JLG 1930ES, 2032ES, 2632ES, 2646ES, 3246ES Maintenance Manual

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Service & Maintenance Manual

Models

1930ES 2032ES 2632ES 2646ES 3246ES

USA Built - S/N-0200239382 to Present

China Built - S/N-B200020297 to Present

Mexico Built - S/N-M200000100 to Present

Belgium Built - S/N-1200025021 to Present

3121656

July 23

, 2018 - Rev H

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.

The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts.

Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR.

HYDRAULIC SYSTEM SAFETY

It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system.

MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS.

• NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

• REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT.

• OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL.

• KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS.

• USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM.

• NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR SAFETY PROP HAS BEEN ENGAGED.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue

Revised

A - December 11, 2014

B - July 28, 2015

C - March 7, 2016

D - June 22, 2017

E - September 11, 2017

F - October 13, 2017

G - December 18, 2017

H - July 23, 2018

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TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

SECTION 1 - SPECIFICATIONS

1.1 MACHINE Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Battery Charger/AC Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lift Speed (No Load in Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Model Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.2 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.3 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.4 Limit Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

High Drive Speed Cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.8 Torque ChartS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SECTION 2 - GENERAL

2.1 Machine Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparation, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Pre-Delivery Inspection and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Annual Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Pressure-Fit Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Lubrication and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

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2.3 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.4 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Platform Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.5 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.6 Preventive Maintenance and Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Footnotes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

SECTION 3 - CHASSIS & SCISSOR ARMS

3.1 Traction System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Drive Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Common Traction System Difficulties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Power Module Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Roll Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Oil Check/Fill Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Brakes - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Hub Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Motor and Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.4 Drive Motor Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

1930ES Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

2032ES/2632ES/2646ES/3246ES Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

3.5 Electric Drive Motor ServicE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Drive Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Drive Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Drive Motor Inspection and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Drive Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.6 Power Module - ZAPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

ZAPI Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.7 MDI (Multifunction Digital Indicator) and Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.8 Battery Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3.9 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Battery Charger Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3.10 Battery Charger/Inverter (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Battery Charger/Inverter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3.11 Limit switch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Pothole Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Rotary Angle Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

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3.12 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Box Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Tilt Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3.13 Scissor Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.14 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.15 Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.16 Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

SECTION 4 - HYDRAULICS

4.1 Cylinders - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Valves - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Solenoid Control Valves (Bang-Bang) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Crossover Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Proportional Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Manual Descent Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 Pump/Motor - Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Pump Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 Cylinder Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cylinders Without Counterbalance Valves and Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.5 Lift Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.6 Hydraulic Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Slide Block Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.7 Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.8 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Steer Cylinder Piston Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

TABLE OF CONTENTS

SECTION 5 - JLG CONTROL SYSTEM

5.1 Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

To Connect the Hand Held Analyzer:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Using the Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Changing the Access Level of the Hand Held Analyzer: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Adjusting Parameters Using the Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Machine Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3 Tilt Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Failure Troubleshooting for The Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.4 Tilt Sensor Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5.5 Elevation Angle Sensor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Tilt vs. Allowed Height Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.6 Elevation Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.7 Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5.8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.9 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5.10 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

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SECTION 6 - DIAGNOSTIC TROUBLE CODES

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 DTC Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-6 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 Multimeter Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Backprobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Min/Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Continuity Measurement Over Long Distances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Requirements: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Applying Silicone Dielectric Compound To Amp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Wedge Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Service - Voltage Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.4 Working With Deutsch Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

DT/DTP Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

DT/DTP Series Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

HD30/HDP20 Series Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

HD30/HDP20 Series Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.5 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Basic check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Automatic Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Switch Wiring - Low Side, High Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.7 Electrical Schematics and Layouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7.6 Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Torque Chart - Sheet 1 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-2. Torque Chart - Sheet 2 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1-3. Torque Chart - Sheet 3 of 5 - (SAE Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

1-4. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1-5. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

3-1. Traction Control Circuit - ZAPI Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2. Disengage Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-3. Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-5. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-6. Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3-7. Spindle DIsassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-8. Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-9. Input Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-10. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-11. Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-12. Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-13. Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-14. Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-15. Drive Motor Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-16. Bearing Pressure Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-17. Wire Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3-18. ZAPI Power Module Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-19. MDI Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-20. Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-21. Battery Charger Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-22. Battery Charger (Delta-Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-23. Battery Charger (Green Power). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-24. Battery Charger/Inverter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-25. Battery Charger/Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-26. Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-27. Pothole Switch Adjustment - 1930ES/2032ES/2632ES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

3-45. Tilt Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-46. Tilt Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-47. Arms and Platform Positioning and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-48. Scissors Arms Assembly (2646ES and 3246ES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-49. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

4-1. Lift Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-2. LIft Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-3. Cylinder Barrel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-4. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5. Gar-Max Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-6. Rod Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-7. Poly-Pak Piston Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-8. Wiper Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-9. Installation of Head Seal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-10. Piston Seal Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-11. Rod Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-12. Lift Cylinder/Pump/Tank Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-13. Lift Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-14. Lift Cylinder Assembly (1930ES) (SH-PAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Lift Cylinder Assembly (1930ES) (Serta) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-16. Lift Cylinder Assembly - Motor/Pump/Tank Assembly (1930ES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

. . . . . . . . 4-18

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5-1. Diagnostic Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2. Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3. Analyzer Flow Chart (Software Version P1.13) - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-4. Analyzer Flow Chart (Software Version P1.13) - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-5. Analyzer Flow Chart (Software Version P1.13) - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

5-6. Analyzer Flow Chart (Software Version P1.13) - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

5-7. Analyzer Flow Chart (Software Version P1.13) - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

7-1. Voltage Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-2. Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3. Continuity Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-4. Current Measurement (DC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-5. AMP Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-6. Connector Assembly (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-7. Connector Assembly (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-8. Connector Assembly (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-9. Connector Assembly (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-10. Connector Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-11. Connector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-12. DT/DTP Contact Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-13. DT/DTP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-14. HD/HDP Contact Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-15. HD/HDP Locking Contacts Into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-16. HD/HDP Contact Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-17. HD/HDP Unlocking Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-18. Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-19. Electrical Components Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-20. Hydraulic Schematic - USA Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-21. Hydraulic Schematic - China Manufactured. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

vi 3121656

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LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-5 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-6 Battery Charger Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-7 Battery Charger/AC Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-8 Battery AC Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-9 Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-10 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1-12 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-14 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-15 Mobil DTE 10 Excel 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-16 Biodegradable Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-17 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-18 Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-19 High Drive Speed Cutout Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-20 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-21 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1-22 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

2-1 Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-3 Preventive Maintenance and Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 ZAPI Power Module Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-2 Battery Algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-3 Tilt Sensor Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-4 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-5 Connector Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

4-1 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-2 Cylinder Piston Nut Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-3 Holding Valve Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-4 Valve Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

5-1 Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-2 Flash Code Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-3 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5-4 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28

3121656 vii

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TABLE OF CONTENTS

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viii 3121656

Page 13

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 MACHINE SPECIFICATIONS

Table 1-1. Operating Specifications

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Maximum Stowed Travel Grade (Grad eabilit y)

Maximum Stowed Travel Grade (Sideslope)

Maximum Platform Height 18.8 ft.

Maximum Tire Load: AN S I: CE :

Ground Bearing Pressure (ANSI) 109 psi

Ground Bearing Pressure (CE) 8.7 kg/cm

Maximum Drive Speed 3 mph

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Horizontal Manual Side Force: ANSI/CSA: ANSI/CSA (Indoor): ANSI/CSA (Outdoor): ANSI/CSA (Zone A): ANSI/CSA (Zone B): CE ( In d oo r) : CE (O u td o or ) : AU S ( I nd o or ) : AUS (Indoor Zone A): AUS (Indoor Zone B): AU S ( O ut do o r) : AU S (O u td o or Z on e A) : AU S (O u td o or Z on e B) :

Inside Steer Angle 90° 90° 90° 90° 90° Outside Steer Angle 69° 73° 73° 67° 67° Electrical System Voltage (DC) 24V 24V 24V 24V 24V Approximate Gross Machine Weight -

ANSI/CSA Approximate Gross Machine Weight -

CE/Australia Approximate Gross Machine Weight - Japan

Ground Clearance with pot hole protection system up

Ground Clearance with pot hole pr

otection system down

25% 25% 25% 25% 25%

5° 5° 5° 5° 5°

5.7 m

1365 lb (620 kg) 1540 lb (699 kg)

(7.7 kg/cm

(123 psi)

(4.8 kmph)

20 ft.

6 m

1660 (755)

1835 lb (832 kg)

81 psi

)

(5.7 kg/cm2 )

6.3 kg/cm

(90 psi)

3 mph

(4.8 kmph)

25.4 ft.

7.75 m

1835 lb (832 kg) 1835 lb (832 kg)

90 psi

(6.3 kg/cm2 )

6.3 kg/cm

(90 psi)

2.75 mph

(4.4 kmph)

26 ft.

7.9 m

2070 lb (939 kg)

2320 lb (1052 kg)

87 psi

(6.1 kg/cm2 )

6.9 kg/cm

(98 psi)

2.5 mph

(4 kmph)

(Depending on model, market, and indoor/outdoor selection, see Table 1-2, Platform Capacities)

100 lb force (445 N)

N/A N/A N/A

N/A 90 lb force (400 N) 45 lb force (200 N) 90 lb force (400 N)

N/A

N/A 45 lb force (200 N)

N/A

2825 lb. 3610 lb.

1558 kg 1966 kg

1821 kg 1637 kg

120 lb force (533 N)

N/A N/A N/A

N/A 90 lb force (400 N) 45 lb force (200 N) 90 lb force (400 N)

N/A

N/A 45 lb force (200 N)

N/A

N/A N/A

N/A 120 lb force (533 N) 100 lb force (445 N)

90 lb force (400 N)

N/A

90 lb force (400 N) 90 lb force (400 N)

N/A

4635 lb. (Single)

4610 lb. (Dual)

2102 kg (Single)

2091 kg (Dual)

2102 kg (Single)

2091 kg (Dual)

150 lb force (667 N)

N/A N/A N/A

N/A 90 lb force (400 N) 90 lb force (400 N) 90 lb force (400 N)

N/A

N/A 90 lb force (400 N)

N/A

4975 lb. 5025 lb.

2737 kg 2926 kg

2257 kg 2257 kg

3.5 in (8.9 cm) 5 in. (12.7 cm)

1 in (2.5 cm) 0.75 in (1.9 cm)

31.8 ft.

9.7 m

2070 lb (939 kg)

2320 lb (1052 kg)

87 psi

(6.1 kg/cm2 )

6.9 kg/cm (98 psi)

2.5 mph

(4 kmph)

150 lb force (667 N) 105 lb force (467 N)

90 lb force (400 N) 45 lb force (200 N)

90 lb force (400 N) 90 lb force (400 N)

45 lb force (200 N)

N/A N/A N/A

N/A

N/A N/A

3121656 1-1

Page 14

SECTION 1 - SPECIFICATIONS

Capacities

Table 1-2. Platform Capacities

NOTE: All platform extension capacities are 250 lbs (120 kg)

Model ANSI/CSA CE INDOOR CE OUTDOOR AUSTRALIAN INDOOR

1930ES

2032ES

2632ES

single cap

2632ES

dual cap to 20 ft

2632ES

dual cap to 26 ft

2646ES

3246ES to 26 ft

Max

Capacity

500 lbs

(227 kg)

800 lbs

(363 kg)

500 lbs

(227 kg)

800 lbs

(363 kg)

500 lbs

(227 kg)

1000 lbs (454 kg)

Zone A

Max

Persons

2 230 kg 2 120 kg 1 230 kg 2 120 kg 1

2 360 kg 2 160 kg 1 360 kg 2 160 kg 1

2 230 kg 2

2 360 kg 2

2 230 kg 2

2 450 kg 2 230 kg 2 450 kg 2 230 kg 2

2 450kg 2 320 kg 1 450 kg 2 320 kg 1

Max

Capacity

Max

Persons

Max

Capacity

N/A N/A 230 kg 2 N/A N/A

N/A N/A 360 kg 2 N/A N/A

N/A N/A 230 kg 2 N/A N/A

Max

Persons

Max

Capacity

Max

Perso ns

AUSTRALIAN

OUTDOOR

Max

Capacity

Max

Pers ons

700 lbs

3246ES to 32 ft

(317 kg)

Zone B

2 320kg 2 320 kg 1 320 kg 2 320 kg 1

Fluid Capacities

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Hydraulic Tank 2 Gal

Hydraulic System (Including Tank) 2.2 Gal

Table 1-3. Fluid Capacities

(7.6 L)

(8.3 L)

2 Gal

(7.6 L)

2.8 Gal

(10.6 L)

3 Gal

(11.3 L)

5.3 Gal

(19.9 L)

1-2 3121656

Page 15

Tires

NOTICE

SECTION 1 - SPECIFICATIONS

Table 1-4. Tire Specifications

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Size

Max Tire Load 2500 lbs (1134 kg) 4000 lbs (1814 kg)

Wheel Bolt Torque 105 - 120 ft lb (142-163 Nm)

Batteries

323mm x 100mm 406 mm x 125 mm

Battery Charger/AC Inverter

Table 1-5. Battery Charger Specifications

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC-

DESCRIPTION

TORY APPROVED BATTERIES.

APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE.

BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. THE USE OF NON APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFORMANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE USE OF NON APPROVED BATTERIES.

Motors

Drive Motor

Type: Shunt Wound, Sepex 24V DC

Power: 0.65 Horsepower @ 3750 rpm

Hydraulic Pump/Electric Motor Assembly (All Models)

Type: Series Wound Permanent Magnet 24V DC

OUTPUT

Nominal DC Output Voltage 24V Maximum DC Output Voltage 33.6V 31.92V Maximum DC Output Current 25A Maximum Interlock Current 1A —

INPUT

AC Input Voltage 85-265VAC 108-132VAC Nominal AC Input Voltage 120VAC - 230VAC 120VAC AC Input Frequency 45-65 HZ Maximum AC Input Current 12A @108VAC

OPERATION

Charging Indicator Yellow LED Red - 30/60/90% 100% Charge Indicator Green LED Fault Indicator Red LED Various LED

PROTECTION

Output Reverse Polarity Electronic Protection - Automatic Reset Output Short Circuit Electronic Protection - Automatic Reset AC Overload Current Limited DC Overload Current Limited —

DESCRIPTION 1001112111 1001177842

MECHANICAL

Operating Temperature –22° F to +122° F (–30° C to +50° C) Housing Shock and Water Resistant Aluminum

Delta-Q

1001112111

Eagle

Performa nce

1001177842

Power: 3kW

3121656 1-3

Page 16

SECTION 1 - SPECIFICATIONS

Table 1-6. Battery Charger Specifications

DESCRIPTION

OUTPUT

Nominal DC Output Voltage 24V Maximum DC Output Voltage 34V Maximum DC Output Current 30A

INPUT

AC Input Voltage 100-240V AC Input Frequency 45-65 HZ Maximum AC Input Current 8.5A

OPERATION

Charging Indicator Yellow LED 100% Charge Indicator Green LED

Table 1-7. Battery Charger/AC Inverter Specifications

DESCRIPTION

AC INVE RTER

Output Power (Continuous) 1000 W

Output Power (Surge) 3000 W

AC Output Current 36 A

AC Output Voltage 115 to 125 VAC

Output Frequency 60 Hz

DC Input Voltage 21.2 to 29 VDC

Remote ON/OFF Yes

Modified Sine Wave -

CHARGER

Nominal DC Output Voltage 28 VDC

Maximum DC Output Voltage 33 VDC

Maximum DC Output Current 23 to 27 ADC

Required Interlock Current 1 A

Input Voltage (AC) 100 to 130 VAC

Nominal Input Voltage (AC) 120 VAC

Input Frequency 54 to 66 Hz

OPERATION

Charging Indicator Yellow LED

100% Charge Indicator Green LED

Faul t In dic ato r Red L ED

PROTECTION

Output Reverse DC Polarity 125 A Replaceable Fuse

Output AC Short Circuit Electronic Protection - Automatic Reset

AC Overload 20 A Internal Slow Blow Charger Fuse

Green Power 1001218595

Xantrex

1001093839

Table 1-7. Battery Charger/AC Inverter Specifications

DESCRIPTION

DC Overload Voltage Limited - Internally Controlled

MECHANICAL

Operatin g Temperature

Housing Shock and Water Resistant Aluminum

Table 1-8. Battery AC Inverter Specifications

DESCRIPTION

AC INV ERTER

Output Power (Continuous) 900 W

Output Power (Surge) 1800 W

AC Out put Cur rent 7.5 A

AC Output Voltage 117 ± 10% VAC

Output Frequency 60 Hz

DC Input Voltage 21.2 to 29 VDC

Modified Sine Wave Yes

PROTECTION

Output Reverse DC Polarity 3 X 25A Replaceable Fuse

MECHANICAL

Operatin g Temperature

Xantrex

1001093839

–40° F to + 185° F

(–40° C to + 85° C)

Power Bright

1001136757

–4° F to + 113° F

(–20° C to + 45° C)

Lift Speed (No Load in Platform)

NOTE: No load in platform on measured lift speeds.

