Home

JLG-1532E2-1932E2-2032E2-2632E2-2646E2-3246E2-SM-2006

Contents

1. BLACK A t 22 1 2 2 2 YEL RED 2 6 1 0 a ot Iw amp Q 2 0 26 BS be me gf By m os 4 9 e x 58 38 SPEED Lal fs o TAN ORANGE 55 4 6 3 3 m 3 1 a a 5 i i H 5 d 5 E g zs LIGHT 9 ALARM RED BLK E BRN 8 BLU BLK 5 5 Ed EJ mM fj 5 E E EE AN 2 i ay 54 45 LE 2 KEEN S 8 e Y o 9046 1 1 1 DIODE MODULE 0610153 2 a se 9 n 23 5 n E ris m g Bo 555 g g 2 a n 5 5 2 5 SUPRESSION DIODES SHOWN pm 1 ER aR BW W 89 SCHEMATICALLY ON COILS BUT ARE 7 5 19 EV PHYSICALLY ON DIODE MODULE WHT YEL 48 1 1 wr z 8 14 8 n 1 RELA 52 22 2 8 24 5 5 i H i 9 1 wes 3 3 SPEED 8 E 5 2 M g e z 4 REL 5 5 owe 20 20 LIFT STEER STEER BRAKE ORIVE DRIVE D BABS BY Be pe paps Fl Fl Fl Ei amp Ei x x x z a a Ei 2 ORANGE 55 4
2. Figure 3 3 Electrical Schematic Proportional Control Sheet 1 of 2 JLG Lift 3120737 SECTION 3 TROUBLESHOOTING T x15 1 id WIPER TRIGGER SWITCH 510 OHM 2 W POT 5 23 510 OHM 2 W gt gt C RIGHT 24 VOLTS gt gt ROCKER SWITCHES por Poer gt NeT 1 24 075 gt gt CENTER DIRECTIONAL CONTROLLER J2 09990999090 2 x ED m TILT LIGHT meus 2 424 VOLTS 056 54 DECK SELECT LIGHT 3 amp 4 U1 it 2801 558 LIFT SELECT LIGHT y MEMBRANE ORANGE 55 4 3 SWITCH 1 gt gt HI ORIVE SWITCH i PAD GREEN 55 11 gt 7 gt DECK SELECT SWITCH 4 2 8 TST LIFT SELECT 224 YEL RED 2 3 1 24 VOLTS SWITCHES 5 595 gt 49 gt post tRac 4 DS Ss ORANGE 55 1 gt gt DRIVE SELECT 4 4 gt gt DRIVE SELECT LIGHT 3 amp E L PED ELEV BK SOR js pex NOT USED 2632 2 NOTE NO CONN
3. PERSONALITY MIN MAX DRIVE ACCEL 0 5 SEC 5 0 SEC DRIVE DECEL 05 5 05 DRIVE 1 25 0 DRIVE SPEED MAX LOW 5096 10096 DRIVE SPEED MAX HIGH 5096 10096 ELEVATION MAX 0 40 POSI TRAC TIME 0 Sec 60 Sec HIGH DRIVE OVERCURRENT 50 Amp 200 Amp HIGH DRIVE TIME OUT 0 Sec 25 LIFT ACCEL 0 5 Sec 5 0 Sec LIFT DECEL 0 0 Sec 1 5 Sec 1 25 LIFT UPMAX 5096 10096 DOWN 3096 10096 DECK ACCEL 0 5 Sec 5 0 Sec DECK DECEL 0 Sec 5 1 25 DECK EXT MAX 0 10096 DECK RET MAX 0 100 STEER STATIC 20 50 STEER DRIVE COMP 0 35 GROUND LIFT UP MAX 0 100 GROUND LIFT DOWN 0 100 GROUND DECK OUT 0 100 GROUND DECKIN 0 100 JLG strongly recommends that these settings not be changed Changing these settings may adversely affect the performance of your machine NOTE Personality settings can be adjusted within the adjustment range in order to achieve opti mum machine performance JLG Lift 3120737 SECTION 2 PROCEDURES 2 23 MACHINE MODEL DEFAULT SETTINGS Table 2 5 Machine Model Default Settings Chart Adjustment 2632E2 3246E3 DRIVE ACCELERATION 1 0sec DRIVE DECELERATION 0 5sec DRIVE CREEP 12 DRIVE SPEED MAX LOW 100 DRIVE SPEED MAX HIGH 85 ELEVATION 42567 POSITRAC TIME 10sec HIGH
4. Figure 2 1 Barrel Support If applicable using a suitable spanner wrench loosen the spanner nut retainer and remove the spanner nut from the cylinder barrel Secure a pull bar to the rod end with a 0 75 16 cap screw fastener A IMPORTANT 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 2 6 Apply Spanner Wrench 2 Figure 2 2 Cylinder Head Retainer Screw Removal 7 Lift Using this as a handle pull out the piston rod and extend until the piston bottoms out on the head Gently tap the piston against the head to drive the rod assembly out Place the rod on a clean surface that will not dam age the chrome 3120737 SECTION 2 PROCEDURES 10 NOTE 11 12 SUPPORT Figure 2 3 Rod Support Vise up on the wrench flats on the end of the rod and remove the piston Locknut Locknut hex sizes are as follows 1532E2 1932E2 1 1 2 in 38 mm 2032 2 2632 2 2646 2 3246 2 1 7 8 in 48 mm Break the piston free and separate from the rod Slide the spacer and head off the rod from the piston shoulder end Cleaning and Inspection 1 3120737 Clean all parts thoroughly an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage
5. 1 1 1 3 Performatice sro oe e ed ys 1 1 1 4 Torque 1 3 1 5 cc 1 3 1 6 Serial Number Locations 1 4 1 4 1 7 Limit Switches cre boue ger dx 1 4 1 8 Cylinder 1 4 1 9 Pressure Settings E ELE RM bLE xs 1 5 1 10 Major Component 1 6 1 11 Critical Stability 1 1 6 SECTION 2 PROCEDURES 2 1 Generali cit de edu OC ie eo pa a aE 2 1 2 2 Servicing and Maintenance 2 1 2 8 Lubrication Information si x rri eI Prev E E eI e 2 2 24 Cylinders Theory 2 8 2 5 Valves Theory of Operation 2 3 2 6 Component Functional 2 4 2 7
6. 4 2 41 2 6 Machine Configuration Programming 2 42 2 7 Help Messages Ide eR CE P Ee E nef vene p Oe gs 2 44 2 8 JLG SMART System Flash Codes amp Help 2 45 2 9 Analyzer Menu 2 47 2 10 Preventive Maintenance and Inspection Schedule 2 b4 3 1 Electrical Troubleshooting Chart 2 3 2 3 2 Hydraulic System Troubleshooting 1 3 3 JLG Lift 3120737 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 4 CAPACITIES Hydraulic Oil Tank 1532E2 1932E2 3 0 gallons 11 4 liters at full mark on tank 2 5 gallons 9 5 liters at add mark on tank 2032E2 2632E2 2646E2 3246E2 3 9 gallons 14 8 liters at full mark on tank 3 4 gallons 12 9 liters at add mark on tank Hydraulic System Including Tank 1532E2 1932E2 Approximately 4 0 gallons 15 0 liters 2032E2 2632E2 2646E2 3246E2 Approximately 5 0 gal lons 19 0 liters 12 COMPONENT DATA Hydraulic Pump Electric Motor Assembly All Models 24 Volts DC motor w single section gear pump 1532 2 1932 2 2 25 8 5 2032E2 2632E2 2646E2 3246E2 3 0 11 4 Ipm Battery Charger 20
7. READ RP drei UNS S debis Gaede ead 2 4 2 8 Cylinder Checking Procedures 2 2 4 2 9 Lift Cylinder Removal and Installation 2 5 2 10 Lift Cylinder Repair cas be ig oboe te ve Ie I deis 2 5 2 11 Brake Cylinder 1 2 8 2 12 Steer Cylinder Repair cien Rm Og aA REDE 2 10 2 13 Drive Motor Sauer Danfoss 4 2 13 2 14 Drive Motor REXtOth 3 Sasa Oe od eoi ea uat eet Bo od E oe 2 14 2 15 Drive Motor Parker i sere maat ao ue RUE eR ER RE a 2 15 2 16 Tilt Switch Adjustment 2 30 2 17 Voltmeter 2 2 2 30 218 Pressure Setting procedures 2 32 2 19 Limit Switch 2 35 2 20 Door Adjustment a ceder o o ee Ae os Deka o Rec 2 35 2 21 JLG SMART System Analyzer Kit Instructions 2 36 2 22 Machine Personality Settings 2 40 2 2
8. 3 7 3 5 Hydraulic Schematic Non Proportional 3 8 3 6 Hydraulic Schematic Proportional Control Sheet 1 of 2 3 10 3 7 Hydraulic Schematic Proportional Control Sheet 2 of 2 3 11 3 8 Harness and Cable Assembly Non Proportional Control Sheet 1 2 3 12 3 9 Harness and Cable Assembly Non Proportional Control Sheet 2 2 3 13 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Torque Requirements 224 DER RA Lue E 1 3 1 2 Hydraulic OF rrt ert Me PEREAT 1 3 1 3 Lubrication Specifications ne o ede ke os etta VER do eR eon Bor dcn 1 3 1 4 Gylinder Specifications cool eu whee a Se Rae OO ce 1 4 1 5 Major Component 1 6 1 6 Critical Stability Weights lt sss nesca eas deiat Ea E EEE Ea ERE 1 6 2 1 Cylinder Component Torque 2 8 2 2 Holding Valve Torque Specifications 1 2 8 2 3 Pressure Settings Chart 2 33 2 4 Machine Personality 05 2 40 2 5 Machine Model Default Settings
9. 14266 3009 IHL ONIH3LN3 1 1 13A3159 399V nue 487 do E T3A31 55300 39NVHO OL 18 SANAN 13 31 401 3HL 110995 NYO SAIM 3S3H ONISSAYd NOISYAA WASKTVNY NOISYAA 245 NI MJ 0 8104 AWAL TUN WAL ISAL H VIRUS pes H SNOIIVHSTIV muni XVN H TIS zi 3501 XVI QRIVATTA JVILISOd ASOT 300 ATA SINANI TIV ISAL gt SWUVIV NIST aang Ciaoo NO ITIL lI nou mvv eon ETE soins 4 WH noun Nouns TDI w t numis soustor 01 edeos3 sse4d 1 0 AALAVIS T AIAH 990TH MO H 1591 WAUSAS EUM H mouv 2 39 JLG Lift 3120737 SECTION 2 PROCEDURES 2 22 MACHINE PERSONALITY SETTINGS 2 40 Table 2 4 Machine Personality Settings
10. 3246 2 1 900 Ib 860 kg Maximum Bearing Pressure 1532E2 93 psi 6 5 kg cm 1932 2 90 psi 6 4 kg cm 2032 2 100 psi 7 0 kg cm 2632 2 120 psi 8 4 kg cm 2646 2 107 psi 7 5 kg cm 3246 2 127 psi 8 9 kg cm 1 4 TORQUE REQUIREMENTS Table 1 1 Torque Requirements 410 210 C NOTE Hyaraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 When temperatures remain consistently below 20 F 7 C JLG recommends the use of Mobil DTE13M hyaraulic oil NOTE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Indus tries for proper recommendations Lubrication Specifications Table 1 3 Lubrication Specifications Key Specifications MPG Multipurpose Grease having a minimum dripping pointof 350 F Excellent water resistance and adhe sive qualities and being of extreme pressure type Timken OK 40 pounds minimum Description Torque Value Dry Interval Hours Wheel Lugs 105 120 ftlb 122 Nm 50 Wheel Hub To Drive 125 1
11. E 5 5 T c cmm zen Iu ub RR Se 22522553 1 I 1 I I T 111 123 1 1 amp z 5 5 5 3 8 8 7 REMOVE THE BLACK WIRE FROM PH 3 3 BLU ORN 52 3 AND INSTALL IN 2T WHEN TILT WITH DRIVE AND LIFT CUTOUT 15 REQUIRED BY THE SALES ORDER HOURMETER a MET zr PH Ba 2 GR T a 3 E amp 2 3 E 2 E 4 a 8 8 8 GROUND CONTROL P LIFT SWITCH gt ELEVATION SWITCH 15 CLOSED WHEN MACHINE IS IN THE STOWED POSITION TILT SWITCH WHT YEL48 1 ORN RED 49 1 2646 3246 LIFT 3 DOWN LIFT CYLINDER 2 WHT YEL 48 1 BLK 1 I CLOSED WHEN LEVEL 1 I 1 1 TILT OPTION Dom Figure 3 1 Electrical Schematic Non Proportional Control Sheet 1 of 2 JLG Lift 3120737 SECTION 3 TROUBLESHOOTING TRIGGER SWITCH YEL RED 2 4
12. ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY DIAGNOSTICS SYSTEMS DATALOG Continued ON Displays total controller on time NOTE Up to four minutes lost at switch off DRIVE Displays total controller drive operation time LIFT Displays total controller lift operation time DECK Displays total controller deck operation time NOTE Not displayed if POWER DECK NO PUMP Displays total controller pump running time NOTE Includes drive lift up deck and steer RENTAL Displays total controller pump running time NOTE Canbe reset ERASE RENTAL Not available in level 3 YES ENTER NOESC ENTERresets rental datalog time to zero MAX TEMP Displays maximum measured heatsink temperature MIN TEMP Displays minimum measured heatsink temperature MAX BATTERY Displays maximum measured battery voltage VERSIONS ASPC Displays controller software version ANALYZER Displays analyzer software version ACTIVATE TESTS Not available once tests are activated YES ENTER NO ESC ENTER activates system test NOTE Cannotbe done while controller is use trigger switch closed RUN SYSTEM TEST ENTER starts system test Machine must befully lowered before run Notavailable until tests are activated ning systems test Displays messages while system test runs Some messages are prompts requiring user intervention ENTER can be pressed if a fault has been noted and to con tinuethe system test NOTE A flashing message is critical and prevents t
13. Y REMOVE ORN RED 49 1 AND INSTALL BLK WIRE ON RELAY TERM A1 FOR 1932 2 AND 3246E2 MACHINES ONLY MP 1870116 Figure 3 2 Electrical Schematic Non Proportional Control Sheet 2 of 2 3120737 JLG Lift 3 5 SECTION 3 TROUBLESHOOTING 3 6 m CONTROL E STOP YEL RED 2 3 2 2 2 02 8 8 8 MULTIPLEXER 8 8 8 BOARD Ht ation 4 KaL YEL RED 2 3 J4 5 i E 4 e dios 8 5 8 8 58 amp 6 8 8358 5 4 5 543 5 12514158814 A 999999999 em 9 9 90960009090 JAN A A AA A PEE 9808608006 YEL RED 2 5 lt 9 4 03 ixl JLG SMART SYSTEM MICROPROCESSOR x10 14 i YEL RED 2 5 T 38 2 5 B 8 1 5 4 G3 xm i 39968 E 5 Y T 2 P x i s z z 3413 8 5g 4 E he nos BLK 5 A 4 2 amp B 3 n 5 E wf E Lr ot 0 8 9 RELAY 4 9 YEL RED 2 3 n 3 1 RUTREN L 9 0 0 0 9 8 OPTION DES b E OPTION TRI EC Pes Sae lt 31
14. 1 JLG Lift Install a pressure gauge at gauge port located at the bottom front of the valve body The port is identi fied by a stamping on the valve body Close the steer valve completely by turning clock wise Once the steer valve is closed activate the steer Switch in either direction until the steer cylinder bot toms out Adjust your Main Pressure to value in the Pressure Settings Chart Once you have adjusted your main pressure be sure and reset your steer pressure back to value in the Pressure Settings Chart 3120737 SECTION 2 PROCEDURES Table 2 3 Pressure Settings Chart mm 1532 2 1932E2 2032 2 Pee EM esci psi bar psi bar psi bar psi bar psi bar Main Relief High Drive 3200 221 3200 221 3200 221 3200 221 3000 207 Lift 2000 138 2300 159 2200 152 2400 165 2100 145 Steer 2000 138 2000 138 2000 138 2000 138 2100 145 3120737 JLG Lift 2 33 SECTION 2 PROCEDURES Lift Shuttle Check Valve Plug Valve Block ad Drive Steer Lift Relief Brake Valve Lift Up Valve gt Main Relief Steer Shuttle Steer Relief Load Sense Steer Valve High Drive Valve Posi Trac Valve Drive Valve Flow Divider Capscrew TORQUE Counterbalance Decel TO 60 IN LBS 7 Nm NOTE When valve components are removed and or replaced the following torque values apply when re install
15. 7 6 95 8 5 1 Lift Cylinder 3 5 38 94 2 00 1532E2 1932E2 2032E2 1 5 3246E2 8 9 99 0 5 1 2632E2 2646E2 3246E2 2 Steer Cylinder 1 50 6 25 0 75 All Models 3 8 15 9 1 9 All Japanese Models 5 Brake Cylinder 2 00 1 75 1 00 All Models 5 1 4 4 2 5 High Drive Cut Out High drive speed is cut out when the platform is raised above the preset height per model as follows Table 1 4 High Drive Cutout Model 1532 2 46 55 12 14 1932 2 48 60 12 15 2032 2 84 21 2646 2 102 2 6 2632 2 114 2 9 3246 2 60 65 15 17 Overload Protection Japanese and French Specification Only When the platform is loaded to 12096 of its rated capacity the lift up and drive functions are cut out and the platform alarm if equipped is sounded for two seconds on two seconds off while the operator tries to activate either lift up or drive Remove weight from the platform to restore lift up and drive functions operation and to silence the alarm if equipped 1 4 JLG Lift 3120737 SECTION 1 SPECIFICATIONS Serial Number Plate 2032E2 2632E2 2646E2 3246E2 Serial Number Plate 1532 2 1932 2 Serial Number Stamped All Models Figure 1 1 Serial Number Location 1 9 PRESSURE SETTINGS Pressure Settings for Non Proportional Control Machines Pressure Settings for Proportional Cont
16. Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary SECTION 2 PROCEDURES 8 Inspect seal and o ring grooves in guide for burrs and sharp edges Dress applicable surfaces as nec essary 9 Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary 10 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly 1 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 2 Pl
17. 4 Install a washer ring onto the rod then carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston spacer onto the rod 6 If applicable correctly place a new o ring and back up rings in the inner piston diameter groove 7 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 8 Carefully place the piston on the cylinder rod ensur ing that the o ring and back up rings are not dam aged or dislodged 9 Place the piston onto the rod until it abuts the spacer end and install the seal and guidelock ring 10 Place the locknut on the end of the cylinder rod and tighten 11 Remove the cylinder rod from the holding fixture 12 Thoroughly rinse the inside of the rod weldment and allow to drain Wipe with a lint free rag A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 13 Clean and visually inspect all parts for material defects and contamination 14 Lubricate the head piston and all seals with hydrau lic fluid prior to installation 15 When the rod is ready to be installed in the rod weld ment liberally apply an anti seize lubricant to the head outer
18. Spring Washer Balance Plate Disc Valve Radial Needle Bearing Bearing Race Distributor Plate Cardan Shaft O Ring Gearwheel Set End Cover Name Plate Washers Screws Plugs Figure 2 5 Drive Motor Sauer Danfoss Dismantling 1 Place motor proper holding device that allows access to the output shaft 2 Carefully remove end cover sideways being sure to catch any parts that may fall from the gearwheel 3 The needles bearings will fall out during dismantling and can be collected and reused The outer ring and thrust bearing need not be removed 3120737 JLG Lift With the housing in the holding device press the shaft out of the housing Collect the needle bearings for possible re use Remove the housing from the holding device and place on a workbench With a screwdriver gently lever the dust seal ring from the housing Extract the shaft seal from the housing Press the remaining parts out using hydraulic equip ment Clean all parts carefully with a low aromatic kero sene 2 13 SECTION 2 PROCEDURES Assembly NOTE Before assembly inspect all parts and replace if nec 2 14 essary Before assembly lubricate all parts with hydraulic oil and grease rubber parts with Vaseline Turn motor housing so the rear end faces upwards Press shaft seal into housing The bearing race can be fitted in any position
19. 45 in 1 2 m 3246 2 48 75 in 1 2 m Machine Height Standard Handrails Stowed 1532E2 600 Ib 270 kg 1932 2 500 Ib 230 kg 2032E2 750 Ib 340 kg 2632E2 500 Ib 230 kg 2646E2 750 Ib 340 kg 3246 2 700 Ib 320 kg 1 2 1532E2 76 5 in 2 0 m 1932E2 78 in 2 0 m 2032 2 79 5 in 2 0 m 2632 2 89 in 2 3 m 2646 2 72 in 1 8 m 3246E2 91 5 in 2 3 m Machine Length 1532 2 1932 2 68 5 in 1 7 m 2032 2 2632 2 2646 2 3246 2 90 in 2 3 m JLG Lift 3120737 SECTION 1 SPECIFICATIONS Machine Width 1532 2 1932 2 31 75 in 0 8 m 2032E2 2632E2 31 75 in 0 8 m 2646E2 3246E2 45 75 in 1 2 m Ground Clearance with Platform Lowered 1532E2 2 50 in 6 3 cm 1932E2 2032E2 2632E2 2646E2 3246E2 2 75 in 8 0 cm NOTE When maintenance becomes necessary or fas tener has loosened refer to Figure 1 2 Torque Chart to determine proper torque value 1 5 LUBRICATION Hydraulic Table 1 2 Hydraulic Oil Hydraulic System Operating With Platform Elevated SAE Viscosity Grade Temperature Range Pothole Protection System Lowered 0 Fto423 F 10W All Models 0 75 in 1 9 cm 18 Cto 5 C 0 Fto210 F 10W 20 10W 30 Maximum Tire Load 18 Cto 99 C 50 Fto210 F 20W 20 1532E2 1 200 Ib 545 kg 1932E2 1 050 Ib 480 kg 2032E2 1 350 Ib 660 kg 2632 2 1 950 Ib 885 kg 2646E2 1 550 Ib 745 kg
20. LIFT DOWN CUTOUT ARMGAURD PROTECTION ACTIVE LIFT DOWN PREVENTED DECK EXTENDED LIFT PREVENTED FUNCTION CUTOUT ACTIVE LIFT UP PREVENTED TILTED amp ABOVE ELEVATION STEER LOCKED OUT RELEASE THEN RESELECT STEER PREVENTED DECK EXTENDED amp ABOVE ELEVATION STEER PREVENTED FUNCTION CUTOUT ACTIVE STEER PREVENTED NOT AVAILABLE STEER PREVENTED TILTED amp ABOVE ELEVATION 3 1 Indicates that a contactor did not close when ener gized OPEN CIRCUIT LINE CONTACTOR The capacitor bank charge did not increase to battery supply when line contactor was energized this could be due to a power wiring error gized 3 2 Indicates that a contactor did not open when de ener WELDED LINE CONTACTOR The capacitor bank charge did not decrease bat tery supply when line contactor was de energized this could be due to a power wiring error 3120737 Lift 2 45 SECTION 2 PROCEDURES Table 2 8 JLG SMART System Flash Codes amp Help Messages Code Description 3 3 Indicates that a contactor coil is short circuit SHORT CIRCUIT LINE CONTACTOR COIL The line contactor was not energized when required due to coil over current protection VALVE OR LINE CONTACTOR ENERGIZED CHECK WIRING The drive circuitto the line contactor or a valve is active when no driver circuitis turned on this could be due to a wiring error to the valves or line contactor 4 2 indicates that
21. NOTE Password 33271 will give you access to level 1 which will permit you to change all machine person ality settings There are some settings that JLG strongly recommends that you do not change These settings are so noted below ELEVATION CUTBACK POSITRAC TIMEOUT HIGH DRIVE CURRENT LIMIT HIGH DRIVE TIME LIMIT A WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROLLER A IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 52 BAR 750 PSI AT A MINIMUM DISTANCE OF 30 5 CM 12 IN 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 3120737 SECTION 2 PROCEDURES jeuoneziueDJQO oJnBiJ 10 HO LNSYYND LS0 QV LON OQ 310 pemen 41136 3NIHOVIA 311918 NOLLdO SALVOIGNI CD 3LON nue qns STHA31 40138 ANY IHL S39NVHO SMV NYO
22. 0061 dra pem 0657 00696 0002 esr 0968 ozel 00218 8411 2 osel 009988 56 48 968 0801 Obr 00044 526 zi 81247 00691 00 ocol 096 oszi 00289 078 1 811 616 00699 00 961 091 000 00168 SEZ d 698 00909 066 789 089 006 008 5 5 9 8 SEO 00608 501 ves 009 099 00899 OZS vL 685 0029 099 Ser 099 009 00918 5 7 6 8 2 009 00576 597 966 oze 0 00966 9L Soc 00966 027 106 082 ose 00106 sec or e Occ 00982 892 poz oel orz 00062 06 8l 00922 ove 08 04 Occ 09606 991 8 9 SOL 00602 06 St 068 04 08488 SEL 0088 59 6688 08 osi 0089 028 86 zi 946 0668 ser 808 06 028 0099 OOL 08 021 96 08 ol 052 58 89 ej e SZ 01818 06 02 09 08 00108 09 05 02 01 06901 08 9 SG 01 0566 58 9 2 05 08 8 Sp 08 0061 OF ZE SZ 0098 82900122201 0611 05 0 Sp 0001 82 06 Over 57700 OL 12 0085 0 ez 02 0208 742 m vL 6L 0016 08800 guis OPZS 0 zz 8i Sz 0219 6L OL i 29 0966 0500 8 9 14181 1478 1481 14 1 1481 141 1181 1391 vi ser 02 eor se 98 00 0602 7900 8 081 09 800 vv 0982 sol SZ 96 0202 8 00 6 89 00
23. Place housing 18 assembly into a soft jawed vise 6 Assemble thrust washer 14 then thrust bearing 15 with the coupling shaft bore down clamping against that was removed from the Torqlink the mounting flange NOTE Torglinks require one thrust washer 14 with 5 the Torqlinks assemble a new backup washer thrust bearing 15 The coupling shaft will be seated 17 and new seal 16 with the seal lip facing toward directly against the thrust the inside of Torqlink into their respective counter bores in housing 18 if they were not assembled in 7 Apply masking tape around splines or keyway on procedure 2 shaft 12 to prevent damage to seal 8 Be sure that generous amount of clean corrosion resistant grease has been applied to the lower outer housing bearing bushing 19 Install the coupling shaft 12 into housing 18 seating it against the thrust bearing 15 in the housings A CAUTION ORIGINAL DESIGN LARGE FRAME TF amp TG TORQLINKS THAT DO NOT HAVE BACKUP WASHER 25 WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER 17 NEW BACKUP WASHER 25 AND NEW SEAL 16 2 24 JLG Lift 3120737 SECTION 2 PROCEDURES THE OUTER BEARING 19 IS NOT LUBRICATED BY THE SYS TEM S HYDRAULIC FLUID BE SURE IT 15 THOROUGHLY PACKED WITH THE RECOMMENDED GREASE PARKER GEAR GREASE SPECIFICATION 045236 LUBRICANT K 70M NOTE Mobil Mobilith SHC 460 NOTE A 10
24. DRIVE OVER CURRENT 140amps HIGH DRIVE TIME OUT 5 0 sec LIFT ACCEL 1 05 LIFT DECEL 0 0sec LIFT CREEP 15 LIFT UP MAX 10096 DECKACCEL 0 5sec DECK DECEL 0 0 sec DECK CREEP 10 DECK EXTENSION SPEED MAX 10 DECK RETRACTION MAX 80 STATIC STEER 30 STEER DRIVE COMP 15 GROUND LIFT UPMAX 100 GROUND DECK IN MAX 50 GROUND DECK OUT MAX 40 NOTE WARNING Changing the machine model will set all person alities back to the factory default settings check the machine model adjustment chart for the correct settings for each model if your machine does not match the proper settings for each model adjust the settings as necessary in accor dance with the chart NOTE JLG strongly recommends that these settings not be changed Changing these settings may adversely affect the performance of your machine 3120737 JLG Lift 2 41 SECTION 2 PROCEDURES 2 24 MACHINE CONFIGURATION INFORMATION must be completed before any personality settings can be changed Changing the personality settings first and then changing the model number of the machine configuration will cause the personality set NOTE The following information is to be used when working with the MACHINE SETUP menu When configuring tings to return to default values the E Series scissor lift the machine configuration Table 2 6 Machine Configuration Programming Information Configuration Digit Number Description Default Setting Befor
25. Remove five six or seven special ring head i bolts 1 using an appropriate 1 2 or 9 16 inch size 4 Remove end cover assembly 2 and seal ring 4 socket Inspect bolts for damaged threads or seal Discard seal ring 1 Special Bolts 8B Stator or Stator Vane 16 Seal 2 End Cover 8C Vane 17 Back up Washer 3 Seal Ring Commutator 8D Stator Half 18 Housing 4 Seal Ring 9 WearPlate 18A O Ring 5 Commutator Ring 10 Drive Link 19 Bearing Bushing Outer 6 Commutator Ring 12 Coupling Shaft 20 Dirt amp Water Seal 7 Manifold 13 Bearing Bushing Inner 21 Plug 8 Rotor Set 14 Thrust Washer 8A Rotor 15 Thrust Bearing Figure 2 6 Parker Drive Motor 2 16 JLG Lift 3120737 SECTION 2 PROCEDURES 5 the end cover 2 is equipped with shuttle valve T components remove the two previously loosened plugs 21 CAUTION BE READY CATCH THE SHUTTLE VALVE OR RELIEF VALVE COMPONENTS THAT WILL FALL OUT OF THE END COVER VALVE CAVITY WHEN THE PLUGS ARE REMOVED NOTE The insert and if included the orifice plug in the end cover 2 must not be removed as they are serviced as an integral part of the end cover 6 Thoroughly wash end cover 2 in proper solvent and blow dry Be sure the end cover valve apertures including the internal orifice plug are free of con tamination Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces Replac
26. TAKEN WHEN INSTALLING THE CYLINDER ROD CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAM AGE TO THE PISTON AND CYLINDER BARREL SURFACES 2 12 With the barrel clamped securely and while ade quately supporting the cylinder rod assembly insert the piston end of the rod assembly into the cylinder barrel Ensure that the piston ring and o ring are not damaged or dislodged Continue pushing the rod into the barrel until the cyl inder rod guide can be inserted into the end of the cylinder barrel Coat the threads of the cylinder rod guide with Loc tite 271 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench On the remaining cylinder rod guide place a new wiper ring rod seal o ring and back up ring into the cylinder rod guide grooves Carefully install the cylinder rod guide onto rod sec tion two and slide the guide into the end of the cylin der barrel Coat the threads of the cylinder rod guide with Loc tite 271 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench Reconnect the hydraulic hoses to the applicable cylinder ports JLG Lift 3120737 SECTION 2 PROCEDURES 2 13 DRIVE MOTOR SAUER DANFOSS Castellated Nut Washer Dust Seal Ring Housing O Ring Shaft Seal Bearing Race Axle Needle Bearing Radial Needle Bearing Parallel Key Shaft Tapered O Ring
27. There should be no scratches or pits deep enough to catch the fingernail Pits or scratches that go to the base metal are unaccept able Chrome should be present over the entire sur face of the rod In the event that an unacceptable condition occurs the rod should be repaired or replaced Visually inspect the inside bore of the head for scratches or polishing Deep scratches are unac ceptable If polishing occurs the bore should be checked for ovality if ovality occurs it is unaccept able Check the condition of the seals looking particularly for metal particles embedded in the seal surface Damage to the seal grooves is unacceptable partic ularly on the sealing surfaces In the event that an unacceptable condition occurs the piston should be replaced Visually inspect the bore on the inside tube assem bly for pits and scratches There should be no scratches or pits deep enough to catch the finger nail 10 11 12 13 14 Inspect threaded portion of barrel for damage dress threads as necessary Inspect threaded portion of piston for damage Dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect threaded portion of head for damage Dress threads as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter
28. assembly has passed inspection to this point inspect the housing bearings bushings 19 and 13 and if they are captured in the housing cavity the two thrust washers 14 and thrust bearing 15 The bearing rollers must be firmly retained in the bearing cages but must rotate and orbit freely All rollers and thrust washers must be free of brinel ling and corrosion The bushing 19 or 13 to cou pling shaft diameter clearance must not exceed 0 010 inch 0 025 mm A bearing bushing or thrust washer that does not pass inspection must be replaced If the housing has passed this inspection the disassembly of the Torglink is completed NOTE The depth or location of bearing bushing 13 in rela tion to the housing wear plate surface and the depth or location of bearing bushing 19 in relation to the beginning of bearing bushing counter bore should be measured and noted before removing the bearings bushings This will facilitate the correct reassembly of new bearings bushings 22 If the bearings bushing or thrust washers must be replaced use a suitable size bearing puller to remove bearing bushings 19 and 13 from hous ing 18 without damaging the housing Remove thrust washers 14 and thrust bearing 15 if they were previously retained in the housing by bearing 13 JLG Lift 2 21 SECTION 2 PROCEDURES Assembly Replace all seals and seal rings with new ones each time you reassemble the
29. degrees apart to retain sta tor and wear plate stationary 3 Assemble the rotor 8A counterbore down if appli cable into stator 8B and onto wear plate 9 with rotor splines into mesh with drive link 10 splines NOTE f the manifold side of the rotor was etched during Torglink disassembly this side should be up If the rotor is not etched and does not have a counterbore use the drive link spline contact pattern apparent on the rotor splines to determine the rotor side that must be against the wear plate 3120737 4 Assemble six vanes 8C or as many vanes that will readily assemble into the stator vane pockets A CAUTION EXCESSIVE FORCE USED TO PUSH THE ROTOR VANES INTO PLACE COULD SHEAR OFF THE COATING APPLIED TO THE STA TOR VANE POCKETS 5 Grasp the output end of coupling shaft 12 with locking pliers or other appropriate turning device and rotate coupling shaft drive link and rotor to seat the rotor and the assembled vanes 8C into stator 8B creating the necessary clearance to assemble the seventh or full complement of seven vanes Assemble the seven vanes using minimum force 6 Remove the two assembled bolts 1 if used to retain stator and wear plate Lift 2 29 SECTION 2 PROCEDURES 2 16 TILT SWITCH ADJUSTMENT NOTE The machine is equipped with a tilt switch sensor factory set to activate when the machine is elevated and out of level in any direction at 5 a
30. direction If the joystick is not activated within three seconds of selecting a function it will be nec essary to re select a function High drive and positive trac tion are used in conjunction with the drive function The motor controller will control current output as pro grammed for smooth operation and maximum cycle time Ground control speeds for platform lift and the optional power deck are also programmed into the motor control ler The motor controller also features an adjustable time limit for positive traction Another power saving feature is the high speed drive current limit This feature will auto matically control the drive speed and controller output when it exceeds the pre set current limit for a specified time and reduce the motor speed thus conserving power For safety the machines are equipped with pothole pro tection and elevation cutback The pothole protection is employed as the platform is raised If the pothole protec tion does not extend the drive function will be disabled When the platform is raised the drive function goes into creep mode The SMART System controller has built in LED to indicate any faults The system stores recent faults which may be accessed for troubleshooting Optional equip ment includes an hourmeter beacon light tilt switch light and or alarm power deck power deck extension limit function cutout and ground alarm These options may be added later but some must be
31. function has ben selected butis not allowed while the high drive functionis inuse PUMP MOTOR AT CURRENT LIMIT Pump motor current has reached the maximum allowed and is being limited STEERSELECTED BUT TRIGGER SWITCH OPEN Steering has been selected butthe trigger switch is open whenthe trigger switch is closed steering will begin if itis still selected TESTS ACTIVE RECYCLE EMS TO END The system tests have been activated normal machine operation is not allowed 2 44 JLG Lift 3120737 SECTION 2 PROCEDURES Table 2 8 JLG SMART System Flash Codes amp Help Messages Code Description 2 1 Indicates problems with EMS inputs STARTUP Neither EMS is active the system is just switching on or is discharging the capacitor bank Awelded line contactor might also cause this 2 2 Indicates problems with platform controls ALL FUNCTIONS PREVENTED NO DATA FROM PLATFORM BOX The signal from the MUX boardin the platform boxis notavailable drive liftand deck functions cannotbe selected FUNCTION PROBLEM PERMANENTLY SELECTED The drive deck function selectis active for more than ten seconds any active function will be stopped FUNCTIONS LOCKED OUT RELEASE THEN RESELECT The selected function is not allowed release the joystick to clear the fault HIGH DRIVE PROBLEM PERMANENTLY SELECTED Thehigh drive function select is active for more than ten seconds the hig
32. gained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular personal ity If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example GROUND ALARM 2 DRIVE 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 all default to the factory recommended settings 2 38 JLG Lift NOTE Refer to the appropriate Machine Personality Set tings Table and the Machine Setup Table in the JLG Service Manual for the recommended factory set tings Refer to the JLG part number of the controller printed on the front label to select the correct table in the manual
33. is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks Cylinders w Single Holding Valves Lift Cylinder IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 3120737 SECTION 2 PROCEDURES 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE WARNING DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Raise platform completely then retract cylinder slightly to avoid trapping pressure Place a suitable overhead lifting device approximately 1 in 2 5 cm below the platform 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the holding valve is defective and must be replaced 5 f no repairs are necessary or when repairs have been made carefully reconnect hy
34. machines LIFT DOWN cutout must activate when the gap between the armsis 5 in to 8 in 13 cm to 20 cm Here it will cutout LIFT DOWN and sound the platform alarm for 1 2 second on 1 2 second off and repeat this for three seconds After three seconds the operator must re selectthe LIFT function and continue to operate LIFT DOWN Ifthe wires to the limit switch used to detect the deck height are cutor the switch has failed the platform alarm will sound as mentioned The operator can re select the LIFT function and then LIFT DOWN for ten seconds at which time it will cut out again and the process must be repeated 9 0 LED Only 0 Flash Codes 1 LED and lamps in platform control box 2 LED andalarm 3 LED lamps in control box and alarm 3120737 JLG Lift 2 43 SECTION 2 PROCEDURES 2 25 JLG SMART SYSTEM HELP MESSAGES AND FLASH CODES Table 2 7 Help Messages NO FLASH CODE IS INDICATED FOR THE FOLLOWING HELP MESSAGES THEY ARE INTENDED TO HINT AT A POSSIBLE PROBLEM IF THE MACHINE IS NOT BEHAVING AS EXPECTED EVERYTHING OK The normal help message in platform mode GROUND MODE OK The normal help message in ground mode ALARM SOUNDING ARMGAURD PROTECTION ACTIVE Arm guard protection has tripped during lift down and is preventing lift down for three seconds ALARM SOUNDING DECK EXTENDED DURING LIFT DOWN The deck extension cutoutis preventing lift down ALARM SOUN
35. matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should checked cleaned and or replaced as necessary at the speci fied intervals required in Section 1 Always examine filters for evidence of metal particles 3120737 SECTION 2 PROCEDURES 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 t is not advisable to mix oils of different brands or types except as recommended as they may not contain the same required additives or be of compa rable viscosities Good grade mineral oils with vis cosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil 1 Refer to Section 1 for recommendations for viscosity ranges 2 JLG recommends Mobilfluid 424 which has an SAE viscosity of 10W 30 and a viscosity index of 152 NOTE Start up of hydraulic system with oil temperatures below 15 26 C is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary
36. on the out put end of shaft Inspect coupling shaft bearing and seal surfaces for spalling nicks grooves severe wear or corrosion and discoloration Inspect for damaged or worn internal and external splines or keyway Replace coupling shaft if any of these con ditions exist NOTE NOTE JLG Lift Minor shaft wear in seal area is permissible If wear exceeds 0 020 inches 0 51 mm diametrically replace coupling shaft A slight polish is permissible in the shaft bearing areas Anything more would require coupling shaft replacement 2 19 SECTION 2 PROCEDURES 16 16 Remove and discard seal ring 4 from housing 18 17 Remove thrust bearing 15 and thrust washer 14 Inspect for wear brinelling corrosion and a full com plement of retained rollers 18 Remove seal 16 and back up washer 17 from Small Frame housing 18 Discard both 2 20 JLG Lift 19 Remove housing 18 from vise invert it and remove and discard seal 20 A blind hole bearing or seal puller is required is 20 Inspect housing 18 assembly for cracks the machined surfaces for nicks burrs brinelling or cor rosion Remove burrs that can be removed without changing dimensional characteristics Inspect tapped holes for thread damage If the housing is defective in these areas discard the housing assem bly 3120737 SECTION 2 PROCEDURES 21 3120737 If the housing 18
37. pattern on the wear plate from rotor rota tion is normal Place rotor set 8 and wear plate 9 on a flat sur face and center rotor 8A in stator 8B such that two rotor lobes 180 degrees apart and a roller vane 8C centerline are on the same sta tor centerline Check the rotor lobe to roller vane clearance with a feeler gage at this com mon centerline If there is more than 0 005 inches 0 13 mm of clearance replace rotor set 3120737 SECTION 2 PROCEDURES NOTE rotor set 8 has two stator halves 8B amp 8D and 12 two sets of seven vanes 8C amp 8E as shown in the alternate construction TG rotor set assembly view check the rotor lobe to roller vane clearance at both ends of rotor Remove drive link 10 from coupling shaft 12 if it was not removed with rotor set and wear plate Inspect drive link for cracks and worn or damaged splines No perceptible lash play should be noted between mating spline parts Remove and discard seal ring 4 from housing 18 13 Remove thrust bearing 11 from top of coupling shaft 12 Inspect for wear brinelling corrosion and a full complement of retained rollers 14 3120737 Check exposed portion of coupling shaft 12 to be sure you have removed all signs of rust and corro sion which might prevent its withdrawal through the seal and bearing Crocus cloth or fine emery paper may be used 15 Remove coupling shaft 12 by pushing
38. plate side of the rotor set stator 8B Install the assembled rotor set 8 onto wear plate 9 with rotor 8A counterbore and seal ring side down and the splines into mesh with the drive link splines NOTE It may be necessary to turn one alignment stud out of the housing 18 temporarily to assemble rotor set 8 or manifold 7 over the drive link NOTE If necessary go to the appropriate Rotor Set Com 2 26 ponent Assembly Procedure JLG Lift NOTE The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor drive link spline contact A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent to determine which side was down The rotor set seal ring groove faces toward the wear plate 9 Apply clean grease to a new seal ring 4 and assemble it in the seal ring groove in the rotor set contact side of manifold 7 The manifold 7 is made up of several plates bonded together permanently to form an integral component The manifold surface that must contact the rotor set has it s series of irregular shaped cavi ties on the largest circumference or circle around the inside diameter The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set Assemble the
39. programmed into the motor controller when installed The SMART System may be accessed by utilizing a cus tom designed hand held analyzer JLG kit no 2901443 which will display two lines of information at a time by scrolling through the program NOTE The date code is determined by the first four digits of the controller serial number which is located on the label attached to the front of the controller The part number of the controller is located on the controller decal 3120737 SECTION 2 PROCEDURES 3120737 To Connect the Hand Held Analyzer 1 Connect the four pin end of the cable supplied with the analyzer to the top connection of the motor con troller and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the SMART System by turning the lower key to the platform position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus
40. selected menus while in access level 2 Remember you may always cancel a selected menu item by pressing the ESC key Changing the Access Level of the Hand Held Analyzer 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 to the ACCESS LEVEL menu For exam ple 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 JLG Lift 2 37 SECTION 2 PROCEDURES Once the correct password is displayed press ENTER The access level should display the following if the pass word was entered correctly MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings Adjusting Configuration Using the Hand Held Analyzer on 1600286 Controllers Once you have
