION SERVICE INFORMATION Platform Control Station Assembly Figure 5 7 Platform Control Station Assembly 1 Assembly Bolts 5 Upper Control Box 2 Nuts 6 Lower Control Box 3 Side Panel 7 Upper Control Box Wiring Harness 4 Mounting Reinforcement Plates Upper Control Box Component Replacement 5 7 1 Disconnect the platform control box and remove NOTE You may have to only loosen the two power bolts and from the machine remove the two closest the top in order to get to the printed circuit board located in the top of the control 2 Place the platform control box on a suitable work box where the drive lift select switch is located bench 3 Loosen and remove the long through bolts that hold the two side control housings together See Figure 5 16 JLG Lift 3121222 SECTION 5 CONTROL COMPONENTS 4 Loosen and remove the four 4 screws from the upper box assembly that hold the cover to the upper b
59. 4 36 Preventative Maintenance Brush Wear Dust Removal Procedure 4 36 Motor Brush Installation 2e III 4 36 4 10 POT HOLE PROTECTION SYSTEM 0 42 4 37 SECTION 5 CONTROL COMPONENTS 5 1 CONTROL COMPONENTS OVERVIEW 5 1 5 2 CONTROL COMPONENTS 5 2 Main Power Contactor 5 2 Elevation Limit 5 2 Grouind Alarm 9 eot oett ee Nerd kiere pt eU dU aeos 5 2 Warning Beacon Frame 5 2 Manual Brake Release 5 3 AC Power Breaker Box Installation CE Specification Machines ONLY 5 8 TRAGTION SYSTEM e iind eet ete m gai e Maeda dens 5 4 Common Traction System 5 4 5 4 POWER MODULE P N 1600346 5 7 II NUR ay hes Dicer e aD E Wi Ue ute obs 5 7 Installation tec ea LR eR EE ae br RIDE E 5 7 Power Module Electrical Evaluation 1 5 8 Power Module
60. ANALYZER _ CAL 6 6 DATA 155 OPTIONAL D IWIN CABLE TED TOGETHER 1001114879 F 2 Figure 9 17 Electrical Schematic Machines with 1001092546 Drive Module 3121222 JLG Lift 9 31 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 1081102 ANNOYS 405835 1111 9038 9 13 1001114879 F 3 109 SIX vnd Y SS3NUVH SISSVHO NO X OL 03123NNO2 Yyyy 30123NNO2 n AYAHAN HE QVO GNS 419 031 LI 048 8 gt NY 134 031 91 07 72 89 431 9 9 gt 111 Gr 2 1901140 0891116 049 4 gt TNv2 21 X2V18 038 0 gt 887 071 gt 29 1 8 93N U1NHH 9 gt gt Ngo kay 1 5 91 13116 Q NH9 A34 2 6 Y gt d01S 3 I E gt 7119 TO NOILISOd Y NOL Sod 00000 5 0401039 40 1 4313 LIMS E I u34Vi848 413 eMS 9 10078572 HOLIMS 1311 SMS LMS 6124 2124 OMS HOLIMSA 37 voj Figure 9 19 Electrical Schematic Ground Control Module Machines with 1001092546 Drive Module 3121222 JLG Lift 9 32 SECTION 9 GENERAL ELE
61. 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 nal 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 JLG Lift 5 21 SECTION 5 CONTROL COMPONENTS 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 Time out Indicates the battery failed to charge within the allowed time This could occur if the battery is of larger capacity than the algorithm is intended for In unusual cases it could mean charger output is reduced due to high 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 displays this fault on a battery pack and the pack is of questionable status rese
62. Connector Assembly Figure 2 9 8 Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SQUEEZE LOCKING LATCHES TO SEAT WEDGE LOCK BOTH SIDES Connector Assembly Figure 3 WEDGE LOCK FLUSH WITH 4 S nd SE SANE 22 772 ae Connector Assembly Figure 4 3121222 JLG Lift 9 9 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 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 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 Service Voltage Reading A CAUTION DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point This practice should be discouraged when dealing with the AMPSEAL plug assembly or any other sealed connector system The resulting pinholes in the insulation will allow
63. Cylinder Rod 1 Remove the piston retaining ring from slot in the end of the cylinder rod 2 Slide piston compression spring and piston guide ring off the end of the cylinder rod JLG Lift 6 15 SECTION 6 MAST COMPONENTS Hydraulic Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Gland Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particularly for metallic particles embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and backup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the event tha
64. Description 110 210 X081 Left Motor Field Cross X082 Inverter Control X083 Right Motor Power Mod M1 X084 Power ModB to Pump Motor X085 Right Motor Power Mod M2 X086 Battery 1 to Inverter X087 Inverter 4 X088 Battery 4 10 Inverter X089 Inverter X090 Right Wheel Brake Solenoid 2 X091 Left Wheel Brake Solenoid AMPCO2P X092 Right Wheel X093 Left Wheel X094 Right Wheel X095 Left Wheel X096 Right Wheel Field from F1 X097 Left Wheel Field from F2 X098 Right Wheel Field Common X099 Left Wheel Field Common X104 1230 Footswitch Chassis DTO8AP X105 1230 Footswitch Platform DTO8AR X106 1230 Footswitch J1 DTM12BP X107 1230 Footswitch J2 DTM12AP X108 1230 Mast Passthru 109 1230 Proximity Switch DTO2P X110 Inverter AC input X111 Inverter AC output X112 Charger AC input JLG Lift 9 19 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 9 MACHINE LOCATION OF COMPONENT X CONNECTORS X011 X024 X025 X080 X081 W M Ve SEE GROUND X086 MODULE DETAIL Figure 9 12 1230ES Location of Component X Connectors on Machine 9 20 JLG Lift 3121222 X010 X002 X001 Ew RQ 5 gt L7 9 21 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS X003 X038
65. Duty Cycle On amp Off time is varied to control the voltage applied to the Arma tures When the MOSFET s spend 5096 of the period On and 50 Off approximately 1 2 of the available power will be applied to the Armatures 50 Duty Cycle Similarly the MOSFET are On continuously 10096 Duty Cycle to apply all available Battery power 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 at 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 Line Contactor Right Field Winding E Left Right Armature Armature il Armature Switch Left Field Winding Power Module Figure 3 2 Drive Motors Schematic 1600346 SEV CON Power Module JLG Lift 3 3 SECTION 3 THEORY OF OPERATION 1230ES Line Contactor 24V Right Field Winding MOSFET Field MOSFETS Left Field Winding Shunt Power Module Figure 3 3 Drive Motors Schematic
66. 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 02 18 NRV ZAPI HEALTH Status LED ON 33406 LiFTUP VALVE 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 ZAPI HEALTH Status LED ON 33407 LIFTDN VALVE SHORTTO LiftUpand Down Prevented Excessive current flow to the Lift Down Solenoid was detected GROUND J2 16 NDV ZAPI HEALTH Status LED ON 4 2 Thermal Limit 504 DTC FAULT MESSAGE DESCRIPTION CHECK 421 POWERMODULETOOHOT 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 ob
67. GA EE BLACK 15 YEL RED 2 5 8 BLACK 10 GA 25 5 ATAN I lIN LINE BATTERY s 5 25 YEL RED 2 5 4 CHARGER DISCONNECT a 3 2 YEL RED 2 5 4 WIRES TO LOCATED ON THIS 5 a ze 2 BLACK II BATTERY 90 BATTERY CABLE BLACK 18 LLLA z 234 5 8 BLACK 1 CONNECTION 55 lt i BULKHEAD 8 z 2 LOCATED N 1 zl ns REAR OF FRAME S Y 2 0 venre STEER YY STEER al 2 E 25 2 23 a 21215 ea l VALVE K 9 valve E a S E d 5 ES 4 o LIFT UP 2c VALVE BLACK 5 1 12 M 3 3 7 see a INE E BLACK MES BLACK 9 a RED 1 1 S ORN RED 49 2 5 5 ORN RED 49 4 S amp ORN RED 49 3 B NOT CHARGING a E OV CHARGING 7 RENOTE LED S 7 7 7 LOCATED IN GC i T QR o t EU ORN RED 49 1 5 E T5 288 RESISTOR 1 4 3 Bs SiS 5 EE L3k 2 meme 2 3 eS 172 WATT L5 REEN COMPLETE 2 GND 01 16 BS ER 5 _ 52 552 z765 om BRAKE REL J1 20 41 YEL RED 2 2 1 piss 9 3 ein TS ORN RED 52 1 TAN 4 2 LIFT SWITCH YEL RED 2 3 1 LIFT DOWN J1 28 E 4610 02 4 BLACK PN 1 HOUR METER 52 2 LIFT DN GND 420 p
68. Hydraulic Oil Check 1 3 1 2 Torque Chart SAE Fasteners Sheet 1 7 1 4 1 3 Torque Chart SAE Fasteners Sheet 2 7 1 5 1 4 Torque Chart SAE Fasteners Sheet 3 7 1 6 1 5 Torque Chart SAE Fasteners Sheet 4 7 1 7 1 6 Torque Chart METRIC Fasteners Sheet 5 7 1 8 1 7 Torque Chart METRIC Fasteners Sheet 6 7 1 9 1 8 Torque Chart METRIC Fasteners Sheet 7 7 1 10 2 1 Platform Mast Support 1 2 5 3 1 Basic Electronic Module Connections 3 2 3 2 Drive Motors Schematic 1600346 SEVCON Power Module 3 3 3 3 Drive Motors Schematic 1001092456 Power 3 4 3 4 SYSTEM zn on ER eth TO combatant Fate qux Ere E vet dens 3 5 3 5 Hydraulic Pump Electrical Schematic 1600423 SEVCON Power Module 3 6 3 6 STEER SYSTEM iiid censere ETAT Pe pa Kg 3 6 4 1 Base Assembly
69. IN THE BRAKE HOUSING THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE JLG Lift 4 13 SECTION 4 BASE COMPONENTS Wheel Drive Motor Assembly Removal From Machine The electric wheel drive assemblies are mounted indepen tent of each other on the base frame at the front of the machine The wheel drive assembly consists of an 24V DC electric motor driving a 45 13 1 ratio gear box the assembly also included a friction disk parking brake assembly This brake assembly is mounted on the end of the drive motor assembly 1 Elevate the machine enough to remove the drive wheel s 2 Before disconnecting machine power at the batter ies power up the machine and turn the steering to expose the back of the drive motor to be removed 3 Now disconnect machine power at the quick discon nect short cable on the machine right side batter Remove the drive wheel mounting lugs and remove the wheel s Disconnect the power brake harness to the drive motor to be removed at the power module Mark the position of and remove the tie straps hold ing the drive motor power harness to the steering linkage Pull the harness throught the base frame until free Before removing the drive motor from the gear box remove the pipe plugs on the gear box cover wheel side and drain the oil from the gear box Remove the two 2 long cap screws attaching the drive motor to the spindle and gear box Carefully slide the dr
70. Lower End Extend Port a Return Port Proportional Lift Selenoid b Valve Port Block c O Ring Seal Cyl 1 Rod Wiper Seal Cyl 1 Gland d Cyl 1 Main Seal Cyl 1 Gland Wire Retaining Ring 10 11 12 Cyl 1 O Ring Seal Cylinder Joint Cyl 2 and 3 End Attach Cap c d Note a Small orifice rated at 4 GPM 115 Liters minute b The proportional selenoid coil has a 28 ohm rating c Apply Loctite 242 to the threads of the cylinder rod on final assembly to the valve port block Torque to 45 ft Ib 200 Nm d Removeable e Fixed Non Removeable Welded to cylinder barrel 3121222 JLG Lift Cyl Cyl Cyl Cyl Cyl Cyl Cyl Cyl Cyl Cyl Cyl Cyl 2 Cap O Ring Seal 2 Joint O Ring Seals 2 Rod Wiper Seal 2 Gland d 2 Main Seal 2 Gland Wire Retaining Ring 2 O Ring 3 Barrel End Cap 8 Piston Retaining Ring 8 Piston 3 Piston Damping Spring 3 Piston Guide Ring 6 13 SECTION 6 MAST COMPONENTS Hydraulic Cylinder Disassemhly Cylinder 2 and 3 Removal from Stack The following disassembly procedures shows the com plete disassembly sequence of the cylinder assembly However your situation may not require complete disas sembly choose which procedures are required to repair the cylinder assembly for your situation DISASSEMBLY OF THE CYLINDER SHOULD BE PERF
71. MM 2 X BLACK 24 1 BATT NEG um 541 RL32 THERMISTOR LINE Ela ES CONTACTOR 55 amp 2 els V Qu BLACK 24 6 BAT NEGATIVE Sg mrs 2 0 In 3 8739 p 83 Pi t l DISCONNECT m 5 CONNECTOR 2 EA T B 2 B I LT BR 6V prae ITI 210 36_NLB_NEG_LTBRAKE 212 ul 32 AWG CABLE RED 2 BAT POSITIVE 12AWG Figure 9 17 Electrical Schematic Machines with 1001092546 Drive Module JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS NOTE AVAILABLE ON 19 20 2630 amp 26 3246ES MACHINE S ON BOARD DIAGNOSTICS DISPLAY IS ONLY ONLY ON BO
72. POI REATUS Ea pos 2 5 Bearings os eme end n e due Wd wee 2 6 viia ee er WADE HEP VEI er eM re Dus 2 6 Bolt Usage and Torque Application 1 2 6 Hydraulic Lines and Electrical Wiring 1 0 2 6 Hydraulic System nre e ae ened eae 2 6 Lubrication and Servicing 0 5 4 2 6 dau eee REG AUR En 2 6 2 4 LUBRICATION 1 1 4 4 2 2 2 6 System Clo eI RENE E EC RR 2 6 Lubrication Specifications 2 7 3121222 JLG Lift TABLE OF CONTENTS Hydraulic Qil 2 o Em XR bs tagen eeu uen t ete 2 7 Changing Hydraulic Oil Eee RW SRL 2 7 SECTION 3 THEORY OF OPERATION 1230 5 OVERVIEW sis sep wat De Rare ee bares i d Og EVE 3 1 3 2 MODES OF OPERATION passionate ace tke fog ea adn cet x E RR ay Be Pa 3 1 Ground MOGe anaes ie adel ee e 3 1 Platform Reto ete ae Gott ER RUE acre don 3 1 3 8 COMMUNICATIONS
73. Procedure 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 CAUTION IF THE MACHINE IS ON ANY INCLINE THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH 1 Make sure the E stop plunger is pushed in and the key is removed from the key switch on the Ground Control Station 2 Remove the 2 Back Cover Bolts 1 The Back Cover Bolts are also the release bolts for the brake The size of the back cover bolts 5 is 0 8 x 20mm long 3121222 3 Remove the 2 Cover Plate Bolts 2 from the front of the cover area near the cable exit The size of the Cover Plate Bolts is 8 32UNC x 500 inches long 4 Remove the Cover Plate 6 Strain Relief 4 Back Cover 7 and Cover O ring 3 5 Insert the Back Cover Bolts 1 into the two holes in the brake housing at the 3 and 9 o clock positions 6 Tighten down bolts and the brake will disengage 7 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
74. Pump commanded power when drive com Interlocks 2 ia Lift up will be prevented under the following circum DRIVE Pump commanded 96 power when drive com adis mand is 10096 Vehicle is tilted elevated and ANALYZER gt MACHINE SETUP gt CUTOUT is set to YES Interlocks Charging of the vehicle s battery is in progress and Steering is prevented whenever conditions are present to ANALYZER gt MACHINE SETUP gt CHARGER INTER prevent drive See Interlocks on Pg 4 LOC is set to DRV amp LIFT UP 3 6 JLG Lift 3121222 SECTION 4 BASE COMPONENTS SECTION 4 BASE COMPONENTS 4 1 BASE ASSEMBLY COMPONENTS 8 _ e 1 2 P o _ O N 7 8 N S 5 4 3 7 Figure 4 1 Base Assembly Components 1 Hydraulic Pump Tank Valve Assy 4 Pot Hole Protection Assembly 7 Left Side Battery Tray Door 2 Steering Linkage Assembly 5 Static Strap 8 Right Side Battery Tray Door 3 Drive Motor Spindle Assemblies 6 Steer Cylinder Assembly 9 Rear Wheel Assembly NOTE Base assembly shown without base top weldment for illustrative purposes only 3121222 JLG Lift 4 1 SECTION 4 BASE COMPONENTS 4 2 BASE FRAME COVERS Battery Tray Side Door Installation Base Top Cover Installation 1 A WARNING NEVER WORK UNDER ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM MOVE R MENT BY BLOCKING OR OVERHEAD SLING
75. Screws 2 Cover Plate 3 Breaker Assembly 4 Mounting Screw Plugs Note Located on left rear of machine just above the machine nameplate 3121222 5 Box to Frame Mounting Screws 6 Breaker Box Base 7 Breaker Box Shield 8 Box to Frame Mounting Screw Nuts and Washers JLG Lift 5 3 SECTION 5 CONTROL COMPONENTS 5 3 TRACTION SYSTEM Refer to Section 3 5 TRACTION Theory of Operation for more detailed information on Traction System Common Traction System Difficulties 5 4 1 Ground Module Interlocks There are a variety of interlocks that prevent Drive due to system events Elevated but Pot Hole Mecha nism Failed to Deploy etc Before investigating Traction System issues examine the JLG Analyzer s HELP Menu while attempting to Drive from Platform Mode Refer to the Section 5 for explanation of the JLG Analyzer Help Messages Power Module Diagnostic Issues The Power Module executes a self test during every power up to ensure proper functionality If a Diag nostic Issue is detected the Power Module will not energize the Line Contactor Instead it will flash the Green LED please refer to Power Module Diagnos tics in Section 5 4 POWER MODULE P N 1600346 Open Circuit Motor Armature This issue will allow the vehicle to drive but one motor will handle the entire traction load Motor overheating and excessive tire wear will result along with a lack of traction control This situatio
76. Set Screw 4 Spanner Wrench Remove the piston kban seal from the piston Loosen and remove the piston set screw from the hole in the side of the piston Using the proper spanner wrench remove the pis ton from the cylinder rod Slide the cylinder head gland off the piston end of the cylinder rod Remove all the seals o rings and backing ring from the cylinder head gland If replacing remove the bushings from the end of the cylinder rod and the cylinder barrel SECTION 4 BASE COMPONENTS Hydraulic Cylinder Component Inspection Cylinder Rod There should be no scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal Chrome should be present over the entire surface of the rod and the lack thereof is unacceptable In the event that an unacceptable condition occurs the rod should be repaired or replaced Cylinder Head Gland Visually inspect the inside bore for scratches or polishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceed 0 007 this is unacceptable Check the condition of the dynamic seals wiper rod seals looking particularly for metallic particles
77. 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 BEFORE REMOVING ANY COMPONENT FROM THE ELECTRICAL SYSTEM DISCONNECT THE BATTERIES USING THE QUICK DIS CONNECT LOCATED ON THE RIGHT SIDE BATTERIES 3121222 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 STABILITY 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 5 8 DO NOT fill to bottom of vent tubes DO NOT allow fluid level to go below the top of the plat
78. TO BE USED FOR OPERATION TO ALL COMPONENTS TO BE ASSEMBLED EXCEPT THE THREADED AREAS WHERE LOCTITE IS TO BE APPLIED Cylinder Assembly This procedure is same for all three cylinders 1 Reassemble the piston compression spring piston guide onto the end of the cylinder rod secure using the piston retaining ring See Figure 6 20 EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON INTO THE CYLINDER BAR REL AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SUR FACES 2 Lubricate the piston assembly and rod with hydrau lic oil slide the rod assembly into the cylinder barrel 3 Install new o rings and seals into the cylinder head gland 4 Lubricate the o rings and seals with hydraulic oil then carefully slide the gland assembly onto the end of the cylinder rod and into the end of the cylinder barrel 5 Rotate the gland until the hole for the retaining ring is lined up with the hole in the cylinder barrel 6 Insert a new retaining ring into the slot with the hook end of the retaining ring facing down and inserted into the hole in the gland See Figure 6 19 7 Using the proper spanner wrench 48mm 1 889 diameter slowly rotate the gland 360 until all the retaining ring has pulled into the slot Fill the open slot with a silicone sealant to prevent dirt from enter ing 3121222 SECTION 6 MAST COMPONENTS Cylinder 2 and Z3 Assembly
79. 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 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 Calibration Failures Some possible reasons that the tilt sensor won t calibrate are a The surface the machine is sitting on is off level by a few degrees flat doesn t imply level park ing lots are often not level b The tilt sensor has failed one or both of the channels X axis and Y axis c Tilt sensor has moisture intrusion that has shifted its output d Water and or corrosion in the box has corrupted electrical connections or caused a tilt sensor or ground control board failure observe any cracks in the box 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 sur
80. amp Lift Prevented 5 9 SECTION 5 CONTROL COMPONENTS 10 CANBUS FAILURE POWER MODULE 6 6 11 5 10 a e f The control system failed to receive messages from the Power Module Check wiring at the Ground Control Box and Power Module Recy cle power to clear difficulty May indicate harness difficulty or a faulty Power Module Resistance between CANH Power Module Pin 10 and CANL Power Module Pin 11 should be 60 ohms 5 with the Power Module nected Resistance between Power Module Pins 10 and 11 harness disconnected should be 120 ohms 596 10 Flashes on Power Module Drive Steer amp Lift Up Prevented OPEN CIRCUIT DRIVE MOTOR WIRING 7 7 a b d The Power Module detected an error in the Power Wiring M1 M2 F1 amp F2 Terminals for the Drive Motors Check power wiring and re cycle power to clear difficulty Alternately there may be an issue open field armature or brush with one of the Drive Motors May indicate field wiring or winding issues 5 Flashes on Power Module Drive amp Steer Prevented 12 POWER MODULE FAILURE PERSONALITY 13 14 JLG Lift RANGE ERROR 9 9 a The Power Module detected an out of range or corrupt personality setting b Enter Access Level 1 on the JLG Analyzer re select Model and cycle EMS after 5 seconds May indicate a Power Module issue if it cannot be reset 1 Flash on Power Module
81. apoy ase pue 511 apoy ui pue 141 uodn jou suaaJos aseaj d suaaJ2s 2 ajqissod smoys aAoqe nofe Z 21846 Siu Burjoeuuoo L 7S8JON 1591 1846 3121222 SECTION 7 JLG CONTROL SYSTEM 9892601001 IdVZ peddinb3 6679601001 10 19945 JezAjeuy 6 1 e1nBi4 540601 10 USppiH 4 SHA
82. boxnearthe manual brake release mode RELEASED FOR TOWING ground control box Driveorliftis 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 3121222 JLG Lift SECTION 8 DIAGNOSTIC TROUBLE CODES 2 5 Function Prevented was lifting 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 Ensure vehicle is not stuck on something preventing movement BRAKES NOT RELEASING X currentwas gt 150A for five seconds Check repair drive motor wiring brakes or mechanical issues Brakes assumedto notbe releasing prop erly 2511 ELEVANGLE SENSOR Theinput 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 The inputvoltage from the elevation Check that the elevation angl
83. commutator end head and bearing assembly care fully supporting the inner race of the bearing See Figure 4 9 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 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 wires 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 7 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 4 7 for proper connections Motor terminals must be assembled as shown See Figure 4 8 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 MOTOR CABLE SECURING NUT STUD TERMINAL SECURING NUT CABLE LUG TERMINAL FLAT WASHER SECURE THIS NUT WITH WRENCH WHILE IN
84. cooler location 3 Confirm that dirt or mud is not blocking the cooling fins of the charger Clean the charger Rinse the charger with a low pressure hose if required Do no use high pressure Do not us a pressure washer 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 bat
85. embedded in the seal surface It is nor mal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring and backup and rod wiper Damage to the seal grooves par ticularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an u
86. fault protection and reporting For safe operation of the vehicle the control system will not allow certain functions under certain conditions These are called interlocks Specific interlocks are discussed below The interlocks discussed assume that all control system devices are functioning properly unless indicated Fault conditions will generate DTC s and additional inter locks Some faults only show up at power up when the control system performs a self test All controls should be left alone during this test Note that the market and model of the machine affects what personalities and setups are visible by the Analyzer The appropriate information is displayed for the given model and market The market and model must be set properly for safe and lawful operation of the machine 3 2 MODES OF OPERATION Ground Mode In Ground Mode all visual indicators LED in the Platform are off In fact the Platform Control Box may be entirely disconnected as a normal measure to secure the vehi cle and this does not prevent Ground Mode operation When the machine is powered up in ground mode only the functions in the Ground control station are operational namely Lift Up and Down Lift Up and Down is controlled by a two position momentary toggle switch with a center off position The switch has the same effect as placing the joystick in the full up or full down position Platform mode In platform mode the Platform Control Box is enabled
87. for obstructions or mechanical problems around the pot HOLE NOT ENGAGED sincethe pot hole protection system hole protection mechanisms failed to deploy Check that the PHP switches are securely mounted Adjust pot hole protection switches Check the pothole protection switches signal and wiring to the ground board The left pot hole protection switch input 24V is from ground board terminal J1 9 and its output 24V when deployed is to ground board terminal J1 10 The right pot hole protection switch input 24V is from ground board terminal J1 17 and its output 24V when deployed is to ground board termi nal J1 18 257 ELEVPROXPERMANENTLY 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 LIFTPREVENTED Manualbrake release modeis activated Push manual brake release switch again or cycle power to clear BRAKES ELECTRICALLY with the switch inthe battery