Table 1-9. Lift Speed

Model Lift Up (Seconds) Lift Down (Seconds)

1930ES 18 - 26 22 - 35

2032ES 25 - 36 30 - 46

2632ES 28 - 38 32 - 40

2646ES 38 - 50 40 - 55

3246ES 50 - 62 58 - 68

1-4 3121656

Page 17

SECTION 1 - SPECIFICATIONS

Travel Speed

Table 1-10. Travel Speed

Model Elevated Speed Maximum Speed

Unit of Measure Mph Sec/25 ft Kmph Sec/7.6 m Mph Sec/25 ft Kmph Sec/7.6 m

1930ES 0.5 28-37 0.8 33 - 38

2032ES 0.5 28-37 0.8 33 - 38

2632ES 0.5 28-37 0.8 33 - 38

2646ES 0.5 28-37 0.8 33 - 38

3246ES 0.5 28-37 0.8 33 - 38

2.75

2.5 6.4 - 8.3

2.5

5.6 - 7.7

6 - 7.9

6.4 - 8.3

4.8

4.4

Model Dimensions

Table 1-11. Dimensions

Model 1930ES 2032ES 2632ES 2646ES 3246ES

5.6 - 7.7

6 - 7.9

6.4 - 8.3

Platform Height - Elevated 18.75 ft

(5.7 m)

Platform Height - Stowed 2.9 ft

(0.9 m)

Working Height 25 ft

(7.6 m)

Overall Stowed Machine Height - Rails Up 6.5 ft

(2 m)

Overall Stowed Machine Height - Rails Folded 5.6 ft

(1.6 m)

Rail Height (From platform floor) 3.6 ft

(1.1 m)

Overall Machine Width 2.5 ft

(0.8 m)

Overall Machine Length - Deck Retracted 6 ft

(1.9 m)

Overall Machine Length - Deck Extended 9 ft

(2.8 m)

Platform Size - Length 6.1 ft

(1.9 m)

Platform Size - Width 2.5 ft

(0.8 m)

Platform Extension Length 3 ft

(0.9 m)

Wheelbase 63 in

(160 c m)

20 ft

(6 m)

3.6 ft

(1.1 m)

26 ft

(7.9 m)

7.2 ft

(2.2 m)

6 ft

(1.8 m)

3.6 ft

(1.1 m)

2.66 ft

(0.81 m)

7.5 ft

(2.3 m)

10.5 ft

(3.2 m)

7.5 ft

(2.3 m)

2.5 ft

(0.8 m)

3 ft (

0.9 m)

74 in

(188 c m)

25.6 ft

(7.8 m)

4 ft

(1.2 m)

32 ft

(9.8 m)

7.5 ft

(2.3 m)

6.2 ft

(1.9 m)

3.6 ft

(1.1 m)

2.66 ft

(0.81 m)

7.5 ft

(2.3 m)

10.5 ft

(3.2 m)

7.5 ft

(2.3 m)

2.5 f

(0.8 m)

3 ft

(0.9 m)

74 in

(188 c m)

26 ft

(7.9 m)

4.2 ft

(1.3 m)

32 ft

(9.8 m)

7.9 ft

(2.4 m)

6.6 ft (2 m)

3.6 ft

(1.1 m)

3.7 ft

(1.2 m)

8.2 ft

(2.5 m)

12.4 ft

(3.8 m)

8.2 ft

(2.5 m)

3.7 f

(1.1 m)

4.2 ft

(1.3 m)

82.30 in

(209 cm)

31.8 ft

(9.7 m)

4.2 ft

(1.3 m)

38 ft

(11.6 m)

7.9 ft

(2.4 m)

6.6 ft (2 m)

3.6 ft

(1.1 m)

3.7 ft

(1.2 m)

8.2 ft

(2.5 m)

12.4 ft

(3.8 m)

8.2 ft

(2.5 m)

3.7 ft

(1.1 m)

4.2 ft

(1.3 m)

82.30 in

(209 cm)

3121656 1-5

Page 18

SECTION 1 - SPECIFICATIONS

1.2 TORQUE REQUIREMENTS

Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware when installing locking fasteners..

Table 1-12. Torque Requirements

Description Tor que Valu e (Dry) Interval Hours

Rear Wheel Spindle Nut 30-40 ft lb

(40-54 Nm)

Wheel Bolts 105 -120 ft lb

(142-163 Nm)

NOTE: Anytime a wheel bolt is replaced, be sure one of the

same length is used. Use bolt shown below on wheels that use the 1/4" (6.4mm) ring.

1.3 LUBRICATION

Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities at least

to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends DTE 11M hydraulic oil.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than DTE 11M is desired, contact JLG Industries for proper recommendations.

Table 1-13. Hydraulic Oil

Hydraulic System Operating

Temperature Ra nge

0°F to +23°F

(-18°C to -5°C)

0°F to 210°F

(-18°C to + 99°C)

50°F to 210°F

(+10°C to +210°C)

SAE Viscosity Grade

10W

10W-20, 10W-30

20W-20

NOTE: After tightening the spindle nut to the proper torque,

loosen completely until you can turn by hand. Finger tighten nut by hand without rotating hub. Install cotter pin by backing nut off, if necessary, in order to line up slot.

When maintenance becomes necessary or a fastener has loosened, refer to Section 1.8, Torque ChartS to determine proper torque value.

Table 1-14. Lubrication Specifications

Key Specifications

MPG Multipurpose Grease having a minimum dripping point of 350° F.

Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API service classification

GL- 5 o r M IL- Sp ec MI L-L- 21 05 .

HO Hydraulic Oil. API service classification GL-3,e.g. DTE 11M.

1-6 3121656

Page 19

SECTION 1 - SPECIFICATIONS

Table 1-15. Mobil DTE 10 Excel 15

ISO Viscosity Grade #15

Density @ 59°F (15°C) 0.8375 kg/l

Pour Point , Max -40°F (-54°C)

Flash Po int, Min . 330°F (182°C)

Viscosity

at 40° C 15.8 cSt

at 100° C 4.07 cSt

Visco sit y Ind ex 168

Table 1-16. Biodegradable Hydraulic Fluid

Specification

ISO Viscosity Grade

Density @ 59°F (15°C)

Pour Poin t, Ma x

Flash Point, Min.

Operating Temperature

Mobil EAL

Envirosyn H 32

0.869 kg/l 0.936 kg/l

-38°F (-39°C)

514°F (268°C)

-20 to 200°F

(-29 to 93°C)

Hydraulic EAL 32

#32

540°F (282°C)

Mobil SHC

-27°F (-33°C)

1.4 to 200°F

(-17 to 93°C)

Pressure Settings

Table 1-17. Pressure Settings

Lift Relief

Model

USA Built China Built

1930ES

2032ES

2632ES

2646ES

3246ES

NOTE: Check your nameplate at the left rear of the machine

1800 psi ± 50 psi

(124 bar ± 3.4 bar)

1800 psi ± 50 psi

(124 bar ± 3.4 bar)

1950 psi +/- 50 psi (134 bar ± 3.4 bar)

2000 psi +/- 50 psi (138 bar ± 3.4 bar)

for country of origin. USA built machines, serial number prefix starts with a 02 (02XXXXXXXX), China built machines, serial number prefix starts with an B2 (B2XXXXXXXX).

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

Steer Relief

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

at 40°C

at 100°C

Visco sit y Ind ex

Viscosity Specifications

33.1 cSt 31.1 cSt

6.36 cSt 6.2 cSt

147 152

3121656 1-7

Page 20

SECTION 1 - SPECIFICATIONS

1.4 LIMIT SWITCHES

Tilt Alarm

Illuminates a light on the platform, sounds an alarm and cuts out lift up and drive when the machine is out of level and above stowed depending on model and speci-

fications.

Table 1-18. Tilt Settings

Model

1930ES 3°

2032ES 3°

2632ES 3°

2646ES 3°

3246ES 3°

Tilt Setting

(front to back)

Tilt Setting

(side to side)

1.5° 2°

2.5° 3°

1.5° 2°

2.5° 3°

1.5° 2°

2.5° 3°

2°

2.5° 3°

2°

2.5° 3°

Maximum Deck

Elevation

18.75 ft (5.7 m) 14 ft (4.3 m) 11 ft (3.4 m)

9 ft (2.7 m)

2 0 f t ( 6 m ) 15 ft (4.5 m) 12 ft (3.7 m)

1 0 f t ( 3 m )

25.4 ft (7.7 m) 2 0 f t ( 6 m )

16 ft (4.9 m)

1 3 f t ( 4 m )

26 ft (7.9 m) 22 ft (6.7 m)

2 0 f t ( 6 m )

31.75 ft (9.7 m) 22 ft (6.7 m)

2 0 f t ( 6 m )

High Drive Speed Cutout

High drive speed is cut out when the platform is raised above the preset height per model as follows:

NOTE: These figures are given with a tolerance of ± 6 in

(0.15 m).

Table 1-19. High Drive Speed Cutout Height

Model High Drive Speed Cutout

1930ES 54 in (1.4 m)

2032ES 66 in (1.7 m)

2632ES 76 in (1.9 m)

2646ES 76 in (1.9 m)

3246ES 76 in (1.9 m)

1-8 3121656

Page 21

1.5 CYLINDER SPECIFICATIONS

Table 1-20. Cylinder Specifications

Description 1930ES 2032ES 2632ES 2646ES 3246ES

Lift Cylinder Bore 2.8 in

(7.1 cm)

Lift Cylinder Stroke 43.2 in

(108 cm)

Lift Cylinder Rod Diameter 1.8 in

(4.5 cm)

Steer Cylinder (Stroke) 6.3 in

(16 cm)

3.1 in

(7.9 cm)

48 in

(122 cm)

2.1 in

(5.5 cm)

6.3 in

(16 cm)

(7.9 cm)

(122 cm)

(5.5 cm)

(16 cm)

1.6 MAJOR COMPONENT WEIGHTS

Table 1-21. Major Component Weights

Component 1930ES 2032ES 2632ES 2646ES 3246ES

Platform 100 lbs

(45 kg)

Manual Platform Extension 45 lbs

Arm Assembly - (Includes Lift Cylinder) 620 lbs

(281 kg)

Chassis w/Wheel/Tire and Drive Assembly 1,067 lbs

(484 kg)

939 lbs

(426 kg)

133 lbs (61 kg)

1,764 lbs

(800 kg)

3.1 in

48 in

2.1 in

6.3 in

(20 kg)

1,213 lbs

(550 kg)

SECTION 1 - SPECIFICATIONS

3.9 in

(9.9 cm)

44.9 in

(114 cm)

2.4 in

(6 cm)

6.1 in

(15.6 cm)

176 lbs (80 kg)

1,645 lbs

(746 kg)

1,554 lbs

(705 kg)

3.9 in

(9.9 cm)

56.8 in

(144 cm)

2.4 in (6 cm)

6.1 in

(15.6 cm)

1.7 CRITICAL STABILITY WEIGHTS

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENTWEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Table 1-22. Critical Stability Weights

Component 1930 ES 2032ES 2632ES 2646ES 3246ES

Counterweight(s) (CE, AUS) 582 lbs (264 kg) 721 lbs (327 kg) 1592 lbs (722 kg) 1956 lbs (887 kg)

Counterweight (ANSI, CSA, JPN) N/A N/A 721 lbs (327 kg) 589 lbs (267 kg)

Wheel and Tire Assembly (each) 22 lbs (9.8 kg) 42 lbs (19 kg)

Wheel/Tire and Drive Assembly (each) 117 lbs (53 kg) 162 lbs (73.4 kg)

Lift Cylinder 176 lbs(80 kg) 205 lbs (93 kg) 263 lbs (119 kg) 283 lbs (128 kg)

Batteries: (each) 220 Amp 220 Amp (used with Inverter/Charger) 245 Amp

60 lbs (27 kg) 66 lbs (30 kg)

N/A

60 lbs (27 kg) 66 lbs (30 kg) 70 lbs (32 kg)

3121656 1-9

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SECTION 1 - SPECIFICATIONS

1.8 TORQUE CHARTS

Figure 1-1. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)

1-10 3121656

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SECTION 1 - SPECIFICATIONS

Figure 1-2. Torque Chart - Sheet 2 of 5 - (SAE Fasteners)

3121656 1-11

Page 24

SECTION 1 - SPECIFICATIONS

Figure 1-3. Torque Chart - Sheet 3 of 5 - (SAE Fasteners)

1-12 3121656

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SECTION 1 - SPECIFICATIONS

Figure 1-4. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners)

3121656 1-13

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SECTION 1 - SPECIFICATIONS

Figure 1-5. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners)

1-14 3121656

Page 27

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service. With proper care, maintenance and inspections performed per JLG's recommendations with any and all discrepancies corrected, this product will be fit for continued use.

Preparation, Inspection, and Maintenance

It is important to establish and conform to a comprehensive inspection and preventive maintenance program. The following table outlines the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult your national, regional, or local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as environment, severity and frequency of usage requires.

Pre-Start Inspection

It is the User’s or Operator’s primary responsibility to perform a Pre-Start Inspection of the machine prior to use daily or at each change of operator. Reference the Operator’s and Safety Manual for completion procedures for the Pre-Start Inspection. The Operator and Safety Manual must be read in its entirety and understood prior to performing the Pre-Start Inspection.

Pre-Delivery Inspection and Frequent Inspection

The Pre-Delivery Inspection and Frequent Inspection shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (which-

ever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

Reference the JLG Pre-Delivery and Frequent Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of these inspections. Reference the appropriate areas of this manual for servicing and maintenance procedures.

Annual Machine Inspection

JLG recommends that the Annual Machine Inspection be performed by a Factory Trained Service Technician on an annual basis, no later than thirteen (13) months from the date of the prior Annual Machine Inspection. JLG Industries, Inc. recognizes a Factory Trained Service Technician as a person who has successfully completed the JLG Service Training School for the subject JLG product model. Reference the machine Service and Maintenance Manual and appropriate JLG inspection form for performance of this inspection.

Reference the JLG Annual Machine Inspection Form and the Inspection and Preventative Maintenance Schedule for items requiring inspection during the performance of this inspection. Reference the appropriate areas of this manual for servicing and maintenance procedures.

For the purpose of receiving safety-related bulletins, it is important that JLG Industries, Inc. has updated ownership information for each machine. When performing each Annual Machine Inspection, notify JLG Industries, Inc. of the current machine ownership.

Preventative Maintenance

In conjunction with the specified inspections, maintenance shall be performed by a qualified JLG equipment mechanic. JLG Industries, Inc. recognizes a qualified JLG equipment mechanic as a person who, by possession of a recognized degree, certificate, extensive knowledge, training, or experience, has successfully demonstrated the ability and proficiency to service, repair, and maintain the subject JLG product model.

Reference the Preventative Maintenance Schedule and the appropriate areas of this manual for servicing and maintenance procedures. The frequency of service and maintenance must be increased as environment, severity and frequency of usage requires.

3121656 2-1

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SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance

Type Frequency

Pre-Start

Inspection

Pre-Delivery

Inspection

Frequent

Inspection

Annual Machine

Inspection

Preventative

Maintenance

Prior to use each day; or At each Operator change.

Prior to each sale, lease, or rental delivery.

In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of more than 3 months; or Purchased u sed.

Annually, no later than 13 months from the date of the prior inspection.

At intervals as specified in the Service and Maintenance Manual.

2.2 SERVICE AND GUIDELINES

General

The following information is provided to assist you in the use and application of servicing and maintenance procedures contained in this book.

Safety and Workmanship

Cleanliness

1. The most important single item in preserving the long service life of a machine is to keep dirt and foreign materials out of the vital components. Precautions have been taken to safeguard against this. Shields, covers, seals, and filters are provided to keep air, fuel, and oil supplies clean; however, these items must be maintained on a scheduled basis in order to function properly.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG Mechanic

Owner, Dealer, or User

Owner, Dealer, or User Qualified JLG Mechanic

component is disconnected, cap or cover all openings to prevent entry of foreign matter.

3. Clean and inspect all parts during servicing or maintenance, and assure that all passages and openings are unobstructed. Cover all parts to keep them clean. Be sure all parts are clean before they are installed. New parts should remain in their containers until they are ready to be used.