41. sharp edges Dress applicable surfaces as nec essary Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper JLG Lift cylinder seal kit is used Refer to the Illustrated Parts Manual Apply a light film of hydraulic oil to all components prior to assembly Using suitable protection clamp the cylinder rod section one in a vise or similar holding fixture Place a new wiper ring rod seal o ring and back up ring into the cylinder rod guide grooves SECTION 2 PROCEDURES Carefully install the cylinder rod guide on rod section one ensuring that the wiper ring and rod seal are not damaged or dislodged Push the guide onto the rod section Place a new piston ring on the piston and a new o ring on the threaded end of cylinder rod section two Carefully place the piston on the threaded end of cylinder rod section two ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go Attach cylinder rod section one to the threaded end of cylinder rod section two and assemble Remove the cylinder rod assembly from the holding fixture Position the cylinder barrel in a suitable holding fix ture A IMPORTANT EXTREME CARE SHOULD BE
42. surface 16 Cover the entire rod assembly with hydraulic fluid and with the rod weldment positioned in a suitable holding fixture insert the rod into the rod weldment 2 8 JLG Lift 17 Using a spanner wrench tighten the cylinder head 18 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 19 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable Refer to Table 2 2 for proper holding valve torque specifications Table 2 1 Cylinder Component Torque Specifications Component Torque Value w Loctite Piston Nut Lift Cylinder 1532E2 375 450 ft Ib 1932E2 508 610 Nm Piston Nut Lift Cylinder 2032E2 800 1000 ft lb 2632 2 2646 2 3246 2 1085 1356 NOTE The following holding valve torque values are for the valve cartridge only The solenoid nut should be torqued to 5 ft Ib 6 8 Nm on all models Table 2 2 Holding Valve Torque Specifications Description Torque Value 1532E2 1932E2 2032E2 20ftlb Hydraforce 1 25 hex 3 4 16 thds 27 1 Nm 2632E2 2646E2 3246E2 25 ftlb Hydraforce 1 hex 7 8 14 thds 33 9 Nm 2 11 BRAKE CYLINDER REPAIR Disassembly A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Tag and disconnect t
43. that problems for which the proba ble cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and eletrically controlled is to determine if the circuit is lacking hydraulic oil and electrical power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the funtion valve then overriding the funtion valve mechani cally If the funtion performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS The first reference for improper function of a hydraulic sys tem where the cause is not immediately apparent should be the troubleshooting chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic check of the circuit components begining with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagram of the various circuits JLG Lift 3 1 SECTION 3 TROUBLESHOOTING 3 2 Table 3 1 Electrical Troubleshooting Chart TROUBLE PROBABLE CAUSE REMEDY All machine functions do not operate Emergency stop switch not activated Activate Emergency stop switch Joystick not in neutral position Release joystick then select function Platform cable not connected to plat
44. the controller is over temperature CONTROLLER TO HOT PLEASE WAIT The controller heat sink temperature reached 75 degrees The controller is shut down until it cools to below 70 degrees 4 4 Indicates problems with the battery supply BATTERY TOOLOW SYSTEM SHUT DOWN Battery voltage is below 17V EMS recycle required BATTERY TOO HIGH SYSTEM SHUT DOWN Battery voltage is above 30 V EMS recycle required 7 7 Indicates problems with a motor CAPACITOR BANK FAULT CHECK MOTOR WIRING The capacitor bankis not charging This is probably due to a power wiring error causing illegal current drain it could also be due to a very low battery supply POINT A LOW CHECK POWER CIRCUITS Pump point is low when the MOSFETs are off This is probably due to power wiring error PUMP MOTOR OPEN CIRCUIT CHECK MOTOR amp WIRING Pump point Ais col lapsing when the pump MOSFETs are pulsed This is probably due to an open circuit pump motor or a power wiring error PUMP MOTOR STALLED CHECK MOTOR amp WIRING The pump MOSFET protec tion circuitis active This is due to massive current drain and could be a stalled pump motor or power wiring error 9 9 Indicates problems with the controller CONTROLLER FAILURE HWFS TEST STALLED The hardware fail safe tests did not complete but no reason can be determined CONTROLLER FAILURE HWFS TEST STALLED 15 The hardware fail safe tests failed because the contactor drive fail safe did not tr
45. the rotor set in its assembled form maintain ing the same rotor vane 8C to stator 8B contact surfaces The drive link 10 may come away from the coupling shaft 12 with the rotor set and wear plate You may have to shift the rotor set on the war plane to work the drive link out of the rotor 8A and warplane Inspect the rotor set in its assembled form for nicks scoring or spalling on any surface and for broken or worn splines If the rotor set component requires replacement the complete rotor set must be replaced as it is a matched set Inspect the war plane for cracks brinelling or scoring Discard seal ring 4 that is between the rotor set and wearplate 2 18 NOTE The rotor set 8 components may become disas sembled during service procedures Marking the sur face of the rotor and stator that is facing with etching ink or grease pencil before removal from Torqlink will ensure correct reassembly of rotor into stator and rotor set intoTorqlink Marking all rotor components and mating spline components for exact repositioning at assembly will ensure maxi mum wear life and performance of rotor set and Torqlink NOTE NOTE 11 JLG Lift Series Torqlinks have a rotor set with two stator halves 8B with a seal ring 4 between them and two sets of seven vanes 8C Discard seal ring only if stator halves become disassembled during the service procedures A polished
46. to default when model number is altered TILT SWITCH Displays adjusts tilt switch presence function POWER DECK Displays adjusts power deck presence DECK EXT LIMIT Displays adjusts deck extension cutout switch presence function FUNCTION CUTOUT Displays adjusts function cutout switch presence function GROUND ALARM Displays adjusts ground alarm presence function DRIVE CUTOUT Displays adjusts drive cutout switch presence function ARMGAURD CUTOUT Displays adjusts armgaurd cutout switch presence function FLASH CODE Displays adjusts how fault flash codes are indicated CALIBRATIONS NOTE Only available at level 1 CURRENT Displays motor current calibration TEMPERATURE Displays heatsink temperature calibration 2 52 Lift 3120737 SECTION 2 PROCEDURES 3120737 2 27 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspected and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services liste
47. 1 1 kmh Maximum Speed 2 25 mph 3 6 kmh JLG Lift 1 1 SECTION 1 SPECIFICATIONS 3246E2 Low Speed 1 4 mph 2 1 kmh Elevated Speed 0 5 mph 0 8kmh Maximum Speed 2 0 mph 3 2 kmh Gradeability Manual Platform Extension Capacity All Models 250 Ib 120 kg 1 person Machine Weight Models 25 Inside Turning Radius 1532 2 1932 2 19 in 0 50 m 2032E2 2632E2 39 in 1 0 m 2646E2 44 in 1 0 m 3246 2 45 in 1 14 m Lift No Load in Platform 1532E2 approx 2940 Ib 1334 kg 1932E2 approx 2970 Ib 1337 kg 2032E2 approx 3890 Ib 1764 kg 2632E2 approx 5325 Ib 2415 kg 2646E2 approx 4280 Ib 1941 kg 3246E2 approx 6180 Ib 2803 kg Wheelbase 1532 2 Up 22 28 seconds Down 28 35 seconds 1932 2 Up 27 35 seconds Down 28 35 seconds 2032E2 Up 27 35 seconds Down 28 35 seconds 2632E2 Up 34 42 seconds Down 39 47 seconds 2646E2 Up 40 48 seconds Down 37 45 seconds 3246E2 Up 56 64 seconds Down 45 55 seconds Platform Capacity 1532E2 1932E2 52 25 in 1 3 m 2032 2 2632 2 2646 2 3246 2 68 5 in 1 7 m Platform Height Elevated 1532E2 15 ft 4 5 m 1932E2 19 ft 5 8 m 2032E2 20 ft 6 1 m 2632 2 2646 2 26 ft 7 9 m 3246 2 32 ft 9 75 m Platform Height Stowed 1532E2 37 5 in 1 0 m 1932E2 39 in 1 0 m 2032 2 38 in 1 0 m 2632 2 45 5 in 1 2 m 2646E2
48. 2Tube P N 406010 is included in each seal kit NOTE The coupling shaft 12 will be flush or just below the housing wear plate surface on Torqlinks when properly seated The coupling shaft must rotate smoothly on the thrust bearing package 9 10 Apply small amount of clean grease to a new seal ring 4 and insert it into the housing 18 seal ring groove One or two alignment studs screwed finger tight into housing 18 bolt holes approximately 180 degrees apart will facilitate the assembly and alignment of components as required in the following proce dures The studs can be made by cutting off the heads of either 3 8 24 UNF 2A or 5 16 24 UNF 2A bolts as required that are over 0 5 inch 12 7 longer than the bolts 1 used in the Torqlink Install drive link 10 the long splined end down into the coupling shaft 12 and engage the drive link splines into mesh with the coupling shaft splines NOTE 3120737 JLG Lift Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mat ing coupling shaft splines 2 25 SECTION 2 PROCEDURES 11 Assemble wear plate 9 over the drive link 10 and alignment studs onto the housing 18 12 13 Apply small amount of clean grease to a new seal ring 4 and assemble it into the seal ring groove on the wear
49. 3 Machine Model Default 0 2 2 41 2 24 Machine Configuration Information 2 42 2 25 Smart System Help Messages and Flash 2 44 2 26 Analyzer Menu Structure 2 47 2 27 Preventive Maintenance and Inspection 2 53 SECTION 3 TROUBLESHOOTING 3 1 Generales sii 341 3 2 Troubleshooting Information 1 1 0 3 1 3 3 Hydraulic Circuit Checks 3 1 3120737 Lift TABLE 5 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Serial Number 1 5 1 2 Torque Chart EUER Eben ntu REI Ege ve Era CENE E ERE RR S EE 1 7 2 1 Lift Cylinder Components 1 2 6 2 1 Suppott o cese CER Sink eee Soe E ce 2 6 2 2 Cylinder Head Retainer Cap Screw 2 6 2 3 Rod Suppott 2 7 2 4 51 18 Installation A RUND deeem e Sese fo
50. 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska Ul Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
51. 3HIG Bn am 1 141 aw sili 18001 S3SOH 149 1411 XS B E B 219092 3HOJ3H3HL t EJ o 9926 AINO y gt SI NIVHQ 3SVO 310N J p es n 331114 Fo 1832534 H SAP F3 926 1OMLNOO mg 999252506 E NO amp OL X 266 2 y 5 d 1 5 ck xr 8 A Te XE T T M 79 2602 s 406 40 4015 SYSGNI TAD 23 9726 9 92 3 8 SECTION 3 TROUBLESHOOTING This page left blank intentionally 3120737 JLG Lift 3 9 SECTION 3 TROUBLESHOOTING 3 10 DRIVE STE ER RIGHT STEER LEFT STEER Li 2 3 4 5 6 A SEEN Nb TB qu g 3 3 8 2 BRAKE 242 pa 3 FU REY 2 1 2mm 1 2mm 0 a 5 1 RIGH y LEFT W w 5 a 71 A X b 2 DECEL 4 SET 6 3000psi ML 3T SET 0 3000 d 2 CONTROL VALVE Figure 3
52. 5 inches 47 6 mm Replace sliding pads when worn to 1 688 inches 42 7 mm 2 4 JLG Lift 2 8 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder w o Holding Valves Brake Cylinder and Steer Cylinder A IMPORTANT OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 1 Using all applicable safety precautions activate motor and fully extend cylinder to be checked Shut down motor 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate motor and activate cylinder extend function Check retract port for leakage 4 cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down motor and carefully disconnect hydraulic hose from cylinder extend port 6 Activate motor and activate cylinder retract function Check extend port for leakage 7 If cylinder leakage
53. 50 ftlb 600 Motor 169 203 Nm Torque nut to 125 150 ft Ibs dry then add extra torque to line up the slot with the hole in the shaft to install the cotter pin 3120737 EPGL Extreme Pressure Gear Lube oil meeting API ser vice classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 Lift 1 3 SECTION 1 SPECIFICATIONS 1 6 SERIAL NUMBER LOCATIONS 1 8 CYLINDER SPECIFICATIONS For machine identification a serial number plate is affixed NOTE All dimensions are given in inches in with the met to the machine On 2032E2 2632E2 2646E2 and 3246E2 ric equivalent centimeters cm given in parenthe the plate is located on the front center of the machine ses frame on 1532E2 and 1932 2 it is located above the right rear tire The serial number will also be stamped on the Table 1 5 Cylinder Specifications front center of the machine frame on all models Description Bore Stroke Rod Diameter 1 7 LIMIT SWITCHES 1532E2 7 6 81 2 5 1 1932E2 The machines are equipped with the following limit 98 switches Lift Cylinder 3 50 38 87 2 00 2032E2 8 9 98 7 5 1 Tilt Alarm Lift Cylinder 3 00 38 94 2 00 Illuminates a light on the d d Um uminates a light on the platform and sounds an alarm ATE when the machine is out of level in any direction depend pied ie d ing on model
54. 6 Hydraulic Schematic Proportional Control S JLG Lift heet 1 of 2 3120737 SECTION 3 TROUBLESHOOTING LIFT CYLINDERS ac ac a e 3 5 3 MT 1 LIFT RELIEF PRESURE TO BE SET FOR EACH M CHINE 1 223 STEER RELIEF BRAKE CYL SET 2100psi A 2792496 A Figure 3 7 Hydraulic Schematic Proportional Control Sheet 2 of 2 3120737 JLG Lift 3 11 SECTION 3 TROUBLESHOOTING BREAKER GROUND CONTROLS AUSTRALIAN SPEC ONLY HOURMETER TILT INDICATOR BATTERY CHARGER AUSTRALIAN SPEC ONLY POTHOLE PROTECTION LIMIT SHITCHES ELEVATION LIMIT SWITCH Figure 3 8 Harness and Cable Assembly Non Proportional Control Sheet 1 of 2 3 12 JLG Lift 3120737 SECTION 3 TROUBLESHOOTING TO BATTERY TERMINAL CONSOLE A TO BATTERY TERMINAL CONTACTOR CONSOLE BOX GROUND CONTROL A LA LIFT LIGHT CYLINDER Figure 3 9 Harness and Cable Assembly Non Proportional Control Sheet 2 of 2 3120737 JLG Lift 3 13 SECTION 3 TROUBLESHOOTING This page intentionally left blank 3 14 JLG Li