88. ground mode HELP 002 GROUND MODE OK LG If ENTER is pressed again the display moves to the fol lowing display MENU HELP PRESS ENTER 3 B 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 LOGGED HELP menu item press ESC then you will be able to scroll LOG 211 using the right and left arrow keys to select a different menuitem 1 Power Cycle Or last recorded fault At this point the analyzer will display the current fault if 3121222 JLG Lift 7 1 SECTION 7 JLG CONTROL SYSTEM 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 To return to the beginning press ESC two times When a top level menu is selected a new set of menu items may be offered If for example you choose Personalities DRIVE LIFT STEER GROUND 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
89. menus while in access level 2 Remember you may always can cel a selected menu item by pressing the ESC key Changing the Access Level of the Hand Held Analyzer When the analyzer is first connected you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a 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 the ACCESS LEVEL menu f 5 07 MENU ACCESS LEVEL 2 V e 7 2 JLG Lift For example 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 N JL IVENU ACCESS LEVEL 1 ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or
90. 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 Table 5 5 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 East Penn GC 110 WNL Trojan T105 PLUS Champion CHGC2 GC2 US BATT EV 145 WNL US BATT 2200 XC Concorde 10xAh AGM J305 DV DT CP DEKA 8G31 Gel Trojan 30 31 XHS US Battery USB2200 T105 DV DT CP Trojan T105 tapped P wo Trojan T105 JLG Lift 5 23 SECTION 5 CONTROL COMPONENTS 9 10 BATTERY CHARGER INVERTER OPTION BATTERY CHARGER ACINVERTER SPECIFICATION INSTALLATION AC INVERTER SPECS The battery charger AC inverter is located in the compart Output Power Continuous 1000W EMITTE zu AC Output Current 36A AC Output Voltage 11510 125 VAC gt Output Frequency 60Hz IN DC Input Voltage 21 21029 VDC Remote ON OFF Yes CHARGER SPECS Nominal DC Output Voltage 28 VDC Maximum DC Output Voltage 33 VDC Maximum DC Output Current 2310 27 AD
91. off and disconnect the batter ies Locate and remove the power module 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 5 5 After installing the new power module begin con necting the wire connectors cables to the module refer to Figure 5 2 if necessary Where noted 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 Check for normal machine operation The power module is located inside the left side access door as shown in Figure 5 5 ZAPI Power Module Loca tion Use the following instructions when replacing the power module 3121222 JLG Lift SECTION 5 CONTROL COMPONENTS 5 12 ZAPI Power Module Electrical Evaluation INTEGRATED HEALTH INDICATOR The ZAPI Power Module provides a green STATUS LED that shines through the cover to indicate module health status The LED shall be illuminated when the device is powered on The LED blinks 2Hz when an internal issue is detected that cannot be repaired by a technician this will trigger replacement of the device Table 5 2 Module Terminal Functions Controllerto Main Line Contactor
92. the brakes are released the machine can be pushed or moved without drive motor power Replace ground board 2 5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 251 ELEVANGLE SENSOR FAULTY VOLTAGE OUT OF RANGE 252 ELEVANGLE SENSORHAS NOT BEEN CALIBRATED The elevation angle sensor input voltage is outside the acceptable range of 0 10V 4 50V The elevation angle sensor has been calibrated 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 voltage disagrees with the ANGLE SNSR voltage replace the ground board Backprobe the elevation angle sensor connector Terminal A should be 4 7V terminal C should be 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 Calibrate the elevation angle sensor to clear fault See Section 5 5 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 2 5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 253 DRIVEPREVENTED Driving is not possible while the vehicleis Check if the char
93. the model number of the machine configuration will cause the personality settings to return to default Shaded entries are not available for the selected market Table 7 1 Machine Configuration Programming Information 4150473 F Machines Equipped with Sevcon 1600346 Power Module ONLY Configuration Setting Model Default Setting per Market Digit Range Deseripuon 112 5 1 0 1230 5 Model 1 1930ES 2 2030ES 3 2630ES 4 2646 5 5 3246 5 2 0 ANSI USA Market 1 ANSI EXPORT 2 CSA 3 CE 0 0 0 4 AUSTRALIA 5 JAPAN 3 0 NO Driveand liftup 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 0 0 0 0 0 Drive Cutout 1 YES Drive and lift up PREVENTED while elevated 5 0 DRIVE ONLY Drive motion PREVENTED while vehicle is charging Charger 1 DRIVE AND LIFT UP Drive and lift up motions ARE PREVENTED while vehicle is 0 0 0 0 0 0 Interlock charging Required for CE 6 0 OT INSTALLED Vehicle alarm will function for Arm Guard if enabled Overload Ground Alarm if LSS enabled and as a horn 1 DESCENT Vehicle alarm will function for Arm Guard if enabled Overload if 55 OUO 2 2 2 0 2 2 enabled as a ho
94. tightened slightly to get the cotter pin installed JLG Lift 5 Before installing the hub cap check wheel hub for 6 excessive end play a Rotate hub by hand hub should rotate freely if too tight back the nut off to the next cotter pin hole b Hub should not be noticeably loose when moved parallel with spindle center line Install wheel torque wheel per specification in Sec tion 4 3 on page 4 3 3121222 SECTION 4 BASE COMPONENTS 4 5 STEERING LINKAGE ASSEMBLY INSTALLATION Steering Linkage Assembly Installation Shown with top of base frame weldment removed for illustrative purposes only 1 Left Steering Knuckle Lug 7 Steer Cylinder Anchor Pin 2 Left Steering Arm Link 8 Cross Link Anchor Pin 3 Right Steering Arm Link 9 Steer Cylinder Steer Right Port 4 Right Steering Knuckle Lug 10 Steer Cylinder Steer Left Port 5 Steering Cross Link 11 King Pin 6 Hydraulic Steer Cylinder 12 Steering Knuckle Stop NOTE All pinned journals must have the proper bushings installed On final assembly apply Loctite 242 to screw threads of the steer cylinder anchor pin keeper screw On final assembly apply Loctite 271 to the spindle to knuckle lug attach screws and torque to 70 ft 16 97 N m 3121222 JLG Lift 4 5 SECTION 4 BASE COMPONENTS 4 6 STEER CYLINDER SERVICING 1 Steer Cylinder Components 1 Rod End
95. to the protocol used to determine the messages meaning Using serial communication allows two wires to replace many more It also allows use of sensor and switch information in multi ple places without duplicating those sensors and switches CAN On bus all modules on the bus are connected to the same wires A CAN bus could be represented on a schematic by a long pair of straight lines with multiple modules connected to them by short pairs of lines It has a termination resistor at both ends of the long lines placed between the two wires These resistors are approximately 120 Ohms On a JLG aerial work platform this is typically in the platform and in the chassis These resistors may be in the harness or in the module A complete CAN circuit measures approximately 60 Ohms between the two wires and these wires are open to the shield Each module on the CAN bus broadcasts its messages according to a priority assigned to the message All the other modules will receive the message and determine if it is important to them Typical message traffic is 300 500 messages per second The high bus speed allow all mod ules to be constantly updated around 20 times per sec ond A CAN network also has error detection and handling for robust communications JLG Lift 3 4 SECTION 3 THEORY OF OPERATION 1230ES Platform Control Station Ignition Ground 1200 3 4 7 65 3 4 7 65
96. you can not adjust the personality settings 3121222 SECTION 7 JLG CONTROL SYSTEM Machine Setup When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value A WARNING FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU LAR MACHINE CAN RESULT IN IMPROPER OPERATION 2 MAG GROUND ALARM 1 For example GROUND ALARM 1 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 3121222 NOTE Refer to the appropriate Machine Personality Set tings Table and the Machine Setup Table on the fol lowing pages in this Service Manual for the default settings 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 NOTICE IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI C
97. 0 0 5 0 Sec N A NOTE These settings may change in order to achieve opti mal performance on a machine by machine basis 3121222 Table 7 4 Machine Personality Adjustment 1001115627 B Machines Equipped with ZAPI 1001092456 Power Module Function Adjustment Range ES DRIVE ACCEL 0 1 5 0 Sec 0 8 DECEL 0 1 1 0 Sec 1 0 MINIMUM 0 2596 0 MAXIMUM 0 100 100 ELEV MAX 0 30 25 LIFT ACCEL 0 1 5 0 Sec 0 5 DECEL 0 1 1 0 Sec 0 1 UP MIN 0 50 20 UP MAX 0 100 100 DNMIN 1 60 45 DN MAX 0 100 85 STEER STATIC 0 100 100 DRIVE 0 100 60 ACCELERATOR FWD MIN 2 20 2 40 V 2 23 FWD MAX 1 00 1 50 V 1 19 REV MIN 2 60 2 80V 2 74 REV 3 50 4 00V 3 78 GROUND HORN 87 107 dB 107 ALARM 87 107 dB 87 LOAD ACCY 0 200 0 OVRDBNCE 0 0 5 0 Sec 3 0 OVRHOLD 0 0 5 0 Sec 5 0 NOTE These settings may change in order to achieve opti mal performance on a machine by machine basis JLG Lift 7 11 SECTION 7 JLG CONTROL SYSTEM 7 4 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 VEHICLE screen 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 softwar
98. 12 7 12 12 6 2 6 5 8 190 260 160 220 18 0 6250 0 2560 215 290 180 245 3 4 10 0 7500 0 3340 340 460 280 380 16 0 7500 0 3730 380 515 315 430 14 0 8750 0 5090 45800 670 910 600 815 500 680 12 1000 06630 5970 95 1355 85 125 745 1015 12 14250 0860 77000 145 1965 1300 170 1085 1475 1 2500 1 0730 96600 2015 2740 1810 2460 1510 2055 NO 5000059 REV J NOTES 1 THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 3121222 2 ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE 10 8 ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM 4 CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10 9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS IF HIGHER LOAD IS REQUIRED ADDITIONAL TESTING IS REQUIRED Figure 1 5 Torque Chart SAE Fasteners Sheet 4 of 7 JLG Lift SECTION 1 MACHINE SPECIFICATIONS Tensile Stress Area Values for Zinc Yellow Chromate Fasteners Ref 4150707 CLASS 8 8 METRIC BOLTS CLASS 8 METRIC NUTS Torque Loctite Loctite 262 242 or 271 OR Vibra OR Vibra TITE 131 TITE 111 or 140 561 3 694 302 0 1990 1490 2090 14 23 0 7 8 78 3 82 34 68 6 201 874 n 79 12 19 125 36 60 15 9 28 55 12 175 8430 367 ss 66 97 154 241 331 469 22 303 639 24 353 811 27 459
99. 121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 3 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly not the circuit in which the switch is placed A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected 1 2 3 4 De energize the circuit Isolate the switch from the rest of the circuit if possible If not possible keep in mind it may affect readings Access the terminals to the switch If the switch has two terminals a Measure resistance across the terminals b Change the switch position c Measure resistance again with the leads in the same positions If the meter was reading short it should read an open If the meter was reading open it should read short 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 termi nals and open otherwise c If the switch has more than one common contact repeat the process for that circuit Limit Switches Limit switches are used to control movement or indicate position Mechanical limit s
100. 163 JLG Lift 4 Wheel lug nuts should be torqued after the first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of opera tion SECTION 4 BASE COMPONENTS 4 4 REAR WHEEL HUB INSTALLATION SE Rear Wheel Hub Installation Hub Cap Cotter Pin Spindle Nut Washer 5 Outer Tapered Roller Bearing a 6 T 8 9 10 Outer Bearing Race a Wheel Mounting Hub a Inner Bearing Race a Inner Tapered Roller Bearing a Hub Seal NOTE a Bearing race 6 8 are press fitted to wheel mounting hub 7 and are only available for service as a complete hub assembly Also before installing or re installing the inner and outer taper roller bearings be certain they are lubricated packed with multi NOTE 4 4 purpose grease Later design incorporated wheels lugs into hub tighten wheel lug nuts same as lug bolts per step 6 below Before assembly check that inner and outer taper roller bear ings are lubricated packed with mutli purpose grease Tighten spindle nut to 30 40 ft Ibs 40 54 nm to properly seat bearings Loosen spindle nut completely until it can be turned by hand Then finger tighten spindle nut by hand without rotating the wheel mounting hub Install cotter pin if necessary nut may be backed off to nearest slot if more than 1 2 the cotter pin hole is visible the nut may be
101. 2 WIRES Figure 9 13 1230ES Location of Component X Connectors on Ground Control Module JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 10 ELECTRICAL LAYOUT AND SCHEMATICS PLATFORM CONSOLE BRAKE BOX DISCONNECT SWITCH 67 PLATFORM Q BU RECEPTACLE ipi TIS P TANK RA E i MODULE J JAPANESE SPEC 42 BEACON LIGHT POTHOLE PROTECTION SWITCHES DIAGNOSTIC ANALYZER LL ge Li I 91 P F GROUND CONTROL BOX DRIVE MOTORS Figure 9 14 1230ES Overview of Electrical System Components 1600346 Drive Module 9 22 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS
102. 21 Spare Digital Output Low Side Driver Digital Output 22 Negative for Overload Lamp Low Side Driver Digital Output 23 Negative for Hourmeter Low Side Driver Digital Output JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS CHARGER INTERLOCK X018 X086 YEL RED 2 5 9 1 19 e 4 GROUND MODULE X008 ORN RED 49 4 J1 29 EN X056 057 lt X082 n 88 1 a INVERTER 020 X010 ui CHARGER a a BLACK 14 1 1 X028 8 ORN RED49 5 REMOTE LED S POS MOUNTED IN 5 ORNIRED49 6 2 2 LOCATED IN GC gt VEHICLE go CHASSIS ORN RED49 7 i 6 4 Eu 7 NC lt 88 6 CONTROL CABLE E 4 lt 5 m X021 X088 Figure 9 20 Battery Charger Inverter Electrical Connection Schematic 3121222 JLG Lift 9 37 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 12 AC POWER RECEPTACLES AND WIRING PLATFORM CE SPEC MACHINES ONLY 0861781 4461198 WIRING DIAGRAM FOR A C PLUG ON PLATFORM GREEN YELLOW BLUE REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER BROWN L BROWN GREEN YELLOW GREEN YELLOW WIRING DIAGRAM FOR A C PLU
103. 3121222 JLG Lift 9 5 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Automatic Switches If the switch is actuated automatically by temperature or pressure for example find a way to manually actuate the switch to test it Do this either by applying heat or pressure for example to the switch These switches may need to be energized to actuate 1 Connect instrumentation to monitor and or control the parameter the switch is measuring 2 Observe switch state in control system with the Analyzer See vehicle or control system documentation on how to do this 3 Operate system such that the switch actuates This could be going over a certain pressure or temperature for 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 side switch The switch provides the ground to the load A low side switch will allow voltage to be present on the load No power is applied because the switch is stopping current flow This voltage can be seen if the measurement is taken with one test lead on the load and the other on the battery nega tive side or grounded to the vehicle What is actually being measu
104. 346 Drive Module 3121222 JLG Lift 9 27 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 28 X3 GROUND CONTROL X22 PLATFORM BOX CONNECTOR i ELEVATION PROX SENSOR 1230 5 ONLY CABLE CONNECTOR LOCATED ON FRAME SENSING MAST SEE SHEET 3 SEE SHEET 2 SWITCH 15 43 ELEVATION PROX o CLOSED WHEN proximity Y T FERROUS MATL SWITCH 40 5 BATT RELAY x H IS PRESENT ZON N 7 gt 00 lt m T TE ORO COL OD reowor coeoo le ale NR as WIRE 15 ONLY LOADED 5 26 5025 8 1230ES MACHINE RH PHP LH PHP m EE SHLICH SWITCH SESS 555 94 4 as suo TS gt RS E ale x m
105. 6cm Hydraulic Tank 0 80 Gal 3L Height From platform floor 438in 111 2cm Hydraulic System Including Tank 1 75 Gal ALL Overall Machine Width 30in 76cm Hydraulic Oil Overall Machine Length 53 5 in 1 36m AR NOTE Machines built in Europe installed hydraulic oil Platform Size Length 49 4 in 1 26m vofluid 15 which has a BLUE TINT for identification Platform Size Width 27 in 69cm purposes only but is fully compatible and can be mixed with any of JLG recommended hydraulic Wheelbase 40 75in 103 5cm oils mentioned following Table 1 8 Hydraulic Oil Tires Hydraulic System Operating Table 1 4 Tire Specifications d Range SAE Viscosity Grade Description Model 1230ES 0 23 F 18 C to 5 C 10W Size io nada 0 Fto210 F 182 Ct0 99 C 10W 20 10W 30 72 in x 3 937 in 2 2 2 2 5 323mmx 100mm 50 Fto210 F 410 C to 210 C 20W 20 Max Tire Load 2500 Ib 1134 kg NOTE oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient Wheel Bolt Torque 120ftlb 163 chemical stability for mobile hydraulic system ser vice JLG recommends Mobilfluid DTE 11M hydrau lic oil which has an SAE viscosity index of 140 Batteries When temperatures remain below 20 F 7 C recommends the use of Mobil DTE13 Aside from Table 1 5 Battery Specifications JLG recommendations it is not advisable to mix oils TT of dif
106. 7 ELEVATION SENSOR CALIBRATION 7 18 SECTION 8 DIAGNOSTIC TROUBLE CODES 8 1 INTRODUCTION mI ee dearest 8 1 8 2 4 8 1 8 3 DIGINDEX sss niat or t eet e eaa 3 8 1 84 DIC CHEGKTABEES IRR EH CO ah ek 8 5 0 0 2 hi AA Vd 8 5 2 1 Power p z e RR EIS eee Uie ae fue ve 8 6 2 2 Platform Controls s nie RERUM MERE ee Nai EE 8 6 2 3 Ground Controls c ama e rh 8 8 2 b Function Prevented irre De RH RE ER RR ERR 8 8 3 1 Line Contactor Open 41 8 10 3 2 Line Contactor Short re 8 10 3 3 Ground Output 8 11 4 2 Thermal Limit SOA 4 8 13 4 4 Battery uoce eds a teed bela ae 8 14 iv JLG Lift 3121222 TABLE OF CONTENTS 6 6 1 2 8 14 6 7 e RR E Qd Ae de tae 8 16 7
107. 7 Electric Motor MP ee E E 8 16 9 1 Tilt Sensot hen ead be Ine 8 18 8 2 Platform Load 1 8 18 9 9 Hardware RUE Ree eed LEER eR 8 18 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 1 GENERAL s oreet eet ute veiba m redactor ed tung 9 1 9 27 MULTIMETER BASICS chain te cee inate Ma eee EID t EHE Ee Pd ro 9 1 9 1 Backprobing ven uen Een eM IE D EE eb 9 1 Max sonst tta EVER ELE ue v rcd 9 1 epe rg Edere iut viene lucet A od dunes 9 1 c 9 1 Continuity Measurement Over Long Distances 9 4 Requlrements t Ey et aee ed tp ur tuts 9 4 Procedure Cur AUS Ep eM CS OU erit 9 4 9 3 ELECTRICAL SWITCH 4 4 9 5 9 5 SWitChes po dtd ge doe etate DL un 9 5 Automatic SwIIChes senes 9 6 Switch Wiring Low Side High 9 6 9 4 APPLYING SILICONE DIELECTRIC COMPOUND TO CONNECTORS 9 7 Assembly cte a e e tei Deque rte Sk aoro a e e 9 8 Disassemibly 2 ei
108. 96 is commanded REV MIN The reverse extent of the centered position Values between this and FWD MIN are where 096 is commanded FWD MAX Joystick voltage where 10096 will be com manded REV Joystick signal voltage where 100 will be commanded Tilt The control system monitors the tilt sensor to determine if the vehicle is tilted excessively This condition is called Tilted In the CE Australia and Japan markets if the vehi cle tilt angle in any direction is greater than or equal to 3 5 the control system considers the machine tilted In 3121222 other markets the vehicle is considered Tilted if the vehi cle tilt angle front to back is greater than or equal to 3 0 or tilt left to right is greater than or equal to 1 59 3 5 TRACTION The traction or drive system moves the vehicle along the ground by electric motors The Armatures rotating wind ings of the separately excited drive motors are wired in parallel to the Power Module s M1 and M2 terminals The M1 Terminal is always at the same voltage as the Bat tery Voltage when the Line Contactor is closed and allows the module to measure current with the internal shunt extremely low impedance The 2 Terminal 15 pulled to Ground by the Armature Switch MOSFET s con nected to B Terminal To provide variable speed control the Armature MOSFET transistors switch On and Off at high frequencies PWM pulse width modulation 16kHz The
109. AGRAM FOR A C PLUG ON CHASSIS GREEN YELLOW f d in BLUE 34 CEE 7 PLUGS 4 SOCKETS SIDE GROUND 200V 250V P L 0275219 JLG Lift 9 39 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 0861731 4461244 WIRING DIAGRAM FOR A C PLUG ON PLATFORM GREEN YELLOW f E tom BLUE REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER BROWN L BROWN 0 E BLUE N N BLUE 1 GREEN YELLOW GREEN YELLOW 4461203 WIRING DIAGRAM FOR A C PLUG ON CHASSIS GREEN YELLOW ww BLUE CEE 7 PLUGS amp SOCKETS GROUND PIN AMERICAN 2 X 4 WALL BOX 200V TO 250V P L 0215452 0861731 4461245 WIRING DIAGRAM FOR A C PLUG ON PLATFORM GREEN YELLOW BLUE REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER BROWN L L BROWN L BLUE N N BLUE 0 ee GREEN YELLOW GREEN YELLOW 4461205 PA WIRING DIAGRAM FOR A C PLUG ON CHASSIS z GREEN YELLOW I n BLUE 4 Q CEE 7 PLUGS amp SOCKETS SIDE GROUND AMERICAN 2 X 4 WALL BOX 200V TO 250V P L 0215453 9 40 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 0861731 WIRING DIAGRAM FOR A C PLUG ON
110. AL 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 Diagnostic Trouble Codes DTC DTC Diagnostic Trouble Codes are indicated on the face of the platform control box as shown SYSTEM FAULT OA 1000 e ZONE ZONE A NOTE Flash codes are also displayed on the handheld ana lyzer For descriptions see Section 8 DIAGNOSTIC TROUBLE CODES JLG Lift 7 3 SECTION 7 JLG CONTROL SYSTEM 1 2200217 210 19945 JazAjeuy 71 7 OSH ON 21001 100100 HAING SNOIIVHSITVO SNOILVNHITVO 1 3 5 1 WSO Z 1 S3A l 1nOlD2 ITIL ISNW T LEE 1 1noino dnjag auly2ey uo Bulpuadap 5141 Ajuo apow A08 XWW ATE THOIVNSISOOV Je pue
111. ALARM SOUNDING TILTED amp ABOVE ELEVATION Control system senses thatthe platform is elevated and the vehicle is tilted and the machine not configured to cutout Check that the machine is tilted If so lower the platform and reposition the machine to a level surface Fully stow the platform The tilt sensor is part of the ground control box Check that the ground control box is secured to the machine Check that the pothole protection switches are securely mounted Check that the elevation angle sensor is securely mounted Check the ANALYZER gt MACHINE SETUP gt MARKET configu ration If 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 ABOVE ELEVATION The platform is elevated and the machine is driving Fully stow the platform 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
112. ARD DIAGNOSTICS E 43 ELEVATION PROX ON 19 20 2630 amp 26 3246ES ONLY 5821 DISPLAY AND BRAKE caviar ay IL 40 5 BATT RELAY NC PIVOT PIN GROUND CONTROL CONTROL STATION SIDE E 6 STATION SIDE OF MACHINE OF MACHINE IN BATTERY COMPARTMENT Gp x REL SW om pneri S25 _ LH PHP BRAKE 8 B m RELEASE BUTTON ON elu 1230 5 MACHINE 15 2 AT REAR OF FRAME e z 522225 a as gt 2 285888 E E s SPE dep mna xj x als v 1 12 jz s P18 41 23 g SLPH SPIT 12 21 E S sat EY PLPH JI 18 P16 12 20 Tce SRPH JI 9 5 15 2 19 31_PRPH POS_RPHP FOOI SNTTCH SP14 2 1 FSW 1 27 X24 22_EMS_PLATFORM ib pz P13 2 13 um NNI BLACK CAN SHIELD AROTB J1 2 CANS 2 15 8 PROT P ELEV SEN 432 CANH 2 6 19 AROTP ELEV SEN ON NOD T0255 AROTP 01 1 21 NROT N ELEV SEN NER 42 23 1 0L 6ND 38_SMB_SW_MAN_BRK 9_LIFT_UP Ma 39_PMB_POS_MAN_BRK SGU JI 8 PMB 1 31 LIFT DOWN 29 NANA NEG ANLYZR 8 1 PTLT POS TLT Dm 28 TX ANALYZER PESCHLCHGRLINTK RK 0 20 X LM SCH JI 26 21 4 27_PANA_POS_ANLYZR 40 2_BATT_RELAY 23 _PNC_POS_LCONT SUA re 102_NRV_NEG_STEER_RT STEEL gt EL
113. At the four bottom corners of the outer mast section remove the pop rivets securing each slide pad to the mast section See Figure 6 5 Item 1 Two 2 riv ets per slide pad The pads may not slide out of the mast section until the platform is lifted later and the upper slide pads on outer mid section pushes them out Disconnect the platform control box main harness connector from the bottom of the platform control box and allow to hang loose for now Remove the platform control box from the platform Remove the AC outlet receptacle box from the out side of the outer mast section Allow the receptacle box to hang loose for now Remove the screws holding the cover plate conseal ing the cables for the receptacle box and platform box to the right side of the mast At the top of the mast See Figure 6 5 Item 2 the cylinder rod for hydraulic cylinder 3 is attached to platform mast section cross support with a bolt and nut through a detent on the side of the rod Remove the locking nut from the hex head bolt holding the cylinder rod in place to the mast cross support Remove the bolt from the cross support It may be necessary to lift or lower slightly on the platform assembly with the lifting strap to remove the bolt Also at the top of the mast opening See Figure 6 5 Item 3 remove the two 2 bolts and nuts attaching the power trak cable guide to the platform rail for the AC receptacle and platform control station elect