Service

Qualification

Fac tor y Tra ine d Service Technician (recommended)

Reference

Service and Maintenance Manual and applicable JLG inspection form.

Service and Maintenance Manual

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 eyebolt or similar bracket lessens, as the angle between the supporting structure and the component becomes less than 90°.

3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been removed and that no adjacent parts are interfering.

2. At any time when air, fuel, or oil lines are disconnected, clear adjacent areas as well as the openings and fittings themselves. As soon as a line or

2-2 3121656

Page 29

SECTION 2 - GENERAL

Component Disassembly and Reassembly

When disassembling or reassembling a component, complete the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck your work to assure that nothing has been overlooked. Do not make any adjustments, other than those recommended, without obtaining proper approval.

Pressure-Fit Parts

When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface.

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. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper. Do not unwrap reusable or new bearings until they are ready to install.

4. Lubricate new or used serviceable bearings before installation. When pressing a bearing into a retainer or bore, apply pressure to the outer race. If the bearing is to be installed on a shaft, apply pressure to the inner race.

Gaskets

Check that holes in gaskets align with openings in the mating parts. If it becomes necessary to hand-fabricate a gasket, use gasket material or stock of equivalent material and thickness. Be sure to cut holes in the right location, as blank gaskets can cause serious system damage.

Bolt Usage and Torque Application

having the same specifications of the original, or one which is equivalent.

3. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accordance with recommended shop practices. (See Torque Chart Section 1.)

Hydraulic Lines and Electrical Wiring

Clearly mark or tag hydraulic lines and electrical wiring, as well as their receptacles, when disconnecting or removing them from the unit. This will assure that they are correctly reinstalled.

Hydraulic System

1. Keep the system clean. If evidence of metal or rubber particles are found in the hydraulic system, drain and flush the entire system.

2. Disassemble and reassemble parts on clean work surface. Clean all metal parts with non-flammable cleaning solvent. Lubricate components, as required, to aid assembly.

Lubrication

Service applicable components with the amount, type, and grade of lubricant recommended in this manual, at the specified intervals. When recommended lubricants are not available, consult your local supplier for an equivalent that meets or exceeds the specifications listed.

Battery

Clean battery, using a non-metallic brush and a solution of baking soda and water. Rinse with clean water. After cleaning, thoroughly dry battery and coat terminals with an anti corrosion compound.

Lubrication and Servicing

Components and assemblies requiring lubrication and servicing are shown in the Lubrication Chart in Section

1. Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware when installing locking fasteners.

2. Use bolts of proper length. A bolt which is too long will bottom before the head is tight against its related part. If a bolt is too short, there will not be enough thread area to engage and hold the part properly. When replacing bolts, use only those

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SECTION 2 - GENERAL

2.3 LUBRICATION AND INFORMATION

Hydraulic System

1. The primary enemy of a hydraulic system is contamination. Contaminants enter the system by various means, e.g., using inadequate hydraulic oil, allowing moisture, grease, filings, sealing components, sand, etc., to enter when performing maintenance, or by permitting the pump to cavitate due to insufficient quantity of oil in supply tube.

2. The design and manufacturing tolerances of the component working parts are very close, therefore, even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty operation. Every precaution must be taken to keep hydraulic oil clean, including reserve oil in storage. Hydraulic system filters should be checked, cleaned, and/or replaced as necessary, at the specified intervals required in the Lubrication Chart in Section 1. Always examine filters for evidence of metal particles.

3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil.

4. It is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. Good grade mineral oils, with viscosities suited to the ambient temperatures in which the machine is operating, are recommended for use.

NOTE: Metal particles may appear in the oil or filters of new

machines due to the wear-in of meshing components.

Hydraulic Oil

Changing Hydraulic Oil

1. Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements must be changed annually unless operating in extreme conditions. If it is necessary to change the oil, use only those oils meeting or exceeding the specifications appearing in this manual. If unable to obtain the same type of oil supplied with the machine, consult local supplier for assistance in selecting the proper equivalent. Avoid mixing petroleum and synthetic base oils. JLG Industries recommends changing the hydraulic oil annually.

2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into another, be sure to clean all possible contaminants from the service container. Always replace the filter and clean magnet any time the system oil is changed.

3. While the unit is shut down, a good preventive maintenance measure is to make a thorough inspection of all hydraulic components, lines, fittings, etc., as well as a functional check of each system, before placing the machine back in service.

NOTE: Refer to section 4 for oil checking and oil changing

procedure.

Lubrication Specifications

Specified lubricants, as recommended by the component manufacturers, are always the best choice, however, multi-purpose greases usually have the qualities which meet a variety of single purpose grease requirements. Should any question arise, regarding the use of greases in maintenance stock, consult your local supplier for evaluation. Refer to Section 1 for an explanation of the lubricant key designations appearing in the Lubrication Chart.

1. Refer to Section 1 for recommendations for viscosity ranges.

2. JLG recommends DTE11 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of

152.

NOTE: Start-up of hydraulic system with oil temperatures

below -15°F (-26°C) is not recommended. If it is necessary to start the system in a sub-zero environment, it will be necessary to heat the oil with a low density, electrical heater to a minimum temperature of -15°F (-26°C).

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SECTION 2 - GENERAL

2.4 CYLINDER DRIFT TEST

Maximum acceptable cylinder drift is to be measured using the following methods.

Platform Drift

Measure the drift of the platform to the ground. Fully elevate the platform. Maximum allowable drift is 2 inches (5 cm) in 10 minutes. If the machine does not pass this test, proceed with the following.

Cylinder Drift

Table 2-2. Cylinder Drift

Cylinder Bore Diameter

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

Drift is to be measured at the cylinder rod with a calibrated dial indicator. The cylinder oil must be at ambient temperature and temperature stabilized.

The cylinder must have the normal load, which is the normal platform load applied.

If the cylinder passes this test, it is acceptable.

NOTE: This information is based on 6 drops per minute cyl-

inder leakage.

Max. Acceptable Drift

in 10 Minutes

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

1. Pinned joints should be disassembled and inspected if the following occurs:

a. Excessive sloppiness in joints. b. Noise originating from the joint during opera-

tion.

2. Filament wound bearings should be replaced if any of the following is observed:

a. Frayed or separated fibers on the liner surface. b. Cracked or damaged liner backing. c. Bearings that have moved or spun in their

housing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to inspection):

a. Detectable wear in the bearing area. b. Flaking, pealing, scoring, or scratches on the

pin surface.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound bearings.

a. Housing should be blown out to remove all

dirt and debris...bearings and bearing housings must be free of all contamination.

b. Bearing/pins should be cleaned with a solvent

to remove all grease and oil...filament wound bearings are dry joints and should not be lubricated.

c. Pins should be inspected to ensure it is free of

burrs, nicks, and scratches which would damage the bearing during installation and operation.

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SECTION 2 - GENERAL

NOTICE

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the “AREA” to be inspected and the “INTERVAL” at which the inspection is to take place. Under the “AREA” portion of the table, the various systems along with the components that make up that system are listed. The “INTERVAL” portion of the table is divided into five columns representing the various inspection time periods. The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked.

The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive. Variances in interval times may occur due to climate and/or conditions and depending on the location and use of the machine.

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. Notify dealer if inspection is overdue.

The inspection and maintenance code numbers are as follows:

1. Check for proper and secure installation.

2. Check for visible damage and legibility.

3. Check for proper fluid level.

4. Check for any structural damage; cracked or broken welds; bent or warped surfaces.

5. Check for leakage.

6. Check for presence of excessive dirt or foreign material.

7. Check for proper operation and freedom of movement.

8. Check for excessive wear or damage.

9. Check for proper tightness and adjustment.

10. Drain, clean and refill.

11. Check for proper operation while pump/motor is running.

12. Check for proper lubrication.

13. Check for evidence of scratches, nicks or rust and for straightness of rod.

14. Check for condition of element; replace as necessary.

15. Check for proper inflation.

16. Decals installed and legible.

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Table 2-3. Preventive Maintenance and Safety Inspection

AREA Interval

PRE-DELIVERY (a)

OR FREQUENT (b)

INSPECTION

PLATFORM

Controller 1,11 1,11

Switches 1,11 1,11

Placards and Decals 1,2 1,2

Control Tags 1,2 1,2

Hoses and Cables 4,8 4,8

Wear Pads 8,12 8,12

Handrails and Chains 1,4 1,4

Lanyard Anchorage Point 1,4,16 1,4,16

CHASSIS

Battery 3,5 3,5

Hydraulic Pump 1,5 1,5

Val ves 1, 5 1,5

Hydraulic Filter 26 26

Hydraulic Hoses and Tubing 1,5 1,5

Hydraulic Oil Tank 3,4,5 3,4,5

Lift Cylinder 1,4,5,6,12,13 1,4,5,6,12,13

Limit Switch 1,7 1,7

Tilt Alarm Switch 1,7 1,7

Placards and Decals 1,2 1,2

Wheel and Tire Assemblies 1,8,9 1,8,9

Drive Motors 1,5,6 1,5,6

Drive Brakes 1,6,8 1,6,8

Drive Torque Hubs 1,3,5,6 1,3,5,6

Steer Cylinder 1,4,5,6,13 1,4,5,6,13

Steer Components 1,4,6,8 1,4,6,8

Wheel Bearings 8,12 8,12

Scissor Arms 1,4 1,4

Safety Props 1,4 1,4

Sliding Wear Pads 8,12 8,12

Pivot Pins/Bolts 1,4,7,8 1,4,7,8

Switches, Ground Control 1,11 1,11

Control Tags 1,2 1,2

ANNUAL (c)

(YEARLY)

INSPECTION

SECTION 2 - GENERAL

Footnotes:

(a) Prior to each sale, lease, or delivery (b) In service for 3 months; or Out of service for 3 months or more; or Purchased used (c) Annually, no later than 13 months from the date of the prior inspection

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SECTION 2 - GENERAL

NOTES:

2-8 3121656

Page 35

SECTION 3 - CHASSIS & SCISSOR ARMS

24V

Line Contactor

Right Field Winding

Left Field Winding

Power Module

Left

Armature

Right

Armature

BF1

BF2

Field

MOSFETS

Armature

MOSFET

Shunt

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 TRACTION SYSTEM

Theory of Operation

The Armatures (rotating windings) of the separatelyexcited drive motors are wired in parallel to the Power Module's -T and +B terminals (ZAPI) . The +B Terminal is always at the same voltage as the +B (Battery Voltage when the Line Contactor is closed) and allows the module to measure current with the internal shunt (extremely low impedance). The -T Terminal is pulled to Ground by the Armature Switch MOSFET's (connected to -B Terminal).

To provide variable speed control, the Armature MOSFET transistors switch On and Off at high frequencies (pulse-width modulation; 16kHz). The Duty Cycle (On & Off time) is varied to control the voltage applied to the Armatures. When the MOSFET's spend 50% of the period On and 50% Off, approximately ½ of the available Battery Voltage will be applied to the Armatures. Similarly, the MOSFET are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the Armatures (as in Driving at Full Speed).

Instead of permanent magnets, the separately-excited drive motors use electro-magnets (called Field Windings) located in the stator (non-rotating) portion of the motor. Field windings are preferable to permanent magnets because the Power Module can adjust the stator's magnetism for optimum motor performance. When climbing a grade a low speeds, the Power Module may apply as much as 40A to the field windings for more electro-motive force. On level terrain, the Power

Module will apply as little as 14A to the fields for higher rotational speeds and better electrical efficiency.

The Field Windings also provide direction reversal for traction. When driving forward, MOSFET switches 1 and 4 turn On to apply positive potential to F2 and ground potential to F1. In reverse, MOSFET switches 2 and 3 turn On to apply positive potential to F1 and ground potential to F2. Theses switches are pulse-width modulated by the Power Module to maintain a fixed relationship between Field and Armature Current (also called the Field Map).

Since the two 24V Armatures are wired in parallel, the drive motors will attempt to rotate at the same speed under all conditions. If one wheel slips, the wheel with traction will demand more current as it slows slightly (under load). In this manner, the system provides effective traction control with no added complexity.

It is essential that the same amount of field current is supplied to both drive motors, or one wheel will pull the vehicle (motor overheating and excessive tire wear would result). Independent field control would require a more complex Power Module, and parallel field windings would require impedance matching. For simplicity, the vehicle uses 12V field windings wired in series to ensure proper distribution of current.

Two electrically-released parking brakes are mounted to the rear of the drive motors. The Ground Module energizes the two 24V electro-magnets when appropriate to allow vehicle motion. The parking brakes can be released electrically for emergency vehicle towing

3121656 3-1

Figure 3-1. Traction Control Circuit - ZAPI Power Module

Page 36

SECTION 3 - CHASSIS & SCISSOR ARMS

3.2 DRIVE MOTOR ELECTRICAL EVALUATION

Several basic electrical tests can be performed on the Drive Motors. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.

Refer to Figure 7-2., Resistance Measurement. Disconnect the Main Battery Disconnect and all drive motor cables during this analysis.

• Resistance < 2 Ohms Red to Black Armature Wires. The heavy red and black conductors are connected to the motor's armature winding. The winding is a very low impedance and should appear to be a short-circuit for an ordinary voltmeter. High resistance can signal corrosion, improper crimps, damaged cabling, worn brushes, a faulty commutator, or an open armature winding.

• Resistance < 2 Ohms Blue to Orange Field Wires. The blue and orange conductors are connected to the motor's field winding. In order to make this measurement, it will be necessary to disconnect the buttsplice on the two orange wires or use a piercing meter probe. As with the armature, the field is a very low impedance and should appear to be a short-circuit for an ordinary voltmeter. High resistance can signal corrosion, improper crimps, damaged connectors, damaged cabling, or an open field winding.

• Resistance 15-25 Ohms Yellow to Brown Brake Wires. The yellow and brown wires are connected to the integral brake. Improper resistance can signal corrosion, improper crimps, damaged cabling, or a faulty solenoid.

• Resistance > 1 MegaOhms Red Armature Wire to Motor Housing. The armature winding should be electrically isolated from the motor housing. Low resistance may be an indication of a crushed cable, a burned cable, or a burned armature winding. Investigate by disconnecting the drive motor cable from the motor and re-measure resistance (isolation).

• Resistance > 1 MegaOhms Blue Field Wire to Motor Housing. The field winding should also be electrically isolated from the motor housing. Low resistance may be an indication of a crushed cable, a burned cable, or a burned field winding. Investigate by disconnecting the drive motor cable from the motor and re-measure resistance (isolation).

• Resistance > 1 MegaOhms Red Armature Wire to Blue Field Wire. The armature and field windings should also be electrically isolated from one another. Low resistance may be an indication of a crushed cable, a burned cable, damaged windings. Investigate by disconnecting the drive motor cable from the motor and re-measure resistance (isolation).

Common Traction System Difficulties

1. Short-Circuit Motor Armature

This issue will allow the vehicle to drive very slowly or not at all. Rapid motor overheating (one motor) will result.

This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform stowed). Under DIAGNOSTICS - TRACTION, the JLG Analyzer's ARM CUR display (Armature Current Reading) will exceed 120A. The FLD CUR display (Field Current Reading) will hover around 40A. Neither wheel will rotate at normal speed, but it will be possible to rotate the drive wheel by hand. The Power Module's self-diagnostics cannot detect this fault since the situation appears identical to climbing a steep grade.

To find the source of the difficulty, pull the Main Battery Disconnect and disconnect the Armature Wiring (heavy red and black conductors) from the suspected drive motor leading to the Power Module's M1 and M2 Terminals. Re-test the traction function. If the remaining drive motor is able to reach full speed (and Armature Current is less than 50A), the drive motor that has been disconnected is fault. Investigate for crushed and burned cables. Note if the drive motor smells burned.

2. Short-Circuit Brake Release

This issue will not allow the vehicle to drive. Rapid motor overheating (both motors) will result. Continued attempts to drive the vehicle may result in armature damage.

This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform stowed). Under DIAGNOSTICS - TRACTION, the JLG Analyzer's ARM CUR display (Armature Current Reading) will exceed 120A. The FLD CUR display (Field Current Reading) will hover around 40A. Neither wheel will rotate, and it will be impossible to rotate either drive wheel by hand. The Ground Module cannot detect this fault during power-up or self-test since energizing the brakes could pose a hazard. However, it may detect this issue during Drive (investigate using JLG Analyzer).