55. 8 580 000200 HOG gf 0 09 _ 086 52 55 8 ozil 0621400 E t Obl ez 096 POO Toporo 6 eI o z 0 006 00 00 Ze Enc BE SZ 076 amp 8L 0 9 6000 oc 09 g 028 9L 085 606000 Ze Ok L 009 1 6 029 199000 ozi 8h 6 Zh os 9 8 086 2090010 Or nme 92 9011 81 1140 82 pon 0 87 S 00148419 3111907 201 807 311900 817 GVOT yayay CND 0 dV 15 dWV 12 8 bu 3288 kehren SLNN 8 51108 8 avs 8 5 lt 2 2202 51138965 dV 031914 KINO S1108 131914 9NIZ 04 SINIYA 1 7 JLG Lift 3120737 SECTION 1 SPECIFICATIONS This page left blank intentionally 1 8 JLG Lift 3120737 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 1 GENERAL This section provides information necessary to perform maintenance on the scissor lift Descriptions techniques and specific procedures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation an
56. Amp SCR 120 240 Volts AC 50 Hz input 24 Volts DC 20 Amp output w auto timer Japanese Specification 100 200 Volts AC 50 60 Hz input 24 Volts DC 20 Amp output w auto timer Batteries 4 1532 2 1932 2 2032 2 2646 2 6 Volt 220 Amp Hour 2632E2 3246E2 6 Volt 245 Amp Hour Steer Drive System Tires 1532E2 1932E2 Standard 12 5 x 4 5 Solid Non Marking Rib Optional 12 5 x 4 5 Solid Rib 3120737 Tires 2032E2 2632E2 2646E2 3246E2 Standard 16 00 x 5 00 Solid Non Marking Optional 16 00 x 5 00 Solid Rib Parking Brake All models Dual wheel rear Single cylin der spring applied hydraulically released Drive Motors 1532 2 1932 2 7 7 in3 126 cm3 displacement 2032E2 14 0 in3 229 4 cm3 displacement 2632E2 19 0 in3 310 3 cm3 displacement 2646E2 16 2 in3 265 5 cm3 displacement 3246E2 18 in3 294 cm3 displacement Hydraulic Filter Inline Return Bypass Type 10 Microns Nominal Platform Size 1532E2 1932E2 31 in x 64 in 0 8 m x 1 6 m 2032E2 2632E2 31 in x 84 in 0 8 m x 2 1 m 2646E2 3246E2 45 in x 84 in 1 1 m x 2 1 m 1 3 PERFORMANCE DATA Travel Speed 1532 2 1932 2 Low Speed 1 5 mph 2 1 kmh Elevated Speed 0 6 mph 1 1 kmh Maximum Speed 2 5 mph 4 0 kmh 2032E2 Low Speed 1 6mph 2 1 kmh Elevated Speed 0 6 mph 1 1 kmh Maximum Speed 2 6 mph 4 2 kmh 2632 2 2646 2 Low Speed 1 4 mph 2 1 kmh Elevated Speed 0 6 mph
57. DING OVERLOADED The function cutout is active some functions may be prevented ALARM SOUNDING TILTED amp ABOVE ELEVATION The machine is tilted while above elevation some functions may be prevented DECK PREVENTED NOT AVAILABLE DIFFERENT FUNCTION SELECTED amp IGNORED DRIVING AT CUTBACK ABOVE ELEVATION Adeck function has been selected but there is no power deck A platform function selection drive lift or deck has been pressed while another func tionisinuse Drive speedis limited to cutback because the machine is above elevation DRIVING AT CUTBACK POTHOLE STILL ENGAGED drive speed is limited to cutback because the pothole protection is still engaged while the machine is not above elevation FUNCTION SELECTED BUT TRIGGER SWITCH OPEN A function has been selected but the trigger switch is open when the trigger switch is closed the function will begin if itis still selected HIGH DRIVE PROBLEM CUTOUT The high drive function has been selected butis prevented by a cutout high drive is not allowed while above elevation or when the deck is extended HIGH DRIVE PROBLEM MOTOR CURRENT EXCEEDED The high drive function was selected but was ended because pump motor current was tohigh JOYSTICK MOVED BUT NO FUNCTION SELECTED The drive lift or deck function must be selected before the joystick is moved from neu tral POSITRAC PROBLEM NOT ALLOWED DURING HIGH DRIVE The positrac
58. ECTION BETWEEN JLG SMART SYSTEM ems ELEVATION SWITCH AND POTHOLE MICROPROCESSOR e u mL EM E PROTECTION SWITCH 2 ripa 5 5 5 5 wr amp OR SWITCH 4 BLK d ay d WHT BLK mr 2006 32 11 BLU ORN 52 4 WHT YEL 48 1 GRND ALARM 3120737 g 000 B THE TORQUE APPLIED TO THE NUTS SECURING THE BATTERY CABLES TO THE CONTROLLER SHOULD NOT EXCEED 60 IN LBS 1870107 Figure 3 4 Electrical Schematic Proportional Control Sheet 2 of 2 Lift 3 7 SECTION 3 TROUBLESHOOTING 3120737 10 UON 9 1 14880821 10 1 092 430NI1A2 NO OL 23 2602 2661 gt lt 1 1 40 3415 9726 9 92 7 OL ra H OL K11O
59. ECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 52 BAR 750 PSI AT A MINIMUM DISTANCE OF 30 5 CM 12 IN 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 INTRODUCTION The JLG designed SMART System is a 24 Volt multiplex motor control unit installed on the electric scissor lift model 3246E2 2 36 JLG Lift The SMART System has reduced the need for exposed terminal strips diodes and trimpots and provides simplic ity in viewing and adjusting the various personality set tings for smooth control of acceleration deceleration creep and max speed for the lift drive steering and optional power deck functions The function select mem brane board in the upper control box also eliminates the need for toggle switches and a separate power enable button as this feature is built into each function select but ton on the board itself The lift drive and optional power deck functions are con trolled by a joystick with steering being controlled by a rocker switch built into the top of the joystick Drive lift and the optional power deck functions are selected by first pushing the appropriate momentary select buttons on the membrane board and then moving the joystick either in the A or B
60. ER CYLINDER REPAIR Disassembly A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 1 Place the cylinder barrel into a suitable holding fix ture 2 Using a suitable hammer tap around the outside of the cylinder barrel and guide to shatter the Loctite 3 Using a suitable spanner wrench carefully remove the guide from the rod clevis end of the cylinder bar rel 4 Attach a suitable pulling device to the clevis end of cylinder rod section one A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 5 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 6 Using a suitable hammer tap around the outside of the cylinder barrel and guide to shatter the Loctite 7 Using a suitable spanner wrench carefully remove the remaining guide from the cylinder barrel Remove and discard the wiper ring rod seal back up ring and o ring 8 Using suitable protection clamp cylinder rod sec tion two in a vise or similar holding fixture 9 Carefully remove cylinder rod section one from cyl inder rod section two and c
61. ON 3 TROUBLESHOOTING 3120737 SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance 3 2 TROUBLESHOOTING INFORMATION The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 3 1 Electrical Troubleshooting and Table 3 2 Hydraulic troubleshoot ing Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and remedial action should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which have more than one probable cause and remedy included This means
62. Place the needle bearings in the outer ring and hold them in place with grease Place the whole bearing into the housing Press the bearing into position using pressure equipment if necessary Carefully insert shaft through bearing housing Place O ring greased in bearing housing O ring recess Place spring washer on balance plate insert O ring in recess and lubricate with grease Place balance plate lightly in position so that it engages Be careful not to damage the O ring Place the disc valve on the shaft with channels upwards so that the long tab on the disc valve engages with the slot in the shaft If there is a difference in the spline length fit the car dan shaft with he long spline end in the output shaft Mark the bottom of the cardan spline that lies adja cent to the long tab on the disc valve 10 11 12 13 14 15 16 17 Place the needles in the outer ring and hold them in place with grease Carefully place the distributor plate on the bearing housing so that the shaft enters the bearing Press the distributor plate until it stops on the housing and line up the screw holes Place the O rings greased in the gearwheel O ring recesses If there is a recess on one end of the splined hole position the gearwheel with recess on the same side as the smallest screw hole stage hole in the gearwheel rim Fit the gearwheel set with this side facing the motor Clockwise Revolution Fit the gearwh
63. RNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3120737 Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss A C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER
64. Torqlink unit Lubricate all seals and seal rings with SAE 10 40 oil or clean grease before assembly NOTE Individual seals and seal rings as well as a complete seal kit are available The parts should be available through most OEM parts distributors or Parker approved Torglink distributors Contact your local dealer for availability NOTE Unless otherwise indicated do not oil or grease parts before assembly Wash all parts in clean petroleum based solvents before assembly Blow them dry with compressed air Remove any paint chips from mating surfaces of the end cover commutator set manifold rotor set wear plate and hous ing and from port and sealing areas WARNING SINCE THEY ARE FLAMMABLE BE EXTREMELY CAREFUL WHEN USING ANY SOLVENT EVEN A SMALL EXPLOSION OR FIRE COULD CAUSE INJURY OR DEATH A WARNING WEAR EYE PROTECTION AND BE SURE TO COMPLY WITH OSHA OR OTHER MAXIMUM AIR PRESSURE REQUIREMENTS 1 If the housing 18 bearing components were removed for replacement thoroughly coat and pack a new outer bearing bushing 19 with clean corro sion resistant grease recommended in the material section Press the new bearing bushing into the counterbore at the mounting flange end of the hous ing using the appropriate sized bearing mandrel which will control the bearing bushing depth Torqlink housings require the use of bearing man drel to press bearing bushing 19 into the housing to a required de
65. WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DUR ING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue February 1998 May 1998 Revised February 1999 Revised November 2 1999 Revised July 21 2000 Revised April 27 2001 Revised September 7 2001 Revised January 16 2002 Revised April 25 2002 Revised May 15 2002 Revised August 26 2003 Revised November 21 2003 Revised May 10 2006 Revised JLG Lift 3120737 TABLE OF 5 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS Generals Hydraulic System Safety a a A C Maintenance ERI ag Re n a a SECTION 1 SPECIFICATIONS 1 1 Capacities wank sie ee EVER GIN e PENIS eeu a iM 1 1 1 2 ComponentDala Ree puse e E E
66. X DOWN Displays if there is no lift down gravity Displays adjusts for power down machines for maximum lift down speed 2 50 JLG Lift 3120737 SECTION 2 PROCEDURES Table 2 9 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY PERSONALITIES Continued DECK ACCEL Displays adjusts deckacceleration DECEL Displays adjusts deck deceleration CREEP Displays adjusts minimum deck speed MAXOUT Displays adjusts maximum deck out speed MAX IN Displays adjusts maximum deck in speed STEER STATIC Displays adjuststeer speed NOTE Used when not driving DRIVE COMP Displays adjusts steer compensation speed NOTE Used as an additive when driving NOTE Only adjustable in access level 1 GROUND MODE LIFT UP Displays adjusts fixed lift up speed LIFT DOWN N A Displays if no power lift down NOTE Adjustable for power down machines DECK OUT Displays adjusts fixed deck speed out NOTE Not displayed if POWER DECK NO DECK IN Displays adjusts fixed deck speed in NOTE Not displayed if POWER DECK NO MACHINE CURRENT Displays adjusts maximum motor current NOTE DO NOT ADJUST 3120737 JLG Lift 2 51 SECTION 2 PROCEDURES Table 2 9 Analyzer Menu Structure TOP LEVEL MENU SUB LEVEL MENU ias DESCRIPTION DISPLAY MACHINE SETUP MODEL NUMBER Displays adjusts machine model NOTE personalities reset
67. accord ingly 2 10 LIFT CYLINDER REPAIR NOTE The following procedures apply to the lift cylinder Repair procedures for the brake and steer cylinders are found in paragraphs 2 11 and 2 12 Disassembly A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA BE SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES FROM CYLINDER OPENINGS PARTICULARY AT THE HEAD 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture JLG Lift 2 5 SECTION 2 PROCEDURES 10 O Ring 11 Back up Ring 12 Wear Ring 13 Seal 14 O Ring 15 Head 16 Wiper 17 Rod Weldment 1 Relief Valve 2 Solenoid Valve 3 Barrel Weldment 4 Locknut 5 6 7 Piston 8 O ring 9 Spacer Guidelock Ring Figure 2 1 Lift Cylinder Components Assembly BARREL CLAMP PROTECTED ROD CLAMP SUPPORT TABLE
68. ace anew wiper ring rod seal o ring and back up ring into the applicable cylinder guide grooves 3 Carefully install the guide on the rod ensuring that the wiper ring and rod seal are not damaged or dis lodged Push the guide onto the rod 4 Place anew piston ring and o rings on the piston 5 Carefully place the piston on the threaded end of the cylinder rod ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go 6 Install the piston locknut on the threaded end of the cylinder rod and torque to 100 120 ft Ib 136 163 Nm 7 Remove the cylinder rod from the holding fixture 8 Position the cylinder barrel in a suitable holding fix ture A DANGER EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 9 With the barrel clamped securely and while ade quately supporting the cylinder rod insert the piston end of the rod into the cylinder barrel Ensure that the piston ring and o ring are not damaged or dis lodged 10 Continue pushing the rod into the barrel until the inder guide can be inserted into the cylinder barrel 11 Using all applicable safety precautions secure the cylinder rod assembly with a new retaining ring 2 10 JLG Lift 12 Reconnect the hydraulic hoses to the applicable cyl inder ports 2 12 STE