114. Bushing 6 Cylinder Rod 11 Main Gland Seal 2 Cylinder Head Gland a T Piston b 12 Wiper Seal 3 O Ring Seal 8 Piston Seal 13 O Ring Seal 4 Backing Ring 9 Bushing 5 O Ring Seal 10 Piston Set Screw NOTE a On final assembly torque cylinder head Gland to 500Nm 112 ft Ib b Apply Loctite 242 to threads before final assembly and torque to 260Nm 55 ft Ib Refer to Section 3 7 STEER Theory of Operation for more detailed information on Steer Cylinder System 4 6 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Steer Cylinder Disassembly NOTICE DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA NOTICE PROTECT THE CYLINDER ROD SURFACE DAMAGE TO THE CYL INDER ROD CHROME FINISH DUE TO SCRATCHING INDENDA TION CHIPPING OR OTHERWISE WILL CAUSE EVENTUAL GLAND SEAL FAILURE THE CYLINDER ROD MUST BE REPLACED IF DAMAGED Cylinder Head Gland Removal 1 Cylinder Head Gland 2 Spanner Wrench 48mm 1 89 Dia 5mm Pin Dia 1 Using the proper size spanner wrench 48mm 1 89 Dia 5mm Pin Dia remove the cylinder head gland turning the head counterclockwise until it is free of the cylinder barrel 2 Carefully slide the complete cylinder rod cylinder head gland piston assembly out of the cylinder barrel 3121222 JLG Lift Piston Removal 1 Piston Kban Seal 3 Piston 2 Piston
115. C Required Interlock Current 1A Input Voltage AC 100to 130 VAC Nominal Input Voltage AC 120 Input Frequency 54to 66 Hz OPERATION Charging Indicator Yellow LED 10096 Charge Indicator Green LED Battery Charger Inverter Assembly Installation Fault Indicator Red LED 1 Charger Inverter Assembly 3 Attach Screws PROTECTION 2 Insulate Mounting Pad 4 Nylon Shoulder Washers Output Reverse DC Polarity 125 AReplaceable Fuse Note a On final assembly apply Loctite 242 to screw threads Output AC Short Circuit Automatic Reset AC Overload 20 A Internal Slow Blow Charger Fuse DC Overload Voltage Limited Internally Controlled MECHANICAL Operating Temperature 40 F to 185 F 40 C to 85 C Housing Shock and Water Resistant Aluminum For further specification and troubleshooting information refer to the manufacturers Charger Inverter Owner s Guide shipped with the machine Publication RM1024 JLG Part 3128406 Also see Section 8 Figure 9 20 Battery Charger Inverter Electrical Connection Schematic for more detailed con nection information LED Power Interlock Cable Identification 1 AC Output Connector 2 AC Input Connector 3 Remote On Off Switch Cable 4 External DC Fuse Location 5 DC Connection 6 DC Connection 5 24 JLG Lift 3121222 SECTION 6 MAST COMPONENTS SECTION 6 MAST COMPONENTS 6 1 MAST COMPONENTS OVERVIEW 3121222
116. CI PLATFORM NEAR ARM PIVOT AND TO PLATFORM I CONTROL BOX BLACK 2 YEL RED 2 5 9 YEL RED 2 5 8 TWIN CABLE BLACK CONNECTION UNDER BLACK PLATFORM m RED BLACK SHIELD RED BLUE YELLOW 1230ES ONLY CONNEC HARNESS IN FRAME NEAR AR TO X22 ON CHASS zov PIVOT ATTACHMENT 155 OPTIONAL IF LSS IS NOT EQUIPPED TWIN CABLE CONNECTOR S ARE CONNECTED TOGETHER Figure 9 18 Electrical Schematic Machines with 1001092546 Drive Module 9 30 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 13 1 RIBBON CAPACITY CABLE SWITCH Jeu BROWN PURPLE I9 LIFT DRIVE JI 9 ORANGE WHITE 17 is HITE JI 10 WHITE GREEN 18 OPTIONAL 12305 ONLY 3 o FOOT SWITCH HORN RIBBON Eg N BUTTON oo 4 1 9 OPTIONAL SCAPACITY 4 HORN SWITCHES ARE MOUNTED IN DIECASTING 13 20 2630 6 AND ATTACHED TO PCB VIA 26 3246ES RIBBON CABLE ONLY FOO SWITCH PLATFORM CONTROL BOX 9 BLACK TE 18 2 CABL 155 MODULE LOCATED AT TOP OF ARMSTACK UNDER PLATFORM 19 20 2630 amp 26 3246ES ONLY n TO RAILS LOAD SENSE PLATFORM MOUNTING ARM MODULE PINS FOR
117. CTION PREVENTATIVE PREVENTATIVE ORFREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION MAST ASSEMBLY Mast Sections 2 5 2 5 Covers and Shields 1 Slide Pads 1 2 PLATFORM ASSEMBLY Platform 1 1 Guard Rails 1 2 4 1 2 4 Gate 1 5 1 5 Floor 1 2 1 2 Lanyard Anchorage Point 1 4 1 4 CHASSIS ASSEMBLY Covers Installation 1 7 1 7 Static Strap 1 1 Wheel and Tire Assemblies 1 2 15 2 15 Drive Motors 1 7 9 Drive Motor Brushes FUNCTIONS CONTROLS Platform Controls 5 6 7 5 6 7 Ground Controls 5 6 5 6 14 Function Control Locks Guards or Detents 5 5 Function Enable System 5 Emergency Stop Switches Ground amp Platform 5 Function Limit or Cutout Switch Systems 5 Brake Release Manual Descent or Auxiliary Power 5 POWER SYSTEM Batteries 19 9 18 Battery Charger HYDRAULIC ELECTRIC SYSTEM Hydraulic Lift Steer Pump 1 2 9 1 2 5 9 25 Hydraulic Cylinders mast and steering 2 7 9 2 9 Steer Cylinder Attachment Pins and Pin Retainers 1 2 1 2 Hydraulic Hoses Lines and Fittings 1 9 1 9 Hydraulic Reservoir Cap and Breather 5 7 5 7 Hydraulic Fluid 11 11 11 Electrical Connections 20 20 Instruments Gauges Switches Lights Horn 5 3121222 JLG Lift 2 3 SECTION 2 GENERAL SERVICE INFORMATION Table 2 2 Preventive Maintenance amp Inspection Schedule Continued INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPECTIO
118. CTRICAL INFORMATION amp SCHEMATICS 9 11 PIN INPUT OUTPUT TYPES Table 9 3 Ground Board J1 Connector X001 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 NotUsed 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 NotUsed 15 Elevation Prox Switch Input 5 16 Ground Power Output 0 17 NotUsed 18 Right PHP 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 RightBrake Release Output Vbatt 24 LeftBrake 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 NotUsed 31 CAN Bus High Input Output Comm 32 CaNBus Low Input Output Comm 33 CAN Bus Shield Output 0 34 NotUsed 35 NotUsed 36 NotUsed 37 Ground Power Output 0 38 NotUsed 39 Master Ignition Connection Power Input Vbatt 40 Master Ground Connection Power Input 0 Table 9 4 Ground Board J2 Co
119. Cable 3 LED Indicator Battery 2 DC Power Cable to Batteries Temp Sensor Cable 5 20 JLG Lift 3121222 SECTION 5 CONTROL COMPONENTS BATTERY CHARGER SPECIFICATION OUTPUT Nominal DC Output Voltage 24V Maximum DC Output Voltage 33 6V Maximum DC Output Current 25A Maximum Interlock Current 1A INPUT AC Input Voltage 85 265VAC Nominal AC Input Voltage 120VAC 230VAC RMS AC Input Frequency 45 65 HZ Maximum AC Input Current 12A RMS 108VAC OPERATION Charging Indicator Yellow LED 10096 Charge Indicator Green LED Fault Indicator Red LED PROTECTION Output Reverse Polarity Electronic Protection Auto matic Reset Output Short Circuit Electronic Protection Auto matic Reset AC Overload Current Limited DC Overload Current Limited MECHANICAL Operating Temperature 22 F to 122 30 C to 50 C Housing Shock and Water Resistant Alu minum Also see Section 8 Electrical Schematics for more detailed electrical connection information 3121222 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 ne
120. Company Corporate Office JLG Industries Inc 1 Drive McConnellsburg PA 17233 9533 717 485 5161 JLG Worldwide Locations 717 485 6417 3121222 JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 461265811111 61 2 65 813058 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 ju JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 4 44 0 161 654 1000 44 0 161 654 1001 Du JLG France SAS 2 1 de Fauillet 47400 Tonneins France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany FF 49 0 421 69 350 20 49 0 421 69 350 45 A JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 Xm JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore T E P Ltd 29 Tuas Ave 4 Jurong Industrial Estate 639379 Singapore 65 6591 9030 El 65 6591 9031
121. Cylinder Removal 1 Cylinder Attach Bolts 2 Hydraulic Cylinder 3 1 Multi stage Hydraulic Cyl 2 Lifting Strap inder Assembly 8 Remove the two 2 bolts attaching hydraulic cylin der 1 to the underside of the base frame 2 Using suitable lifting equipment and strap slide the cylinder assembly out the bottom of the mast Lift the mast assembly free of the frame place on a assembly place on a suitable workbench suitable workbench for disassembly JLG Lift 3121222 SECTION 6 MAST COMPONENTS ol Wi 1 Attach Screws Figure 6 13 Power Trak Removal 3 Power Trak Guide 2 Power Trak Hanger Bracket a Note 3 a Remove bracket from slot in mast and remove power trak harness from the mast If the power trak assembly was left attached to the the mast assembly to remove it now remove the two 2 screws attaching the power trak guide to the mounting lug at the top of the mast Slide the hanger bracket out of the slot in the front of the mast sec tion Now slide the complete power trak assembly with cables out of the top of the mast assembly 4 3121222 Figure 6 14 Mast Sections Disassembly 1 Outer Mid Mast Section 4 Slide Pads 2 Inner Mid Mast Section 5 Pad Attach Rivets 3 Mount Inner Mast Section To remove the mast sections from each other slide the mast sections apart unti
122. Digital Input 10 Ground Lift Down Switch High Sensing Digital Input 11 Left Pothole Switch High Sensing Digital Input 12 Spare Negative Reference Power 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 Connect to 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 Connect to 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 Connectto 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 Driv
123. ENO MAINTENANCE SAFETY PRECAUTIONS 1 A o GENERAL o i RESI ti aa aia eee re MEE E EMI V A B HYDRAULIC SYSTEM SAFETY oe Dd E EE esser A MAINTENANGE RE CBE E EA YU Pu A REVISION LOG iiie ru eR PUPPI aee veu eb ue B SECTION 1 MACHINE SPECIFICATIONS 1 1 OPERATING nar paa E hm hh 1 2 Platform EUER ED a dep 1 2 Dimensional Data ERE 1 2 D cw DE 1 2 Batteries C eee See eo Ga Pa Pa 1 2 Critical Stability Weights 1 2 1 22 LUBRICATION sy ente ERR P LER FUE Melk eae a a Sa ee tee ld 1 2 2 222 4 44 e ERR 1 2 Hydraulic Oil has pnd trata nana ter Ron de Mote Kee eR 1 2 Lubrication Specifications 1 3 Oil Check Procedure inii ERA ees 1 3 1 8 CYLINDER SPECIFICATIONS 2 1 3 1 4 TORQUE REQUIREMENTS p iist sie hh mrs 1 8 1 5 SERIAL NUMBER LOCATIONS
124. ER ROD SURFACE DAMAGE TO THE CYL INDER ROD CHROME FINISH DUE TO SCRATCHING INDENTA TION CHIPPING OR OTHERWISE WILL CAUSE EVENTUAL GLAND SEAL FAILURE THE CYLINDER ROD MUST BE REPLACED IF DAMAGED 1 Lubricate and place a new o ring in the groove on the tapered end of cylinder rod 1 NOTE The cylinder rod and valve body threads need to be clean and free of oil when the valve body is assem bled to the cylinder assembly so the loctite applied to the cylinder rod threads will set properly 2 Clean the threads of the tapered end of the cylinder rod of cylinder 1 and apply Loctite 242 to the threads 3 Apply a light film of hydraulic oil to the rod surface above the threaded area to lubricate the o ring when installing the valve body to the cylinder rod end 4 Be certain the threads inside the valve body are clean and dry of any debris or oil 5 Using the proper fixture to keep the cylinder rod from turning and protect the cylinder rod from dam age insert the valve body onto the end of the cylin der rod and tighten then torque to 200 Nm 45 ft Ib Hydraulic Cylinder Assembly Testing If a hydraulic cylinder testing fixture is not available to fully pressurize the cylinder then the cylinder must be checked for proper operation and leaks after installation of the mast assembly to the machine IF A TEST FIXTURE IS USED TO TEST THE HYDRAULIC CYLIN DER DO NOT EXCEED THE MAXIMUM RATED PRESSURE SET TING OF THE HYDRA
125. 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 machine in platform mode If DTC 662 is present trouble shoot that DTC before continuing 8 14 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 6 6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK 662 CANBUS FAILURE PLAT FORM MODULE In platform mode the control system failed to receive messages from the plat form board Turn on machine in ground mode If DTC 661 is not present check for 24V between platform box connector terminals D and A If not 24V test continuity from platform box connector socket A to ground board connector socket J1 6 and test continuity from 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
126. Figure 6 1 Mast Components 1 Platform Assembly 4 Mast Assembly 2 Tool Tray 5 AC Power Receptacle 3 Mast Cover Plate 6 Manual Storage Box JLG Lift 6 1 SECTION 6 MAST COMPONENTS 6 2 PLATFORM TOOL TRAY INSTALLATION Platform Tool Tray Installation 1 Tool Tray 2 Attach Screws a Note a Do not use a screw with the threaded portion longer than 1 2 in 12mm when attaching to the side of the mast 6 3 MAST COVER PLATE INSTALLATION Mast Cover Plate Installation 1 Mast Cover Plate 2 Rivet Nuts 3 Top of Mast Assembly 6 2 JLG Lift 6 4 PLATFORM AC RECEPTACLE BOX INSTALLATION AC Receptacle Box Installation 1 AC Voltage Receptacle Box Components 2 Attach Screws Note See AC POWER RECEPTACLES AND WIRING PLAT FORM CE SPEC MACHINES ONLY on page 9 38 for receptacle wiring connections of available AC plug types 3 Platform Mast Assembly 3121222 SECTION 6 MAST COMPONENTS 6 5 MAST ASSEMBLY COMPONENTS 07 A cj EN EE 3 i A I of
127. G ON CHASSIS GREEN YELLOW BLUE IEC 60309 PLUGS 4 SOCKETS 100V TO 130V YELLOW P L 0275216 0861781 WIRING DIAGRAM FOR A C PLUG ON PLATFORM GREEN YELLOW Karon BLUE 4 4461201 REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER BROWN BROWN N N BLUE GREEN YELLOW GREEN YELLOW WIRING DIAGRAM FOR A C PLUG ON CHASSIS GREEN YELLOW son BLUE 60309 PLUGS amp SOCKETS 200V TO 250V BLUE P L 0275217 9 38 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 4461258 3121222 0861782 WIRING DIAGRAM FOR A C PLUG ON PLATFORM BROWN GREEN YELLOW GREEN YELLOW BLUE 4 REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER L BROWN BLUE GREEN YELLOW GREEN YELLOW WIRING DIAGRAM FOR A C PLUG ON CHASSIS BLUE 4 CEE 7 PLUGS 4 SOCKETS GROUND PIN 200V TO 250V P L 0275218 0861782 4461207 WIRING DIAGRAM FOR C PLUG ON PLATFORM L GREEN YELLOW EK ron BLUE REFERENCE WIRING DIAGRAM F OR CIRCUIT BREAKER BROWN z BLUE BROWN BLUE GREEN YELLOW 1 GREEN YELLOW WIRING DI
128. GE IMPROPER 8 1 Tilt Sensor Drive Steer and Lift Prevented The System Module voltage at the F1 and F2 terminals was improper at power up expected to be gt 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 SOR NOT CONNECTED OR FAULTY DTC FAULT MESSAGE DESCRIPTION CHECK 811 TILTSENSORNOT CALI Thetiltsensorcalibrationhasnotbeen Calibrate 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 Calibrate the tilt sensor see Section 5 2 Replace then calibrate tilt sensor see Section 5 2 8 2 Platform Load Sense DTC FAULT MESSAGE DESCRIPTION CHECK 821 LSSCELL 1 ERROR Aproblem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 822 155 42 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 Refer to Section 2 3 Troubleshooting in the LSS manual
129. 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 8 Torque Chart METRIC Fasteners Sheet 7 of 7 1 10 JLG Lift 3121222 SECTION 2 GENERAL SERVICE INFORMATION SECTION 2 GENERAL SERVICE INFORMATION 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 ma
130. INTERNAL ERROR agrees with the feedback from the power PCB Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 8 20 JLG Lift 3121222 SECTION 8 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 ZAPI HEALTH Status LED FLASHING 99146 POWER MODULE FAILURE Drive Steer 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 M
131. ION 4 BASE COMPONENTS 4 9 HYDRAULIC PUMP MOTOR VALVE ASSEMBLY SERVICE PROCEDURE Refer to Section 3 6 PUMP LIFT MAST Theory of Opera tion for more detailed information on Pump Motor Valve System Common Difficulties 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 battery compartment The vehicle should be placed on a firm level surface for all analysis 1 Ground Module Interlocks There are a variety of interlocks that prevent Lift Up due to system events Tilted Elevation Angle Sensor Not Calibrated etc Before investigating Pump Sys tem issues examine the JLG Analyzer s HELP Menu while attempting to Lift Up from Ground Mode Refer to Section 5 for explanations of the Analyzer Help Messages 2 Power Module Diagnostic Issues The Power Module executes a self test during every power up to ensure proper functionality If a Diag nostic Issue is detected the Power Module will not energize the Line Contactor Instead it will flash the Green LED Since these issues may impact both the Traction and Pump Systems please refer to the sec tion for Power Module Diagnostics 3 Open Circuit between Terminal and Pump Motor Positive Terminal This is
132. K UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVER HEAD SLING 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 INTRODUCTION REVISION LOG REVISION LOG Original Issue of June 8 2006 Manual July 13 2006 Manual January 23 2007 Manual February 26 2007 Manual March 22 2007 Manual March 30 2007 Manual April 11 2007 Manual 15 2007 Manual Revised November 30 2007 Manual June 4 2008 Manual November 11 2008 Manual August 18 2010 Manual August 31 2011 Manual February 22 2012 b JLG Lift 3121222 TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAG
133. LE LS 1 32 ENIM 101 NLV NEG STEER LT S 101 STR LT PGAL JI 7 SEE E gSZAOZS BATT RELAY p 40 6 BATT RELAY CGAL J1 3 103 NEG L 103_NUV_NEG_LIFT_UP NLB JI 34 NOV 2 17 gt 05 PDV POS LFT DN dd 106 NEG LFT DN diera WRB 11 33 NDV 42 16 gt 6 CYL HARNESS CONTROLLER m HAWG NO CONNECTOR ON 123065 zug 4AWG CABLE P zz 4 AWG 555 PUMP CABLE gls CONNECT ION LOCATED AT gt 2 ARM PIVOT 231 BLUE ATTACHMENT ON 444 em ZN FRAME E Huc LIFT STEER UP VALVE LEFT VALVE amp RED 2 11 1 8 STEER x 2 RTGHT VALVE e BLACK 2 1 8 5 T x42 ZN ORANGE k LIFT DOWN VALVE LOCATED ON 2 BROWN CYL PORT BLOCK z 5 5 zu gt m 8 C225 _ P A g3 25 5 5 Te 2 d z BLUE 4 6 X28 RT BR T NOTES T ze ALL WIRES ARE 18 AWG UNLESS OTHERWISE NOTED LT BR 2 5 2 ALL WIRES ARE WHITE IN COLOR UNLESS OTHERWISE NOTED OR S4 PLB POS C BRAKE LARGER THAN 18 AWG 36 NLB NEG LTBRAKE 212 2 AWG CABLE 3121222 1001114879 F 1 Figure 9 17 Electrical Schematic Machines with 1001092546 Drive Module JLG Lift 9 29 SECTION 9 GENERAL ELECTRICAL INFORMATION
134. LOAD SENSE WHITE TO PLATFORM BLACK 8 2 CONNECTS TO B 38IGMAL T T SIGNAL BLACK 2 JI 9 DII HIGH SENSING DIG INPUT CAL CLOCK 2 2 CAL CLOCK 11 3 6ND 2 CONNECTS TO GND diy 1 12 48 2 CONNECTS TO B 11 5 DOL HIGH SIDE DIG OUTPUT 11 6 002 HIGH SIDE DIG OUTPUT j OM VOLUN 11 1 013 HIGH SENSING DIG INPUT 5 1 816NAL 11 8 DI2 HIGH SENSING 016 INPUT EXCITE 3 FR JI 10 GND 2 CONNECTS TO GND YEL RED 2 5 8 EXCITE 4 4 BLACK 1 AUT 8 PWR SUP HOST ONT STS SIGNAL 5 5 SIGNAL 11 2 GND GROUND FROM HOST CNTL SYS E pice SHIELD BLACK J2 8 CANS 2 CONNECTS TO 5 1 IGNAL V SIGNAL tb g J2 7 CANL 2 CONNECTS TO CANL I CAL 2 CAL CLOCK m 12 6 2 CONNECTS TO CANH I EXCITE 3 3 exciTe RL Suc f 12 4 CANbus INTERFACE HIGH PIN STE 0 12 9 CANL 1 CANbus INTERFACE LOW S S1GMAL 5 5 SIGNAL 12 5 CANS 1 SHIELD TERMINATION NOT GND 0 CAL DATA 6 6 CAL DATA J2 3 TRP 1 120 OHM CANbus TERMINATOR 3 1GNAL J2 10 TRP 2 120 OHM CANbus TERMINATOR gt CLOCI 2 2 CAL CLOCK 12 1 PRE REGULATED SUPPLY FOR JLG ANALYZER EXCITE 3 s excite RR J2 2 TX 5 232 FOR JLG ANALYZER sENCITE 4 PIN 12 11 RX 85 232 FOR JLG ANALYZER SIGNAL S 5 SIGNAL J2 12 GND GROUND FOR JLG
135. 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 Module compartment for a short circuit most likely near area where cylinder retracts between frame side sheets or near pot hole mechanism If the symptoms change suspect a short circuited or mechanically frozen pump motor A clamp on ammeter set for 200A DC can be placed on either Pump Motor Cable for verification During Lift Up the ammeter will read approximately 150A 4 29 SECTION 4 BASE COMPONENTS 4 30 Figure 4 10 Main Electrical Power Connections 1600346 SEVCON Power Module 1 Right Side Batteries 6 Right Drive Motor 2 Left Side Batteries T Left Drive Motor 3 Power Module 8 Battery Power Quick Disconnect 4 Main Power Contactor Relay 9 To Battery Charger 5 Hydraulic Pump Motor 10 To Charger or Inverter Option If Equipped JLG Lift 3121222 SECTION 4 BASE COMPONENTS Figure 4 11 Main Electrical Power Connections 1001092456 ZAPI Power Module 1 Right Side Batteries 6 Right Drive Motor 2 Left Side Batteri
136. N PREVENTATIVE PREVENTATIVE ORFREQUENT c YEARLY MAINTENANCE MAINTENANCE INSPECTION INSPECTION GENERAL Operation amp Safety Manual in Storage Box 21 21 21 ANSI amp EMI Handbooks in Storage Box 21 21 21 Capacity Decals Installed Secure Legible 21 21 21 All Decals Placards Installed Secure Legible 21 21 21 Walk Around Inspection Performed 22 Annual Machine Inspection Due 21 No Unauthorized Modifications or Additions 21 21 All Relevant Safety Publications Incorporated 21 21 22 General Structural Condition and Welds 2 4 2 4 Fasteners Pins Shields and Covers 1 2 Grease and Lubricate to Specifications 22 22 Function Test of All Systems 22 22 Paint and Appearance 7 7 Notify JLG of change in Machine Ownership 22 Change only when serviced Fill half full Replace when system brush wear indicator warning is activated Every two years drain and remove hydraulic oil reservoir clean pick up screen refill with fresh hydraulic fluid Maintenance and Inspection Table Codes 1 Check for proper and secure installation 2 Visual inspection for damage cracks distortion or N DA 17 excessive wear Check for proper adjustment Check for cracked or broken welds Operates properly Clean and free of debris Interlocks function properly Check for signs of leakage Decals installed and legible 11 12 13 14 15 16 Check for proper fl
137. NotUsed 6 NotUsed 7 Indoor Outdoor Select Switch Active Low Input Vbatt Table 9 8 Platform Board J4 Pin Function Type Range V 1 Ground Power Output 0 2 NotUsed 3 NotUsed 4 NotUsed 5 NotUsed 6 NotUsed 7 Horn Switch Active Low Input Vbatt Table 9 9 Power Module Connector X027 1600346 Power Module Pin Function Type Range V 1 Ignition Power Input Vbatt 2 NotUsed 3 NotUsed 4 NotUsed 5 NotUsed 6 NotUsed 7 NotUsed 8 Line Contactor High Side Power Output Vbatt 9 NotUsed 10 CAN Bus High Input Output Comm 11 CAN BusLow Input Output Comm 12 NotUsed Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 9 10 Power Module J1 1001092456 Power Module ONLY Pin Function Type 1 Primary Elevation Sensor Analog Input 0 5V Analog Input 2 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
138. ODULE 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 3121222 JLG Lift 8 21 SECTION 8 DIAGNOSTIC TROUBLE CODES 2 NOTES 8 22 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 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 should be obtained before proceeding with any maintenance 9 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 n
139. 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 INTERNAL 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 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
140. ON TIV INOIND p TIID TIID HITIT VOM Td Inolno rsrqvod qvo1 riv 1n01n2 c 5 114 1n0102 1 avo 100102 1 t VOT 4 i a a MEUM PERNS ATA MH IND d MS INO 10 SHA 1 S HOLIMSLOOA 20 SHA 1 S HOLIMSLOOA SNOISWSA Xd MS 881 X AJA SST OSTON 1 0 9 9T 55999 107805101 EVAN W 1VIN3N 7 7 INAS was JAIA LON 1 nal SOLLSONDVIG 6001 0 La NO NO 430 NMOG 49315 14871 4331 53001 510621 10 1455 5 590551 10 MOSNAS 3ojuspprH 4 19 USppiH UspPIH 36012 aaLvAata 8 n 7 USNS N8dO MS 5 WYOALVTd WYOALV Id LOVELY pa masas HeH 340 410 SAV LLV8 AWRLLVH AON 001 0 __ Le uno dnd 5907001 0001 00 001 xxx l _ La __ SM no 00 WAV WAd WAV 0
141. ORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA Removing the Valve Block Assembly Figure 6 17 Valve Block Removal 1 Valve Block 4 Direction for Removing 2 Cyl 1 Cylinder Rod 5 Direction for Installing 3 O Ring Seal PROTECT THE CYLINDER ROD SURFACE DAMAGE TO THE CYL INDER ROD CHROME FINISH DUE TO SCRATCHING INDENDA TION CHIPPING OR OTHERWISE WILL CAUSE EVENTUAL GLAND SEAL FAILURE THE CYLINDER ROD MUST BE REPLACED IF DAMAGED 1 Wrap the cylinder rod to protect it from damage then clamp the cylinder rod into a vise or device to keep it from turning while removing the valve block assembly 2 Using the proper size wrench approx 55mm 2 165 turn the valve block assembly counterclock wise to remove it from the end of the cylinder rod 6 14 JLG Lift Figure 6 18 Cylinder 2 and 3 Assembly Removal 1 Rod Attach Cap 3 Oyl 2 and 3 Assem 2 Cylinder Joint bly Using the proper size wrench 44mm 1 732 remove cylinder 2 rod attach cap by turning the cap counterclockwise to remove Once the attach cap is removed from cylinder 2 rod slide the cylinder 2 and 3 assembly out of the joint sleeve Move the cylinder 2 and 3 assembly to a suitable workbench for disassembly 3121222 SECTION 6 MAST COMPONENTS Cylinder Rod Assembly Removal from the Cylinder Barrel The following disassembly procedure for removing the gland end of the cylinder is t
142. PLATFORM GREEN YELLOW BLUE D 6 REFERENCE WIRING DIAGRAM FOR CIRCUIT BREAKER BROWN L BROWN BLUE N N BLUE GREEN YELLOW m GREEN YELLOW 4461249 WIRING DIAGRAM FOR PLUG ON CHASSIS GREEN YELLOW BLUE AFSNIT 107 2 01 PLUGS 8 SOCKETS GROUND PIN KEYED AMERICAN 2 X 4 WALL BOX 200V TO 250V P L 0215454 3121222 JLG Lift 9 41 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 12 HYDRAULIC SCHEMATIC qo ili IC 15 LITERS MIN 4 GPM STEERING LIFT TANK rap Los 1250 PSI NL p 86 BAR ram 1250 51 BAR IGHT LEFT EE 1600 Ps M 110 BAR 10 MICRON F 262cu in L 2792703_C Figure 9 21 Hydraulic Diagram 2792703_B 3121222 9 42 JLG Lift Battery posts terminals and related accessories contain lead and lead compounds chemical known to the State of Califormia to cause cancer and reproductive harm WASH HANDS AFTER HANDLING An Oshkosh Corporation