To find the source of the difficulty, remove the rear cover from either drive motor. Insert voltmeter leads into the white connector leading to the brake solenoid (yellow and brown wires) and attempt to drive (Platform Mode). The Ground Module will apply approximately 24V to the brake release solenoids (wired in parallel) during drive, but will reduce this voltage in the event of a shortcircuit. If this voltage is improper (less than 8V),

3-2 3121656

Page 37

SECTION 3 - CHASSIS & SCISSOR ARMS

investigate using resistance measurement (refer to Drive Motor Electrical Evaluation). Suspect damaged cabling, burned cabling, or faulty brake release solenoids. Trace the brake release cabling from the Power Module Compartment to the Ground Module Connector J1-24.

3. Open-Circuit Brake Release

This issue will not allow the vehicle to drive. Rapid motor overheating (both motors) will result. Continued attempts to drive the vehicle may result in armature damage.

This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform stowed). Under DIAGNOSTICS - TRACTION, the JLG Analyzer's ARM CUR display (Armature Current Reading) will exceed 120A. The FLD CUR display (Field Current Reading) will hover around 40A. It is possible that one wheel may rotate, or neither may rotate (depending on the location of the open-circuit). Listen for the brake release solenoid when activating drive. The Ground Module cannot detect this fault during power-up or selftest since energizing the brakes could pose a hazard. However, it may detect this issue during Drive (investigate using JLG Analyzer).

If one wheel rotates, the open-circuit is located in the wiring for that specific drive motor (Power Module compartment or Drive Motor Cable). Investigate for improper crimps, unlatched connectors, damaged cables, or open brake release solenoids (refer to Drive Motor Electrical Evaluation).

If neither wheel rotates, the open-circuit is located in the wiring between the Power Module compartment and Ground Module. Using a voltmeter, measure the brake release voltage on either brake connector in the Power Module compartment during drive (should be approximately 24V). Investigate for improper crimps, unlatched connectors, damaged harnessing, or a faulty Ground Module. As an alternative, insert a short piece of wire with a Deutsch Female Crimp directly into Ground Module's J1-24 and measure voltage as a diagnostic measure (eject vehicle harness from that pin).

Power Module Electrical Evaluation

Several basic electrical tests can be performed on the Power Module. Failure of one of these evaluations is significant and may indicate that the device is physically damaged. If a Power Module is suspected to be faulty, thoroughly examine the rest of the system for possible damage.

Refer to Figure 7-2., Resistance Measurement. Disconnect the Main Battery Disconnect and all cables from

the Power Module during this analysis. Wait 60 seconds after power is disconnected to allow internal charge to dissipate (risk of hazard, improper readings otherwise).

• Resistance >100kOhms all Terminals to Housing. Ensure that there is an open-circuit between all terminals of the Power Module and the module's aluminum housing. The device is fully potted and all electronics are insulted from the housing. Place the Black meter lead on the housing and use the Red meter lead to probe all terminals.

• Resistance < 2 Ohms between +B and M1. Ensure that there is a short-circuit between the +B and M1 Terminals. Internally, there is a low-impedance current measurement shunt for the Armature portion of Traction. Place the Red meter lead on +B, and the Black meter lead on M1.

• Resistance >1 MegaOhms between F1 and -B; F2 and -B. Ensure that there is an open-circuit between the two Field Terminals (F1 & F2) and -B. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on -B and the Red meter lead on F1 / F1.

• Resistance >1 MegaOhms between F1 and +B; F2 and +B. Ensure that there is an open-circuit between the two Field Terminals (F1 & F2) and +B. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on +B and the Red meter lead on F1 / F1.

• Resistance >100kOhms between P and -B. Ensure that there is an open-circuit between the P and the B Terminals. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on -B, and the Red meter lead on P. Note that a measurement of increasing resistance (capacitor charge) is normal, but a persistently low impedance is not.

• Resistance >1kOhms between M2 and -B. Ensure that there is an open-circuit between the M2 and -B Terminals. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on -B, and the Red meter lead on M2. Note that a measurement of increasing resistance (capacitor charge) is normal, but a persistently low impedance is not.

• Resistance 120 Ohms between Pins 10 & 11. Ensure that the resistor that terminates the CANbus is within tolerance between pins 10 and 11 on the 12 position Mini-Fit Jr (Connector "B"). Place the Red meter lead on pin 10, and the Black meter lead on pin

11. The resistance should measure between 110 - 130 Ohms.

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Page 38

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTICE

CAUTION

3.3 TORQUE HUB

THE PROCEDURES WITHIN THIS SECTION APPLY TO ALL MACHINES AND TORQUE HUBS. PROCEDURES THAT APPLY TO SPECIFIC MACHINES AND TORQUE HUBS WILL BE SO NOTED BY PROPER SERIAL NUMBERS.

NOTE: These instructions will cover how to completely

assemble and disassemble the Torque-Hub unit. However, if the unit is under warranty you should contact JLG Industries, Inc. for a replacement unit. The warranty will no longer be valid if the unit is disassembled by non-JLG personnel.

TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DISASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT’S GEARS AND SEALANTS ARE WORKING PROPERLY.

Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests.

IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE ADEQUATELY BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR EVEN DEATH.

NOTE: The brake must be released before performing the

roll test. This can be accomplished by connecting the brake release cable and depressing button. The brake can also be released by following the manual disengage procedures outlined in this section.

RETURN BRAKE RELEASE CABLE BEFORE RETURNING TO NORMAL OPERATION.

Leak Test

The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your leak checking fitting starts to fall after the unit has been pressurized and allowed to equalize. Leaks will most likely occur at the pipe plugs, the main seal or wherever o-rings are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where the o-rings or gaskets meet on the exterior of the unit, then checking for air bubbles. If a leak is detected in a seal, o-ring or gasket, the part must be replaced, and the unit rechecked. Leak test at 10 psi for 20 minutes.

NOTE: Due to the small air volume inside this Torque-Hub, it

will pressurize to 10 psi very quickly. If the pressure becomes excessive in the unit the seals will be destroyed.

Oil Check/Fill Procedure

The torque hub unit is shipped with ISO 68 viscosity oil (hydraulic fluid). It is designed to utilize the same oil throughout its service life. However, should it need to be checked/serviced use the following procedure.

In the event of servicing, fill the unit with ISO grade 68 hydraulic oil (80W gear oil or 20W engine oil).

NOTE: The gearbox capacity is 10 oz of oil.

1. To check the oil level, rotate the wheel so that the plugs in the cover are at 12 o-clock and 3 o-clock.

2. Allow the oil to settle than slowly remove the plug at 3 o-clock.

3. If oil begins to come out the oil level is sufficient.

4. If no oil is noticed at the 3 o-clock plug remove both plugs.

5. Slowly add oil at the 12 o-clock plug location until oil begins to seep out at the 3 o-clock plug location.

6. Apply pipe dope or teflon tape to the cover plugs and reinstall into the cover.

7. TIghten to 6 ft lbs - 8 ft lbs (8.4 Nm to 11.2 Nm).

Roll Test

The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You should be able to rotate the wheel or hub of the gearbox by hand. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for improper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency.

3-4 3121656

Page 39

Brakes - Manual Disengage Procedure

CAUTION

1. Brake Cover

2. Cover Bolts

3. Disengage Holes

Figure 3-2. Disengage Procedure

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Chock wheels or secure machine with tow vehicle.

2. Ensure battery disconnect switch is in to the "OFF" position.

3. Remove the two Cover Bolts and Brake Cover.

4. Insert the Cover Bolts into the two Disengage Holes in the brake housing.

5. Tighten down the Cover Bolts and the brake on that drive motor will disengage.

6. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually.

7. After towing is complete, chock wheels and remove Cover Bolts from Disengage Holes.

8. Reinstall Brake Cover.

3121656 3-5

AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST BE REMOVED FROM THE BRAKE DISENGAGE HOLES. THE BRAKES CANNOT BE ENGAGED WITH THE DISENGAGE BOLTS IN THE BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE.

Page 40

SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

1. Drive Motor

2. Motor Mounting Bolts

3. Washers

4. Motor Cable

Figure 3-3. Motor Removal

Drive Motor Removal

3. Remove the two motor mounting bolts and washers.

ENSURE THE BATTERY DISCONNECT SWITCH IS IN THE OFF

4. Gently remove the drive motor (1).

POSITION BEFORE REMOVING DRIVE MOTOR.

1. Disconnect the motor cable from the power control module.

2. Drain the oil out of the unit by removing the cover plug. Note the condition of the oil, replace if necessary.

3-6 3121656

Page 41

Main Gearbox Disassembly

1. Spindle Sub-Assembly

2. Spiral Snap Ring

3. Input ring Gear

4. Input Sun Gear

5. Cover O-Ring

6. Cover Thrust Washer

7. Cover

8. Cover Snap Ring

9. Pipe Plug

10. Input Carrier Sub-Assembly

11. Hub Sub-Assembly

Figure 3-4. Main Gearbox Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Using a screwdriver, pry off the cover snap ring.

2. Remove cover. Cover Thrust washer should be in the inner counter bore of the cover.

NOTE: To grip the cover for removal a pipe may need to be

inserted into the pipe plug holes.

3. Remove input sun gear.

4. Remove input carrier sub-assembly.

5. Remove cover o-ring.

6. Remove input ring gear.

NOTE: The input ring gear is held in with a press fit on its

outside diameter. Insert jacking screws (1/4-20UNC grade 8) with at least 1.5 inches of thread length into

3121656 3-7

each of the three tapped holes to force the ring gear out. Be sure and alternate between the jacking screws to keep the ring gear from becoming misaligned in the bore. The screws will push against the outer race of the main bearing. This bearing will have to be replaced afterwards.

7. Using a screwdriver remove spiral snap ring.

8. Pull hub sub-assembly off of the spindle subassembly.

Page 42

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining Ring

Figure 3-5. Input Carrier Disassembly

Input Carrier Disassembly

1. Remove retaining rings from each of the 3 planet shafts.

NOTE: Do not overstress these retaining rings when remov-

ing them.

2. Remove thrust plate.

3. Remove a thrust washer from each planet shaft.

4. Slide each input planet gear off the planet shaft.

5. Remove 22 needle bearings from the bore of each planet gear.

6. Remove the thrust washer from each planet gear.

7. Remove retaining ring from output sun gear.

8. Slide output sun gear out from the center of the input carrier.

9. Remove the three planet shafts from the input carrier.

3-8 3121656

NOTE: The planet pins are held in with a press fit. To avoid

damage to the parts, use an arbor or hydraulic press to remove the planet pins.

Page 43

Hub Disassembly

1. Seal

2. Hub

3. Main Bearing

Figure 3-6. Hub Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Remove main wheel bearing.

NOTE: This part is held in the hub with a press. To remove

have the hub sitting seal side up. Use a plate or rod with a large enough diameter push in the inner race of the bearing. Apply force to the push the bearing out. This bearing will need to be replaced upon reassembly.

3121656 3-9

2. Remove main lip seal.

NOTE: This lip seal is also held in with a press fit. Remove

the lip seal only if the hub or seal needs to be replaced. The lip seal will most likely become damaged during removal. Try not to damage the hub bore.

Page 44

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Spindle Sub-Assembly

2. Main Bushing

3. Shaft Ball Bearing

4. Tanged Washer

5. Thrust Washer

6. Output Planet Gear

7. Output Planet Pins

8. Main Bearing

9. O-Ring

10. Shaft Seal

11. Snap Ring

12. Needle Roller Bearings

Figure 3-7. Spindle DIsassembly

Spindle Disassembly

1. Place unit on bench with planet gears facing up.

2. Remove 3 output planet shafts.

NOTE: These planet shafts are held in with a press fit. Use

the tapped hole in the end of the pin in conjunction with a slide hammer or similar tool to remove them.

3. Remove the output planet gear, thrust washer, and tanged washer out of each gear “window” of the spindle.

NOTE: The output planet gears are a very similar size to the

input planet gears, tag or label the planet gears to avoid confusion.

4. Using a screwdriver remove the shaft bearing snap ring.

5. Remove the shaft ball bearing from the center bore.

3-10 3121656

6. Press out the motor shaft seal from the center bore.

7. Remove the main bearing from the outside diameter of the spindle.

NOTE: This bearing is held in with a press fit. You will need to

pry against the spindle to remove it. The bearing will need to be replaced when this is done.

8. Press out the main bushings at the top of the spindle neck.

9. Remove the motor O’ring from the groove on side opposite from the carrier side.

Page 45

SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Sub-Assembly

1. Using an appropriate pressing tool, press in the 2 main bushings in the upper bore of the spindle. The lower bushing needs to be flush with the bottom of the bore and the upper bushing needs to be flush with the bottom of the bore.

2. Using the clevis pin from the steering linkage or an M12 bolt, drive the flanged steer link bushing into the appropriate spindle ear hole. If the wheel drive is for the left wheel then, with the carrier side up and kingpin bore oriented to the top, put the steer link bushing in the left ear.

3. Using the appropriate pressing tool, press on main bearing until it is fully seated.

4. Insert the motor shaft bearing into the center bore of the spindle. The bearing is a slight slip fit, but it may require some press to assemble if the bearing becomes misaligned.

5. Retain the bearing with the spiral retaining ring.

6. Line the bore of the output planet gear with 22 needle rollers. Use grease to retain the needle rollers in the bore.

7. Place tanged thrust washer into each planet “window” of the spindle. Make sure the tang sits in the cast groove on the inside of the window.

8. Place a thrust washer onto the plane gear. Line up the bores as best as you can. Use grease to hold the thrust washer in place.

9. Slide the planet gear into the window with the tanged washer until the bores line up.

10. Insert an output planet pin into the planet pin hole of the spindle and through the bores of the thrust washers and the planet gear.

11. Before pressing the planet pin into the spindle make sure the gear spins freely.

12. Press the planet pin into the spindle until it bottoms out. Make sure the planet gear turns freely after the planet pin is pressed in.

13. Repeat Steps 6-12 for the other two output planet gears.

14. Turn the spindle over so that the carrier is down.

15. Using a flat plate or rod, press the motor shaft seal into the center bore so that it is flush with the face of the spindle.

16. Grease and install the motor O’ring into the groove.

CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING CONTACT WITH THE BRAKE DISCS. IF THIS OCCURS IT WILL DEGRADE THE BRAKES PERFORMANCE.

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Page 46

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Seal

2. Hub

3. Main Bearing

Figure 3-8. Hub Disassembly

Hub Sub-Assembly

1. Put hub on a table with the tapped holes facing down.

2. Using a flat plate in conjunction with a pressing tool, press in the seal so it is flush with the edge of the hub.

NOTE: The seal has a thin outer shell that can be easily dam-

aged if not installed with care. It is a good idea to start the seal into the bore with a rubber mallet before pressing.

3-12 3121656

3. Flip the hub over.

4. Using an appropriate pressing tool, press the main bearing into the bore until it bottoms out.

Page 47

Input Carrier Sub-Assembly

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining Ring

Figure 3-9. Input Carrier Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Press 3 input planet shafts into the 3 holes of the input carrier. The head of the input planet shaft needs to sit flush in the counter bore of the input carrier hole.

2. Insert output sun gear into the splined bore of the input carrier. The gear tooth end of the output sun gear should protrude in the opposite direction of the input planet shaft.

3. Using retaining ring pliers. Install the retaining ring into the groove of the output sun gear. Make sure that the ring is correctly seated in the groove and that the output sun gear cannot be pulled out of the input carrier.

4. Load 22 needle rollers into the bore of each input planet gear. Retain the needle bearings in the bore with a coating of grease.

5. Place a thrust washer on each side of the input planet gear. Line up the bores as well as you can

3121656 3-13

NOTE: Do not overstress the snap ring.

visually. Additional grease may help hold everything together.

6. Place the input planet gear and thrust washers onto the input planet shaft sticking out from the carrier. When you slide the input planet shafts into the bores, the needle bearings will try to push out. If you have the thrust washers lined up properly they will contain the needle bearings within the input planet-gear.

7. Repeat 5 & 6 for the other 2 planet gears.

8. Put the thrust plate onto the three input planet shafts. Use the 3 holes on the innermost bolt circle. The other 3 holes are for a different gear ratio.

9. Using the appropriate retaining ring pliers put a retaining ring into the groove of each planet shaft.

Page 48

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Spindle Sub-Assembly

2. Spiral Snap Ring

3. Input ring Gear

4. Input Sun Gear

5. Cover O-Ring

6. Cover Thrust Washer

7. Cover

8. Cover Snap Ring

9. Pipe Plug

10. Input Carrier Sub-Assembly

11. Hub Sub-Assembly

Figure 3-10. Main Gearbox Disassembly

Main Gearbox Assembly

1. Inspect seal surface of spindle. Remove any debris that may be present.

2. Apply a coating of grease to the lip seal of the hub sub-assembly.

3. Place Spindle Sub-Assembly on table with carrier side up.

4. Carefully install the hub sub-assembly (seal side down) onto the spindle. This installation should be a slip fit and takes place in 3 stages.

a. Stage 1: The hub slides together until the gear

teeth of the hub hit the gear teeth of the 3 output planets.