69. adjustments with motor operating and hyaraulic oil at normal operating temperature In addition all functions must be operated from the platform control station in order to achieve full pump speed It may be necessary to use an assistant to adjust the pressure settings while operating the func tions from the platform control station Lift Relief for Non Proportional Control Machines Install a pressure gauge at gauge port MP located at the inside top of the valve body The port is identified by a stamping on the valve body Disconnect the hose from valve port 3 then plug the hose and the valve port From the platform control station activate the Lift Up function by pressing the LIFT switch and activating the controller to the full forward position Adjust Lift Relief to value in the Pressure Settings Chart Shut down hydraulic system and remove pressure gauge Steer Adjustment for Non Proportional Control Machines With pressure gauge at MP port on control valve activate steer in either direction Adjust Steer Relief to value in the Pressure Settings Chart Main Relief Pressure Switch for Non Proportional Control Machines 1 2 32 Install a pressure gauge at gauge port MP located at the bottom front of the valve body The port is identi fied by a stamping on the valve body Disconnect the power from the drive valve on top of the valve body Activate drive by moving the joystick to the full for
70. are as follows HELP DIAGNOSTICS RUN SYSTEMS TEST NOTE Ensure machine is fully lowered before running systems test ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS level 0 Manufactures Access Only If you press ENTER at the HELP PRESS ENTER display and a fault is present during power up the analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read HELP EVERYTHING OK If ENTER is pressed again the display moves to the fol lowing display LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the current fault if any are present You may scroll through the fault logs to view what the last fifteen faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ESC two times NOTE The STARTUP 2 1 is not a fault It is used to sepa rate faults between powerups When a top level menu is selected a new set of menu items may be offered for example PLATFORM GROUND SYSTEMS DATA LOG VERSIONS DRIVE LIFT STEER GROUND MODE MACHINE Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases such as DRIVE 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
71. arefully remove the pis ton from the cylinder rod Remove and discard the piston seal and o ring 10 Carefully remove the guide from cylinder rod section one Remove and discard the o ring back up ring rod seal and wiper ring 3120737 SECTION 2 PROCEDURES a Locknut Seal Piston O Ring Piston Barrel Rod O Ring Ring Back up 25 Seal 10 Wiper 11 Guide 7 11 Figure 2 5 Steer Cylinder Assembly Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 3120737 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary 10 Inspect seal and o ring grooves in guide for burrs and
72. be enough travel to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the X nut and repeat steps 3 through 7 2 17 VOLTMETER ADJUSTMENT 1 JLG Lift Park the machine on a flat level surface and ensure the machine is level If the motor is not running turn the ignition switch to on Connect the black lead of the voltmeter to ground and the red lead to the small wire protruding from the pot on the bottom of the sensor Adjust the leveling nuts to obtain the highest possi ble voltage reading between 4 0 and 4 3 volts Check the voltage at the trip point in all four direc tions If the voltage reading is not symmetrical repeat step 4 above 3120737 SECTION 2 PROCEDURES Figure 2 8 Tilt Switch Leveling Voltmeter Adjustment Steer Solenoids Left top Right bottom Brake Lift Dump Second Speed B Second Speed A Steer Relief Slow Speed Adjust Tow Drive Flow Divider Decel Main Relief Lift Relief Block Manifold Steer Shuttle Orifice Note Torque valve cartridges to 34 41 Nm 25 35 ft Ib Note Torque all coil nuts to 11 14 Nm 8 10 ft Ib Note Torque drive valve bolts to 6 Nm 60 in Ib Figure 2 9 Control Valve Components 3120737 JLG Lift 2 31 SECTION 2 PROCEDURES 2 18 PRESSURE SETTING PROCEDURES NOTE Make all pressure
73. c tion that has been cut out provided the platform alarm has been installed Cuts out HIGH DRIVE when deckis extended and below elevation Cuts out DRIVE when deckis extended and above elevation This digitis used with a power deck Sounds platform alarm for one second on one second off one second on and three seconds off while operator tries to perform the function that has been cut out and dur ingthe LIFT DOWN function provided the platform alarm has been installed JLG Lift 3120737 SECTION 2 PROCEDURES Table 2 6 Machine Configuration Programming Information Default Setting Configuration Digit Number Description Before Programming 5 0 No function cutout installed 0 FUNCTION CUTOUT 1 Overload switch for French Japanese machines Cuts outall functions Sounds platform alarm for two seconds two seconds off while operator tries to perform the function that has been cut out provided the platform alarm is installed 6 0 No ground alarm installed 0 GROUND ALARM 1 Descent alarm Sounds when LIFT DOWN is active 2 Travel alarm Sounds when DRIVE function is active 3 Motion alarm Sounds whenever the DRIVE LIFT or DECK function is active 7 0 No drive cutout switch installed 0 DRIVE CUTOUT 1 Cuts out DRIVE when deckis elevated above a predetermined elevation varies with machine model 8 0 No arm guard cutout 0 ARM GUARDS 1 European CE Specification
74. d in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries A IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM NOTE This machine requires periodic safety and mainte nance inspections by a JLG Dealer The inspection and maintenance code numbers are as fol lows 1 Check for proper and secure installation 2 Check for visible damage and legibility 3 Check for proper fluid level 4 Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while pump motor is running 12 Check for proper lubr
75. d oper ation of machine components and systems NOTE Maintenance procedures provided in this section apply to all scissor lift models covered in this man ual Procedures that apply to a specific model will be so noted A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness 1 most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital compone
76. dL SERVICE amp MAINTENANCE Models 1532E2 1932E2 2032 2 2632 2 2646 2 3246 2 3120737 10 2006 JG INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintenance of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is pro vided A WA
77. draulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic system and run cylinder through one complete cycle to check for leaks 2 9 LIFT CYLINDER REMOVAL AND INSTALLATION Lift Cylinder Removal 1 Place the machine on a flat and level surface Raise the platform and attach a suitable lifting device to the platform 2 Remove the bolts and locknuts securing the cylinder to the upper inner arm assembly Drop the cylinder out of the saddle on the inner arm assembly 3 Retract the lift cylinder rod completely 4 Tag and disconnect the hydraulic lines then cap the lift cylinder hydraulic lines and ports 5 Remove the bolts and locknuts securing the barrel end to the lower arm assembly 3120737 6 Carefully remove the cylinder from the scissor lift and place in a suitable work area Lift Cylinder Installation 1 Install lift cylinder in place using suitable slings aligning barrel end in lower arm assembly cylinder saddle 2 Afterthe cylinder barrel is in place Secure it with the bolts and locknuts 3 Remove oylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports 4 Extend the cylinder rod until the cylinder head aligns with upper inside cylinder saddle Set the head of the cylinder in the saddle and replace the bolts and locknuts 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust
78. e Programming 1 MODEL NUMBER MODEL 1532E3 MODEL 1932E3 MODEL 2033E3 MODEL 2046E3 MODEL 2646E3 MODEL 2658E3 MODEL 3246E2 MODEL 2632E2 3 2 TILT SWITCH No tilt switch installed Tilt switch installed for North american CE and optional for Latin American machines This digit will allow the SMART System to indicate when the machine is out of level by lighting the lightin the platform box If the machine is elevated and tilted the SMART System will also sound the platform alarm continuously No functions are cutback or cutout Tilt switch for Australia Japanese and option for Latin American machines This digit will allow the SMART System to indicate when the machine is out of level by lighting the lightin the platform box If the machine is elevated and tilted the SMARIT Sys tem will also sound the platform alarm continuously and the lift up and drive func tions are cutout 3 POWER DECK No power deck installed Machine equipped with power deck 4 DECK EXT LIMIT SWITCH 2 42 Deck extension limit switch not installed This cannot be zero if there is a power deck installed Cuts out LIFT DOWN when deck is extended This digitis used with roll out decks that require a deck extension cutout Sounds platform alarm for one second on one sec ond off one second on and three seconds off while operator tries to perform the fun
79. e end cover as necessary NOTE A polished pattern not scratches on the cover from rotation of the commutator 5 is normal Discolora tion would indicate excess fluid temperature thermal shock or excess speed and require system investi gation for cause and close inspection of end cover commutator manifold and rotor set 3120737 JLG Lift Remove commutator ring 6 Inspect commutator ring for cracks or burrs Remove commutator 5 and seal ring 3 Remove seal ring from commutator using an air hose to blow air into ring groove until seal ring is lifted out and dis card seal ring Inspect commutator for cracks or burrs wear scoring spalling or brinelling If any of these conditions exist replace commutator and commutator ring as a matched set SECTION 2 PROCEDURES 9 that are on both sides of the manifold NOTE 10 Remove manifold 7 and inspect for cracks surface scoring brinelling or spalling Replace manifold if any of these conditions exist A polished pattern on the ground surface from commutator or rotor rota tion is normal Remove and discard the seal rings 4 The manifold is constructed of plates bonded together to form an integral component not subject tofurtherdisassemblyforservice Compare configura tion of both sides oft hem an if old to ensure that same surface is reassembled against the rotor set Remove rotor set 8 and warplane 9 together to retain
80. eel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel is vertically over the mark on the cardan shaft Turn the gearwheel set counterclockwise until the cardan shaft and gearwheel engage 15 Turn the gear wheel rim to line up the screw holes Counterclockwise Revolution Fit the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel is vertically over the mark on the cardan shaft Turn the gearwheel set clockwise until the cardan shaft and the gearwheel engage 15 Turn the gearwheel to line up the screw holes Rotate the end cover to line up the screw holes Use new washers and a 13 mm socket spanner Torque to 330 380 Ib in 3 75 4 25 daNm Screw in plastic plugs Turn the motor over and strike the dust seal into place with a plastic hammer and suitable mandrel Secure the key in place with tape 2 14 DRIVE MOTOR REXROTH Disassembly 1 o iv qm JLG Lift Place the drive motor vertically in a vice with the out put shaft pointing downwards Using a 17mm spanner wrench loosen the 7 cover bolts remove the cover with the bolts Lift off the displacer and the intermediate disk Remove the cardan shaft Remove the control sleeve Remove the check valves consisting of ball limit stop and filler filler only when one valve is installed Turn the drive around in the vise so that the output shaft is facin
81. for scoring or other damage and ovality and tapering Replace as necessary Inspect spacer for burrs and sharp edges If neces sary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary 15 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary 16 If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper JLG Lift cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly Using a special tool pictured in the following illustra tion install a new rod seal into the applicable cylin der head gland groove SEAL TOOL 1 7004275 1 1 2 87004276 2 7002826 WIPER P4 SEAL CYLINDER HEAD Figure 2 4 Rod Seal Installation 2 7 SECTION 2 PROCEDURES A IMPORTANT WHEN INSTALLING NEW PARKER TYPE PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Using a soft mallet tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable head gland groove as shown below 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head
82. form box oratbase Re connect cable to platform box and check wiring atbase Battery voltage out of range If battery cahrger is plugged in Check voltage with VOM Unplug battery charger Battery voltage too low Check voltage with VOM Plugin battery charger Line contactor open circuit Loose wiring connections online contactor or atharness connection Check wire terminations on line contactor and harness connection at base Tighten connections as necessary Open coil online contactor Clean corrosion from line contactor Replace line contactor Faulty wiring atbase Repair or replace wiring as necessary Line contactor welded Replace the line contactor Line contactor or other driver short circuit or tripped Point A short circuit Motor stalled Determine cause Repair or replace motor as necessary Motor open circuit Faulty motor Replace motor No drive function when platform fully low ered Lift function okay Malfunctioning limit switch Use VOM to verify limit switch inputs Adjust or repair malfunctioing limit switch No drive function when platform elevated Lift function okay Malfunctioning limit switch Use VOM to verify limit switch inputs Adjust or repair malfunctioing limit switch Platform above drive cutout height Lower platform below drive cutout height Machine cannotlift down Lift up function okay Loose wiring