143. Retaining Washer 7 Steering Knuckle Lug 4 Knuckle Lug Attach Screws a 8 Drive Motor Power Harness c NOTE Before removing the drive motor spindle assembly disconnect machine power then disconnect the drive motor wiring harness item 8 either from the power module and unstrap from the harness from the steering arms or by removing the drive motor cover and disconnecting from the motor a Remove the spindle retaining ring item 2 lower and support drive motor spindle assembly just enough to access the top of the knuckle attach screws and remove them On final assembly apply Loctite 271 to the spindle to knuckle lug attach screws and torque to 70 ft 16 97 b Coat king pin with moly paste lubricant prior to installation of spindle assembly 4 10 JLG Lift 3121222 SECTION 4 BASE COMPONENTS 4 8 WHEEL DRIVE ASSEMBLY SERVICING The component parts of the left and right drive motor assemblies are identical The left drive motor is run in the reverse direction of the right motor FOR DETAILS ON THE TRACTION SYSTEM ELECTRICAL THEORY OF OPERATION SEE SECTION 4 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 Make all measurements with a voltmeter set to resistance scale Ohms Disconnect the Main Battery Disconnect and all drive motor cables du
144. SULATING WASHER APPLYING TORQUE MOTOR HOUSING Figure 4 8 Motor Terminal Assembly 8 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 9 Assemble strain relief bushing 14 around jacket of wire harness and slide into slot in cover 10 Align cover plate 12 with groove in frame and field and affix using 2 screws 11 Reinstall motor per instructions See Page 4 28 PRESS FIXTURE MUST PRESS AGAINST OUTER RACE BEARING END HEAD HELD STATIONARY ARMATURE ASS EMBLY ASSEMBLED END HEAD BEARING AND RETAINING RING PRESS FIXTURE MUST PRESS AGAINST INNER RACE HELD STATIONARY Figure 4 9 Bearing Replacement Procedure JLG Lift 4 17 SECTION 4 BASE COMPONENTS Main Gear Box Disassembly SPINDLE SUB ASSEMBLY HUB SUB ASSEMBLY INPUT CARRIER SUB ASSEMBLY Main Gear Box isassembly 1 Using a screwdriver pry the end of the Retaining Ring 19 out of the groove in the Hub Subassembly then grasp the loose end of the Retaining Ring 19 with pliers and pull the rest of the way out 2 Remove Cover 11 Thrust Washer 21 should remain in the inner counterbore of the Cover 11 when removed NOTE To remove the cover the motor must be
145. ULIC SYSTEM SEE SECTION 1 SPECIFICATIONS FOR MAXIMUM HYDRAULIC SYSTEM PRES SURE SETTINGS JLG Lift 6 17 SECTION 6 MAST COMPONENTS 27 NOTES 6 18 JLG Lift 3121222 SECTION 7 JLG CONTROL SYSTEM SECTION 7 JLG CONTROL SYSTEM 1 1 ELECTRONIC CONTROL SYSTEM The top level menus are as follows Also see menu flow charts Figure 7 1 and Figure 7 2 To Connect the Hand Held Analyzer es 1 Connect the four pin end of the cable supplied with DIAGNOSTICS the analyzer to the four position connector on the PCB and connect the remaining end of the cable to ACCESS LEVEL the analyzer PERSONALITIES See Table 7 3 on Page 7 11 NOTE The cable has a four pin connector at each end of MACHINE SETUP See Table 7 1 on Page 7 9 the cable the cable cannot be connected back wards ACTIVATE TESTS 2 Power up the Control System by turning the lower CALIBRATION key to the platform position and pulling both emer If you press ENTER at the HELP PRESS ENTER display gency stop buttons on and a fault is present during power up the analyzer dis play will scroll the fault across the screen If there was no Using the Analyzer fault detected during power up the display will read In platform mode With the machine power on and the analyzer connected HELP 001 properly the analyzer will display the following EVERYTHING OK In
146. URE 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 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 Prevented 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
147. age 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 HEALTH Status LED ON 7711 PUMP P LOW CHECK POWER CIRCUITS Drive Steer and Lift Prevented While steering or lifting up the voltage measured at the System Module s P terminal did not agree with the predicted value for at least 1000mS This issue may be caused by an open circuit of the pump wiring BF2 and P terminals or an internal fault Pump feedback does not increase more than 1 3V Pump feedback is less than 20 Battery Voltage Battery Voltage pump feedback is greater than 4V ZAPI HEALTH Status LED ON 7741 ARMATURE BRAKING CUR 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 3121222 JLG Lift 8 17 SECTION 8 DIAGNOSTIC TROUBLE CODES 7 1 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 7742 FIELD VOLTA
148. ame Mounted Elevation Limit Switch LI 3 Elevation Limit Switch Installation 1 Attach Screws 4 Mounting Holes in Frame AM 2 Elevation Limit Switch 5 Attach Nuts Warning Beacon Installation 3 Switch Mounting Block g 1 Beacon Assembly 2 Attach Screws Note Located on right front of machine frame behind drive wheel assembly next to mast Note Located on base frame just above the left rear wheel 5 2 JLG Lift 3121222 SECTION 5 CONTROL COMPONENTS Manual Brake Release Switch S LL Manual Brake Release Switch Installation 1 Release Switch 3 Nut 2 Washer 4 Charger Step Plate Cover Note Located on rear of machine under charger step plate cover ho 6 AC Power Breaker Box Installation CE Specification Machines ONLY The AC power breaker box is wired inline on the power cir cuit of the AC receptacle box mounted in the platform See illustration below for mounting instructions for Infor mation on the various plugs types and specific wiring for each plug type see Section 9 12 AC POWER RECEPTA CLES AND WIRING PLATFORM CE SPEC MACHINES ONLY in Section 9 of this manual AC Power Breaker Box Installation CE Specification Machines ONLY 1 Cover Plate Mounting
149. amming Information 4150473 F Machines Equipped with Sevcon 1600346 Power Module 7 9 7 2 Machine Configuration Programming Information 1001115626 8 Machines Equipped with ZAPI 1001092456 Power Module 7 10 7 8 Machine Personality Adjustment 4150472 H Machines Equipped with Sevcon 1600346 Power 7 11 7 4 Machine Personality Adjustment 1001115627 Machines Equipped with ZAPI 1001092456 Power 0 7 11 7 5 Tilt Cutout Settings EPIS BD REIN WW bam OA e Ever 7 13 9 1 Connector Loading 1 9 14 9 2 X Connector ID 9 17 9 3 Ground Board J1 Connector X001 1600346 Power Module 9 33 9 4 Ground Board J2 Connector 002 9 33 9 5 Ground Board J3 Connector 003 9 34 9 6 Platform Board J1 Connector 050 9 34 9 7 Plattorm Board J9 ur RR S RR BUR YU ERR RR pt ROT pud ea 9 34 9 8 Platiorm Board sic RUE eR ue ER UNE PEL 9 34 9 9 Power Module Co
150. ate areas of this manual for servicing and maintenance proce dures Annual Machine Inspection The Annual Machine Inspection must be performed by a qualified JLG equipment mechanic on an annual basis no later than thirteen 13 months from the date of the prior Annual Machine Inspection JLG Industries Inc recog nizes a qualified JLG equipment mechanic 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 appropri ate JLG inspection form for performance of this inspec tion 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 equipment mechanic as a person who by possession of a recognized degree certificate extensive knowledge train ing or experience ha
151. attery 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 improper wire harness ing range by the interface PCB 11V connection Drive Steer and Lift Prevented ZAPI HEALTH Status LED ON 4421 LOGIC SUPPLY VOLTAGE 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 1005 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 10uS connection Drive Steer and Lift Prevented ZAPI HEALTH Status LED ON 6 6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK 661 CANBUS
152. bove 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 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 KEYSWITCH FAULTY Both platform and ground modes are Check 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 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
153. c Ae M eene p ee dak eg uet 9 10 Wedge Lock er Be A Reel EE Pa Tre tem 9 10 Service Voltage 9 10 9 5 WORKING WITH DEUTSCH CONNECTORS 4 9 12 DT DTP Series 1 9 12 DT DTP Series n 9 12 HD30 HDP20 Series 9 12 HD30 HDP20 Series 1 9 13 9 6 X CONNECTOR 2 7 4 4 9 18 9 7 CONNECTOR LOADING DIAGRAMS 1 9 14 9 8 X CONNECTOR ID 1 0 2 41 9 17 9 9 MACHINE LOCATION OF COMPONENT X CONNECTORS 9 20 9 10 ELECTRICAL LAYOUT AND 5 2 0 9 22 9311 PIN INPUT OUTP T TYPES DA A Ree E NEP 9 33 9 12 AC POWER RECEPTACLES AND WIRING PLATFORM CE SPEC MACHINES ONLY 9 38 9 12 HYDRAULIC SCHEMATIC 1 9 42 3121222 JLG Lift V TABLE OF CONTENTS LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1
154. chine 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 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 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 3121222 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 appropri
155. circuit The left brake is powered TERY the left brake was commanded off with 24V from ground board J1 23 and its ground is to ground board J1 30 37 Brake solenoid resistance should measure about 20 Ohms Inspect the wiring for physical damage Replace ground board 3313 RIGHTBRAKESHORTTO Voltagewasdetectedontherightbrake 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 board J1 24 and its ground is to ground board J1 30 37 Inspect the wiring for physical damage Replace ground board 3314 LEFTBRAKE OPEN CIRCUIT Currentflowto the leftbrake solenoid was Check for continuity through this circuit The left brake is powered not detected during normal left brake with 24V from ground board J1 23 and its ground is to ground operation board J1 30 37 Brake solenoid resistance should measure about 20 Ohms 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 R
156. cle harness from that pin 3121222 5 4 POWER MODULE P N 1600346 NOTICE 1230ES SCISSORS BUILT STARTING IN MID YEAR 2010 REPLACED THE SEVCON POWER MODULE P N 1600473 WITH THE ZAPI POWER MODULE P N 1001092456 The Sevcon Power Module is located at the front left side of the machine inside the compartment as shown in Fig ure 5 3 below Use the following instructions when remov ing and installing the power module Figure 5 3 Power Module Installation 1 Power Module 2 Mounting Screws Removal 1 Turn off power machine power and disconnect the batteries NOTE Note the wire terminal locations when removing the Power Module See Figure 5 1 2 Disconnect all wires from the power module and remove the module mounting bolts remove module from the machine Installation 1 Besure that the terminals are oriented as shown 2 After installing the power module begin connecting the wires back to the controller Reference Figure 5 1 JLG Lift 5 7 SECTION 5 CONTROL COMPONENTS DO NOT OVERTIGHTEN THE TERMINAL BOLTS OR DAMAGE TO THE UNIT COULD OCCUR 3 Torque the terminal bolts to 5 ft Ib 7 Nm 4 After all connections to the power module are made the battery can be reconnected AS a 9 Figure 5 4 Sevcon Power Module Terminals
157. control system uses a combination of the elevation proximity switch and pothole protection switches to deter mine if the platform is elevated If these sensors do not agree a fault is thrown Joystick The joystick is used to command both lift and drive The Lift Drive switch selects which one is applicable This command may be modified by the control system based on interlocks and personalities On the joystick there are three switches and the control handle The joystick control handle sensor is not a simple potentiometer There is a position sensing element and signal conditioning circuitry in it to generate the position signal It is powered by 5VDC supplied from the platform controller When centered it will output approximately 2 5VDC Fully forward it will output approximately 1 VDC Fully backward it will output approximately 4 VDC On the handle is the trigger switch that must be depressed in order to operate the vehicle This prevents unintentional movement To pass start up tests the three switches must be open and the joystick must be centered Joystick personalities to define the centered position where command is 0 minimum and maximum for ward as well as minimum and maximum reverse can be accessed Joystick system Personality settings can be changed via ANALYZER gt PERSONALITIES gt ACCEL ERATOR as follows FWD MIN The forward extent of the centered position Values between this and REV MIN are where 0
158. cor rectly Also check that the lead on the 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 05 A 3121222 JLG Lift 9 1 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Voltage Measurement Resistance Measurement Figure 9 1 Voltage Measurement DC Figure 9 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 contact with meter leads tance Circuit power must be turned OFF before testing resistance Disconnect component from circuit before testing f meter is not auto ranging set it to the correct range See multimeter s operation manual Use firm contact with meter leads 9 2 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Continuity Measurement Current Measurement m Q 1 ho MEME Figure 9 3 Continuity Measurement Some meters require a separate button press to enable audible continuity t
159. ction to the charger and the charger still displays no lights at all return the charger for service FAULT LED Flashing The Fault LED flashes to indicate the micro controller inside the battery charger has detected a fault The fault detected is indicated by the number of flashes Count the number of flashes to determine the fault With any battery system the most common problem will be a faulty battery connection Because of the high 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 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
160. d 4 Retain the Motor Shaft Bearing 15 installing Spiral Retaining Ring 28 into groove in Spindle 1 5 Use the Output Planet Pin 10 as a pressing tool to install the Planet Bushing 26 into the bore of each Planet Gear 9 The shaft will help guide the bushing into the bore as well as prevent damage from the press 6 Place Tanged Thrust Washer 32 into each planet window of the Spindle 1 Make sure the tang sits in the cast groove on the inside of the window 7 Placea Thrust Washer 25 onto the Output Planet Gear 9 Line up the bores as best as you can Use grease to hold the Thrust Washer in place 8 Slide the Output Planet Gear 9 into the window with the Tanged Thrust Washer 32 until the bores line up 9 Insert an Output Planet Shaft 10 into the Planet Shaft hole of the Spindle 1 and through the bores of the Thrust Washers 25 amp 32 and the Planet Gear 9 10 Before pressing the Output Planet Shaft 10 into the Spindle 1 make sure the gear spins freely continued next page 4 22 JLG Lift 3121222 SECTION 4 BASE COMPONENTS 11 Press the Output Planet Shaft 10 into the Spindle 1 until it bottoms out Make sure the Output Planet Gear 9 turns freely after the Planet Shaft is pressed in 12 Repeat Steps 5 11 for the other two Output Planet Gears 9 13 Turn the Spindle 1 over so that the carrier end is down 14 Using a flat plate or rod press the Motor Shaft Seal 17 i
161. d 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 able range of 0 50V 4 5V oris unstable Check the joystick signal and its wiring The joystick input 5V is from the platform board terminal J1 5 its output 2 5V with 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 STEERSWITCHESFAULTY Thesteerleftandsteerrightinputs were Check if the steer switches 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
162. d in Table 5 5 Battery Algorithms Contact JLG if your specific battery model is not listed Each time AC power is applied with the battery pack not connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the Yellow Charging LED A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause 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 Remove the AC power from the charger and recon
163. der to the hollow rod of the second cylinder That extends the second cylinder The barrel of the second cylinder is attached to the barrel of the third cylinder A port in the barrel of the second cylinder passes fluid to the third cylin der This extends the third cylinder and lifts the platform To bring down the platform the lift down valve opens pro portional to joystick position and allows fluid out of the cylinder allowing it to retract by gravity Figure 3 4 LIFT SYSTEM The Power Module 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 ter minal of the pump connects to the P Terminal of the Power Module which switches current through MOSFET transis tors to the Battery Negative 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 and 50 Off approximately 1 of the available Battery power will be applied to the pump motor Similarly the MOSFET are On continuously 10096 Duty Cycle to 3121222 JLG Lift 3 5 SECTION 3 THEORY OF OPERATION 1230ES apply all available Battery power to the pump motor as in 3 7 STEER Lift Up at full speed Steering is actuated by a doubl
164. dicated cycle power then select proper model Then enter per sonality settings recorded above 8 18 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 9 9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 996 POWER MODULE 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 ZAPI HEALTH Status LED FLASHING 997 POWER MODULE FAILURE The power module detected an errorin _ 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 FUNCTIONLOCKED OUT Thepowermodule software versionisnot Replace power module to clear fault POWER MODULE SOFT compatible with the restof the system WARE VERSION IMPROPER 9910 FUNCTIONLOCKED OUT The platform board software versionis Reprogram platform board PLATFORM MODULE SOFT notcompatible with the restof the system WARE VERSION IMPROPER 9911 FUNCTIONLOCKED OUT Theload sensing system module soft _ Replace LSS m
165. e action hydraulic cylinder Line Contactor To change steering angle of the drive wheels the steer left or steer right solenoid is energized and the pump is ener gized Pressure is applied to one side of the piston and drained from the other The pump speed and thereby the rate of steering angle change is adjusted based on drive speed This adjustment is modified by steer personality settings Series DC Pump Motor Power Module STEERING Figure 3 5 Hydraulic Pump Electrical Schematic erm Homme me mme ete he tte he RIBR AR 1600423 SEVCON Power Module When the Control System is energized the voltage at the P Terminal will be approximately 24 referenced 10 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 Personalities Lift system Personality settings can be changed via ANA LYZER gt PERSONALITIES gt LIFT ACCEL Time to ramp from 096 to 100 command DECEL Time to ramp from 10096 to 096 command cH UP MIN Minimum pump speed up Creep Figure 3 6 STEER SYSTEM UP MAX Maximum pump speed up Personalities DN Minimum pump Speed down Creep Steer system Personality settings can be changed via DN MAX Maximum pump speed down ANALYZER gt PERSONALITIES gt STEER STATIC
166. e brushes 3 that are worn below their usable length 600 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 commutator failure and excessive brush wear 3 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 4 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 torqued 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 4 16 JLG Lift Figure 4 7 Drive Motor End View Brake End 5 Visually inspect the armature 2 assembly for signs of overheating or physical damage Visually inspect the seal surface of the shaft for excessive wear Check for grounded circuits using a dielectric tester by applying voltage between
167. e machine 6 Loosen the bleeder valve on the cylinder being bled Be certain the other end of the bleeder tube is in the catch container 7 Setthe platform control station to platform lift mode and push the joystick to lift the platform Do not allow the platform to lift to far off the stowed position re lower and lift again if necessary 8 Watch the bleeder tube when a constant flow of oil 1 no bubbles is visible close the bleeder valve Mast Lower End Installation 9 Remove the bleeder tube and line wrench and move 1 Control Cable P Clamp a 3 Left Front Mast Mounting to the next cylinder in sequence Repeat steps 6 2 Route Cable Through Notch Bolt b through 8 until all three cylinders are bleed 10 It is recommended that the platform be cycled up Note a Install clamp between washer and nut of the right rear and down a few full lifts Then repeat step 1 mast mounting bolt 11 Finally repeat steps 6 through 10 again then cylinder b An extra washer may be required to space the screw bleeding is completed away from the RED manual descent button on the lift cylin der Torque mast mounting bolts to 62 ft Ibs 88 Nm Mast Installation Completion tighten in an X cross tightening pattern d tig dd Once mast is installed and properly bled to remove the air from the hydraulic lift system wipe off any excess hydrau 12 Atthe top of the mast if reinstalling the power trak lic oil
168. e machine if error still exists replace System Module 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 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 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 10065 Cycle machine if error still exists replace System Module ZAPI HEALTH Status LED FLASHING 3121222 JLG Lift 8 19 SECTION 8 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 FAIL
169. e platform assembly be removed See Section 6 6 before removing the mast 3 Lower the platform assembly approximately half way assembly separately down the mast then reinstall the slide pads at the bottom corners of the platform mast section See Figure 6 5 Item 1 4 Continue to lower the platform assembly at the top of the mast guide the cylinder rod of hydraulic cylin der 3 into the cross support located at the top of the platform assembly mast section Install the detent bolt and nut tighten securely See Figure 6 5 Item 2 5 Pullthe electrical harness cables out through the top of the platform mast section and lay over the right side of the mast 6 Reattach the power trak cable guide using the two 2 bolts and nuts to the lug at the top of the platform mast section See Figure 6 5 Item 2 7 Route the electrical cables down the right side of the mast section and reinstall the metal cable cover using the two 2 screws previously removed 8 Reattach the AC receptacle box to the side of the mast and install the platform control box to the plat form control box mounting plate Attach the platform control box cable harness to the bottom of the con trol box 1 9 Reconnect machine power at the right side batteries quick disconnect connector 10 Power machine up and cycle the mast up and down few times look inside the top of the mast to cer tain the power trak and harness cables are fr
170. e platform is elevated Drive may be prevented by a different interlock however Drive will be prevented if any of the following occur e Vehicle is tilted elevated and ANALYZER gt MACHINE SETUP gt CUTOUT is set to YES Batteries are being charged is applied to ground board J1 29 Vehicle is elevated above the calibrated Drive Cutout height and ANALYZER gt MACHINE SETUP gt DRIVE CUTOUT is set to YES 3121222 SECTION 3 THEORY OF OPERATION 1230ES 3 6 PUMP LIFT MAST An electrically driven hydraulic pump provides hydraulic pressure to actuate the steering and lift up Lift down is powered by gravity The lift actuator is a three stage hydraulic cylinder The cylinder pistons are not sealed so fluid can flow from one cylinder to the next The area of the piston that fluid touches on both sides does not provide lift because the forces on both sides cancel each other The area of the piston with the rod behind it provides the lifting force necessary because no pressure is there to cancel the force applied by the pressure on the other side To lift the platform the solenoid energizes and opens the lift up valve The pump speed is set proportional to joy stick position Fluid flows into the first cylinder through the hollow rod This extends the barrel of the first cylinder The rod to the second cylinder is attached to the barrel of the first cylinder Fluid is passed by a port in the first cylin
171. e procedure show above for motor cover removal Once the motor cover is removed blow any accumulated brush dust from inside the cover and around the brushes and armature commutator Check brushes 4 36 JLG Lift 3121222 SECTION 4 BASE COMPONENTS 4 10 POT HOLE PROTECTION SYSTEM Pot Hole Protection System Components Some components hidden for illustrative purposes only 1 PHP Actuator Platform 9 PHP Link Plate 2 Right Left PHP Limit Switch 6 Right PHP Bar 3 Right Side Counterbalance Link T Left PHP Bar 4 Left Side Counterbalance Link 8 Spacer Tube and Torsion Springs FLANGE BEARING MUST BE ORIENTED AS SHOWN TOWARDS LINK PLATE e STELLE 1 2 3 4 PHP Pin and Flange Bearing Installation 1 PHP Link Plate Pin 2 Flange Bearing 3 PHP Counterweight Link 4 Retaining Ring 3121222 JLG Lift 4 37 SECTION 4 BASE COMPONENTS Actuator Limit Switch Counterweight Installation Machines Prior to S N 0130013258 1 Actuator Attach Screws Nuts 6 Torsion Spring c 2 PHP Actuator Assembly 7 Tube Spacer 3 Limit Switch a 8 Counterbalance Link Mounting Pin 4 Limit Switch Mounting Block b 9 Pin Retaining Ring 5 Limit Switch Attach Screw