3-14 3121656

b. Stage 2: Find the planet gear that is tight and

turn it until you feel it go into mesh with the hub gear teeth, apply slight downward pressure to the hub and then find the next gear that is tight and do the same.

c. Stage 3: Once all the planet gears are in mesh

apply pressure to the hub, it should go on the rest of the way.

5. Install retaining ring into the groove on the OD of the spindle carrier. This is a spiral retaining ring so it will not require pliers. You will need to pull the retaining ring apart and work it into the groove.

Page 49

SECTION 3 - CHASSIS & SCISSOR ARMS

6. Using an appropriate pressing tool, press the Input Ring gear (recessed side down) into the hub subassembly.

NOTE: Do not use excessive pressing force because it will be

reacted by the main wheel bearings.

7. Install the input carrier sub-assembly into mesh. The output sun portion of the sub-assembly will mesh with the output planet gears and the planet gears mounted on the sub assembly will mesh with the input ring gear.

8. Install the input sun gear into the area between the 3 input planet gears.

9. Apply a coating of grease to the cover o’ring and install it into the o’ring groove of the hub.

NOTE: It may be helpful to stretch the o’ring out prior to

assembly to avoid pinching or shearing when the cover is assembled.

10. Apply a heavy coating of grease to the cover thrust washer and place it in the center counter bore of the cover. The grease will help keep it in the bore during assembly.

11. Center the cover in the hub bore so that the “JLG” logo is up. Push it into the bore.

NOTE: Do not hit the cover with a hammer or mallet, shocks

may cause the cover thrust washer to dislodge and drop into the gear cavity prior to the cover getting positioned properly. If all the parts are to size and assembled properly, the cover should not need excessive force to assemble.

12. Install the cover retaining ring into the hub groove.

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Page 50

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Drive Motor

2. Motor Mounting Bolts

3. Washers

4. Motor Cable

Figure 3-11. Drive Motor Assembly

Motor and Brake Assembly

1. Insert the drive motor into the back of the gearbox. The drive motor will pilot on the four bosses in the gearbox. Try to keep the end of the motor shaft from causing damage to the lip seal in the gearbox.

NOTE: The motor may need to be rotated to line up the sun

gear splines with the motor shaft splines.

2. Install the two motor mounting bolts and washers. Torque to 9 - 11 ft-lbs (12 - 15 Nm).

3-16 3121656

3. Connect the end of the Motor Cable to the Power Module.

4. Fill the gearbox with oil ISO grade 68 oil or oil of a similar viscosity (80W gear oil or 20W engine oil). The gearbox will need to be filled with 10 oz of oil.

Page 51

Tightening and Torquing Bolts

BOLT A

BOLT B

Figure 3-12. Assembly Tool 1

Figure 3-13. Assembly Tool 2

Figure 3-14. Assembly Tool 3

If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque.

The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle.

1. Tighten (but do not torque) bolt "A" until snug.

2. Go to the opposite side of the bolt circle and tighten bolt "B" until equally snug.

3. Crisscross around the bolt circle and tighten remaining bolts.

4. Now use a torque wrench to apply the specified torque to bolt "A".

5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remaining bolts.

SECTION 3 - CHASSIS & SCISSOR ARMS

Assembly Tools

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Page 52

SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

1. Drive Cables

2. Cable Clamp

3. Spacer Plate

3.4 DRIVE MOTOR CABLE ROUTING

1930ES Only

BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING.

1. Orient the drive cables going back towards the rear of the machine as shown below.

4. Place the Green Clamp on the clamping rings as shown below.

5. Bolt the clamp onto the underside of the frame.

a. The Spacer goes between the frame and the

Clamp.

b. Place the Larger Washer against the clamp.

6. Connect the drive motor cables to the power module.

7. Tuck all wires into the power module compartment and install cover.

2. Loop the cables forward towards the front of the machine then up and back so that the clamping rings on the cables are aligned together.

3. Obtain the Cable Clamp and hardware.

1. Cable Clamp

2. Spacer Plate

3. Capscrew, Washers, and Nut

8. Reconnect battery cable plug. Power up machine and operate the drive function to ensure drive motors operate properly.

3-18 3121656

Page 53

2032ES/2632ES/2646ES/3246ES Only

CAUTION

BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING.

1. Orient the drive cables going back towards the rear of the machine. Loop the cables forward towards the front of the machine then up and back. Place the Green Clamp on the clamping ring as shown below.

SECTION 3 - CHASSIS & SCISSOR ARMS

2. Obtain the Cable Clamp and hardware.

1. Bolt, Washers, and Nut

2. Cable Clamp

3. Bolt the Green Clamp onto the backside of the frame using the the back hole drilled in step #4. The roll pins inserted in the front-most holes act as a stop to prevent the clamp from turning.

1. Drive Cable

2. Roll Pin

NOTE: When bolting the green clamp onto the frame, place

the larger washer against the clamp on the outside of the clamp.

4. Connect the drive motor cables to the power module..

5. Tuck all wires into the power module compartment and install cover.

6. Reconnect battery cable plug. Power up machine and operate the drive function to ensure drive motors operate properly.

3. Cable Clamp

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Page 54

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Wire Harness

2. Frame & Field Assembly

3. Armature Assembly

4. Brush Spring

5. Brush & Terminal Assembly

6. Brush Box Assembly

7. Retaining Ring

8. Bearing

9. Commutator End Head

10. Grommet

11. Brake Assembly

12. Gasket Seal Kit

13. Cover Plate Kit

14. Cover Plate Mounting Screws

15. Brake Cover Mounting Screws

16. Terminal Cover Mounting Screws

Figure 3-15. Drive Motor Components

3.5 ELECTRIC DRIVE MOTOR SERVICE

3-20 3121656

Page 55

SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

NOTE: Reference Figure 3-15., Drive Motor Components for

part names and locations when servicing the Drive Motor.

Periodic maintenance consisting of inspections of motors, batteries and wiring circuitry is recommended.

ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE OPERATION.

Servicing Guidelines

Since the operating environment of industrial equipment varies widely, the following are suggested for periodic maintenance inspection intervals.

• Normal Service – Perform routine inspection (outlined in the Inspection and Service portion of this section) every 1,000 hours of drive time.

• Severe Service – Perform routine inspection every 500 hours of drive time. Severe service environments are listed below:

a. Dusty or dirty locations like cement plants,

lumber and flour mills, coal mining, stone quarries, etc.

b. High temperature areas like steel mills, found-

ries, etc.

c. Environments with sudden temperature

change, such as in refrigeration plant, etc.

Drive Motor Troubleshooting

1. Turn off power to unit and disconnect main battery power. Disconnect drive motor connections from the Power Module.

2. Verify field continuity between the blue and orange wires. If available, use a 4-wire ohmmeter to verify the field resistance per the applicable motor specification below.

3. Verify armature continuity between the red and black wires. If available, use a 4-wire ohmmeter to verify the field resistance per the applicable motor specification below.

Model

1930ES 0.21 Ohms 0.037 Ohms

Field Resistance @

75°F (24°C)

Armature Resistance

@ 75°F (24°C)

b. Armature terminals and the case of the motor. c. Field connector pins to the armature terminals.

5. Verify continuity in 2 pin brake connector (yellow and brown wires). Measure the brake resistance and verify that it is between 18 and 22 Ohms.

Drive Motor Disassembly

NOTE: Refer to Figure 3-15.

1. Remove the two Cover Plate Mounting Screws (14) holding the Cover Plate (13) in place and remove the cover plate from the motor.

2. Remove the Brake Cover Mounting Screws (15) holding the Brake (11) in place and set aside. These screws are used to manually release the brakes.

3. Remove the two Terminal Cover Mounting Screws (16). Slide the strain relief of the Wire Harness (1) out of the cover and remove the cover from the motor.

4. Discard the Gasket (12) that was located under the brake and terminal covers.

5. Remove the wire harness from the motor by disconnecting the brake connection and armature connections. Cut the field connection close to the crimp connection on the motor side.

6. Install the two Brake Cover Mounting Screws (15) into the threaded holes in the brake assembly and tighten to manually release the brake (see Figure 3-3.).

7. Remove the three screws holding the brake assembly to the motor. Carefully remove the brake assembly, brake disc and reaction disc from the motor by sliding off of the shaft.

8. Remove the screws holding the Commutator End Head (9) in place and remove the commutator end head from the frame and field assembly. The Armature (2) will be attached to the commutator end head.

9. Pull back the Brush Springs (4) in the commutator end head, pull the brush back and rest the springs on the side of the brush. The brushes should move freely within the holders.

10. Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly.

11. Remove the Snap Ring (7) and Bearing (8) from the commutator end head. Discard the bearing.

2032ES/2632ES/2646ES/

3246ES

4. Using a dielectric tester, verify that there are no shorts between the following items:

a. Field connector pins and the case of the motor.

3121656 3-21

0.127 Ohms 0.051 Ohms

Drive Motor Inspection and Service

NOTE: Refer to Figure 3-15.

1. Carefully blow out any accumulated carbon dust and dirt from the Commutator End Head (9) and

Page 56

SECTION 3 - CHASSIS & SCISSOR ARMS

the Frame & Field Assembly (2) using clean, oil free, compressed air.

2. Replace Brushes (5) that are worn below their usable length of 0.6 in (1.5 cm), show signs of uneven wear or signs of overheating, such as discolored brush shunts and brush springs. Brushes should always be replaced in complete sets of four. Use identical replacement parts; do not substitute brush grades as the brushes are matched to the motor type and application to provide the best service. Substituting brushes of the wrong grade can cause premature commutator failure and excessive brush wear.

3. Make sure the Brush Box Assembly (6) is tight on the commutator end head. Replace brush box assemblies in the commutator end head if they are physically damaged or brush holders are loose on the brush plate.

4. Visually inspect the frame and field assembly for overheating or other signs of damage. Check all wiring to ensure that the insulation is in good condition. Verify that pole screws are torqued to 250 300 in-lb (28.2 - 33.9 Nm). Verify field resistance using a suitable ohmmeter per the appropriate motor specification. Verify that the field is electrically isolated from the frame using a dielectric tester. Replace as necessary.

5. Visually inspect the Armature Assembly (3) for signs of overheating or physical damage. Visually inspect the seal surface of the shaft for excessive wear. Check for grounded circuits using a dielectric tester by applying voltage between the commutator and the shaft. Visually inspect the commutator for excessive wear and overheating. Replace as necessary.

6. Visually inspect the brake surfaces for excessive wear. Replace Brake Assembly (11) if necessary.

7. Visually inspect the Wire Harness (1) for frayed insulation, loose terminals, or other damage. Replace as necessary.

Drive Motor Reassembly

NOTE: Refer to Figure 3-15.

1. After inspection and servicing, reassemble the wiring in the Commutator End Head (9) as originally found. Ensure the wiring does not contact metal parts and that it allows the brushes to move unrestricted in the holders. Motor terminals must be assembled as shown Figure 3-17. Torque bottom terminal nut to 110 - 140 in-lb (12.4 - 15.8 Nm).

2. After the motor has been disassembled, it is recommended that new bearings be installed because bearings may have been damaged during removal. Although the bearings may appear and

feel good, the bearing races could be “brinelled” (races or balls deformed) and may exhibit noise and vibration problems or fail within a relatively short period of service. Press a new bearing into the commutator end head, pressing on the outer race only. See Figure 3-16.. Replace the Retaining Ring (7) in the retaining ring groove.

3. Press the Armature (3) commutator end into the commutator end head and bearing assembly, carefully supporting the inner-race of the bearing. See Figure 3-16.

4. Carefully release the Brush Springs (4) allowing the Brushes (5) to contact the commutator. Make sure brush shunts do not interfere with spring movement.

1. Press Fixture must press against Outer Race

2. Bearing

3. End Head (held stationary)

4. Armature Assembly

5. Assembled End Head, Bearing, and Retaining Ring

6. Press Fixture must press against Inner Race (held stationary)

Figure 3-16. Bearing Pressure Guidelines

5. Assemble the commutator end head to the Frame & Field Assembly (2) and tighten the screws to 120

- 140 in-lb (13.6 - 15.8 Nm). Make sure to align the field connection with the notch in the commutator end head. Seal wires where they exit from commutator end head with the Grommet (10).

6. Place the Gasket Seal (12) in the bottom of the notch in the commutator end head. Align wires from the Brake Assembly (11) into the notch in the

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Figure 3-17. Wire Harness Connections

commutator end head. Secure brake assembly to commutator end head using three bolts.

7. Install Wire Harness (1) to motor by connecting the brake connectors and securing the armature terminals to the terminal studs. Crimp the field connection (red/orange to orange and blue to blue) together and heat shrink. Motor terminals must be assembled as shown in Always secure the bot-

tom nut with a wrench as you tighten the top nut. Torque top nut to 90 - 110 in-lb (10.2 - 12.4

Nm).

8. Remove manual release screws from brake assembly. Apply new Gasket (12) and affix brake cover to motor using the 2 manual release screws.

9. Attach terminal cover to the commutator end head using two terminal cover screws.

10. Slide the strain relief of the wire harness into the slot of the terminal cover. Align cover plate with groove in frame and field and affix using two cover plate screws.

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SECTION 3 - CHASSIS & SCISSOR ARMS

MACHINE FRONT

ZAPI POWER MODULE

3.6 POWER MODULE - ZAPI

Figure 3-18. ZAPI Power Module Location

Table 3-1. ZAPI Power Module Specs

Operating Voltage ( B+) 14.5 to 40 VDC

Maximum Current Limits: Ar m at u re Fi e ld Pu m p

300 A

40 A

180 A

Standby Current 150 mA

Temperature Range: Op e ra ti n g St o ra ge Th e rm al L im i t

-40°C to 75°C

-40°C to 125°C 75°C to 90°C

Switching Frequency 16 kHz

The power module is located behind a protective cover at the front of the machine as shown in Figure 3-18., ZAPI Power Module Location. Use the following instructions when replacing the power module.

1. Turn machine power off and disconnect the batteries.

2. Locate and remove the power module protective cover from the machine.

3. Note the wire terminal locations when removing the old power module.

4. Disconnect all wire connectors and cables from the old power module and remove it from the machine.

5. When installing the new power module, be sure that the terminals are oriented as shown in Figure 3-18.

6. After installing the new power module, begin connecting the wire connectors/cables to the module.

7. Torque all terminal bolts to torque specifications shown on the front of the module.

8. After all connections to the power module are made, the batteries can be reconnected.

9. Reinstall the power module cover, then check for normal machine operation.

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ZAPI Power Module Electrical Evaluation

P/N - 1001092456

"HEALTH"

(STATUS LED)

INTEGRATED HEALTH INDICATOR

The ZAPI Power Module provides a green STATUS LED that shines through the cover to indicate module "health" status. The LED shall be illuminated when the device is powered on. The LED blinks (2Hz) when an internal issue is detected that cannot be repaired by a technician. It should be noted that this will trigger replacement of the device.

SECTION 3 - CHASSIS & SCISSOR ARMS

ZAPI Power Module - "HEALTH" (Status LED)

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NOTICE

MDI and Brake Release Bracket

1. Diagnostic Port

2. Brake Release Plugs

1. MDI Connected

2. Brake Release Connected

3.7 MDI (MULTIFUNCTION DIGITAL INDICATOR) AND BRAKE RELEASE

Installation:

ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE PUSHED IN TO THE OFF POSITION BEFORE CONNECTING AND MOUNTING THE MDI AND BRAKE RELEASE BRACKET.

Brake Release Button on the backside of the mounting bracket.

NOTE: The brake release plugs have no polarity, therefore,

can be connected to either post on the button.

4. Connect the MDI harness to the Diagnostic Port.

1. Open the Battery Cover on the right side of the machine (ground control station side). Lifting up on the battery tray and pulling out will allow for maximum extension.

2. Locate the Diagnostic Port (1) and Brake Release Plugs (2).

5. Using a 5/32" allen wrench, mount the MDI and Brake Release Bracket onto the wall of the battery compartment. (appropriate mounting holes are pre-existing) Apply Loctite #242 to the screws and torque to 3.6 ft-lb (5 Nm). (Refer to Figure 3-19.)

3. Apply di-electric grease to the two Brake Release Plugs. Connect the Brake Release Plugs to the

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NOTICE

Figure 3-19. MDI Installation/Removal

1. MDI & Brake Release Bracket

2. Screw, M5 x 16

3. Washer, 5mm

ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE PUSHED IN TO THE OFF POSITION BEFORE DISCONNECTING THE MDI AND BRAKE RELEASE BRACKET.