83. ft 3120737 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport 5 6 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone
84. g up Remove the keyed shaft 3120737 SECTION 2 PROCEDURES 8 Loosen the 8 socket head cap screws on the flange mounting using a 4mm allan wrench 9 Withdraw the flange from the shaft while holding the flange in a special fixture 10 Turn the motor around again Attach a mandrel and press the output shaft with bearing out of the motor housing with the help of a lever press Assembly 1 The output shaft with pressed on and adjusted tapered roller bearing and cylindrical shaft is to be centrically positioned onto the housing edge Press the complete assembly into the housing to the limit stop with the help of the press NOTE Do not jam 2 Before mounting the flange put a mounting sleeve onto the shaft NOTE Be sure that the seal is thoroughly oiled 3 Position the flange with slight pressure into the housing Take care to avoid damage to the seals 4 Screw in the 8 socket head cap screws Using a Torque wrench tighten to 80 in Ib 8 Nm 5 After turning the motor around introduce the control sleeve Make sure that the cylindrical roll of the out put shaft clicks into the groove of the control sleeve 6 Insert the O ring into the housing 7 Installation of the check valves Insert 2 ball valves and carefully drive them in using a mandrel 8 Insert the limit stop and put the filler into position for the lower valve 9 Put the cardan shaft into position Note that the marked tooth must comply with the ma
85. h drive function will be stopped FUNCTION SELECTED BUT TRIGGER NEVER CLOSED Occurs after ten seconds with the joystick in neutral but trigger switch never closed JOYSTICK FAULTY WIPER OUT OF RANGE Occurs if wiper voltage is invalid JOYSTICK FAULTY CENTER OUT OF RANGE Occurs if center tap voltage is invalid JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER JOYSTICK LOCKED OUT RELEASE THEN RESELECT PORITRAC PROBLEM PERMANENTLY SELECTED TRIGGER INTERLOCK TRIPPED Trigger switch was closed for more than ten sec onds with no function selected WAITING FOR TRIGGER SWITCH TO BE OPEN Trigger switch was closed when plat form mode was selected 2 3 Indicates problems with ground controls GROUND FUNCTIONS LOCKED OUT RELEASE THEN RESELECT A ground mode function lift or deck was selected when ground mode was selected 2 5 Indicates a function is prevented due to a cutout DECK PREVENTED FUNCTION CUTOUT ACTIVE DRIVE PREVENTED DECK EXTENDED amp ABOVE ELEVATION DRIVE PREVENTED DRIVE CUTOUT ACTIVE Drive is selected while drive cutoutis active and drive cutoutis configured to prevent drive DRIVE PREVENTED FUNCTION CUTOUT ACTIVE Drive is selected while function cutout overload is active and configured to cut out drive functions DRIVE PREVENTED POTHOLE NOT ENGAGED DRIVE PREVENTED TILTED amp ABOVE ELEVATION Driveis selected while tilted and above elevation and tiltis configured to prevent drive
86. he hoses from the cylinder ports A WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Place the cylinder barrel into a suitable holding fix ture 3 Using a suitable pair of snap ring pliers carefully remove the retaining ring from the cylinder barrel 3120737 SECTION 2 PROCEDURES 1 Locknut 2 Piston 3 O Ring 4 Seal Piston 5 O Ring 6 Barrel 7 Guide 8 0 Ring 9 Ring Back up 10 Z Seal 11 Ring Retaining 12 Wiper 13 Rod Figure 2 5 Brake Cylinder Assembly Cleaning and Inspection 1 Attach a suitable pulling device to the cylinder rod end A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 2 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 3 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 4 Carefully remove the piston locknut and piston from the cylinder rod Remove and discard the piston ring and o rings 5 Carefully remove the guide from the cylinder rod Remove and discard the o ring back up ring rod seal and wiper ring 6 Remove the cylinder rod from the holding fixture 3120737 Lift
87. he sys tem test from running 3120737 Lift 2 49 SECTION 2 PROCEDURES Table 2 9 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY ACCESS LEVEL Displays the current access level Level 3 Personalities cannot be changed Level 2 Most personalities can be changed Level 1 All personalities can be changed CODE Allows access level password to be entered Use LEFT RIGHT to select digit Use UP DOWN to change digit Use ENTER to update access level PERSONALITIES DRIVE ACCEL Displays adjusts drive acceleration DECEL Displays adjusts drive deceleration CREEP Displays adjusts minimum drive speed LOW Displays adjusts maximum low drive speed NOTE Used when high drive not selected HIGH MAX Displays adjusts maximum high drive speed NOTE Used when high drive not selected ELEVATED MAX Displays adjusts maximum drive speed elevated NOTE Used when elevation or pothole cutout switches are limiting max speed NOTE Only adjustable in access level 1 POSI TRAC Displays adjusts posi trac engaged time out HIGH DRIVE AMP Displays adjusts high drive motor overload current NOTE Only adjustable in access level 1 HIGH DRIVE Displays adjusts high drive motor overload time out LIFT ACCEL Displays adjusts lift acceleration DECEL Displays adjusts lift deceleration CREEP Displays adjusts minimum lift up speed MAX UP Displays adjusts maximum lift up speed MA
88. ication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 16 Check Inspection Decal for current inspection stamp NOTE Inspection and Maintenance Code 10 to be per formed every two years 800 hours JLG Lift 2 53 SECTION 2 PROCEDURES Table 2 10 Preventive Maintenance and Inspection Schedule Daily Weekly Monthly 3 Month 6 Month 1 Year PLATFORM AREA Controller 111 Switches 111 Placards and Decals 12 Control Tags 12 Hose and Cable 4 8 Wear Pads Handrail and Chains CHASIS AREA Batteries Battery Charger Hydraulic Pump Motor Valves Hydraulic Filter See Lubrica tion Chart Hydraulic hoses and tubing Hydraulic Oil Tank Hydraulic Tank Breather Lift Cylinder Limit Switch Placards and Decals Wheel and Tire Assemblies Drive Motors Drive Brake Steer Cylinder Steer Components Wheel Bearings A Sizzor Arms 14 Safety Prop 14 Wear Pads Pivot Pins Bolts 14 7 8 Switches Ground Control 111 Control Tags 12 Hose and Cable 48 Pothole Protection System 1 7 JLG Lift 3120737 SECTI
89. ing the components Shuttle Valve Cartridges 25 30 ft Ib 34 41 Nm Steer Relief Cartridges 25 30 ft Ib 34 41 Nm Check Valve Cartridges 25 30 ft Ib 34 41 Nm Main Relief Cartridge 25 30 ft Ib 34 41 Nm Tow Valve Cartridge 25 30 ft Ib 34 41 Nm Flow Divider 25 30 ft Ib 34 41 Nm Brake Valve Cartridge 35 40 ft 47 54 Nm Load Sense 25 30 ft Ib 34 41 Nm Lift Relief Cartridge 25 30 ft Ib 34 41 Nm Counterbalance Valve Cartridges 35 40 ft Ib 47 54 Nm Drive Valve Cartridge 35 40 ft Ib 47 54 Nm Socket Head Cap Screws 60 in Ib 7 Nm Figure 2 10 Control Valve Components 2632E2 3246E2 w Proportional 2 34 JLG Lift 3120737 SECTION 2 PROCEDURES FIRE EXTINGUISHER TERMINAL CONNECTOR Figure 2 11 Quick Welder Installation 2 19 LIMIT SWITCH ADJUSTMENT Elevation Switch 2 20 DOOR ADJUSTMENT NOTE On the 1532E2 1932E2 3246E2 there is a platform limit switch located at the head of the lift cylinder on the middle inside arm When activated the switch cuts out the Drive function if the Pothole Protection is not set The cut out heights are set at a maximum of the following NOTE Model In m 1532E2 84 2 1 1932E2 104 2 6 3246E2 112 2 8 3120737 JLG Lift There is an eccentric bolt on the hinge side under neath of each door If the door needs raised or low ered this can be accomplished by turn
90. ing these bolts Adjust these bolts to the outside to avoid drag on the pothole protection system when the door is opened There are two bolts on top of each door in the cor ners These are designed to take the weight off the pothole protection system and distribute it around the underside of the frame if the machine were to be run over any uneven terrain or dropped into any void The clearance between the top of the bolts and the frame should be a min of 3 4 in to a max of 1 1 2 in 2 35 SECTION 2 PROCEDURES 2 21 JLG SMART SYSTEM ANALYZER INSTRUCTIONS NOTE The following instructions involving the JLG SMART System Control are used only for Model 3246E2 with the Proportional Control option Da Ja s J9 Torque Battery Cable J7 46 45 J4 4 5 1 UB J2 Figure 2 12 JLG SMART System Controller A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CON TROLLER FOR THE PROPER MACHINE CONFIGURATION INCLUDING OPTIONS REFER TO ANALYZER KIT NO 2901443 A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROLLER IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL EL
91. ip within the allowed test time NOTE Anytime a reading of a 15 code appears the controller must be replaced 2 46 JLG Lift 3120737 SECTION 2 PROCEDURES between items in the same level The UP DOWN arrow 2 26 ANALYZER MENU STRUCTURE keys alter a value if allowed In the following structure descriptions an intended item is selected by pressing ENTER pressing ESC steps back to the next outer level The LEFT RIGHT arrow keys move Table 2 9 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY HELP PRESS ENTER HELP Displays current help fault message LOGGED HELP Log of most recent help fault messages LEFT RIGHT view DIAGNOSTICS ASPCIN Displays current controller mode NEUTRAL DRIVE FORWARD LIFT etc PLATFORM JOYSTICK Displays joystick demand 0 100 Preceded by for forward up out or by for reverse down in STEER Displays steer status NONE LEFT RIGHT etc POSI TRAC Displays posi trac switch status OPEN CLOSED HIGH DRIVE Displays high drive switch status OPEN CLOSED TRIGGER Displays trigger switch status OPEN CLOSED DRIVE Displays drive mode select switch status OPEN CLOSED LIFT Displays lift mode select switch status OPEN CLOSED DECK Displays deck mode select switch status OPEN CLOSED Not displayed if POWER DECK GROUND UP Displays ground lift up switch status OPEN CLOSED DOWN Displays gro
92. is found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed 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 Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 2 3 LUBRICATION INFORMATION Hydraulic System JLG Lift 1 The primary enemy of a hydraulic system is contam ination 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 suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign
93. manifold 7 over the alignment studs and drive link 10 and onto the rotor set Be sure the correct manifold surface is against the rotor set 3120737 SECTION 2 PROCEDURES 16 Apply grease to a new seal ring 4 and insert it in the seal ring groove exposed on the manifold a 17 Assemble the commutator ring 6 over alignment 19 If shuttle valve components items 21 were studs onto the manifold removed from the end cover 2 turn a plug 21 EN loosely into one end of the valve cavity in the end cover A 3 16 inch Allen wrench is required 20 Assemble a new seal ring 4 into end cover 2 and assemble end cover over the alignment studs and onto the commutator set If the end cover has only 5 bolt holes be sure the cover holes are aligned with the 5 threaded holes in housing 18 The correct 5 bolt end cover bolt hole relationship to housing port bosses 18 Assemble a new seal ring 3 flat side up into com mutator 5 and assemble commutator over the end of drive link 10 onto manifold 7 with seal ring side up 3120737 JLG Lift 2 27 SECTION 2 PROCEDURES NOTE 21 2 28 If the end cover has a valve 24 or has five bolt holes use the line you previously scribed on the cover to radially align the end cover into its original position Assemble the 5 or 7 special bolts 1 and screw in finger tight Remove and replace the two alignment studs with bolts after the other bol
94. nd will cut out drive Consult factory for tilt sensor adjustment The only field adjustment necessary is leveling the switch on the spring loaded studs There are two methods of adjustment a manual adjustment and an adjust ment using a voltmeter CAUTION TILT ALARM SWITCH LEVELING PROCEDURE MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 2 30 Park the machine on a flat level surface and ensure the machine is level Ensure switch mounting bracket is level and securely attached Level the base of the indicator by tightening the three flange nuts Tighten each nut through approxi mately one half of its spring travel DO NOT ADJUST THE NUT DURING THE REMAINDER OF THE PROCEDURE With the electrical connections complete slowly tighten one of the Y nuts until the circuit is closed the light on the Platform Control Console illumi nates the tilt alarm sounds Slowly back off the nut counting the number of turns until the circuit is closed again Figure 2 7 Tilt Switch Leveling Manual Adjustment Divide the number of turns determined in step 4 in half Tighten the nut this many turns The line deter mined by this nut and the X nut is now parallel to the ground Repeat steps 3 through 5 for the remaining Y nut The switch is now level Individually push down on one corner at a time there should
95. nts Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 3 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 Disa