172. e sensor is securely mounted DETECTING CHANGE angle sensor did not change 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 e Check contactor main contact wiring 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 while contactor should be closing If this happens replace contactor Replace the line contactor 312 CONTACTORDRIVERPER 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
173. e 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 7 12 Enter Access Level 1 and go to the CALIBRATION TILT SENSOR LEVEL VEHICLE screen 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
174. e 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 Inspect the wiring for physical damage Replace ground board 3310 STEERRIGHTOPENCIR The ground board did notdetectcurrent Check for continuity through this circuit Steer right solenoid CUIT flow to the steer right solenoid during 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 The ground board detected voltage while 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 Inspect the wiring for physical damage Replace ground board 3312 LEFT BRAKE SHORT The ground board detected voltage while Check for continuity through this
175. ed 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 repair or replace the elevation angle Sensor 007 DRIVINGAT CUTBACK POT While stowed drive speed is reduced Check for obstructions around the pot hole protection mecha HOLE STILL ENGAGED since the control systemdetectedthatthe 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 control Normal operation should resume after a power cycle SYSTEM POWERED DOWN system enters a low power state topre Check batteries charge condition etc serve battery charge 009 DRIVEPREVENTED ELE The platform is elevated a
176. ed 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 9 8 HD HDP Contact Installation 8 Grasp contact about 25mm behind the contact crimp barrel 9 Hold connector with rear grommet facing you 9 12 JLG Lift 3121222 SECTION 9 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 9 9 HD HDP Locking Contacts Into Position NOTE For unused wire cavities insert sealing plugs for full environmental sealing HD30 HDP20 Series Disassembly zT Figure 9 10 HD HDP Contact Removal 11 With rear insert toward you snap appropriate size extractor tool over the wire of contact to be removed 12 Slide tool along into the insert cavity until it engages contact and resistance is felt 13 Pull contact wire assembly out of connector TOOL INSERTED TO UNLOCK CONTACT TOOL AND CONTACT REMOVED Figure 9 11 HD HDP Unlocking Contacts NOTE Do Not twist or insert tool at an angle 9 6 X CONNECTOR REFERENCES Throughout t
177. ee of interference and not being pinched in any way 11 If operation is OK reinstall the mast section top cover Figure 6 6 Mast Installation Front of frame shown cutaway for illustrative purposes only 1 Mast Assembly 2 Fastening Hardware 6 6 JLG Lift 3121222 SECTION 6 MAST COMPONENTS Mast Removal NOTE To ease removal and installation of the mast assem bly it is recommended that the complete machine be elevated on suitable stands to allow easy access to the mounting bolts on the base of the mast assem bly Lower the mast assembly completely before begin ning the mast removal process to ensure no residual pressure remains in the lift cylinder Attach an overhead crane by strap through the cross supports on the top of mast sections Figure 6 7 Mast Base Mounting Hardware Front of frame shown cutaway for illustrative purposes only 1 2 NOTE 3121222 Mast Assembly Fastening Hardware 3 20 Ga 0359 in Mounting Shim Remove the four 4 bolts nuts washers and shims from the base mount of the mast Access the bolts and nuts through the access holes in the bottom and front of the base frame Before removing the mast off the machine you must decide which way you want to disconnect the har ness cables to the AC receptacle box and platform control box running thro
178. egative 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 are still attached to the contact and contacts are seated in the connector Min Max Use of the Min Max recording feature of some meters can help when taking measurements of intermittent conditions while alone For example you can read the voltage applied to a solenoid when it is only operational while a switch far from the solenoid and meter is held down Polarity Finding a negative voltage or current reading when expecting a positive reading frequently means the leads are reversed Check what reading is expected the location of the signal and that the leads are connected to the device under test
179. ent on an angle keep in mind that the capacity of an eyebolt or sim ilar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees 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 Pressure Fit Parts Figure 2 1 Platform Mast Support Tool When assembling pressure fit parts use an anti seize or 1 Elevate platform outer mast 1 approximately 3 ft 1m molybdenum disulfide base compound to lubricate the 2 Place JLG P N 1001094004 mast support tool 2 between mating surface the mast and the front frame by hooking the bracket 3 over the front frame plate at bottom as shown above 3 Lower the platform until the bottom edge of the platform outer mast section 1 is resting on the hook bracket 4 at the top of the mast support tool 3121222 JLG Lift 2 5 SECTION 2 GENERAL SERVICE INFORMATION Bearings When a bearing is removed cover it to keep o
180. eplace ground board 8 12 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 3 3 Ground Output Driver 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 STEER LEFT VALVE SHORT Drive Steer and Lift Up Prevented Excessive current flow to the steer left solenoid detected J2 9 TO GROUND NLV e ZAPI HEALTH Status LED ON 33299 LINE CONTACTOR COIL Drive Liftand Steer Prevented Voltage from an external source was detected on the Negative SHORT TO BATTERY Main Line Contactor 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 TOBATTERY J1 12 J1 17 J1 23 J2 14 or J2 15 Normally these pins are grounded by the System Module All functions are prevented to protect the control system ZAPI HEALTH Status LED ON 33303 NEGATIVE SUPPLY SHORT Drive Lift and Steer Prevented 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
181. er Digital Output 35 Spare Digital Output Low Side Driver Digital Input High Sensing Digital Output 3121222 JLG Lift 9 35 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 36 Table 9 11 Power Module J2 1001092456 Power Module ONLY Pin Function Type 1 Spare Connectto 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 CANbusHigh Serial 0 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 Connect to 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
182. er mast section mounting plates are aligned with the holes in the base frame mounting plates See Figure 6 7 Check the side to side play between the mast mount and the frame mount shim equally to both sides until side to side play is removed Install the mast mounting bolts nuts and washers with the nuts inboard 3121222 SECTION 6 MAST COMPONENTS 11 Before tightening the mast mounting bolts nuts Multi Stage Hydraulic Cylinder Cylinder Bleeding check mast for vertical front rear and left right Procedure plumb Per following table Plumb maximum Front Rear 3in 76mm NOTICE Plumb maximum Left Right 2 in 50mm THE THREE STAGE CYLINDER MUST BE BLED IN THE SEQUENCE OF CYL 1 THEN CYL 42 THEN CYL 3 Tighten the mast mounting bolts nuts to 62 ft Ibs 88Nm in the following sequence 1 First check that hydraulic oil level is between the min max markings on the side of the pump reser 1 Left Front 3 Left Rear voir 2 Right Rear 4 Right Front 2 In the platform if necessary remove the mast cover from the top of the mast assembly 3 Place the proper size 90 angled line wrench on the bleeder valve of cylinder 1 See Figure 6 3 for orientation of bleeder valves 4 Attach a plastic tube to the bleeder valve on cylinder 1 use a tube long enough to hang over the side of the mast assembly and place the loose end into a container to catch the hydraulic fluid 5 Power up th
183. es T Left Drive Motor 3 Power Module 8 Battery Power Quick Disconnect 4 Main Power Contactor Relay 9 To Battery Charger 5 Hydraulic Pump Motor 10 To Charger or Inverter Option If Equipped 3121222 JLG Lift 4 31 SECTION 4 BASE COMPONENTS Pump Components The following is a complete disassembly assembly of the machines pump motor valve assembly NOTE During reassembly of the pump motor assembly lubricate all seals and o rings with JLG recom mended hydraulic fluid Also keep all internal metal parts clean and coated with hydraulic fluid to prevent surface corrosion JLG recommends replacing all seals and o rings when disassembling and reassembling the pump motor unit Figure 4 12 Hydraulic Pump Hydraulic Line and Electrical Connections Steer Right Hyd Line 6 Steer Right Solenoid Steer Left Hyd Line 7 Steer Left Solenoid Cyl Lift Up Hyd Line 8 Pump Motor Pos Cyl Return Hyd Line 9 Pump Motor Neg Cylinder Lift Up Solenoid oF 4 32 JLG Lift Hydraulic System Pressure Check Port The port for hydraulic system lift pressure check is pro vided on the valve body of the hydraulic pump assembly as shown in the following illustration Hydraulic Pressure Check Port 2 Pressure Check Port Shown with Optional Fitting 1 Pump Valve Body 3121222 SECTION 4 BASE COMPONENTS Hydraulic Syste
184. es when charging or operating BATTERY FILLER CAP m 1 8 FLUID LEVEL FULLY CHARGED BATTERY VENT TUBE Figure 5 8 Battery Fluid Level JLG Lift 5 19 SECTION 5 CONTROL COMPONENTS Battery Installation Left Side Battery Installation 1 Batteries 4 Washer 2 Bolt 5 Locking Nut 3 Hold Down Clamp 6 Attach Battery Temperature Sensor To This Terminal TS y Right Side Battery Installation 1 Batteries 4 Washer 2 Bolt 5 Locking Nut 3 Hold Down Clamp See Section 1 of this manual for battery specifications 5 9 BATTERY CHARGER INSTALLATION The battery charger is located in the compartment at the rear of the machine remove the charger step plate cover to gain access to the charger T Battery Charger Assembly Installation 1 Battery Charger Assembly 3 AC Voltage Input Cable 2 Attach Screws Washers 4 LED Power Interlock Cables LED Power Interlock Cable Identification 1 Charger Interlock
185. essive grades or there is a drive motor issue that causes high armature current brake applied when driving short circuited armature etc c 8 Flashes on Power Module LIFT UP AT CUTBACK POWER MODULE CUR RENT LIMIT 4 2 a The Pump portion of the Power Module has reached thermal limit Allow to cool by waiting for temperature to fall b May indicate that the vehicle s lift function is being used outside duty cycle considerations or there is a pump motor issue that causes high current worn brushes worn commutator etc c 8 Flashes on Power Module BATTERY VOLTAGE TOO LOW SYSTEM SHUT DOWN 4 4 a 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 Recharge batteries or check for damaged batteries b May indicate low battery charge a battery charger issue or a power wiring issue c 7 Flashes on Power Module d Drive Steer amp Lift Up Prevented BATTERY VOLTAGE TOO HIGH SYSTEM SHUT DOWN 4 4 a The Power Module momentarily measured excessively high Battery Voltage gt 37 0V and the Ground Module de energized the Ignition Relay to protect system devices This may be due to improper battery charging or incorrect voltage batteries being used b May indicate a battery charger issue wrong bat tery type is installed or a faulty Power Module c 7 Flashes on Power Module d Drive Steer
186. esting 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 9 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 f 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 3121222 9 3 SECTION 9 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 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 ci
187. face 1 JLG Lift On the Analyzer go the Diagnostics System and read the tilt angle If either angle reports 20 0 there is an electrical electronic failure tilt sensor control board electrical connections a Take the Ground Control box off of the machine and open 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 b NOT LEVEL tilt sensor has either developed an offset or it is too unlevel as mounted on the machine 3121222 SECTION 7 JLG CONTROL SYSTEM 3121222 7 5 TILT SENSOR ELECTRICAL EVALUATION This basic check using the JLG Analyzer can be used to test the Tilt Sensor If angle measurements read 20 0 then 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 t
188. ferent brands or types as they may not contain Description Model 1230ES the same required additives or be of comparable Voltage 24V System Series 6V per battery deep cycle viscosities If use of hydraulic oil other than Mobil fluid DTE 11M is desired contact JLG for proper Amp Hour Standard Battery 220 Amp Hour 2 20 HR Rate recommendations Reserve Capacity 447 Minutes 1 2 JLG Lift 3121222 SECTION 1 MACHINE SPECIFICATIONS Lubrication Specifications Table 1 9 Lubrication Specifications NOTE Care should be taken not to introduce any impurities dirt water etc while cap is removed Key Specifications MPG Multipurpose Grease having a minimum dripping point of 350 Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil Mobil DTE 11M or Nervofluid 15 Europe Table 1 10 Hydraulic Oil Specifications Specification Mobil DTE 11M Nervofluid 15 ISO Viscosity Grade 15 15 Gravity API 31 9 Pour Point Max 40 F 40 C 40 C 40 Flash Point Min 330 166 C 175 C 347 Viscosity Specifications at 40 C 15 cSt 14 9 2 9 at 100 C 4 1 cSt 3 8mm s at 100 F 80 SUS 81210 43505 cp at 30 F 3 200
189. ficulty with Line Contactor coil wiring or a faulty Power Module c No Flash Code on Power Module d Drive Steer amp Lift Up Prevented 3 LINE CONTACTOR MISWIRED ON OR WELDED 3 2 a The Power Module s Line Contactor Drive Cir cuitry passed power up self tests but the Line Contactor was closed at power up or failed to open when de energized b May indicate a faulty Line Contactor difficulty with Line Contactor coil wiring or difficulty with power wiring c 4 Flashes on Power Module d Drive Steer amp Lift Up Prevented 4 CONTACTOR DRIVER PERMANENTLY ON 3 2 a The Power Module s Line Contactor Drive Cir cuitry failed to de energize during power up self tests b May indicate difficulty with Line Contactor coil wiring or a faulty Power Module c No Flash Code on Power Module d Drive Steer amp Lift Up Prevented 5 POWER MODULE TOO HOT PLEASE WAIT 4 2 a The Power Module for Drive Steer and Lift Up has reached thermal cutout Allow to cool by powering down 3121222 JLG Lift e 7 8 9 b May indicate that the vehicle is operating in extremely high ambient temperatures or a faulty Power Module c 8 Flashes on Power Module DRIVING AT CUTBACK POWER MODULE CUR RENT LIMIT 4 2 a The Traction portion of the Power Module has reached thermal limit Allow to cool by waiting for temperature to fall b May indicate that the vehicle is operating on exc
190. from accessible surfaces of the mast and hydraulic reach down into the power trak compartment and cylinder If necessary check the lift system hydraulic pres pull the power trak assembly up attach the hanger sure setting Cycle the mast up and down a few times then bracket to the top of the mast assembly See Figure check at the top and bottom of the mast for any hydraulic 6 13 oil leaks 13 Re install the platform assembly See Platform Instal lation on page 6 5 3121222 JLG Lift 6 11 SECTION 6 MAST COMPONENTS 6 8 MULTI STAGE HYDRAULIC CYLINDER SERVICING Refer to Section 3 6 PUMP LIFT MAST Theory of Operation for more detailed information on Hydraulic System Overview The hydraulic cylinder for this machine is a multi stage three cylinder design 6 12 Cyl 3 Cyl 3 Cyl 3 Cyl 3 Cyl 3 Cyl 1 Figure 6 15 1230ES Lift Cylinder Internal Components Top End Gland 7 Wiper Seal 8 Main Seal 9 Gland Wire Retaining Ring 10 Gland O Ring Seal 11 End Cap a JLG Lift Cyl 1 Cyl 1 Cyl 1 Cyl 1 Cyl 1 Piston Retaining Ring Piston Piston Guide Ring Piston Damping Spring Rod Guide Spacer 3121222 SECTION 6 MAST COMPONENTS 1 gt Figure 6 16 1230ES Lift Cylinder Internal Components
191. g Investigate by discon necting the drive motor cable from the motor and re measure resistance isolation Resistance 1 mOhm Blue Field Wire to Motor Housing The field winding should also be electrically isolated from the motor housing Low resistance may be an indication of a crushed cable a burned cable or a burned field winding Investigate by disconnecting the drive motor cable from the motor and re mea sure resistance isolation Resistance 1 mOhm Red Armature Wire to Blue Field Wire The armature and field windings should also be electrically isolated from one another Low resis tance 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 4 11 SECTION 4 BASE COMPONENTS Roll And Leak Testing 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 NOTE The brake must be released before performing the roll test This can be accomplished by supplying 24 Volts D C to the gray 2 pin brake connector The Roll Test The purpose of the roll test is to determine if the unit s gears are rotating freely and properly You should be able to rotate the wheel or hub of the gearbox by hand
192. g ring pliers install the Retaining Ring 24 into the groove of the Output Sun Gear 8 Make sure that the Retaining Ring 24 is correctly seated in the groove and that the Output Sun Gear 8 cannot be pulled out of the Input Carrier 7 5 Place a Thrust Washer 25 on each side of the Input Planet Gear 5 Line up the bores as well as you can visu ally Additional grease may help hold everything together 6 Place the Input Planet Gear 5 and Thrust Washers 25 onto the Input Planet Shaft 6 sticking out from the Input Carrier 7 Repeat 5 4 6 for the other 2 Planet Gears 8 Putthe Thrust Plate 23 onto the three Input Planet Shafts 6 Use the three holes on the innermost bolt circle The other three holes are for a different gear ratio 9 Using the appropriate retaining ring pliers put a Retaining Ring 18 into the groove of each Input Planet Shaft 6 NOTE Do not overstress the Retaining Rings 18 3121222 JLG Lift 4 25 SECTION 4 BASE COMPONENTS Main Gear Box Sub Assembly SPINDLE SUB ASSEMBLY HUB SUB ASSEMBLY INPUT CARRIER SUB ASSEMBLY 4 26 1 2 3 4 5 6 T 8 Main Gear Box Sub Assembly Inspect seal surface of Spindle 1 Remove any debris that may be present Apply a coating of grease to the Lip Seal not shown in the Hub Subassembly Place Spindle 1 Sub Assembly on table with carrier side up Carefully install the Hub Subassembly sea
193. g tolerances of the compo nent 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 gener ally results in faulty operation Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Cloudy oils indicate a high moisture content which per mits organic growth resulting in oxidation or corrosion 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 operating are recommended for use NOTE Metal particles may appear in the oil of new machines due to the wear in of meshing compo ticles is found in the hydraulic system drain and flush the nents entire system Disassemble and reassemble parts on clean work sur face Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assem bly 2 6 JLG Lift 3121222 SECTION 2 GENERAL SERVICE INFORMATION 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 g
194. ger 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 power source and VENTED CHARGERCON cleischarging is configured to 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 loadis 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
195. gt ZEROED should be about OV when stowed and about 0 15V at cutback 005 DRIVE amp LIFT UP PRE VENTED TILTED amp ELE VATED Driving is not possible since the platform is elevated and the chassis is not level Check that the machine is tilted If so lower the platform and reposition the machine to a level surface Fully stow the platform The tilt sensor is part of the ground control box Check that the ground control box is secured to the machine Check that the pothole protection switches are securely mounted Check that the elevation angle sensor is securely mounted Check the ANALYZER gt MACHINE SETUP gt MARKET configu ration If 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 3121222 JLG Lift SECTION 8 DIAGNOSTIC TROUBLE CODES 0 0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 006 Thevehicle hasreachedthe maximum Check that the zone is set appropriately for the platform load HEIGHT ZONE A height and further lift up motion is Check that the platform height is at the rat
196. gure 6 14 1 Power Trak Cable 2 Power Trak Guide 3 Power Trak Assy Power Trak Shield Installation 5 Shield Mounting Bolts 6 Mounting Nuts 7 Power Trak Shield Assy 4 Tie Strap JLG Lift 6 9 SECTION 6 MAST COMPONENTS Slide the inner mid and the mount inner mast sec tions into the outer mid mast section At the top of the mast assembly install the power trak assembly into the power trak compartment of the mount inner mast section See Figure 6 13 Attach the power trak hanger bracket to the mount inner mast section See Figure 6 13 Slide the multi stage hydraulic cylinder into the hydraulic cylinder compartment of the mast assem bly See Figure 6 12 Attach the cylinder rod of cylinder 1 and 2 into their anchor cross bars at the top of the mast assembly Secure using the proper bolt and nut assembly See Figure 6 11 6 10 1 Tool Simular Fabricate 2 Detent in Cylinder Rod Hydraulic Cylinder Installation 3 Rod Anchor Brackets Mast Installation 1 10 JLG Lift Move the mast assembly near the machines base frame At the top of the mast assembly attach a lift ing strap and lift the mast assembly into a vertical position Open the bleeder valve at the top of hydraulic cylin der 1 then pull the cyl
197. he mast fully extended Do not exceed the MAXIMUM pressure settings 4 33 SECTION 4 BASE COMPONENTS Pump Motor Valve Assembly Removal Installation a 1 ee Hydraulic Pump Valve Tank Installation 1 Pump Valve Tank Assembly 2 Pump Assy Mounting Screw Nuts 3 Static Strap 4 Valve Bank Solenoid Connections 5 Steer Lift Up Return Hydraulic Lines 6 Pump Motor Power Connection Terminals a NOTE a Apply dielectric grease to terminals during installation of cables Torque nuts to 5 7 ft Ib 7 9 Nm A CAUTION BE CERTAIN THE MAST IS FULLY LOWERED BEFORE REMOV ING ANY HYDRAULIC LINES FROM THE PUMP UNIT WEAR PRO TECTIVE GEAR WHEN WORKING AROUND PRESSURIZED HYDRAULIC LINES REMOVE CONNECTIONS CAREFULLY AND CAP ALL LINES 1 4 34 Disconnect machine electrical power using the quick disconnect on the left side batteries Disconnect the pump motor power cables from the power terminals on the side of the motor housing JLG Lift Label and then unplug the harness connectors from the lift up and steer solenoids on the pump valve bank assembly Label and careful
198. he pin retaining ring 3121222 JLG Lift 4 39 SECTION 4 BASE COMPONENTS 27 NOTES 4 40 JLG Lift 3121222 SECTION 5 CONTROL COMPONENTS SECTION 5 CONTROL COMPONENTS 5 1 CONTROL COMPONENTS OVERVIEW Control Components Overview 1 Platform Control Station 5 Warning Beacon 9 Main Contactor Power Relay 2 Ground Control Station 6 Right Side Batteries 10 Elevation Cut Back Sensor 3 Manual Brake Release Switch 7 Ground Alarm 11 Left Side Batteries 4 Battery Charger or Inverter Charger 8 Power Module 3121222 JLG Lift 5 1 SECTION 5 CONTROL COMPONENTS 5 2 CONTROL COMPONENTS SERVICE Ground Alarm Main Power Contactor Relay The main power contactor relay is located on the bulk head on the right front inside the compartment as shown following Ground Alarm Installation 1 Ground Alarm 2 Attach Screws Main Power Relay Installation Note Remove the charger step plate cover on the rear of the machine mounted just above the battery charger 1 Main Power Relay 2 Attach Screws Note See See Figure 5 1 for electrical wiring connections Warning Beacon Fr
199. he same for cylinders 1 2 and 3 3121222 Figure 6 19 Cylinder Rod Gland Removal 4 Cylinder Gland 5 Spanner Wrench Tool 48mm 1 889 Dia Cylinder Barrel Gland Wire Retaining Ring Retaining Ring Slot Hole co 1 Using pliers and small screwdriver fish the end of wire retaining ring out of the slot on the gland end of the cylinder barrel 2 Place the spanner wrench pins 48mm 1 889 diameter into the slots in the end of the gland 3 Now slowly rotate the gland pulling the gland retain ing ring out of the slot in the side of the cylinder bar rel Keep rotating gland until the hood end of the retaining ring is aligned with the hole in the slot and lift the retaining ring completely free of the cylinder barrel 4 Place a container below the end of the cylinder bar rel and carefully pull the gland out of the end of the cylinder barrel Allow any hydraulic oil to drain NOTICE 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 5 Carefully slide the rod assembly out of the cylinder barrel and place on a clean surface preferably a workbench Piston Removal from Cylinder Rod Figure 6 20 Cylinder Rod Piston Removal 1 Piston Retaining Ring 2 Piston 3 Compression Spring 4 Piston Guide Ring 5 Retaining Ring Slot on