1. Remove the two Screws (2) and Washers (3).

2. Disconnect Brake Release and MDI from the electrical harnesses.

3. Remove Bracket.

5. Power machine and check to ensure LEDs on MDI work. Check to ensure Brake Release Button works. If the Software Version is not P1.13 or higher, "Error" will display on the LCD. If a fault exists, the trouble code will display on the LCD. (Refer to Section 6.)

6. Using zip ties, tie back cables and wires to prevent damage to the cables and wires.

Removal:

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NOTICE

3.8 BATTERY REMOVAL

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.

BEFORE BATTERY REMOVAL CAN BEGIN, ENSURE THAT THE BATTERIES HAVE BEEN PROPERLY DISCONNECTED TO AVOID SERIOUS INJURY OR POSSIBLE DEATH.

4. Adjust the lifting device to take the weight of the battery door and remove door from under the machine.

5. Once the battery door is removed from the machine, battery replacement/maintenance can begin.

6. After any maintenance on the batteries or replacement of the batteries is complete lift the battery door back onto the machine.

7. Make sure the rollers are replaced and tight.

8. Reconnect batteries and check for proper operation.

1. Pull the battery door completely out and disconnect the batteries.

2. Rest the battery door onto the forks of a fork truck, or suitable lifting device. Be sure the forks or lifting device are properly centered over the weight of the battery door.

3. Using a phillips screwdriver, remove the battery door rollers located at the rear corners of the battery door.

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CAUTION

1/8 "

BATTERY

FILLER CAP

FLUID LEVEL OF FULLY

CHARGED BATTERY

VENT TUBE

PLATES

Figure 3-20. Battery Fluid Level

Battery Maintenance and Safety Practices

ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER.

BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA.

ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING WATER TO THE BATTERIES, A NON-METALLIC CONTAINER AND/ OR FUNNEL MUST BE USED.

DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Check the electrolyte level of the batteries often, adding only distilled water when required. When fully charged, battery fluid level should be 1/8" below vent tubes. (See Figure 3-20.).

• DO NOT fill to bottom of vent tubes.

• DO NOT allow fluid level to go below the top of the plates when charging or operating.

3.9 BATTERY CHARGER

The Battery Charger is located on the top of the chassis at the rear of the machine. Raise and secure scissor arms with arm prop to gain access to the charger.

Figure 3-21. Battery Charger Location

1. AC Voltage - Input Cable

2. Charger Interlock Cable

3. DC Power Cable to Batteries

4. LED Indicator Cable

Figure 3-22. Battery Charger (Delta-Q)

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SECTION 3 - CHASSIS & SCISSOR ARMS

DANGER

MAF02550

1. Charger Interlock Cable

2. LED Indicator Cable

3. Power Cable

Figure 3-23. Battery Charger (Green Power)

Battery Charger Maintenance

5. For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instructions recommended by the battery manufacturer.

6. Make sure charger connections to battery terminals are tight and clean.

7. Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle.

Battery Charger Troubleshooting

No Lights at all

No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger.

1. Check the connections to AC power. Check for AC voltage between 90 and 260 VAC at the charger.

2. If the AC voltage is verified to be correct at the connection to the charger, and the charger still displays no lights at all, return the charger for service.

FAULT LED Flashing

USE CHARGER ONLY ON BATTERY SYSTEMS WITH AN ALGORITHM SELECTED THAT IS APPROPRIATE TO THE SPECIFIC BATTERY TYPE. OTHER USAGE MAY CAUSE PERSONAL INJURY AND DAMAGE.

LEAD ACID BATTERIES MAY GENERATE EXPLOSIVE HYDROGEN GAS DURING NORMAL OPERATION. KEEP SPARKS, FLAMES, AND SMOKING MATERIALS AWAY FROM BATTERIES. PROVIDE ADEQUATE VENTILATION DURING CHARGING. NEVER CHARGE A FROZEN BATTERY.

STUDY ALL BATTERY MANUFACTURERS’ SPECIFIC PRECAUTIONS SUCH AS RECOMMENDED RATES OF CHARGE AND REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING.

RISK OF ELECTRIC SHOCK. CONNECT CHARGER POWER CORD TO AN OUTLET THAT HAS BEEN PROPERLY INSTALLED AND GROUNDED IN ACCORDANCE WITH ALL LOCAL CODES AND ORDINANCES. A GROUNDED OUTLET IS REQUIRED TO REDUCE RISK OF ELECTRIC SHOCK - DO NOT USE GROUND ADAPTERS OR MODIFY PLUG. DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL. DISCONNECT THE AC SUPPLY BEFORE MAKING OR BREAKING THE CONNECTIONS TO THE BATTERY WHILE CHARGING. DO NOT OPEN OR DISASSEMBLE CHARGER. DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE DAMAGED IN ANY WAY - REFER ALL REPAIR WORK TO QUALIFIED PERSONNEL. NOT FOR USE BY CHILDREN.

The Fault LED flashes to indicate the micro-controller inside the battery charger has detected a fault. The fault detected is indicated by the number of flashes. Count the number of flashes to determine the fault.

With any battery system, the most common problem will be a faulty battery connection. Because of the high likelihood of a battery connection problem, it is always worthwhile to confirm that all connections are good before checking for any other problems.

[1 Flash] - High Battery Voltage

1. Indicates a high battery voltage. Check that the battery charger voltage is consistent with the battery pack voltage. The first two digits of the four digit model name indicate the battery voltage the charger supports.

2. Check for wiring errors.

3. This fault will automatically clear and the charger will restart charging when this problem is removed.

4. High battery voltage could also occur if there is another source charging the battery. Disconnect any other sources during charging.

5. If this problem does not clear after the battery voltage is confirmed to be less than 2.4V per cell, return the charger for service.

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[2 Flashes] - Low Battery Voltage

1. Indicates either a battery failure, no battery connected, or a lower than expected battery voltage. Check the battery and battery connections.

2. Check the nominal battery voltage. The first two digits of the four digit model name indicate the battery voltage the charger supports. Confirm that a nominal battery voltage is the same as the charger voltage.

3. This fault will clear automatically when the low battery voltage problem is rectified.

4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service.

[3 Flashes] - Charge Time-out

Indicates the battery failed to charge within the allowed time. This could occur if the battery is of larger capacity than the algorithm is intended for. In unusual cases it could mean charger output is reduced due to high ambient temperature. It can also occur if the battery is damaged, old, or in poor condition.

1. Check the battery for damage such as shorted cells and insufficient water. Try the charger on a good battery.

2. If the same fault occurs on a good battery, check the connections on the battery and connection to AC, and the AC voltage itself.

3. Confirm that the nominal battery pack voltage is the same as the battery charger voltage.

4. This fault must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.

5. If a charger displays this fault on a battery pack, and the pack is of questionable status, reset the charger by disconnecting AC for 30 seconds, and then reconnect the AC to start a new charge cycle. After a few charge cycles, this problem could stop occurring as the pack "recovers."

[4 Flashes] - Check Battery

This fault indicates the battery pack could not be trickle charged up to the minimum level required for the normal charge cycle to be started.

1. Check that none of the battery pack connections between modules are reversed or incorrectly connected.

2. Check that one or more cells in the battery are no shorted.

3. Confirm that the nominal battery pack voltage is the same as the battery charger voltage.

4. Try the charger on a good battery.

5. If this fault occurs, the battery is likely in poor condition. Try to recover the pack with a charger that can charge the individual cells - such as an automotive charger. Be sure to set this charger to the appropriate voltage - 6V per 6V battery, 12V per 12V string/battery.

[5 Flashes] - Over Temperature

This fault indicates the charger has become too hot during operation. Though not damaging to the charger, charge time will be extended significantly.

1. This fault indication will not clear automatically, but the charger will restart charging automatically when the temperature drops. The fault indication must be cleared manually by unplugging the AC, waiting 30 seconds and reconnecting the AC power.

2. If possible, move the machine to a cooler location.

3. Confirm that dirt or mud is not blocking the cooling fins of the charger. Clean the charger. Rinse the charger with a low pressure hose if required. Do no use high pressure. Do not us a pressure washer.

[6 Flashes] - Over Load/Over Temperature

This fault indicates that the batteries will not accept charge current, or an internal fault has been detected in the charger. This fault will nearly always be set within the first 30 seconds of operation. If it occurs after the charger has started charging normally, be sure to make a note of it.

1. Remove excessive AC loads from inverter if installed.

2. Try to clear the fault by unplugging the AC, waiting 30 seconds and reconnecting the ac power.

3. Check all battery connections. Look for a high resistance connection.The most likely reason for this fault is a fault in the battery such as a bad battery connection, an open cell, or insufficient water.

4. This fault will occur if an internal fuse inside the charger blows. If the green wire is shorted to ground even momentarily, this fuse will blow. To check the fuse, measure with an ohmmeter between the green and red wires with the AC disconnected. If a short circuit is not measured, the fuse has blown. Return unit to a service depot to have this fuse replaced.

5. If this fault occurs after battery charging has started, confirm that AC power was not interrupted and that all battery connections are good.

6. If all battery connections are good, an internal fault has been detected and the charger must be brought to a qualified service depot.

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Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell

These symptoms indicate over-charging or high battery temperature. These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack. The most likely cause for this problem is incorrect charge algorithm setting and/ or high ambient temperatures.

1. Confirm that the battery pack is not too small usually > 50Ah.

2. Confirm that the nominal battery voltage matches the charger output voltage.

3. Confirm the correct battery charge algorithm. If the battery pack is new, the algorithm will need to be changed if the pack is not the same as the old one. for instructions on how to determine and change the battery charge algorithm see the following sub-section.

4. If the output voltage of the charger seems excessive, return the charger for service. Contact JLG to get the expected battery voltage settings for the charger in question. Be sure to have the charger’s serial number and charge algorithm setting available when calling.

Checking/Changing the Battery Charge Algorithm

The charger is pre-loaded with programming algorithms for the specific batteries detailed in Table 3-2, Battery Algorithms. Contact JLG if your specific battery model is not listed. Each time AC power is applied with the battery pack not connected, the charger enters an algorithm select/display mode for approximately 11 seconds. During this time, the current Algorithm # is indicated on the Yellow Charging LED. A single digit Algorithm # is indicated by the number of blinks separated by a pause. A two digit Algorithm # is indicated by the number of blinks for the first digit followed by a short pause, then the number of blinks for the second digit followed by a longer pause.

To check/change the charging algorithm:

1. Disconnect the charger positive connector from the battery pack. Apply AC power and after the LED test, the Algorithm # will display for 11 seconds.

2. To change the algorithm, touch the connector to the battery’s positive terminal for 3 seconds during the 11 second display period and then remove. The Algorithm # will advance after 3 seconds. Repeat this procedure until the desired Algorithm # is displayed. A 30 second time-out is extended for every increment. Incrementing beyond the last Algorithm will recycle back to the first Algorithm. When the desired Algorithm is displayed, touch the charger connector to the battery positive terminal until the output relay makes a clicking noise (approx. 10 seconds). The algorithm is now in the permanent memory.

3. Remove the AC power from the charger and reconnect the charger’s positive connector to the battery. It is recommended to check a newly changed algorithm by repeating the above steps 1 and 3.

Table 3-2. Battery Algorithms

Algorithm # Battery Type

43 Harris Battery Discover EVGC6A-A (AGM)

35 JLG P/N 0400242

23 D ouglas Flooded (JLG default)

GES Battery A1055

Trojan T105

East Penn GC-110-WNL

Trojan T105 PLUS Champion CHGC2 GC2 US BATT EV-145-WNL

US BATT 2200 XC

8 Concorde 10xAh AGM

7 J305 DV/DT CP

6DEKA 8G31 Gel

5 Trojan 30/31XHS

4 US Batter y USB2200

3 T105 DV/DT CP

2 Trojan T105 tapped

1 Trojan T105

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SECTION 3 - CHASSIS & SCISSOR ARMS

3.10 BATTERY CHARGER/INVERTER (OPTION)

The Battery Charger/Inverter is located on the top of the chassis at the rear of the machine. Raise and secure scissor arms with arm prop to gain access to the charger.

Figure 3-24. Battery Charger/Inverter Location

Battery Charger/Inverter Troubleshooting

The Fault LED Flash Codes are the same as the Battery Charger (see Battery Charger Troubleshooting on pages 3-29 and 3-30).

For further specification and troubleshooting information refer to the manufacturers’ Charger/Inverter Owner’s Guide shipped with the machine. Publication RM1024-JLG - Part # 3128406.

Use the information below to supplement the information in the Inverter/Charger manual. First, go through the troubleshooting in the Owner’s Guide (JLG part number 3128406), then use the procedures below. For control of the Inverter/Charger there is an 8 position connector on a cable entering the case of the Inverter/ Charger. Looking at the pins of the connector, terminals are numbered clockwise starting with number 1 nearest the notch. Terminal 8 is in the center.

No charge voltage:

1. Disconnect control cable from Inverter/charger.

2. Turn on machine.

3. Inverter/charger control cable 8 position connector socket 1 should have Vbatt present. If it is not, check charger interlock connector, 2 position, socket 1. If voltage is present there replace the Inverter/Charger data interface harness. If Vbatt is not present at the 2 position connector socket 1, check the circuit through the chassis harness back to Ground Module terminal J1-19.

Loads will not start when there is no external AC/ Inverter will not produce AC power:

1. Check that Inverter/Charger switch is in ON position.

2. Disconnect control cable from the Inverter/Charger.

3. Turn on machine.

4. Inverter/Charger control cable socket 2 should have Vbatt present when the switch is ON. If not check that there is Vbatt on the switch Yellow/Red wire. Vbatt signal originates from Ground module pin J1-19 then goes to harness Interlock connector terminal 1 (Yellow/Red wire), then to switch.

1. AC Output Connector

2. AC Input Connector

3. Remote On/Off Switch Cable

Figure 3-25. Battery Charger/Inverter

4. External DC Fuse Location

5. DC (+) Connection

6. DC (-) Connection

LED(s) suspected to be bad:

1. Disconnect Inverter/Charger control cable from the charger (8 position connector) and the 6 position connector at the chassis harness. There should be continuity between the following:

a. 8 pos. terminal 3 to 6 pos. terminal 3 b. 8 pos. terminal 4 to 6 pos. terminal 5 c. 8 pos. terminal 5 to 6 pos. terminal 4 d. 8 pos. terminal 6 to 6 pos. terminal 6

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SECTION 3 - CHASSIS & SCISSOR ARMS

2. Disconnect Inverter/Charger control cable at the 6 position connector and the chassis harness at the 4 position connector at the Ground Box. There should be continuity between the following:

a. 6 pos. terminal 3 to 4 pos. terminal 1 b. 6 pos. terminal 4 to 4 pos. terminal 3 c. 6 pos. terminal 5 to 4 pos. terminal 2 d. 6 pos. terminal 6 to 4 pos. terminal 4

3. If wiring is found to be good, the LED printed circuit card is likely to be bad.

Interlock Cable suspected to be bad or vehicle thinks charging is in progress, but it is not:

1. Disconnect Interlock (2 position) connector on the Inverter/Charger control cable.

2. Turn on machine.

3. There should be Vbatt present on the Interlock connector socket 1.

4. Turn off machine.

5. Disconnect Inverter/Charger control cable at the charger.

6. Inverter/Charger connector (8 position) pin 6 should have continuity to Interlock connector pin 2 and then to ground module socket J1-29.

Ground Module powered while key is off or similar behavior:

This condition can be caused by various ground module outputs getting shorted to battery. If not done already, cycle power and check for fault codes. If no fault codes, perform the following:

1. Disconnect the Inverter/Charger control cable at the 8 position connector and the 2 position Interlock connector.

2. Set digital multimeter to diode check or continuity check to check diode in Inverter/Charger control harness. If the meter does not have these features a low range Ohm scale (20 Ohms for example) will work.

3. Place red lead on 8 position connector pin 1. Place black lead on Interlock connector pin 1.

4. Meter should read an open. Swap leads. Meter should read a short. If either condition is not good, replace Inverter/Charger control cable.

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3.11 LIMIT SWITCH LOCATIONS

Figure 3-26. Limit Switch Locations

5. Pothole Switch (Typical on opposite side of machine)

6. Rotary Angle Switch

SECTION 3 - CHASSIS & SCISSOR ARMS

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SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-27. Pothole Switch Adjustment -

1930ES/2032ES/2632ES

Pothole Switch Replacement

Rotary Angle Sensor Replacement

Removal:

1. Lower platform to the stowed position.

2. Disable the machine and disconnect the batteries.

3. Remove the screws securing the sensor cover to the frame and remove the sensor cover.

4. Disconnect the wiring harness from old/existing rotary angle sensor. Disconnect the sensor from the arm pin and remove the sensor.