96. on lift cylinder s at holding valve Repair wiring on lift cylinder s at holding valve JLG Lift 3120737 SECTION 3 TROUBLESHOOTING Table 3 2 Hydraulic System Troubleshooting Chart TROUBLE PROBABLE CAUSE REMEDY Hydraulic pump noisy Air bubbles in oil reservoirto low Replenish oil as necessary Oil filter dirty Clean and or replace filter as necessary Pump cavitating Vacumein pump dueto oil starvation Oil is reservoir too low Replenish oil as necessary Restricted reservoir air vent Clean vent Oil viscosity too high Drain system and replace with recom mended oil Refer to Table 1 2 Hydralic Oil System overheating Oil viscosity too high Drain system and replace with recom mended oil Refer to Table 1 2 Hydralic Oil 3120737 JLG Lift SECTION 3 TROUBLESHOOTING 3 4 2 2 PLATFORM W DRIVE C T OUT YEL RED 2 2 CONTROL 5 2 YEL RED 2 3 YEL RED 2 3 ue BATTERY DISCARGE INDICATOR EWELE OPTION YEL RED 2 3 IYEL RED 2 3 E YEL RED 2 7 e 49 2 NOT USED IN G PLAT CONT X BLK PLATFORM YEL RED 2 8 ORN RED 49 3 6 YEL BLK 2 8 E 2 5 72
97. orough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDERS THEORY OF OPERATION Oylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the inder rod will retract A holding valve is used in the Lift circuit to prevent retrac tion of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its
98. pth of 0 151 0 161 inches 3 84 4 09 mm from the end of the bearing counterbore 2 02 JLG Lift NOTE Bearing mandrel must be pressed against the let tered end of bearing shell Take care that the hous ing bore is square with the press base and the bearing bushing is not cocked when pressing a bear ing bushing into the housing A CAUTION IF THE BEARING MANDREL SPECIFIED IN THE TOOLS AND MATERIALS REQUIRED FOR SERVICING SECTION IS NOT AVAILABLE AND ALTERNATE METHODS ARE USED TO PRESS IN BEARING BUSHING 13 AND 19 THE BEARING BUSHING DEPTHS SPECIFIED MUST BE ACHIEVED TO INSURE ADEQUATE BEARING SUPPORT AND CORRECT RELATIONSHIP TO ADJA CENT COMPONENTS WHEN ASSEMBLED A CAUTION BECAUSE THE BEARING BUSHINGS 13 AND 19 HAVE A PRESS FIT INTO THE HOUSING THEY MUST BE DISCARDED WHEN REMOVED THEY MUST NOT BE REUSED 3120737 SECTION 2 PROCEDURES 2 The Torqlink inner housing bearing bushing 13 can now be pressed into its counterbore in housing 18 flush to 0 03 inch 76 mm below the housing wear plate contact face Use the opposite end of the bearing mandrel that was used to press in the outer bearing bushing 19 3 Press a new dirt and water seal 20 into the housing 18 outer bearing counterbore The Torqlink dirt and water seal 20 must be pressed in until its flange is flush against the housing 3120737 JLG Lift 2 23 SECTION 2 PROCEDURES 4
99. r agis 2 7 2 5 Brake Cylinder Assembly 2 9 2 5 Steer Cylinder 1 2 11 2 5 Drive Motor Sauer 5 2 1 2 13 2 6 Parker Drive iecerei ziea i e ded e eet ee 2 16 2 7 Tilt Switch Leveling Manual 2 30 2 8 Tilt Switch Leveling Voltmeter 2 31 2 9 Control Valve 2 31 2 10 Control Valve Components 2632E2 3246E2 w Proportional Control 2 34 2 11 Quick Welder 2 35 2 12 SMART System 2 36 2 13 Organizational 2 39 3 1 Electrical Schematic Non Proportional Control Sheet 1 2 3 4 3 2 Electrical Schematic Non Proportional Control Sheet 2 2 3 5 3 3 Electrical Schematic Proportional Control Sheet 1 2 3 6 3 4 Electrical Schematic Proportional Control Sheet 2 2
100. r new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices 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 2 2 1 Keep the system clean If evidence of metal or rub ber particles
101. related control valve 2 5 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is JLG Lift 2 3 SECTION 2 PROCEDURES machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit Relief Valves Relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of tra
102. rking on the control sleeve 10 Position the intermediate disk 11 Insert the O ring into the recess of the displacer 12 Place the displacer so that the tooth marking on the cardan shaft on the displacer side meshes with the tooth base of the rotor gearwheel that is located centrally at the lowest point in the outer profile of the rotor gearwheel This is only possible at 6 positions 13 Insert O ring 14 Insert spacer 15 Remount cover tighten the 7 hexagon bolts using a torque wrench torque to 60Nm 43 ft Ib The output shaft should turn easily 3120737 2 15 DRIVE MOTOR PARKER Disassembly and inspection 1 Place the Torqlink in a soft jawed vice with cou pling shaft 12 pointed down and the vise jaws clamping firmly on the sides of the housing 18 mounting flange or port bosses Remove manifold port O Rings 18 if applicable A WARNING IFTHETORQLINK IS NOT FIRMLY HELD IN THE VISE IT COULD BE DISLODGED DURINGTHE SERVICE PROCEDURES CAUSING INJURY 2 Scribe an alignment mark down and across the Lift Torqlink components from end cover 2 to hous ing 18 to facilitate reassembly orientation where required Loosen two shuttle or relief valve plugs 21 for disassembly later if included in end cover 3 16 or 3 8 inch Allen wrench or 1 inch hex socket required 2 15 SECTION 2 PROCEDURES ing rings under the bolt head Replace damaged bolts 3
103. rol Machines Main Relief Max 3000 psi 50 0 psi 207 bar 3 4 0 bar Main Relief Max 3200 psi 207 bar Steer Relief Max 2000 psi 110 bar Lift Up Relief Max 1532E2 2000 psi 110 bar 1932E2 2300 psi 159 bar 2032 2 2200 psi 152 bar 2632E2 2646E2 3246E2 2400 psi 165 bar 3120737 Steer Relief Max 2100 psi 145 bar Lift Up Relief Max 2100 psi 145 bar JLG Lift 1 5 SECTION 1 SPECIFICATIONS 1 10 MAJOR COMPONENT WEIGHTS Table 1 6 Major Component Weights 1 11 CRITICAL STABILITY WEIGHTS A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY SUCH AS BATTERIES OR SOLID TIRES WITH ITEMS OF DIFFERENT Platform 31 in x62in 1532 2 1932 2 250 113 WEIGHT OR SPECIFICATION DO NOT MODIFY UNIT IN ANY WAY Platform 31 in x84 in 2032E2 2632E2 388 176 TO AFFECT STABILITY Platform 46 in x 84 in 2646E2 3246E2 450 204 Manual Platform Extension 1532E2 1932E2 156 71 Table 1 4 Critical Stability Weights Manual Platform Extension 2032E2 2632E2 156 71 Component 1532 2 1932 2 2032E2 2632E2 2646E2 3246E2 Manual Platform Extension 2646E2 3246E2 215 98 Tires Solid 2416 3116 3110 Arm Assembly 1532 2 Includes Lift Cylinder 482 219 Each 11kg 14kg 14 kg Arm Assembly 1932 2 Includes Lift Cylinder 616 279 Tires Solid Non 24lb 300 3010 Arm As
104. sembly 2032 2 Includes Lift Cylinder 1 052 477 110 14 14 Arm Assembly 2632E2 Includes Lift Cylinder 3 380 1 535 Motor Pump 41 415 4ilb Arm Assembly 2646 2 Includes Lift Cylinder 1 736 787 Assembly 19kg 19kg 19kg Arm Assembly 3246 2 Includes Lift Cylinder 2 156 980 Batteries 631b 631b 631b Chassis 1532E2 1932E2 w Solid Tires 1 760 798 Standard 29kg 29kg 29kg Chassis 2032E2 w Solid Tires 2 324 1 054 Each Includes 464 Ib 211 kg Counterweight Batteries 25210 25210 252 Chassis 2632E2 w NonmarkingTires 2267 1 028 Standard 114kg 114kg 114kg Chassis 2646E2 w Solid Tires 1932 876 Chassis 3246E2 w Solid Tires 2 253 1 022 1 6 Lift 3120737 SECTION 1 SPECIFICATIONS yeys oenbjoj 72 1 8 3avio avs avs uinipeo oj Ajdde jou 9JoN 0126 000857 5266 prez 0992 0986 OOZZvL 0062 916 71 0905 00508 57 0662 0962 0986 0059 5002 g ht OOSLEL 0006 59 2 0902 0212 00181 0921 zi 0252 00581 5692 106 08 0862 00090 g 088 006707 0062 01 91 oost 0002 00996
105. ssembly 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 Washing It is a good practice to avoid pressure washing electronic components Should pressure washing be utilized to wash areas containing electronic components JLG Indus tries Inc recommends a maximum pressure of 750 PSI 52 bar at a minimum distance of 12 in 30 5 cm away In addition JLG Industries Inc also recommends that these components are indirectly sprayed for brief time periods to avoid heavy saturation 3120737 JLG Lift 2 1 SECTION 2 PROCEDURES Pressure Fit Parts Hydraulic System When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 Ifa bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable o
106. to heat the oil with a low density 110VAC heater to a minimum temperature of 15 F 26 C 3 The only exception to the above is to drain and fill the system with Mobil DTE 13M oil or its equivalent This will allow start up at temperatures down to 20 F 29 C However use of this oil will give poor per formance at temperatures above 120 F 49 C Sys tems using DTE 13M oil should not be operated at temperatures above 200 F 94 C under any con dition Changing Hydraulic Oil 3120737 1 Use of any of the recommended crankcase or hydraulic oils increases JLG s recommended oil change interval to 800 hours However filter ele ments must be changed after the first 50 hours of operation and every 400 hours thereafter When changing the oil use only those oils meeting or exceeding the specifications appearing in this man ual If you are unable to obtain the same type of oil supplied with the machine consult your local sup plier for assistance in selecting the proper equiva lent Avoid mixing petroleum and synthetic base oils 2 Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance measure is to make a th
107. ts are in place Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22 26 ft 105 45 55 ft 105 61 75 m for the seven 3 8 24 threaded bolts JLG Lift NOTE The special bolts required for use with the relief or shuttle valve 24 end cover assembly 2 are longer than the bolts required with standard and cover assembly Refer to the individual service parts lists or parts list charts for correct service part number if replacement is required 22 Torque the two shuttle valve plug assemblies 21 in end cover assembly to 9 12 ft Ibs 12 16 m if cover is so equipped Torque the two relief valve plug assemblies 21 in end cover assembly to 45 55 ft 61 75 N m if cover is so equipped Thrust Washers Housing 8 Thrust Bearing Not To Scale 3120737 SECTION 2 PROCEDURES One Piece Stator Construction A disassembled rotor 8A stator 8B and vanes 8C that cannot be readily assembled by hand can be assembled by the following procedures 1 Place stator 8B onto wear plate 9 with seal ring 4 side down after following Torqlink assembly procedures 1 through 13 Be sure the seal ring is in place 2 f assembly alignment studs are not being utilized align stator bolt holes with wear plate and housing bolt holes and turn two bolts 1 finger tight into bolt holes approximately 180
108. und lift down switch status OPEN CLOSED OUT Displays ground deck out switch status OPEN CLOSED Not displayed if POWER DECK NO IN Displays ground deck in switch status OPEN CLOSED Not displayed if POWER DECK 3120737 Lift 2 47 SECTION 2 PROCEDURES Table 2 9 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY DIAGNOSTICS SYSTEMS SYSTEMS Continued BATTERY Displays measured battery voltage NOTE Only accurate when line contactor closed TEMPERATURE Displays measured heatsink temperature PUMP VOLT Displays calculated pump motor voltage PUMP AMP Displays calculated pump motor current ELEVATION Displays elevation cutout switch status OPEN CLOSED Closed with platform fully lowered FUNCTION C O Displays function cutout switch status OPEN CLOSED Not displayed if FUNTION CUTOUT NO DECKC O Displays function cutout switch status OPEN CLOSED Not displayed if POWER DECK NO DRIVEC O Displays function cutout switch status OPEN CLOSED Not Displayed if DRIVE CUTOUT NO POTHC O Displays pothole cutout switch status OPEN CLOSED TILT Displays tilt switch status LEVEL TILTED Not Displayed if TILT SWITCH NO ARMGUARD Displays armguard cutout switch status OPEN CLOSED Not displayed if ARMGUARD CUTOUT NO 2 48 JLG Lift 3120737 SECTION 2 PROCEDURES Table 2 9 Analyzer Menu Structure
109. vel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral reliefs are provided for each side of the circuit 2 6 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The main hydraulic pump is an integral part of the electric motor pump assembly located at the rear of the battery and ground control tray on the frame of the machine The pump is a single section pump that provides an output of 3 0 11 4 Ipm 2 7 WEAR PADS Sliding Pads The original thickness of the sliding pads is 1 87
110. ward position Adjust Main Relief to value in the pressure setting chart Reinstall the electrical connections to the drive valve Lift Relief Adjustments for Proportional Control Machines Install a pressure gauge at gauge port MP located at the inside top of the valve body The port is identified by a stamping on the valve body Disconnect the hose from valve port 3 then plug the hose and the valve port From the platform control station activate the Lift Up function by pressing the LIFT switch and activating the controller to the full forward position Adjust Lift Relief to value in the Pressure Settings Chart Shut down hydraulic system and remove pressure gauge Steer Adjustment for Proportional Control Machines With pressure gauge at MP port on control valve activate steer in either direction Activate drive by pressing the drive switch and acti vating the controller to the full forward position While holding the controller activate steer right and check steer right pressure If necessary adjust steer right pressure to value in the Pressure Settings Chart Activate drive by pressing the drive switch and acti vating the controller to the full forward position While holding the controller activate steer left and check steer left pressure If necessary adjust steer left pressure to value in the Pressure Settings Chart Main Relief and High Drive Pressure Switch for Proportional Control Machines

Download Pdf Manuals

Related Search

JLG 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 SM 2006

Related Contents

Manhattan 431736 ink cartridge  ドリブンスプロケット 取扱説明書  Teka THPD70 User Manual  ABRI - Cuscini Design  TechGrow Controlador de CO2 T  「取扱説明書（基本編）」(PDF：4768KB)  1 2 3 4 ENERGY STAR® Program Requirements for Computers  脱臭風防ケースFW-100 取扱説明書 Rev.0102  

Copyright © All rights reserved. Failed to retrieve file