200. he 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 TRACTION the JLG Analyzer s ARM CUR display Armature Current Reading will hover around 350A The FLD CUR dis play Field Current Reading will hover around 40A Neither wheel will rotate and it will be impossible to rotate either drive wheel by hand The Ground 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 3121222 SECTION 5 CONTROL COMPONENTS Figure 5 1 Main Electrical Power Connections 1600346 SEVCON Power Module 1 Right Side Batteries 6 Right Drive Motor 2 Left Side Batteries T Left Drive Motor 3 Power Module 8 Battery Power Quick Disconnect 4 Main Power Contactor Relay 9 To Battery Charger 5 Hydraulic Pump Motor 10 To Charger or Inverter Option If Equipped 3121222 JLG Lift 5 5 SECTION 5 CONTROL COMPONENTS
201. hers is the first consideration when engaging in the maintenance of equipment Always be conscious of component weight and 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 ade quate support is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR B HYDRAULIC SYSTEM SAFETY 1 It should be particularly noted that the machines hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system 2 Relieve system pressure by lowering the platform completely to direct any line pressure back into the return line to the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss 3121222 JLG Lift 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 DANGER WARNING CAU TION AND OTHER INSTRUCTIONS ON MACHINE AND IN SERVICE MANUAL KEEP STANDING SURFACES AND HAND HOLDS FREE OF OIL GREASE WATER ETC NEVER WOR
202. his Service Manual electrical connectors are given a three digit identifier number preceded with an X for identifying and locating the specific connector See Section 9 8 X CONNECTOR ID INDEX for description of X connectors and Figure 9 12 on page 9 20 and Figure 9 13 on page 9 21 for location of X connectors on the machine Example of X connector usage nomenclature X006 21 refers to terminal 21 pin and socket of connector X006 X006 21 soc refers to the socket side of terminal 21 connector X006 X006 21 pin refers to the pin side of terminal 21 connector X006 3121222 JLG Lift 9 13 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 7 CONNECTOR LOADING DIAGRAMS Table 9 1 Connector Loading Diagrams JLG Lift ID Description Diagram 2 Amp 2 position plug E J 9 On 87 D E AMPO2R Amp 2 position recepta cle LI 1 _ O 2 Amp Commercial 2 positio
203. icle 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 1 0 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 Footswitch 1 YES Vehicleis fitted with a footswitch 7 10 JLG Lift 3121222 SECTION 7 JLG CONTROL SYSTEM 7 3 MACHINE PERSONALITY ADJUSTMENT SETTINGS Table 7 3 Machine Personality Adjustment 4150472 H Machines Equipped with Sevcon 1600346 Power Module Function Adjustment Range DRIVE ACCEL 0 1 5 0 Sec 0 8 DECEL 0 1 1 0 Sec 1 0 MINIMUM 0 25 0 MAXIMUM 0 100 100 ELEV MAX 0 25 18 LIFT ACCEL 0 1 5 0 Sec 0 5 DECEL 0 1 1 0 Sec 0 1 UP MIN 0 50 10 UP MAX 0 100 100 DNMIN 1 60 42 DN MAX 0 100 61 STEER STATIC 0 100 100 DRIVE 0 100 60 ACCELERATOR FWD MIN 2 20 2 40V 2 25 FWD MAX 1 00 1 50V 1 20 REV MIN 2 60 2 80 V 2 75 REV MAX 3 50 4 00 V 3 80 GROUND HORN 87 107 dB 107 ALARM 87 107 dB 87 LOAD ACCY 0 200 Kg N A OVRDBNCE 0 0 5 0 Sec N A OVRHOLD
204. ied JLG Service and Maintenance Manual Maintenance Maintenance Manual User Mechanic 2 2 2 2 PREVENTIVE MAINTENANCE AND JLG Lift INSPECTION SCHEDULE See Table 2 2 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 3121222 SECTION 2 GENERAL SERVICE INFORMATION Table 2 2 Preventive Maintenance amp Inspection Schedule INTERVAL AREA ON MACHINE PRE START a 3 MONTH 6 MONTH PRE DELIVERY b ANNUAL d INSPE
205. inder rod out the bottom of the cylinder approximately 2 ft 61cm Carefully lift the mast assembly over the machine and center it into the opening where the mast is mounted on the machine If the power trak assembly harness was left attached to the base frame when the mast was removed lift it off the base frame and hold it vertically As the mast assembly is lowered take the top end of the power trak assembly and feed it into the power trak com partment on the front side of the mast assembly Lower mast assembly down or pull cylinder rod out of cylinder 1 and align the holes in the bottom of the rod assembly with the holes in the base frame Secure using the proper bolts apply Loctite 242 to the threads of the rod attach bolts on final assembly See Figure 6 10 Re connect the lift down valve harness connector to the lift down valve mounted on the front of the cylin der rod assembly Re connect the extend and return lines to the back of the cylinder rod assembly See Figure 6 9 Carefully lower the mast assembly while lowering feed the power trak assembly into the mast and lift the power trak assembly till it is completely over top of the lift down valve assembly See Figure 6 2 Feed the control cables through the notch in the baf fle plate inside the mast Install the P clamp onto the control cables for attachment to the right rear mast mounting bolt Continue to lower the mast until the holes in the mount inn
206. ine 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 59 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 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 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 sta
207. ines Equipped with ZAPI 1001092456 Power Module 7 6 7 4 Analyzer Menu Flow Chart Sheet 2 of 3 1001096495 Machines Equipped with ZAPI 1001092456 Power Module 7 7 7 5 Analyzer Menu Flow Chart Sheet 3 of 3 1001096495 Machines Equipped with ZAPI 1001092456 Power Module 7 8 9 1 Voltage Measurement 0 ee mmn 9 2 9 2 Resistance 2 2 2 2 2 2 9 2 9 3 Continuity 1 7 9 3 9 4 Current Measurement 9 3 9 5 Connector Installation b dete dac ees y ee We eed ee 9 11 9 6 DT DTP Contact Installation 9 12 9 7 DT DTP Contact REMOVAL ce Rep erat ed oce RR Robe Lob guten qe egg 9 12 9 8 HD HDP Contact 9 12 9 9 HD HDP Locking Contacts Into Position 4 9 13 9 10 HD HDP Contact Removal 1 42 9 13 9 11 HD HDP Unlocking Contacts 9 13 9 12 1230 5 Location of Component X Connectors on Machine
208. ing 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 AMP Connector 3121222 JLG Lift 9 7 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Assembly Check to be sure the wedge lock is in the open or as shipped position See Connector Assembly Figure 1 Proceed as fol lows CONTACT PARTIALLY INSERTED RETENTION FINGERS DIAPHRAGM MATING SEAL WEDGE LOCK SHOWN IN OPEN POSITION Connector Assembly Figure 1 1 insert a contact push it straight into the appropriate circuit cavity as far as it will go See Connector Assembly Fig ure 2 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 Connector Assembly Figure 2 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 Connector Assembly Figure 3 4 Slide the wedge lock into the housing until it is flush with the housing See Connector Assembly Figure 4 SS EN Ss Sy PULL BACK ON WIRE RETENTION FINGERS HOLDING CONTACT
209. ive 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 BANKFAULT 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 of 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 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 8 16 JLG Lift 3121222 SECTION 8 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 situati
210. ive motor assembly out of the gear box spindle assembly and place on work bench les CONNECT OTHER END OF CABLE TO POWER CONTROLLER 3 Wheel Drive Assembly Removal 1 Drive Motor Assembly 3 Drive Motor Mounting Bolts 2 Mounting Bolt Washers NOTE Removal same for left and right drive motor 4 14 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Drive Motor Disassembly Figure 4 5 Drive Motor Disassembly 1 Remove the 2 8 32UNC x 500in long screws holding the cover plate 12 in place See Figure 4 6 and remove the cover plate from the motor 2 Remove the 2 M5 x 0 8 x 20mm long screws holding the cover 15 in place and set aside These screws are needed later to manually release the brake Slide the strain relief bushing 14 and wire harness out of the cover and remove the cover from the motor Remove strain relief bushing from wire harness and set aside 3 Discard the O ring 13 located inside the cover 4 Remove the wire harness 8 from the motor by disconnecting the field connection brake connection and arma ture connections See Figure 4 7 5 Install the 2 cover mounting screws into the threaded holes in the brake assembly and tighten to manually release the brake See Figure 4 7 or image in the Manual Disengage Procedure See Figure 4 4 6 Remove the screws holding the brake assembly 11 to the motor Carefully remove the brake assembly and fric
211. l side down onto the Spindle 1 This installation should be a slip fit and takes place in 3 stages Stage 1 The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 output planets Stage 2 Find the Planet Gear that is tight and turn it until you feel it go into mesh with the hub gear teeth apply slight downward pressure to the hub and then find the next gear that is tight and do the same Stage 3 Once all the Planet Gears are in mesh apply pressure to the hub it should push on the rest of the way Install Retaining Ring 27 into the groove on the OD of the Spindle 1 carrier This is a Spiral Retaining Ring so it will not require pliers You will need to pull the Retaining Ring 27 apart and work it into the groove continued next page JLG Lift 3121222 SECTION 4 BASE COMPONENTS NOTE NOTE NOTE 14 15 3121222 Using the appropriate pressing tool T 174356 press in the Input Ring Gear 3 into the bore of Hub Subassem bly Do not use excessive pressing force because it will be reacted by the main wheel bearings Install the Input Carrier Subassembly into mesh The Output Sun Gear 8 portion of the Input Carrier Subassem bly will mesh with the Output Planet Gears 9 and the Input Planet Gears 5 mounted on the Input Carrier Subas sembly will mesh with the Input Ring Gear 3 Install the Input Sun Gear 4 into the area between the three Input Planet Gears 5 Ap
212. l the rivets attaching the slide pads to the bottom corners of the mast sec tions are exposed Remove the rivets from the slide pads on the mast sections you want to remove at the bottom of the outer mid and inner mid mast sec tions then slide the mast section out the bottom Mast Reassembly Refer to the Mast Disassembly illustrations when required 1 NOTE If required assemble the external slide pads to the top of the outer mid inner mid and mount inner mast section Orient the groove in the pads to the side of the mast and attach with the proper rivets from the inside of the mast See Figure 6 3 Always mount slide pads with the groove oriented to the side of the mast not the front or rear for clear ance of the pad mounting rivets during opera tion See Figure 6 3 The slide pads are available in two thicknesses JLG P N 1001092165 9 7 mm thick round notch on ends JLG P N 4700042 8 7 mm thick NO round notch on end Always use the 1001092165 slide pad unless mast tube clearances prevent installation Slide the inner mid and the mount inner mast sec tions into the outer mid mast section Allow the mounting holes for the bottom slide pads of the inner mid mast section to be exposed See Figure 6 14 Push the bottom slide pads into the bottom of the outer mid and the inner mid mast sections mount with the groove in the pad towards the side of the mast Attach with the proper rivets See Fi
213. 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 5 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 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 measu
214. lly there is a low imped ance current measurement shunt for the Armature portion of Traction Place the Red meter lead on B and the Black meter lead on M1 RESISTANCE gt 1 OHMS 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 1M OHMS BETWEEN F1 AND F2 AND Ensure that there is an open circuit between the two Field Terminals F1 4 F2 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 and the Red meter lead on F1 F1 RESISTANCE gt 100 OHMS BETWEEN P AND Ensure that there is an open circuit between the P and the B Terminals Internally there are MOSFET transistors between these terminals that should be high impedance when the module is un powered Place the Black meter lead on B and the Red meter lead on P Note that a measurement of increasing resistance capacitor charge is normal but a persis tently low impedance is not RESISTANCE gt 1 OHMS BETWEEN 2 AND Ensure that there is an open circuit between the M2 and B Terminals Internally there are MOSFET tran sistors between these terminals that sho
215. load sense system 3124288 824 1155 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 The load sensing system module has not e Empty platform Calibrate LSS see Section 2 2 Calibration in the BRATED been calibrated 155 manual 3124288 Refer to Section 2 3 Troubleshooting in the 155 manual 3124288 9 9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 991 LSSWATCHDOG RESET Aproblem has been detected with the Refer to Section 2 3 Troubleshooting in the LSS manual load sense system 3124288 992 155 EEPROM ERROR 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 hasbeen detected withthe Refer to Section 2 3 Troubleshooting in the LSS manual EXCITATION load sense system 3124288 994 LSS INTERNAL ERROR problem has been detected withthe e 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 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 in
216. ly disconnect the hydraulic lines from the top of the valve bank assembly Finally remove the two 2 mounting screws and nuts from pump mounting plate under the pump and remove the pump motor valve assembly from the machine 3121222 SECTION 4 BASE COMPONENTS Hydraulic Pump Valve Tank Assembly 1 Pump Motor Assembly 9 Tank 2 Motor to Pump Coupler 10 Tank Breather Cap 3 Pump to Frame Mounting Flange 11 Main Pressure Relief 4 Pump Valve Body 12 Left Steer Pressure Relief 5 Tank Oil Ring Seal 13 Right Steer Pressure Relief 6 Hydraulic Pump 14 Lift Steer Valve Body T Pick Up w Filter Screen 15 Lift Selenoid Valve 8 Return Flow Filter Diffuser 16 Left Right Steer Selenoid Valve 3121222 JLG Lift 4 35 SECTION 4 BASE COMPONENTS Motor Cover Motor Installation for wear replace if necessary Once complete reassemble for operation do not overtighten the motor cover bolts NOTICE into the aluminum valve body 8 Nm 70 in Ib DISCONNECT THE BATTERIES BEFORE PERFORMING THESE Motor Brush Installation PROCEDURES This procedure requires removing the pump to frame mounting bolts and nuts and rotating the pump assembly horizonally far enough to allow removal of the pump motor cover No pump connections hyraulic or electrical need be disconnected Once pump motor cover has been removed inspect the rotor commutator for excessive wear before installing a new brush set
217. m Pressure Settings Perform final hydraulic pressure setting with oil at normal operating temperature If pressure is set when cold func tion may not operate properly after oil has warmed Turning relief adjustment screw clockwise increases pressure turning adjustment screw counterclockwise decreases pressure DO NOT EXCEED MAXIMUM PRESSURE SETTINGS See Figure 4 13 Table 4 2 Hydraulic System Pressure Settings MAXIMUM PRESSURE 122065 SETTING Main 1600 PSI 110 Bar Steer Left Right 1250 PSI 86 Bar Table 4 3 Hydraulic Pump Solenoid Specifications Component Coil Rating Lift Up Solenoid 28 Steer Left Right Solenoid 33 Ohm Figure 4 13 Relief Pressure Setting Locations 1 Pump Valve Body 4 Main Pressure Relief 2 Steering Right Pressure Relief 5 Pressure Gauge Check 3 Steering Left Pressure Relief Port 3121222 JLG Lift To check the lift pressure attach pressure gauge to the check port on top of the valve body To check steer pressure remove either the left or right steer hose fitting on the valve body and plumb a pressure gauge at that point Power up machine warm up oil to normal operating temperature Check initial pressure for each function lift and steering Adjust pressure relief according to settings shown in Table 4 2 Lift pressure setting must be adjusted to raise the maximum capacity allowed in the platform with t
218. meter and profile as the original Replacement tires must be the same size and rating as the tire being replaced Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque A WARNING WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN LUG NUTS AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE LUG NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the lug nuts or permanently deforming the mounting holes in the wheels The proper procedure for attaching wheels is as follows 3121222 1 Start all lug nuts by hand to prevent cross threading DO NOT use lubricant on threads or nuts 2 Tighten lug nuts in the following sequence Figure 4 2 Wheel Lug Nut Tightening Sequence 3 The tightening of the lug nuts should be done in stages Following the recommended sequence tighten lug nuts per wheel torque Table 4 1 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 20 30 ft Ibs 65 80 ftIbs 105 120 ftIbs 28 42 Nm 91 112 142
219. 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 9 10 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS WIRE STRANDS MUST BE VISIBLE IN THIS AREA WIRE STRANDS AND INSULATION MUST gt 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 9 5 Connector Installation 3121222 JLG Lift 9 11 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 5 WORKING WITH DEUTSCH CONNECTORS DT DTP Series Assembly Figure 9 6 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 wedges are not oriented Thy may go in either way NOTE The receptacle is shown use the same procedure for plug DT DTP Series Disassembly Figure 9 7 DT DTP Contact Removal 5 Remove wedgelock using needlenose pliers or a hook shap
220. n Gear 8 8 Slide Output Sun Gear 8 out from the center of the Input Carrier 7 9 Remove the three Planet Shafts 6 from the Input Carrier NOTE The Planet Shafts 6 are held in with a press fit To avoid damage to the parts use an arbor or hydraulic press to remove the Planet Shafts 6 3121222 JLG Lift 4 19 SECTION 4 BASE COMPONENTS Hub Disassembly Hub Disassembly 1 Remove Main Wheel Bearing 14 NOTE This part is held in the hub with a press fit To remove have the hub setting seal side up Use a plate or rod with a large enough diameter push in the inner race of the bearing Apply force to the push the bearing out This bearing will need to be replaced upon reassembly 2 Remove main Lip Seal 16 NOTE This Lip Seal 16 is also held in with a press fit Remove the Lip Seal only if the hub or seal needs to be replaced The Lip Seal will most likely become damaged during removal Try not to damage the hub bore 4 20 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Spindle Disassemhly Spindle Disassembly 1 Place unit on bench with Planet Gears 9 facing up 2 Remove three Output Planet Shafts 10 NOTE These Planet Shafts are held in with a press fit Use the tapped hole in the end of the pin in conjunction with a slide hammer or sim ilar tool to remove them 3 Remove the Output Planet Gear 9 Thrust Washer 25 and Tanged Washer 32 out each of gea
221. n Programming Information 1001115626 B Machines Equipped with ZAPI 1001092456 Power Module Only Charger Interlock DRIVE AND LIFT Drive and lift up motions are prevented while vehicle is charg Configuration Setting Market Default Setting Digit Range 1 2 83 4 0 1230ES 1 1930ES 1 2 2030ES Setto your applicable ES Model Model 3 2630ES 0 through 5 4 2646ES 5 3246ES 0 ANSI USA 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 0 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 1 Drive Cutout 1 YES Drive and lift up prevented while elevated 5 0 DRIVE ONLY Drive motion prevented while vehicle is charging 1 ing Required for CE 0 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 0 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 veh
222. n and tighten to 20Nm 5 ft Ib inside the cylinder barrel are clean and free of any debris 6 Place a new piston kban seal onto the piston NOTICE EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON INTO THE CYLINDER BAR REL AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SUR FACES 8 Carefully slide the loaded cylinder rod assembly into the cylinder barrel 9 Screw the cylinder head in until tight torque the 2 inder head to 55Nm 112 ft Ib using the proper NR spanner wrench 10 Reinstall the steer cylinder back onto the machine 11 Power up machine and cycle the steering left and right until the steering is working smoothly 12 Check the hydraulic oil level in the hydraulic oil tank located on the pump valve tank assembly Oil level should be between min and max on the side of the tank Cylinder Head Installation 1 Cylinder Head Gland 2 Spanner Wrench 48mm 1 89 Dia 5mm Pin Dia 3121222 JLG Lift 4 9 SECTION 4 BASE COMPONENTS 4 7 DRIVE MOTOR SPINDLE ASSEMBLY INSTALLATION Drive Motor Spindle Assembly Installation Left front shown installation same for both sides 1 DriveMotor Spindle Assembly 5 60mm Thrush Washer 2 60mm External Retaining Ring 6 King Pin welded to frame b 3 Spindle
223. n 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 should be less than 50A One wheel will rotate at full speed while the other will not rotate at all The Power Module s self diagnostics cannot detect this fault unless both armatures are open cir cuit To find the source of the difficulty pull the Main Bat tery Disconnect and investigate the wiring pathways from the Power Controller s M1 and 2 terminals to the armature on the motor that does not rotate Investigate for issues like improper crimps loose terminals and corrosion Short Circuit Motor Armature This issue will allow the vehicle to drive very slowly or not at all Rapid motor overheating one motor will result This situation can be detected by elevating the vehi cle s front wheels and engaging drive platform stowed Under DIAGNOSTICS TRACTION the JLG Analyzer s ARM CUR display Armature Current Reading will hover around 350A The FLD CUR dis play Field Current Reading will hover around 40A Neither wheel will rotate at normal speed but it will JLG Lift 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 disconnec
224. n 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 Refer to Section 2 3 Troubleshooting in the LSS manual 3124288 664 CANBUS FAILURE ACCES module has stopped com Turn on machine in platform mode If 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 messages not The control system failed to receive messages from the Chassis TILT SENSOR received for 1000 mS while is Tilt Sensor located inside the Ground Control Box present on J1 28 Ensure that B is present on pin 1 of the sensor and B is present on pin 4 Check the CANbus wiring to pins 2 and 3 of the sensor ZAPI HEALTH Status LED ON 6 7 Accessory ING DTC FAULT MESSAGE DESCRIPTION CHECK 671 ACCESSORY FAULT An accessory module is reporting a fault See accessory module documentation for troubleshooting 7 7 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 771 OPENCIRCUIT DRIVE The power module detected a problemin 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 Dr
225. n plug Amp 4 position plug E 4 6 Qe M 4 1 pg 4 Amp 4 position recepta cle 9 Amp 9 position plug Conxall 8 position plug 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 9 1 Connector Loading Diagrams Continued ID Description Diagram DHD14P Deutsch 14 position HD series alum Plug DHD14R Deutsch 14 position HD series alum Receptacle DRC40P Deutsch 40 position plug DTO2P Deutsch 2 position DT series plug d On e z DTO2R Deutsch 2 position DT series receptacle 2 1 2E Deutsch 3 position DT series plug 3121222 JLG Lift 9 15 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS Table 9 1 Connector Loading Diagrams Continued series mini plug with B key ID Description Diagram Deutsch 6 position DT series plug DTOGR Deutsch 6 position DT series receptacle Deutsch 8 position DT series plug with A keys Ca sms 55 DTO8AR Deutsch 8 position DT series receptacle with A keys DTM12AP Deutsch 12 position DT series mini plug with A key Tm ners
226. na LON 0 dVO1 WAT i NOLLOIN O JNDV I TIIOO 14 0 CELA r 34 WINO AARIG 0 YADUVHO TIV LnOL02 C NOLLOIN O SAA T ON 0 LNHOSHQ T SOIT ARCET ILNOdXH 0 ei VINO SABIC 0 SLE CATIVISNI KINO NYOH 0 Ae nil NT SEIS E ISNV I LON 0 dVO1 WAVTY PONE 1 ON 0 ein 0 WINO HABIG 0 VSA ISNV 0 3100100 KINO 0 VO TG NT SEWED NIV Tv XVN OL UALNAO XVIN OL ILNOHS NHdO NHdO dN LAT NHHIS 1148918 JNSV IV SSqHLSIG amp SAS FANRLLVH AMHLIVH CAMHLLVH 1 NYOH HARKI pf NYOH 4 1 YsOORLL KH IHON Q HSO TO CHSO IO NHdO NHdO LAT NAMOA LIT 539726 5 9 9 30595 SHO 0C 1590861 SAOETI 4000 SITIdWOO 1581 TALNO 1581 SHATVA 1891 SNYTVE 5431 1891