Installation:

1. Connect the wiring harness to the new rotary angle sensor.

2. Position and connect rotary angle sensor to the arm pin as shown below.

3. Rotate the sensor as described in the image above.

NOTE: The sensor is spring loaded. DO NOT rotate past its

internal stops.

4. Install the rotary angle sensor cover and secure to

1. With the machine in the stowed position and the battery door open, remove the old pothole switch.

2. Mount the new limit switch and harness to crank with the washer placed behind the switch.

3. Adjust the switch by inserting an 1/8" shim between the link and the switch plunger.

4. Push the switch to fully depress the plunger and tighten the switch screws.

5. Repeat this procedure on the opposite side.

6. Raise and lower the machine from the ground control several times to ensure that the switch is functioning properly.

NOTE: From the platform, raise and lower the machine and

check that the switch is operating properly by cutting back to elevated speed when the pothole is deployed. Drive will be cutout if pothole is not set.

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the frame with the two screws.

5. Reconnect the batteries.

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SECTION 3 - CHASSIS & SCISSOR ARMS

3.12 GROUND CONTROL STATION

NOTE: Anytime the ground control box is removed, the tilt

sensor must be re-calibrated. Refer to Section 5.3, Tilt Sensor Calibration to re calibrate the tilt.

Box Disassembly

1. Disconnect the batteries.

2. Remove the three bolts at the bottom of the ground control station.

5. Remove the six bolts at the back of the ground control and separate.

3. Remove the four bolts where the control cable enters into the control box.

4. Remove plug and place control box face down on a suitable work bench.

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SECTION 3 - CHASSIS & SCISSOR ARMS

1. Ground Control Station

2. Tilt Sensor (JLG P/N 4000021 or

1001114936)

Figure 3-45. Tilt Sensor Location

1. Tilt Sensor

2. Sensor Mount

3. Screw, 3.5 x 0.6 x 16 LG

4. Screw, 3.5 x 0.6 x 10 LG

Figure 3-46. Tilt Sensor Removal

Tilt Sensor Replacement

Tilt Sensor Removal:

1. Disconnect the batteries.

2. Open the Ground Control Station to gain access to the Tilt Sensor Assembly. (refer to prior mentioned procedures)

3. Remove the four Screws (3), to remove the Tilt Sensor (1) and Sensor Mount (2) from the Ground Control Box.

4. The Tilt Sensor (1) can be removed from the Sensor Mount (2) by removing the three Screws (4).

NOTE: Follow the above procedures in reverse order when

installing the tilt sensor assembly. After installing, be sure to calibrate the tilt sensor (refer to Section 5.3, Tilt Sensor Calibration).

Table 3-3. Tilt Sensor Harness

Wire Color Function Connector Pin

Red VCC 1

White CANH 2

Green CANL 3

Black Ground 4

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CAUTION

NOTICE

3.13 SCISSOR ARMS AND PLATFORM POSITIONING AND SUPPORT

PLATFORM IS HEAVY AND PRESENTS A CRUSHING HAZARD. TAKE GREAT CARE WHEN REMOVING PLATFORM OR SCISSOR ARM ASSEMBLY

The arm stack can be supported by using an overhead crane,(See Figure 3-47.). If an overhead crane is not available the stack may also be lifted by using a forktruck using the following instructions:

1. With the forks on the forktruck slid close together, enter from the front of the machine and place the forks on the cross tube of the second arm weldment below the platform.

2. Slowly lift the arm stack with the forktruck while the manual descent valve is being engaged (this allows the oil to drain back into the tank).

3. Place machine on safety prop and leave the forktruck in place.

4. At this point the lift cylinder removal may begin. (Refer to Section 4.7, Lift Cylinder Removal)

If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and platform removal.

3.14 PLATFORM REMOVAL

1. Support the platform using an overhead crane with straps capable of lifting at least 250 lbs (114 kg) (See Figure 3-47.). Refer to Section 3.13, Scissor Arms and Platform Positioning and Support.

2. Disconnect the battery plug at the chassis. Disconnect platform cable and foot switch cable, if applicable, from railing. Route the cables out through the hole at the rear of the platform to free platform of any constraints. If platform is equipped with an outlet plug, disconnect and route cable out of platform.

3. Remove the bolts attaching the pins and slide blocks at each corner to the arm stack. Carefully remove the four pins attaching the platform to the arm stack.

4. Lift the platform from the armstack and set aside.

NOTE: When attaching platform back onto scissor arm

assembly, follow removal procedures in reverse order.

FOR MACHINES EQUIPPED WITH LOAD SENSING SYSTEM (LSS), ENSURE ARROWS ON THE LSS PIN ARE POINTING DOWN

BEFORE INSERTING BOLTS INTO PIN. NOT APPLICABLE FOR MACHINES WITHOUT LSS.

3.15 SCISSOR ARMS REMOVAL

1. Remove platform (refer to Section 3.14, Platform Removal).

2. Disconnect all wiring and cables attached to scissor arm assembly.

3. Remove lift cylinder (refer to Section 4.7, Lift Cylinder Removal).

4. The scissor arms can be removed as a complete unit or individually.

Removing scissor arm assembly as a complete unit:

1. Remove the pin attaching the bottom scissor arms to the rear of the frame by removing the bolt.

2. Place two straps around each end of the the entire scissor arm assembly. Using an overhead crane, slowly and carefully move the arm stack forwards so that slide blocks at front of machine slide out the front of the slide channel on the frame.

NOTE: Overhead crane and straps must be capable of lifting

at least 1545 lbs (701 kg).

3. Once slide blocks are clear of machine, the scissor stack can be moved to a more desirable location for further arm disassembly.

Removing scissor arms individually:

1. Start with the top arms (closest to platform).

2. Secure each arm section being removed using an overhead crane with suitable lifting straps.

3. Remove the bolts securing the connecting pins in place.

4. Remove the pins from the arms.

5. Remove the arm section from the machine using the overhead crane.

6. Repeat previous steps for remaining arm sections.

NOTE: When attaching scissor arm assembly back onto

frame, follow removal procedures in reverse order.

Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware when installing locking fasteners.

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Page 74

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-47. Arms and Platform Positioning and Support

3-40 3121656

Page 75

SECTION 3 - CHASSIS & SCISSOR ARMS

MAF02560

For serial numbers - SN B200020297 through B200020981 and SN 0200239382 through 0200241220

For serial numbers - SN 0200241221 to Present,

SN M200000100 to Present and

SN B200020982 to Present

Figure 3-48. Scissors Arms Assembly (2646ES and 3246ES)

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Page 76

SECTION 3 - CHASSIS & SCISSOR ARMS

3.16 PLATFORM CONTROL STATION

Printed Circuit Board Replacement

1. Disconnect the platform control box and remove from the machine.

2. Place the platform control box on a suitable work bench.

3. Loosen and remove the long through bolts that hold the two side control housings together.

NOTE: You may have to only loosen the two power bolts

and remove the two closest the top in order to get to the printed circuit board located in the top of the control box where the drive/lift select switch is located.

4. Loosen and remove the four bolts that hold the bottom of the control box.

5. Disconnect the plug from the printed circuit board.

6. Remove the bolts attaching the printed circuit board to the control box.

7. Replace board and reassemble control box.

3-42 3121656

Page 77

Joystick Controller

Figure 3-49. Joystick

SECTION 3 - CHASSIS & SCISSOR ARMS

Table 3-4. Joystick Specifications

Input Voltage +5 (±0.1) VDC

Current Consumption 10 mA @ 12 VDC

Output: Handle Centered 2.5 (±0.1) VDC

Output: Full Positive (Reverse) Deflection 4 (±0.1) VDC

Output: Full Negative (Forward) Deflection 1 (±0.1) VDC

3121656 3-43

Ter m Color Func tion

1RED HANDLE COM

2 VIOLET TRIGGER N.O.

3-- SPARE

4YELLOW ROCKER RT

5 GREEN ROCKER LT

6-- SPARE

7 WHITE/RED +5VDC

8 WHITE/BLACK GROUND

9BROWN SIG OUTPUT

Table 3-5. Connector Chart

CONNECTOR PINOUT

Page 78

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTES:

3-44 3121656

Page 79

SECTION 4. HYDRAULICS

SECTION 4 - HYDRAULICS

4.1 CYLINDERS - THEORY OF OPERATION

Cylinders are of the double acting type. The Lift and Steer systems incorporate double acting cylinders. A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions. Directing oil (by actuating the corresponding control valve to the piston side of the cylinder) forces the piston to travel toward the rod end of the barrel, extending the cylinder rod (piston attached to rod). When the oil flow is stopped, movement of the rod will stop. By directing oil to the rod side of the cylinder, the piston will be forced in the opposite direction and the cylinder rod will retract.

NOTE: The lift cylinder is a single acting cylinder which takes

hydraulic pressure to extend and gravity to retract.

A holding valve is used in the Lift circuit to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve.

4.2 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way, three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is spring-loaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also avoided by relieving circuit pressure. The relief valve is installed in the circuit between the pump outlet (pressure line) and the cylinder of the circuit, generally as an integral part of the system valve bank. Relief pressures are set slightly higher than the load requirement, with the valve diverting excess pump delivery back to the reservoir when operating pressure of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator requires an operating pressure lower than that supplied to the system. When the circuit is activated and the required pressure at the actuator is developed, the crossover relief diverts excess pump flow to the reservoir. Individual, integral relief’s are provided for each side of the circuit.

Proportional Valve

Flow is proportional to the amount of voltage supplied to the valve coil. Voltage is gained by the machine controller and determined by the position of the joystick.

Manual Descent Valve

The manual descent valve is located on top of the holding valve on the lift cylinder. The holding valve is a normally closed solenoid valve, and holds the platform in place when raised. When activated, the valve opens to permit lift down. The holding valve is connected to the manual descent valve, which is connected to a cable which, when pulled, manually opens the lift down port of the valve and allows the platform to be lowered in the event hydraulic power is lost.

Relief Valves

Main relief valves are installed at various points within the hydraulic system to protect associated systems and components against excessive pressure. Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control. The relief valve provides an alternate path for the continuing flow from the pump,

3121656 4-1

Page 80

SECTION 4 - HYDRAULICS

-B

Series DC

Pump Motor

24V

Line Contactor

Power Module

4.3 PUMP/MOTOR - THEORY OF OPERATION

The Power Module (see Figure 3-18., ZAPI Power Module Location on page 3-24) is essentially a "low-side" switch for the pump motor. The positive terminal of the pump is tied to Battery Positive after the Line Contactor. The negative terminal of the pump connects to the P Terminal of the Power Module, which switches current through MOSFET transistors to the Battery Negative.

For variable speed pump operation, the MOSFET transistors switch On and Off at high frequencies (16kHz). The Duty Cycle is varied to control the voltage applied to the pump motor. When the MOSFET's spend 50% of the period On and 50% Off, approximately ½ of the available Battery Voltage will be applied to the pump motor. Similarly, the MOSFET are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the pump motor (as in Lift Up at full speed).

When the Control System is energized, the voltage at the P Terminal will be approximately +24V (referenced to -B) when the pump is static. The P Terminal will be approximately at +1V (referenced to -B) when the pump is running at full speed (Lift Up from Ground Mode).

Pump Motor Electrical Evaluation

Several basic electrical tests can be performed on the Pump Motor. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.

Refer to Figure 7-2., Resistance Measurement. Make all measurements with a voltmeter set to resistance scale (Ohms). Disconnect the Main Battery Disconnect and all pump motor cables during this analysis.

• Resistance < 5 Ohms between Motor Termninals. The internal windings are very low impedance and should appear to be a short-circuit for an ordinary voltmeter (other tests can determine if the windings are truly shorted). High resistance can signal worn brushes, a faulty commutator, or open windings.

• Resistance > 1 MegaOhms between Motor Termi- nals and Motor Housing. The internal windings should be electrically isolated from the motor housing. Low resistance may be an indication of a broken motor terminal, damaged brush, faulty commutator, or burned winding.

Common Difficulties

The following difficulties can be examined using the JLG Analyzer, a voltmeter, and simple hand tools. Unless otherwise noted, the Control System shall be energized in Ground Mode during testing. For a convenient Ground Reference, place the black meter lead on the negative post of the left battery in the left-side battery compartment. The vehicle should be placed on a firm, level surface for all analysis.

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Page 81

SECTION 4 - HYDRAULICS

1. Open-Circuit between +B Terminal and Pump Motor Positive Terminal

This issue will allow the vehicle to drive, but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show PUMP PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.

As shown in the diagram, the voltage measured between the Pump Motor Positive Terminal and Ground Reference should be 24V. If it is not, examine the cable between the terminal and the Power Module compartment. Inspect crimps for corrosion and ensure that bolted connections are tight. Ensure that the cable is not crushed where it passes between the frame side sheets and the cylinder assembly.

2. Open-Circuit between Pump Motor Negative Terminal and P Terminal

After ensuring there is not an Open-Circuit between the +B Terminal and Pump Motor Positive Terminal, check that the voltage measured between the Pump Motor Negative Terminal and Ground Reference is 24V. If not, examine the issues within Open-Circuit Pump Motor. This voltage should ramp to approximately 0V when Lift Up is operated from Ground Mode. If not, examine the cable between the terminal and the Power Module compartment (P Terminal). Inspect crimps for corrosion and ensure that bolted connections are tight. Ensure that the cable is not crushed where it passes between the frame side sheets and the cylinder assembly.

brushes or broken terminals. After examination, re-connect the Pump Motor Positive Terminal and the Main Battery Disconnect.

4. Short-Circuit between Pump Motor Positive and Negative Terminals

This issue will allow the vehicle to drive, but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show an erratic reading for PUMP PWM % and PUMP CUR will hover around 150A when Lift Up is operated from Ground Mode.

Pull the Main Battery Disconnect to completely de-energize the Control System. Next, detach both Pump Motor Terminals and insulate them independently. Re-connect the Main Battery Disconnect and re-try Lift Up. If the same symptoms persist (erratic PUMP PWM%, PUMP CUR around 150A), examine the cabling between the Pump Motor and Power Module compartment for a short-circuit (most likely near area where cylinder retracts between frame side sheets or near pothole mechanism). If the symptoms change, suspect a short-circuited (or mechanically frozen) pump motor.

A clamp-on ammeter (set for 200A DC) can be placed on either Pump Motor Cable for verification. During Lift Up, the ammeter will read approximately 150A.

3. Open-Circuit Pump Motor

Pull the Main Battery Disconnect to completely de-energize the Control System. Next, detach the cable from Pump Motor Positive Terminal. Using a voltmeter set for resistance measurement (Ohms), ensure that the resistance between the Pump Motor Positive and Negative Terminals is less than 2 Ohms. If not, examine the pump motor for worn

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SECTION 4 - HYDRAULICS

Figure 4-1. Lift Pressure Setting

1. Large Nut

2. Pressure Setting Screw

3. P port

4.4 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system

component is replaced or when improper system operation is suspected.

Cylinders Without Counterbalance Valves and Steer Cylinder

1. Using all applicable safety precautions, activate pump motor and fully extend cylinder to be checked.

2. Carefully disconnect hydraulic hoses from retract port of cylinder. There will be some initial weeping of hydraulic fluid which can be caught in a suitable container. After the initial discharge, there should be no further drainage from the retract port.

3. Activate pump motor and extend cylinder.

4. If cylinder retract port leakage is less than 6-8 drops per minute, carefully reconnect hose to port and retract cylinder. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repair must be made.

5. With cylinder fully retracted, shut down machine power and carefully disconnect hydraulic hose from cylinder extend port.

6. Activate pump motor and retract cylinder. Check extend port for leakage.

7. If extend port leakage is less than 6-8 drops per minute, carefully reconnect hose to extend port, than activate cylinder through one complete cycle and check for leaks. If leakage continues at a rate of 6-8 drops per minute or more, cylinder repairs must be made.