227. nacceptable condition occurs the tube assembly should be repaired or replaced Steer Cylinder Assemhly NOTE Prior to cylinder assembly ensure the proper JLG seal kits are used see the JLG Parts Manual APPLY A LIGHT FILM OF THE HYDRAULIC OIL TO BE USED FOR OPERATION TO ALL COMPONENTS TO BE ASSEMBLED EXCEPT THE THREADED AREAS WHERE LOCTITE IS TO BE APPLIED Piston Installation 1 Threaded End of Rod a 4 Piston Set Screw c 2 Piston b 5 Piston Kban Seal 3 Cylinder Head Gland NOTE a Apply Loctite 242 on final assembly b Torque piston to 260Nm 55 ft Ib c Apply Loctite 222 and torque to 20Nm 5 ft Ib 1 Load the seals o rings and backing ring onto the cylinder head gland 2 Lubricate the cylinder rod surface with clean hydrau lic oil then slide the cylinder head gland assembly onto the rod 3 Check that the threads on the cylinder rod and inside the piston are clean and free of any hydraulic 4 Apply Loctite 242 to the threads of the cylinder rod and thread the piston onto the end of the cylinder rod tighten piston with the proper spanner wrench and torque the piston to 260Nm 55 ft Ib JLG Lift 3121222 SECTION 4 BASE COMPONENTS 5 Apply Loctite 222 to the threads of the piston set 7 Lubricate the o ring seals on the cylinder head screw thread the screw into the hole in the side of Check that the threads on the cylinder head and the pisto
228. nd is to ground board J1 27 nspect the wiring for physical damage Replace ground board 336 LIFTDNOPENCIRCUIT 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 detected voltage while e 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 3121222 JLG Lift 8 11 SECTION 8 DIAGNOSTIC TROUBLE CODES 3 3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK 338 STEER LEFT OPEN CIRCUIT The ground board did notdetectcurrent Check for continuity through this circuit Steer left solenoid resis flow to the steer left solenoid during 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 th
229. nd replaced When serviced fill the unit with 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 Cil Filling Instructions 10 oz of gearbox oil will fill the gearbox cavity approxi mately half full To check the oil level rotate the wheel so that the cover plugs are at 12 o clock and 3 o clock Allow the oil to settle Slowly loosen the 3 o clock plug If oil begins to come out then the oil level is sufficient If no oil is noticed at the 3 o clock plug location then remove both plugs Slowly add oil at the 12 o clock plug location until oil begins to seep out of the 3 clock plug location Re install and tighten plugs to 6 8 ft lbs Drive Motor Power Harness Routing DRIVE MOTOR CABLE SHOULD BE MARKED 14 356 FROM THE STRAIN RELIEF THIS MARK SHOULD BE LINED UP WITH THE FRONT SET OF PROTRUSIONS ON THE STEERING LINKS ON EACH SIDE AT THE REAR SET OF PROTRUSIONS ON THE LINK THE CABLE SHOULD BE TIE STRAPPED A WORM GEAR CLAMP SHOULD BE ADDED AT THIS LOCATION INSTALLATION TORQUE 5 6Nm THE CABLE SHOULD NOT HAVE SLACK OR EXCESS LENGTH BETWEEN THE TWO CLAMPING POINTS Figure 4 3 Drive Motor Power Harness Routing 3121222 SECTION 4 BASE COMPONENTS Wheel Drive Brake Manual Disengage Procedure CM BIR LSS MANUAL RELEASE HOLES Figure 4 4 Brake Manual Disengage
230. nnector X002 Pin Function Type Range V 1 Ignition Power Output Vbatt 2 Ground EMS 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 Output Vbatt 3121222 JLG Lift 9 33 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 34 Table 9 5 Ground Board J3 Connector X003 Pin Function Type Range V 1 TiltSensor Power Power Output 12 2 TiltSensorX Axis PWM Input 12 3 TiltSensorY Axis PWM Input 12 4 Ground Power Output 0 Table 9 6 Platform Board J1 Connector X050 Pin Function Type Range V 1 Masterlgnition Power Input Vbatt 2 Master Ground Power Input 0 3 CANBusHigh Input Output Comm 4 CANBusLow 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 NotUsed 14 NotUsed 15 SteerLeftSwitch Input Vbatt 16 Steer Right Switch Input Vbatt Table 9 7 Platform Board J3 Pin Function Type Range V 1 Ground Power Output 0 2 NotUsed 3 NotUsed 4 NotUsed 5
231. nnector X027 1600346 Power Module 9 34 9 10 Power Module J1 1001092456 Power Module 9 35 9 11 Power Module J2 1001092456 Power Module 9 36 viii JLG Lift 3121222 SECTION 1 MACHINE SPECIFICATIONS 3121222 SECTION 1 MACHINE SPECIFICATIONS Table 1 1 Operating Specifications Description Model 1230ES Platform Maximum Platform Height 12 3 66 m LiftUp Time w maximum rated load 11 17 seconds Lift Down Time w maximum rated load 11 25 seconds Driving Maximum Drive Speed Stowed 3mph 4 8 kph Elevated 0 5 mph 0 8 kph Maximum Stowed Travel Grade Gradeability 25 14 Maximum Stowed Travel Grade Sideslope 5 Inside Turning Radius 44in 11 2cm Outside Turning Radius 57 6in 1 46 Chassis Approximate Gross Machine Weight Global 1775 lb 805 kg ANSI CSA 1740 Ib 790 kg CE AUS JPN Maximum Tire Load per wheel 880 Ib 400 kg Ground Bearing Pressure 123 PSI 8 7 kg cm Ground Clearance pothole protection system up pothole protection system down 2 6 in 66 mm 0 5 12 2 mm Maximum Operating Wind Speed 28 mph ANSI CSA 0 m s CE AUST Indoor Use Only Maximum Horizontal Manual Side Force Platform fully extended with Maximum load
232. not attempt to lift on an angle or the hydraulic cylinder may be dam aged Also when lifting the mast assembly if you detached the power trak from the top of the mast it will need to be lowered out the bottom of the mast as the mast is lifted upwards Carefully lift the mast assembly up out of the frame far enough to gain access to the wire harness con nector for the lift down selenoid and the hydraulic lines connected to hydraulic cylinder 1 still attached to the base frame 6 7 SECTION 6 MAST COMPONENTS Mast Disassemhly 1 Lift Down Valve Selenoid 2 Extend and Return Hydrau Harness lic Lines a Note Figure 6 9 Hydraulic Cylinder Connections Removal a Open hydraulic lines carefully have a container ready to catch draining oil cap ports and lines immediately once Figure 6 11 Hydraulic Cylinder Top End Bolts Removal lines are removed 1 Cylinder 1 Attach Bolt 2 Cylinder 2 Attach Bolt Nut Nut Disconnect the wire harness connector from the lift down valve selenoid Disconnect and cap the 1 At the top of the mast remove the bolts and nuts extend and return hydraulic lines on the bottom of attaching the cylinder rods for cylinder 1 and 2 to hydraulic cylinder 1 their cylinder anchor cross bars Figure 6 10 Hydraulic Cylinder Bottom End Bolts Removal Figure 6 12 Hydraulic
233. nto the center bore so that it is flush with the face of the Spindle 1 3121222 JLG Lift 4 23 SECTION 4 BASE COMPONENTS Hub Sub Assembly Hub Sub Assembly 1 Put Hub 2 on a table with the tapped holes facing down 2 Using a flat plate in conjunction with a pressing tool press in the Seal 16 so it is flush with the edge of the hub NOTE NOTE The Seal has a thin outer shell that can be easily damaged if not installed with care It is a good idea to start the Seal into the bore with a rubber mallet before pressing 3 Flip the Hub 2 over 4 Using the appropriate pressing tool T 174356 press the Main Bearing 15 into the bore until it bottoms out 4 24 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Input Carrier Sub Assembly Input Carrier Sub Assembly 1 Usethe Input Planet Shaft 6 as a pressing tool to install the Planet Bushing 26 into the bore of each Planet Gear b The shaft will help guide the bushing into the bore as well as prevent damage from the press 2 Press three Input Planet Shafts 6 into the three holes of the Input Carrier 7 The head of the Input Planet Shaft 6 needs to sit flush in the counterbore of the Input Carrier 7 hole 3 Insert Output Sun Gear 8 into the splined bore of the Input Carrier 7 The gear tooth end of the Output Sun Gear 8 should protrude in the opposite direction of the Input Planet Shafts 6 4 Using retainin
234. o JLG with a detailed description of the diagnostic steps taken 7 6 ELEVATION ANGLE SENSOR ELECTRICAL EVALUATION These basic checks using the JLG Analyzer can be used to test the Elevation Atrecrqwetngle Sensor If the prob lem is still occurring perform the Tilt vs Allowed Height Evaluation described below 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 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 mach
235. odule to clear fault LSS MODULE SOFTWARE wareversionis notcompatible with the VERSION IMPROPER restofthe system 9912 POWER MODULE FAILURE The ground board detected armature Refer to Drive Motor Electrical Evaluation in Section 3 5 SYSTEM MONITOR field or pump current while functionwas Refer to Pump Motor Electrical Evaluation in Section 4 8 notcommanded Referto Power Module Electrical Evaluation in Section 3 6 9924 FUNCTIONS LOCKED OUT The control system s memory indicates Use the JLG analyzer to adjust all machine setup and personality MACHINE NOT CONFIG that the vehicle has not been configured settings 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 1005 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 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 Cycl
236. on 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 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 is an open circuit between the System Module s 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 3005 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 Volt
237. ox Upper Control Box Cover Installation 1 Upper Box Assembly 3 Attach Screws 2 Upper Box Cover Upper Control Box Circuit Board Installation 1 Circuit Board Assembly 2 Board Attach Screws 3 Upper to Lower Control Box Harness Connector 4 Front Button Switch to Circuit Board Ribbon Cables 1 Disconnect the upper to lower box harnness con nector from the printed circuit board and unplug the lift drive switch blade terminals 3121222 2 Disconnect the two 2 front button switch ribbon cables from the circuit board 3 Remove the five 5 screws attaching the printed cir cuit board to the control box 4 Replace board and reassemble upper control box Upper Control Box Faceplate Component Installation 1 Upper Control Box Housing 4 Face Plate Backing Plate 2 Face Plate Attach Screws 5 Button Switch 3 Face Plate Decal 6 Drive Lift Mode Select Switch 1 Remove the six 6 faceplate attach screws and the lift drive mode selector switch attach nut 2 Carefully lift the faceplate decal and backing plate out of the upper control box housing 3 If replacing either of the button switches the ribbon cable must be disconnected from the printed circuit board on the back if not already done 4 Replace component and reassemble JLG Lift 5 17 SECTION 5 CONTROL COMPONENTS Lower Control Box Component Replacement
238. ox is removed the tilt sensor must be recalibrated Refer to Section 7 4 TILT SENSOR CALIBRATION to recalibrate the tilt O E 1 Remove the three bolts at the bottom of the ground control station 3121222 JLG Lift 2 Remove the four screws where the control cable enters into the control box Remove plug and place control box face down on a suitable work bench Remove the six screws at the back of the ground control and separate Pull the pin connectors from the printed circuit board Remove the two screws inside the control box that affix the printed circuit board to the control box Replace the printed circuit board and reassemble the ground control box 5 13 SECTION 5 CONTROL COMPONENTS NY L7 N K rane Q 5 c gt 5 14 Figure 5 6 Ground Control Station Assembly Rear Cover Battery LED Circuit Board Main Ground Control Circuit Board 1600473 Drive Module Only Front Cover LED Indicator Decal Control Functions Decal Hourmeter Blank Plug Unused Controls Indicators Mounting Plate JLG Lift Torx Screws Main Connector X001 Torx Screws Controls Indicators Mouting Plate Torx Screws Rear Cover to Fron
239. ply a coating of grease to the Cover 11 O ring 20 and install it into the o ring groove of the Hub Subassem bly It may be helpful to stretch the O ring 20 out prior to assembly to avoid pinching or shearing when the Cover 11 is assembled Apply Loctite 380 or 480 glue to Cover Thrust Washer 21 and place it in the center counter bore of the Cover 11 so that the steel face of the washer is out of the bore Make sure that both the Cover Thrust Washer 21 and the Cover 11 have good clean surfaces for the Loctite to properly adhere Center the Cover 11 in the hub bore so that the JLG logo is up Push it into the bore Install the Cover Retaining Ring 19 into the groove of the Hub Sub assembly JLG Lift 4 27 SECTION 4 BASE COMPONENTS Motor Assembly CONNECT OTHER END OF CABLE TO POWER CONTROLLER Motor Assembly 1 Insert motor 13 into back of the gearbox Motor will pilot on the 4 bosses in the gearbox Try to keep the end of the motor shaft from causing damage to the lip seal in the gearbox NOTE The motor may need to be rotated to line up the sun gear splines with the motor shaft splines 2 Install the 2 Motor Mounting Bolts M7 and Washers M8 Tighten to 9 11 ft Ibs 3 Connectthe end of the power cable to the power controller route cable per instruction in Figure 4 3 Fill the gearbox with oil See Oil Type amp Capacity on Page 4 12 4 28 JLG Lift 3121222 SECT
240. r window of the Spindle 1 NOTE The Output Planet Gears 9 are a very similar size to the Input Planet Gears 5 tag or label the Planet Gears to avoid confusion Press out Bushing 26 from the bore of each Planet Gear 9 Bushings cannot be reused when removed Use appropriate tool to remove the shaft bearing Retaining Ring 28 Remove the shaft Ball Bearing 15 from the center bore Press out the Motor Shaft Seal 17 from the center bore gt Remove the Bearing 14 from the outside diameter of the Spindle 1 NOTE This bearing is held in with a press fit You will need to pry against the Spindle 1 to remove it A new bearing should be used when the unit is reassembled 9 Press out the Main Bushings 12 at the top of the Spindle 1 neck 3121222 JLG Lift 4 21 SECTION 4 BASE COMPONENTS Spindle Sub Assemhly Spindle Sub Assembly 1 Using the appropriate pressing tool 7207925 press in the 2 Main Bushings 12 in the upper bore of the Spindle 1 The lower bushing needs to flush with the bottom of the bore and the upper bushing needs to be flush with the bottom of the bore 2 Using the appropriate pressing tool 1 182377 press on Main Bearing 14 until it is fully seated 3 Insert the Motor Shaft Bearing 15 into the center bore of the Spindle 1 The bearing is a slight slip fit but it may require some press to assemble if the bearing becomes misaligne
241. rcuit 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 and 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 9 4 JLG Lift 3
242. re ceded with an X for identifying and locating the specific connector on the machine See Section 9 8 XXCONNECTOR ID INDEX for description of X connectors and Figure 9 12 page 9 20 and Figure 9 13 on page 9 21 for location of X connectors on the machine Example of X connector usage nomenclature X006 21 refers to terminal 21 pin and socket of connector X006 X006 21 soc refers to the socket side of terminal 21 connector X006 X006 21 pin refers to the pin side of terminal 21 connector X006 8 3 DTC INDEX 0 0 2 1 2 2 2 3 001 EVERYTHING OK enin te pete awit eis o qe ate e bte LA ie bt e eta 6 3 002 GROUND MOBE toe nth ek thai rb c der E a e dort cR rede S 6 3 003 ALARM SOUNDING TILTED amp ABOVE ELEVATION 6 3 004 DRIVING AT CUTBACK ABOVE ELEVATION 6 3 005 DRIVE LIFT UP PREVENTED TILTED 8 ELEVATED 6 4 006 LIFT UP PREVENTED MAX HEIGHT ZONE A 777 7777 6 4 007 DRIVING AT CUTBACK POTHOLE STILL ENGAGED 2 6 4 008 FUNCTIONS LOCKED OUT SYSTEM POWERED DOWN 2 6 4 009 DRIVE PREVENTED ELEVATED ABOVE DRIVE CUTOUT HEIGHT 6 4 211 POWER CYCLE oe open eo a beet ea Elbe E 6 4 212 KEYSWITGH EAULTY rta trt reme tee re ire ra d eee t a te sta ca eR eps 6 5 221 FUNCTION PROBLEM HORN PERMANENTLY SELECTED 0 6 5 222 FUNCTION PROBLEM
243. re 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 Cont CANBUS FAILURE PLAT FORM MODULE Continued In platform mode the control system failed to receive messages from the plat form board Disconnect platform box connector Open platform box Discon nect platform board connector Platform box socket E to platform board J1 3 should 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 3121222 JLG Lift 8 15 SECTION 8 DIAGNOSTIC TROUBLE CODES 6 6 Communication 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 Check for 24V betwee
244. rease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 2 LUBRICATION of this Service Manual for an explanation of the lubricant key designa tions appearing in the Lubrication Chart Hydraulic Oil For best performance JLG recommends the use of ISO Vg grade 15 oil with a viscosity range between 15 250 SUS at 100 degrees F 32 54 cST at 40 degrees C Refer to Section 1 2 LUBRICATION of this Service Manual for recommended hydraulic oils 3121222 Changing Hydraulic Oil Use of any of the recommended hydraulic oils eliminates the need for changing the oil on a regular basis If it is nec essary to change the oil use only those oils meeting or exceeding the specifications appearing in this manual If unable to obtain the same type of oil supplied with the machine consult local supplier for assistance in selecting the proper equivalent Avoid mixing petroleum and syn thetic base oils JLG Industries recommends changing 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 contaminants from the service container While the unit is shut down a good preventive mainte nance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well functional check of each
245. red is the voltage drop across the switch This could mis lead a technician into thinking the load is receiving power but not operating To produce an accurate picture of power or voltage applied to the load measure voltage across the load s power terminals Also the technician can measure the volt age at both power terminals with respect to battery ground The difference between those two measurements is the voltage applied to the load 9 6 JLG Lift 3121222 SECTION 9 GENERAL ELECTRICAL INFORMATION amp SCHEMATICS 9 4 APPLYING SILICONE DIELECTRIC COMPOUND AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons To prevent oxidation at the mechanical joint between male and female pins To prevent electrical malfunction caused by low level conductivity between pins when wet Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors 1 To prevent oxidation and low level conductivity silicone dielectric grease must be packed completely around male and female pins on the inside of the connector after the mating of the housing to the header This is easily achieved by using a syringe to fill the header with silicone dielectric compound to a point just above the top of the male pins inside the header When assembling the housing to the header it is possible that the housing will become air locked thus preventing the housing latch from engag
246. removed Slide a rod through the motor shaft hole and gently tap with a rubber hammer to force the cover out Remove Input Sun Gear 4 Remove Input Carrier Subassembly Remove Cover 11 O ring 20 Remove Input Ring Gear 3 NOTE The Input Ring Gear 3 is held in with a press fit on its outside diameter Insert jacking screws 1 4 20UNC grade 8 with at least 1 5 inches of thread length into each of the three tapped holes to force the ring gear out Be sure and alternate between the jacking screws to keep the ring gear from becoming misaligned in the bore The screws will push against the outer race of the main bearing This bearing will have to be replaced afterwards 7 Using a screwdriver remove Spiral Retaining Ring 27 8 Pull Hub Subassembly off of the Spindle 1 Subassembly 4 18 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Input Carrier Disassembly Input Carrier Disassembly 1 Remove Retaining Rings 18 from each of the three Planet Shafts 6 NOTE Do not overstress these Retaining Rings when removing them 2 Remove Thrust Plate 23 3 Remove Thrust Washer 25 from each Planet Shaft 6 4 Slide each Input Planet Gear 5 off the Planet Shaft 6 5 Press out Bushing 26 from the bore of each Planet Gear 5 Bushings cannot be reused when removed 6 Remove the other Thrust Washer 25 from each Planet Shaft 6 7 Remove Retaining Ring 24 from Output Su
247. rical cables It may be necessary to pull down or push up on the rear of the platform to keep the platform level while lifting it off of the mast assembly 3121222 SECTION 6 MAST COMPONENTS 3121222 Figure 6 5 Platform to Mast Installation 1 Platform Outer Mast Section Lower Slide Pad Location 2 Lift Cylinder 3 Attach Bolt and Nut Location 10 While feeding the electric harness cables for both the AC receptacle box and the platform control sta tion into the top of the mast carefully start to lift the platform sliding it up off of the mast assembly Once clear of the mast assembly move to a suitable area for later assembly 3 Power Trak Guide Plate Attach Bolts and Nuts Platform Installation 1 JLG Lift Using an overhead crane with lifting strap lift the platform assembly up over the main mast assembly Before lowering the platform assembly onto the mast be certain the electrical cables for the AC receptacle box and platform control station are within the top of the mast assembly to prevent dam age to the cables SECTION 6 MAST COMPONENTS NOTE It may be necessary to pull down or push up on the 6 7 MAST ASSEMBLY rear of the platform to keep the platform level while lifting it off of the mast assembly It is recommended that th
248. ring this analysis 1 Resistance 2 Ohms Red to Black Armature Wires The heavy red and black conductors are connected to the motor s armature winding The winding is a very low impedance and should appear to be a short circuit for an ordinary voltmeter other tests can determine if the armature is truly shorted High resistance can signal corrosion improper crimps damaged cabling worn brushes a faulty commuta tor or an open armature winding 2 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 mea surement 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 cir cuit for an ordinary voltmeter High resistance can signal corrosion improper crimps damaged con nectors damaged cabling or an open field winding 3121222 JLG Lift 3 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 fault solenoid Resistance 1 mOhm Red Armature Wire to Motor Housing The armature winding should be electrically isolated from the motor housing Low resistance may be an indication of a crushed cable a burned cable or a burned armature windin
249. rn 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 7 0 NOTINSTALLED Load Sensing System LSS is not fitted to the vehicle Load 1 CUTOUT PLT Load Sensing System LSS is fitted and Platform Controls are pre vented in the event of an Overload Ground Controls remain functional This is the M 0 1 0 1 0 1 default setting for CE machines 2 CUTOUT ALL Load Sensing System LSS is fitted Platform and Ground Controls are prevented in the event of an Overload 8 0 PEERLESS Vehicle is fitted with Peerless drive motors 1 1 1 1 1 1 Drive Motors 1 ADVANCED DC Vehicle is fitted with Advanced DC drive motors 9 0 0 NOTINSTALLED Vehicle is not fitted with an Elevation Prox Sensor Vehicle has Elev Prox Left amp Right Brake Release Outputs and Maintained Brake Release functionality 1 1 INSTALLED Vehicle is fitted with an Elevation Prox Sensor original ES 0 0 0 0 010 Series Vehicle has a single Brake Release Output and Momentary Brake Release functionality 10 0 0 FLOODED Batteries are conventional lead acid type 0 0 0 0 0 0 Battery 1 1 AGM Batteries are absorbed glass mat type 11 0 NO Vehicle is not fitted with a footswitch 0 0 0 0 0 1 Footswitch 1 YES Vehicle is fitted with a footswitch 3121222 JLG Lift 7 9 SECTION 7 JLG CONTROL SYSTEM Table 7 2 Machine Configuratio
250. rtup 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 7 5 Tilt Cutout Settings Tilt Setting Tilt Setting 1230ES front to back side to side ANSI CSA 3 1 5 CE AUS 3 4 3 4 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 7 1 ELEVATION SENSOR CALIBRATION 1 Be sure that the machine is parked and stowed on level ground Attach the analyzer near the ground control station 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 the Maximum High Drive Cut Out Height table in section 1 of this manual for proper speed cut out height JLG Lift 7 13 SECTION 7 JLG CONTROL SYSTEM 27 NOTES JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES
251. rus ion 0 3750 0 0775 4940 30 23 35 48 28 38 1 2 0 5000 9050 ak N 5 65 NOTES 1 4 DO PO Co PO OO Co 45 CO 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 9 16 0 5625 0 1820 11600 110 149 80 108 120 163 98 133 163 90 122 0 6250 0 2560 16300 170 230 130 176 190 258 153 207 3 4 1 353 200 271 0 8750 0 4620 29400 430 583 320 434 475 646 386 523 637 350 475 1 0000 0 6630 42200 700 949 530 719 735 1000 633 858 1085 600 813 114 1 2500 0 9690 53800 1120 1518 840 1139 1175 1598 1009 1368 1681 920 1247 1979 1100 1491 2278 1260 1708 117 2630 1460 1979 2983 2224 NO 5000059 REV J ANEROBIC THREAD LOCKING COMPOUND 0100011 _ 242 Vibra TITE 121 Medium Strength Blue 0100019 271 Vibra TITE 140 High Strength Red 0100071 262 Vibra TITE 131 Medium High Strength Red Figure 1 2 Torque Chart SAE Fasteners Sheet 1 of 7 JLG Lift 3121222 SECTION 1 MACHINE SPECIFICATIONS 3121222 Values for Zinc Yellow Chromate Fasteners Ref 4150707 SAE GRADE 8 HEX HD BOLTS amp GRADE 8 NUTS Toga Torque Torque B TM TM Size
252. s 10 Left Side Countbalance Link NOTE Assembly same for both the left and right side PHP components a When the pothole is in the deployed position bars down adjust limit switch plunger just past click re tighten mounting block screws to frame b Apply Loctite 4222 to mounting block screw threads on final tightening c Hook spring through slot in frame and the other end around the counterweight lug then slide the attach pin through the frame spring counterweight tube spacer install the pin retaining ring 4 38 JLG Lift 3121222 SECTION 4 BASE COMPONENTS Actuator Limit Switch Counterweight Installation Machines S N 0130013258 to Present 1 Actuator Attach Screws Nuts 6 Torsion Spring c 2 PHP Actuator Assembly T Tube Spacer 3 Limit Switch a 8 Counterbalance Link Mounting Pin 4 Limit Switch Mounting Bracket b 9 Pin Retaining Ring 5 Limit Switch Attach Screws 10 Left Side Countbalance Link NOTE Assembly same for both the left and right side PHP components a When the pothole is in the deployed position bars down adjust limit switch plunger just past click re tighten mounting block screws to frame b Apply Loctite 4222 to mounting screw threads on final tightening c Hook spring through slot in frame and the other end around the counterweight lug then slide the attach pin through the frame spring counterweight tube spacer install t
253. s 4 15 Drive Motor Inspection and 0 4 16 Drive Motor 4 17 Main Gear Box 4 18 Input Carrier 1 4 19 Hub Disassembly 59 peur E i 4 20 ii JLG Lift 3121222 TABLE OF CONTENTS Spindle 4 21 Spindle Sub Assembly 41 4 22 Hub S b Assembly Lose bere rae We Re o pues P Rate 4 24 Input Carrier Sub Assembly 4 25 Main Gear Box 4 26 Motor Assembly tema RR DAR GRE ORE RE VH RE e UR eae 4 28 4 9 HYDRAULIC PUMP MOTOR VALVE ASSEMBLY SERVICE PROCEDURE 4 29 Common Difficulties ncm c a a RR ge RU ha ee Cc 4 29 Pump Components 4 32 Hydraulic System Pressure Check Port 4 32 Hydraulic System Pressure 0 4 33 Pump Motor Valve Assembly Removal Installation 4 34 Motor Cover Motor Installation
254. s 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 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 closed up or down duringpower upin Check the lift switch signal and wiring to the ground board The lift ground mode switch input 24V is from ground board terminal J2 4 and its outputs 24V when closed are to ground board terminals J2 6 J2 7 up and down Replace ground board 232 GROUNDLIFTUP DOWN Theliftup down inputs are closed simul Check if the lift switch is obstructed or jammed TOGETHER taneously Checkthe 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
255. s successfully demonstrated the ability and proficiency to service repair and maintain the subject JLG product model Reference Table 2 2 Preventive Maintenance amp Inspection Schedule and the appropriate areas of this manual for servicing and maintenance procedures The frequency of service and maintenance must be increased as environ ment severity and frequency of usage requires Lift 2 1 SECTION 2 GENERAL SERVICE INFORMATION Table 2 1 Maintenance and Inspection Requirements PRIMARY SERVICE EREQUENGY RESPONSIBILITY QUALIFICATION Hap aries Pre Start Priorto use each day or User or Operator User or Operator Operator and Safety Manual Inspection Ateach Operator change Pre Delivery Prior to each sale lease or Owner Dealer or Qualified JLG Service and Maintenance Manual Inspection rental delivery User Mechanic and applicable JLG inspection form Frequent In service for 3 months or Out of service Owner Dealer or Qualified JLG Service and Maintenance Manual Inspection for a period of more than months or Pur User Mechanic and applicable JLG inspection form chased used Annual Annually no later than 13 months from the Owner Dealer or Qualified JLG Service and Maintenance Manual Machine date of the prior inspection User Mechanic and applicable JLG inspection form Inspection Recommended Preventative Atintervals as specified in the Service and Owner Dealer or Qualif
256. so See Battery Tray Side Door Installation Base Top Cover Installation Same for both sides 1 Base Top Cover 2 4 Attach Screws Washers 1 Battery Tray Door 4 Base Frame Hinge 2 Cutout in Base Frame 5 Door Latch Pin Step Plate Battery Charger Cover Installation 3 Washer s NOTE Before assembly lubricate coat the door hinge pins with Loctite Moly Paste Lubricant JLG Part No 3020039 Lift door 1 into cutout in base frame 2 align the upper and lower hinge pins on the door with the holes in the upper and lower base frame hinge 4 and lower door until set If door needs any adjustment up or down to align with the latch pin slot 5 remove the door and add or remove washers 3 at the upper hinge pin Step Plate Battery Charger Cover Installation 1 Step Plate Cover 2 Attach Screws Washers Nuts 4 2 JLG Lift 3121222 SECTION 4 BASE COMPONENTS 4 3 WHEELS AND TIRES DRIVE AND REAR Tire Wear and Damage Inspect tires periodically for wear or damage Tires with worn edges or distorted profiles require replacement Tires with significant damage in the tread area or side wall require immediate evaluation before replacing the machine into service Wheel and Tire Replacement Replacement wheels must have the same dia
257. st be dures contained in this chapter maintained on a scheduled basis in order to function roperly Safety and Workmanship uiu At any time when oil lines are disconnected clear adja Your safety and that of others is the first consideration cent areas as well as the openings and fittings them when engaging in the maintenance of equipment Always selves As soon as a line or component is disconnected be conscious of component weight Never attempt to cap or cover all openings to prevent entry of foreign mat move heavy parts without the aid of a mechanical device ter Do not allow heavy objects to rest in an unstable position 2 When raising a portion of the equipment ensure that ade Clean and inspect all parts during servicing or mainte quate support is provided nance 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 WARNING should remain in their containers until they are ready to be NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLAT used FORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING Components Removal and Installation 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 compon
258. steer and lift up prevented DTC FAULT MESSAGE DESCRIPTION CHECK 321 LINE CONTACTOR MIS Battery voltage was presentatthe power Check wiring of contactor WIRED ON OR WELDED module B terminal at power up 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 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 8 10 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 3 2 Line Contactor Short Circuit DTC FAULT MESSAGE DESCRIPTION CHECK 322 CONTACTOR DRIVER PER 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 BATTERY The ground board detected voltage while Ensure ANALYZER g
259. structed 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 3121222 JLG Lift 8 13 SECTION 8 DIAGNOSTIC TROUBLE CODES 4 2 Thermal Limit 50 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 has 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 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 Theload sensing system module May be due to improper battery charging or incorrect voltage bat TOO HIGH momentarily measured b
260. sue 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 0 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 4 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 10096 and PUMP CUR 0 0A when Lift Up is operated from Ground Mode 3121222 JLG Lift After ensuring there is not an Open Circuit between the 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 Mode If not examine the cable between the termi nal and the Power Module compartment P Termi nal Inspec
261. system before placing the machine back in service JLG Lift 2 7 SECTION 2 GENERAL SERVICE INFORMATION NOTES 2 8 JLG Lift 3121222 SECTION 3 THEORY OF OPERATION 1230ES 3121222 SECTION 3 THEORY OF OPERATION 1230ES 3 1 OVERVIEW The GROUND MODULE is the master system controller Most functions are dispatched and coordinated from this module all other system modules handle sub tasks All characterized information values are stored into the ground module i e Personalities Machine Setups or Calibrations If the ground module is reprogrammed this information is lost The technician should record Personal ities and Machine Setups before programming so they can be restored afterwards Otherwise default values can be used as a starting point to restore previous configura tion The PLATFORM MODULE reads switch and joystick posi tions and relays that information to the GROUND MOD ULE It uses information from the CAN bus for operator display It also reports faults pertaining to devices in the Platform Control Station In ground mode the platform control station may be removed from the vehicle without affecting operation The POWER MODULE controls the main contactor drive motors and hydraulic pump motor via commands from the CAN bus It also measures current applied to these loads and input voltage for
262. t 3121222 SECTION 1 MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners Ref 4150707 Torque Torque TM TM T Bolt Dia Tensile Clamp Load 242 bud 271 Loctite 262 Stress Area See Note 4 OR Vibra TITE 111 or or Vibra TITE 131 140 OR Precoat 859 K 0 15 PI 0 18 LL o poe owe 4 40 0120 0064 OT AP T 9 0 0 00661 J 12 14 41 6 32 01380 0 009 T Jh T J LT 40 01380 000015 J 14 1 32 060 00400 _ T T JJ LT 36 01640 00474 TO 10 24 01900 00175 A 4 11 L 1 32 01900 T A4 9 14 20 0250 0 0318 280 143 16 129 15 1 28 0250 0 0364 32800 164 19 148 17 m Sam 18 Nm 1 24 03125 0 0580 520 25 35 25 35 20 25 LT 24 0 3750 0 0878 790 50 70 45 35 50 716 14 0435 0 1063 950 70 95 6 9 50 70 1 20 0437 0 1187 1070 80 no 70 95 6 80 v2 13 0 5000 01419 1250 105 145 95 130 80 10 20 05000 01599 _ 1440 120 165 10 150 90 120 L 1 18 0 625 0 2030 1 0 6250 0 2260 0 2030 2 18250 170 230 20350 210 285 8
263. t 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 up solenoid was commandedoffat tance should measure about 30 Ohms The lift up solenoid is power up powered with 24V from ground board J1 25 and its ground is to ground board J1 30 37 nspect the wiring for physical damage Replace ground board 334 LIFTUP 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 LIFTDNSHORTTOBATTERY The ground board detected voltage while Check ANALYZER gt MACHINE SETUP gt ELEV PROX is set to the lift down solenoid was commanded NOT INSTALLED 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 grou
264. t Cover Plastite Screws Main Board to Rear Cover 10 Amp Circuit Breaker Ground Control Platform Lift UP DOWN Switch Keyswitch Ground Platform OFF Control Emergency Stop Switch Tilt Module Battery LED Indicator Connector Harness X010 3121222 SECTION 5 CONTROL COMPONENTS Tilt Sensor JLG P N 1810140 and 1001114933 1 Ground Control Station 2 Tilt Sensor JLG P N 1810140 or 1001114936 Figure 5 45 Tilt Sensor Location Tilt Sensor Removal NOTE NOTE 3121222 Refer to Figure 5 46 Tilt Sensor Removal for num bers in parenthesis Disconnect the batteries Open the Ground Control Station to gain access to the Tilt Sensor Assembly refer to prior mentioned procedures Remove the four Screws 3 to remove the Tilt Sen sor 1 and Sensor Mount 2 from the Ground Con trol Box The Tilt Sensor 1 can be removed from the Sensor Mount 2 by removing the three Screws 4 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 1 Tilt Sensor JLG P N 1810140 or 1001114936 2 3 4 Sensor Mount Screw 3 5 x 0 6 16 LG Screw
265. t an unacceptable condition occurs the head should be replaced Piston Visually inspect the outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indi cates uneven loading and when this occurs the diameter should be checked for out of roundness If out of round ness exceeds 0 007 this is unacceptable Check the con dition of the dynamic seals and bearings looking particularly for metallic particles embedded in the bearing and in the piston seal surface Remove the seals and bearings Damage to the seal grooves particularly on the sealing surfaces is unacceptable In the event that an unacceptable condition occurs the piston should be replaced Tube Assembly Visually inspect the inside bore for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 0 5 inch long and primarily in the circumfer ential direction are acceptable provided they cannot cut the piston seal The roughness of the bore should be between 10 and 20 inches RMS Significant variation greater than 8 inches difference are unacceptable In the event that an unacceptable condition occurs the tube assembly should be repaired or replaced 6 16 JLG Lift Hydraulic Cylinder Assembly NOTE Prior to cylinder assembly ensure the proper JLG seal kits are used see the JLG Parts Manual APPLY A LIGHT FILM OF THE HYDRAULIC OIL
266. t 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 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 Short Circuit between Pump Motor Positive and Negative Terminals This issue will allow the vehicle to drive but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate Under DIAGNOSTICS PUMP the JLG Analyzer will show an erratic reading for PUMP PWM and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode Pull the Main Battery Disconnect to completely de energize the Control System Next detach both Pump Motor Terminals and insulate them indepen dently Re connect the
267. t the Armature Wiring heavy red and black conductors from the sus pected drive motor leading to the Power Module s M1 and 2 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 Open Circuit Motor Field This issue will allow the vehicle to drive very slowly or not at all Rapid motor overheating both motors will result This situation can be detected by elevating the vehi cle s front wheels and engaging drive platform stowed Under DIAGNOSTICS TRACTION the JLG Analyzer s ARM CUR display Armature Current Reading will hover around 350A The FLD CUR dis play Field Current Reading will be erratic or low less than 10A Neither wheel will rotate at normal speed but it will be possible to rotate the drive wheel by hand To find the source of the difficulty pull the Main Bat tery Disconnect and disconnect the Field Wiring two blue wires leading to F1 and F2 Terminals from the Power Module Using a voltmeter set for resis tance scale Ohms investigate if there is a short cir cuit less than 5 Ohms between the two blue wires this is normal If not investigate for improper crimps burned cables damaged cables or dam aged field windings Short Circuit Brake Release This issue will not allow t
268. t 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 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 5 22 JLG Lift 5 Flashes Over Temperature This fault indicates the charger has become too hot during operation Though not damaging to the charger charge time will be extended significantly 1 This fault indication will not clear automatically but the charger will restart charging automatically when the temperature drops The fault indication must be cleared manually by unplugging the AC waiting 30 seconds and reconnecting the AC power 2 If possible move the machine to a
269. t ttt 6 12 422 DRIVING AT CUTBACK POWER MODULE CURRENT LIMIT 6 12 423 LIFT UP AT CUTBACK POWER MODULE CURRENT LIMIT 6 12 4 4 441 BATTERY VOLTAGE TOO LOW SYSTEM SHUTDOWN 6 12 442 BATTERY VOLTAGE TOO HIGH SYSTEM SHUTDOWN ttti 6 12 443 LSS BATTERY VOLTAGE TOO LO D ME D LIE 6 12 444 LSS BATTERY VOLTAGE TOO LOW te emt dM PL S A LM UT 6 12 446 LOGIC SUPPLY VOLTAGE OUT OF RANGE 6 12 4421 LOGIC SUPPLY VOLTAGE OUT RANGE itecto tore tette ntpote etate sit 6 12 4422 LOGIC SUPPLY VOLTAGE OUT OF RANGE 6 13 8 2 JLG Lift 3121222 SECTION 8 DIAGNOSTIC TROUBLE CODES 6 6 661 CANBUS FAILURE POWER MODULE ttt ttt ttt ttc 6 13 662 CANBUS FAILURE PLATFORM MODULE s ttt 6 14 663 CANBUS FAILURE LOAD SENSING SYSTEM MODULE ttt 6 15 664 CANBUS FAILURE ACCESSORY MODULE 0000 6 15 6635 CANBUS FAILURE CHASSIS TILT 6 15 6 7 67i ACCESSORY FAULT 6 15 7 7 771 OPEN CIRCUIT DRIVE MOTOR WIRING attt 7 15 772 STALLED TRACTION MOTOR OR POWER WIRING ERROR 7 16 773 CAPACITOR BANK FAULT CHECK POWER 7 16 774 SHORT CIRCUIT FIELD WIRING
270. tery connections are good an internal fault has been detected and the charger must be brought to a qualified service depot 3121222 SECTION 5 CONTROL COMPONENTS 3121222 Excessive Battery Watering Requirements or Strong Sulphur Rotten Egg Smell These symptoms indicate over charging or high battery temperature These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack The most likely cause for this problem is incorrect charge algorithm setting and or high ambient temperatures 1 Confirm that the battery pack is not too small 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 algorithm will need to be changed if the pack is not the same as the old one for instructions on how to determine and change the battery charge algorithm see the following sub 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 Checking Changing the Battery Charge Algo rithm The charger is pre loaded with programming algorithms for the specific batteries detaile
271. the commutator and the shaft Visually inspect the commutator for exces sive wear and overheating Replace as necessary 6 Visually inspect the brake surfaces for excessive wear Remove any RTV Silicone sealant that may be present on the friction disc cover or commutator end head Replace brake assembly 11 if neces sary 7 Visually inspect the wire harness 8 for frayed insu lation loose terminals or other damage Replace as necessary 3121222 SECTION 4 BASE COMPONENTS 3121222 Drive Motor Reassembly See Figure 4 5 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 See Figure 4 8 Torque bot tom terminal nut to 110 140 in Ib 12 4 15 8 N m 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 4 9 Replace the snap ring 6 in the snap ring groove Press the armature 2 commutator end into the
272. to Cylinder 1 Figure 6 21 Cyl 2 3 to Cylinder Joint Assembly 1 Cyl 2 Cylinder Rod 2 Cyl 2 Hole in Rod 3 Passage Hole in Joint 4 Cyl 1 Cylinder Rod 1 Replace the o rings in the cylinder joint and rod attach cap Lubricate the o rings with hydraulic oil however keep any oil off of the threads in the rod attach cap NOTE The attach cap threads need to be clean and free of oil when assembled to the cylinder rod so the loctite applied to the cylinder rod threads will set properly 2 Lay cylinder 1 assembly and cylinder 72 3 assem bly on the workbench in their approximate assem bled position 3 At the bottom end of the cylinder 2 3 assembly locate the hole on the side of the tapered cylinder rod end on cylinder 2 This hole should be closely aligned with the hole passage inside the cylinder joint of cylinder 1 assembly when assembled See Figure 6 21 4 Just before final assembly apply Loctite 242 to the threads on the tapered end of the cylinder rod of the cylinder 2 3 assembly Slide the cylinder 72 3 assembly tapered cylinder rod end into the cylinder joint attached to cylinder 1 aligning the hole in the tapered cylinder rod end to the hole in the cylinder joint 5 Install the rod attach cap to the tapered end of the cylinder rod and torque the cap to 200 Nm 45 ft Ib 3121222 Valve Body Installation PROTECT THE CYLIND
273. ugh the power trak in the mast You can either disconnect the cables from their source at the rear of the machine in the charger compartment and free the cables through to the front of the machine so the cables come out with the mast Or disconnect the power trak from the top of the mast and allow it slide out through the bottom of the mast as it is lifted off of the machine This method also requires the AC receptacle box and the platform control box cable to be disconnected and feed down through the mast with the power trak 1 Attach Screws 2 Power Trak Hanger Figure 6 8 Power Trak Removal 3 Power Trak Guide b 4 Hyd Cyl 1 Bleeder Valve Bracket a Note NOTE NOTE JLG Lift a Remove hanger bracket from slot in mast and push down into the mast b If platform has already been removed this will be hanging loose If removing the power trak from the mast use the fol lowing steps See illustration above a Remove the attach screws from the power trak guide bracket b Push the power track and cables down into the mast past the hanger bracket slot in the side of the mast At the top of the mast carefully open the bleeder valve on the top of the main hydraulic cylinder 1 attached to the base frame While lifting the mast assembly out of the frame hyaraulic cylinder 1 will still be attached to the base frame lift slowly straight up ONLY do
274. uid level Check for chafing and proper routing Check for proper tolerances Properly lubricated Torqued to proper specification Returns to neutral or off position when released No gouges excessive wear or cords showing Properly inflated and seated around rim 18 Proper and authorized components 19 Fully charged 20 No loose connections corrosion or abrasions 21 Verify 22 Perform 23 Sealed properly 24 Overrides Platform controls 25 Remove pump motor cover and blow away any brush wear dust from cover brushes and brush holder assembly Footnotes a Prior to use each day or at each Operator change b Prior to each sale lease or delivery c In service for 3 months or Out of service for 3 months or more or Purchased used d Annually no later than 13 months from the date of the prior inspection JLG Lift 3121222 SECTION 2 GENERAL SERVICE INFORMATION 2 3 SERVICING AND MAINTENANCE Cleanliness GUIDELINES The most important single item in preserving the long ser vice life of a machine is to keep dirt and foreign materials General out of the vital components Precautions have been taken uu M to safeguard against this Shields covers seals and fil The following information is provided to assist you in the ters are provided to keep the wheel bearings mast sec use and application of servicing and maintenance proce tions and oil supply clean however these items mu
275. uld be high impedance when the module is unpowered Place the Black meter lead on B and the Red meter lead on M2 Note that a measurement of increasing resis tance 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 3121222 SECTION 5 CONTROL COMPONENTS Power Module Diagnostics The Power Module has the ability to detect many fault sce narios and communicate them to the JLG Analyzer Use ful diagnostic information can also be determined from the Green LED located on the Power Module 1 OPEN CIRCUIT LINE CONTACTOR 3 1 a The Power Module s Line Contactor Drive Cir cuitry passed power up self tests but the Line Contactor did not close when energized b May signal an open circuit between and the Line Contactor a faulty Line Contactor or an open circuit between the Line Contactor and the Power Module Terminal c 4 Flashes on Power Module d Drive Steer amp Lift Up Prevented 2 CONTACTOR DRIVER PERMANENTLY OFF 3 1 a The Power Module s Line Contactor Drive Cir cuitry failed to energize during power up self tests b May indicate a faulty Line Contactor dif
276. ut dirt and abrasives Clean bearings in nonflammable cleaning sol vent and allow to drip dry Compressed air can be used but do not spin the bearing Discard bearings if the races and balls or rollers are pit ted scored or burned 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 Lubricate new or used serviceable bearings before instal lation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bearing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 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 origi nal or one which is equivalent Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accordance
277. witches are just like manually operated switches except that the moving object operates the switch These switches can be tested the same way as a standard switch by manually operating the sensing arm Another type of limit switch used by JLG is the inductive proximity switch also referred to as a prox switch Inductive prox imity 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 T 2 3 Remove prox switch from its mount Reconnect harness if it was disconnected for step 1 and turn on machine Hold switch away from metal and observe switch state in the control system diagnostics using the Analyzer See vehi cle or control system documentation on how to do this Place sensing face of switch on the object to be sensed by the switch If that is not available use a piece of ferrous metal physically similar to it The switch state in the control system diagnostics should change When reinstalling or replacing switch be sure to follow mounting instructions and properly set the gap between the switch and object sensed
278. with recommended shop practices or the Torque Chart Figures in Section 1 of this Service Manual 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 Keep the system clean If evidence of metal or rubber par Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 2 LUBRICATION Ser vice 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 Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound 2 4 LUBRICATION INFORMATION Hydraulic System The primary enemy of a hydraulic system is contamina tion 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 system warm up or leaks in the pump supply The design and manufacturin

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