4.5 LIFT PRESSURE SETTING PROCEDURE

1. Place 120% of the rated load of the machine on the platform.

2. Increase lift pressure to raise the platform and set the safety prop.

3. Locate the Large Nut (1) on the underside of the valve block.

4. Using a 7/8 in. wrench, remove the large nut (1). This will expose the Pressure Setting Screw (2).

5. Remove plug from P port (3) and install a pressure gauge.

6. Raise the platform and take a pressure reading.

7. Adjust the Pressure Setting Screw to reach the proper lift pressure per model as listed in Table 4-

4-4 3121656

Page 83

SECTION 4 - HYDRAULICS

CAUTION

Table 4-1. Pressure Settings

Lift Relief

Model

USA Built China Built

1930ES

2032ES

2632ES

2646ES

3246ES

NOTE: Check your nameplate at the left rear of the machine

1800 psi ± 50 psi

(124 bar ± 3.4 bar)

1800 psi ± 50 psi

(124 bar ± 3.4 bar)

1950 psi +/- 50 psi (134 bar ± 3.4 bar)

2000 psi +/- 50 psi (138 bar ± 3.4 bar)

for country of origin. USA built machines, serial number prefix starts with a 02 (02XXXXXXXX), China built machines, serial number prefix starts with an B2 (B2XXXXXXXX).

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

1900 psi ± 50 psi

(131 bar ± 3.4 bar)

Steer Relief

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

1500 psi

(103 bar)

Oil Check Procedure

1. With the scissor lift on a flat and level surface and the platform empty, elevate machine and swing safety prop out of it’s stowed position.

2. Continue to elevate the platform until the fill plug, located on the right side of the tank attached to the lift cylinder, is fully accessible.

ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.

NOTE: The 2632ES/2646ES/ 3246ES platforms will have to

be raised higher than the 1930ES and 2032ES in order to access the oil plug.

8. Remove pressure gauge and replace the plug into the P port.

9. Replace the bronze washer with a new bronze washer and large nut over the pressure setting screw. Do not use old bronze washer. Using the old bronze washer will cause leakage.

10. Torque the large nut to 160 in. lb (16 Nm).

Alternate Lift Pressure Setting Procedure:

1. Increase lift pressure to raise the platform and set the safety prop.

2. Remove plug from port P (3) and install a pressure gauge.

3. Remove the solenoid from the lift valve.

4. Set the pressure actuating lift function from the ground or platform.

5. Remove the pressure gauge from port P (3) and replace plug.

6. Replace the solenoid on the lift valve.

4.6 HYDRAULIC OIL FILL

NOTE: The hydraulic oil level should be checked every 6

months. Always check the oil level any time any maintenance is performed that would effect the hydraulic oil level.

3. Wipe all dirt and debris from the filler plug area.

4. Slowly remove the fill plug venting any pressure that may be built up in the reservoir.

5. To check the oil level, lower platform so it rests on the safety porp.

THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK.

6. With the plug removed, the oil level should be completely full, at the top of the fill port with scissor arms resting on the safety prop. from the fill port.

7. If additional oil is required, add proper grade of oil by using a funnel with a flexible spout or a plastic squeeze bottle. Fill until oil weeps out of opening.

NOTE: Care should be taken not to introduce any impurities

(dirt, water etc.) while plug is removed.

8. Replace plug and torque to 40 ft. lbs. (56 Nm).

9. Any time a hydraulic component is removed or replaced, cycle the scissor arms several times and refer to steps 3 and 4 to recheck oil level.

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Page 84

SECTION 4 - HYDRAULICS

CAUTION

NOTICE

Lower Slide Pad Channel

Upper Slide Pad Channel

Slide Block Lubrication

Lube - White Lithium Grease (GREDAG 741)

Interval - Every 6 months

1. With the platform empty, elevate machine and swing safety prop out of it’s stowed position.

ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED.

2. Locate the Lower and Upper Slide Pads and wipe/ pressure wash all dirt and debris from the slide channel area (1, 2).

3. Apply a layer of grease along the inside and bottom of the lower slide channel (1) on both sides of the machine.

4. Apply a layer of grease along the inside and top of the upper slide channel (2) on both sides of the machine.

4.7 LIFT CYLINDER REMOVAL

NOTE: If there is a pump failure, a crane or a forktruck can

be used to raise the platform. Refer to Figure 3-47., Arms and Platform Positioning and Support.

Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware when installing locking fasteners.

1. Raise the platform and place on the safety prop. It may be necessary to use an overhead crane or fork truck to secure the platform and scissor arms before lift cylinder removal begins. (See Figure 3-

47.)

2. Cut any wire ties that attach any cables or hoses to the lift cylinder.

PULL THE BATTERY DISCONNECT BEFORE REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER ASSEMBLY.

3. Remove the valves connectors, the two battery cables and the manual decent cable.

NOTE: To avoid having to readjust the manual descent,

remove the large nut located behind the manual descent bracket as shown. (See Figure 4-2.)

4. Ensuring that the deck and scissor arms are properly secure, remove the top lift cylinder pin and rest the top of the cylinder on the arm cross tube directly below the cylinder.

5. Remove the bolt form the lower cylinder pin and have someone assist you in lifting the cylinder from the scissor arms.

6. Set the cylinder with pump and motor assembly intact on a clean workbench.

7. Remove the 4 bolts that attach the pump/motor assembly to the lift cylinder.

8. Remove the bolt from the bracket that attaches the hydraulic reservoir to the lift cylinder.

9. Separate the cylinder from the pump/motor assembly.

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Page 85

SECTION 4 - HYDRAULICS

1. Battery Cables

2. Valves

3. Manual Descent

4. Steer Hoses

5. Top Cylinder Bolt (Torque 41 ft. lb.)

6. Bottom Cylinder Bolt

Figure 4-2. LIft Cylinder Removal

3121656 4-7

Page 86

SECTION 4 - HYDRAULICS

NOTICE

Figure 4-3. Cylinder Barrel Support

Figure 4-4. Cylinder Rod Support

4.8 CYLINDER REPAIR

NOTE: The following are general procedures that apply to

all of the cylinders on this machine. Procedures that apply to a specific cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source to the port block fitting in the manifold located on the cylinder.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Operate the hydraulic power source and extend the cylinder. Shut down and disconnect the power source. Adequately support the cylinder rod, if applicable.

3. If applicable, remove the cartridge-type holding valve and fittings from the cylinder port block. Discard o-rings.

4. Place the cylinder barrel into a suitable holding fixture.

7. Being careful not to mar the surface of the rod, use a punch or wooden dowel and hammer to drive the rod guide about one inch down into the cylinder bore. Using a screw driver, carefully push one end of the round retaining ring back towards the inside of the cylinder and then slip the screwdriver tip under that end. Pull the ring out of the groove toward the wall mouth. Once one end of the retaining ring is free from the groove, the remainder can be easily pried free using ones fingers or pliers.

8. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

9. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

10. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible.

NOTE: For steer cylinder piston removal, see Steer Cylinder

Piston Removal on page 4-9 following.

11. Loosen and remove the cap screw(s), if applicable,

5. Mark cylinder head and barrel with a center punch for easy realignment. Loosen the cylinder head setscrew.

NOTE: Steps 6 and 7 apply only to the steer cylinder.

6. Using a spanner wrench, loosen the spanner nut retainer, and remove spanner nut from cylinder barrel.

4-8 3121656

which attach the tapered bushing to the piston.

12. Insert the cap screw(s) in the threaded holes in the outer piece of the tapered bushing. Progressively tighten the cap screw(s) until the bushing is loose on the piston.

13. Remove the bushing from the piston.

14. Screw the piston CCW, by hand, and remove the piston from cylinder rod.

Page 87

SECTION 4 - HYDRAULICS

STEEL

BUSHING

GAR-MAX BUSHING

ARBOR

Figure 4-5. Gar-Max Bearing Installation

15. Remove and discard the piston o-rings, seal rings, and backup rings.

16. If applicable, remove the piston spacer from the rod.

17. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applicable. Discard the o-rings, back-up rings, rod seals, and wiper seals.

Steer Cylinder Piston Removal

1. Using the spanner holes, rotate the piston until the end of the retaining ring can be seen through the cross-drilled retaining ring hole.

2. Insert a flathead screwdriver (or similar tool) into the cross-drilled retaining ring hole.

3. Using the screwdriver, guide the retaining ring into the cross-drilled retaining ring hole while turning the piston.

4. Continue turning the piston approximately one (1) full turn until the start of the retaining ring is again aligned with the cross-drilled retaining ring hole.

5. Lift up on the retaining ring so that the hook on the start of the retaining ring releases from the hole in the rod.

6. Pull the retraining ring all the way out of the crossdrilled retraining ring hole.

7. Slide the piston over the rod in the direction of the spanner holes to remove.

9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary.

10. Inspect threaded portion of head for damage. Dress threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs and sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering. Replace as necessary.

13. If applicable, inspect rod and barrel bearings for signs of correct excessive wear or damage. Replace as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs,

dirt etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other dam-

age. If steel bushing is worn or damaged, rod/ barrel must be replaced.

c. Lubricate inside of steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

NOTE: Install pin into the Gar-Max bearing dry. Lubrication

is not required with nickel plated pins and bearings.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning solvent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or other damage. If necessary, dress rod with Scotch Brite or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage. Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scoring or other damage. Check inside diameter for tapering or ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress threads as necessary.

6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston as necessary.

7. Inspect threaded portion of piston for damage. Dress threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs and sharp edges. Dress applicable surfaces as necessary.

14. Inspect travel limiting collar or spacer for burrs and sharp edges. If necessary, dress inside diameter surface with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of dirt or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary.

3121656 4-9

Page 88

SECTION 4 - HYDRAULICS

NOTICE

Figure 4-6. Rod Seal Installation

Figure 4-7. Poly-Pak Piston Seal Installation

Figure 4-8. Wiper Seal Installation

Figure 4-9. Installation of Head Seal Kit

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper cyl-

inder seal kit is used. See your JLG Parts Manual (3121167).

Apply a light film of hydraulic oil to all components prior to assembly.

1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

3. Place a new “O-ring and back-up seal in the applicable outside diameter groove of the cylinder head.

WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION.

2. Use a soft mallet to tap a new wiper seal into the applicable cylinder head gland groove. Install a new wear ring into the applicable cylinder head glandgroove.

4. Install washer ring onto rod, carefully install the head gland on the rod, ensuring that the wiper and rod seals are not damaged or dislodged. Push the head along the rod to the rod end, as applicable.

5. Carefully slide the piston spacer on the rod.

NOTE: Upper telescope cylinder piston has an o-ring

installed inside the spacer.

6. If applicable, correctly place new o-ring in the inner piston diameter groove. (The backup ring side facing the O-ring is grooved.)

7. If applicable, correctly place new seals and guide lock rings in the outer piston diameter groove. (A tube, with I.D. slightly larger than the O.D. of the piston is recommended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on

one side. This side faces the solid seal.(See magnified insert in Figure 4-9. The split of seals and backup rings are to be positioned so as not to be in alignment with each other.

4-10 3121656

Page 89

SECTION 4 - HYDRAULICS

NOTICE

BACKUP

RI NGS

O-RI NG

PISTON

SPLIT SEAL

SEAL

SPLIT BACKUP RING

T - RI NG

SPLIT

BACKUP

RIN G

Figure 4-10. Piston Seal Kit Installation

Figure 4-11. Rod Assembly Installation

7. Retorque the capscrews evenly and progressively in rotation to the specified torque value.

8. Remove the cylinder rod from the holding fixture.

9. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 4-10.)

10. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

11. With the barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

12. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

13. Secure the cylinder head gland using the washer ring and socket head bolts.

1. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.

2. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged.

3. Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing.

NOTE: When installing the tapered bushing, piston and

mating end of rod must be free of oil.

4. Assemble the tapered bushing loosely into the piston and insert JLG capscrews (not vendor capscrews) through the drilled holes in the bushing and into the tapped holes in the piston.

5. Tighten the capscrews evenly and progressively in rotation to the specified torque value.

6. After the screws have been torqued, tap the tapered bushing with a hammer (16 to 24 oz.) and brass shaft (approximately 3/4" in diameter) as follows;

a. Place the shaft against the cylinder rod and in

contact with the bushing in the spaces between the capscrews.

b. Tap each space once; this means the tapered

bushing is tapped 3 times as there are 3 spaces between the capscrews.

14. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

15. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. (See Table 4-3, Holding Valve Torque Specifications).

Table 4-2. Cylinder Piston Nut Torque Specifications

Description

Lift Cylinder

Nut Torque

Value

250-300 ft lb

(339-407 Nm)

Setscrew

torque Value

N/A

3121656 4-11

Page 90

SECTION 4 - HYDRAULICS

NOTICE

16. Push the piston onto the rod until it abuts the spacer end and install the attaching nut.

Table 4-3. Holding Valve Torque Specifications

Description Tor que Value

Integrated Steer

Integrated Proportional Valve

Integrated Blocking Valve

Relief

Coil Nuts Hand Tighten

15 ft lb

(20 Nm)

15 ft lb

(20 Nm)

15 ft lb

(20 Nm)

33 ft lb

(45 Nm)

WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #242 TO THE PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT. REFER TO TABLE 4-2, CYLINDER PISTON NUT TORQUE SPECIFICATIONS.

NOTE: Reverse the procedure Steer Cylinder Piston Removal

on page 4-9 for installing the steer cylinder piston.

17. Remove the cylinder rod from the holding fixture.

18. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

19. With barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading o-ring and seal ring are not damaged or dislodged.

20. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

21. If applicable, secure the cylinder head retainer using a suitable chain wrench.

22. After the cylinder has been reassembled, the rod should be pushed all the way in (fully retracted) prior to the reinstallation of any holding valve or valves.

23. If applicable, install the cartridge-type holding valve and fittings in the port block using new orings as applicable. Refer to Table 4-3, Holding Valve Torque Specifications.

4-12 3121656

Page 91

SECTION 4 - HYDRAULICS

Pump Removal

1. Place the pump/motor assembly on a clean workbench.

NOTE: Drain the hydraulic oil by carefully removing the oil

fill plug located on the left side of the hydraulic reservoir.

3. If replacing filter, pull old filter off the end of the tube and push new filter onto the end of tube.

4. Thoroughly clean the tank and clean any debris from the magnet.

5. Wipe out tank with clean, lint free rag, taking care not to introduce debris or dirt.

6. Replace the tank. Torque mounting bolts to 20-25 in-lb.

7. If only replacing the oil filter and maintenance is complete, reinstall cylinder assembly on machine, remove fill plug and refill tank with proper grade of oil by using a funnel. Fill until oil weeps out of opening.

8. Replace plug and torque to 40 ft. lbs (56 Nm).

2. Remove the oil tank from the lift cylinder as follows:

a. Slowly loosen and remove the four bolts that

hold the tank on to the cylinder.

b. Carefully remove the tank from the valve body

taking care not to damage internal pickup tube or o-ring gasket on tank.

c. Place tank on a suitable work bench or work

area.

NOTE: The filter and bypass are located on the pickup tube

inside the tank.

The filter should be changed once a year.

3121656 4-13

9. To remove the oil pickup line, squeeze retainer and slide outward.

10. Replace the o-ring if necessary.

Page 92

SECTION 4 - HYDRAULICS

11. Remove allen nut on the return/filter line and rotate large retainer ring to remove return/filter line.

12. Replace the return/filter line oring if necessary.

13. With the return line and the pickup tube removed, the pump can be removed.

14. Loosen and remove the two hexhead nuts from the pump and block. Remove pump from valve body.

NOTE: Be sure to remove and discard the plastic plug at the

oil inlet on the new pump before installing.

15. Check oring on valve body and replace if necessary before installing the new pump. Lubricate orings before assembling.

NOTE: There are two orings used to seal the pump to the

valve body, one for the pump inlet (shown above) and one on the pump boss around the drive coupler.

4-14 3121656

Page 93

Motor Removal

1. Remove the four bolts attaching the motor to the valve body.

SECTION 4 - HYDRAULICS

2. Pull motor from valve body.

3. Once all maintenance is performed and lift cylinder assembly is reinstalled on the machine, remove fill plug and refill tank with proper grade of oil by using a funnel. Fill until oil weeps out of opening.

4. Replace plug and torque to 40 ft. lbs.

3121656 4-15

Page 94

SECTION 4 - HYDRAULICS

TOP VIEW

Figure 4-12. Lift Cylinder/Pump/Tank Assembly

Table 4-4. Valve Torque Values

Item Description Torq ue

1 Bi-directional Relief Valve 33 ft lbs (45 Nm)

2 Solenoid NA

3 Proportional Valve 15 ft lbs (20 Nm)

4 Check Valve 33 ft lbs (45 Nm)

5 Blocking Valve 15 ft lbs (20 Nm)

6 4 Way Directional Valve 15 f t lbs (20 Nm)

7Extend Port NA

8Retract Port NA

4-16 3121656

Page 95

SECTION 4 - HYDRAULICS

OPPOSITE SIDE OF

CYLINDER PORT BLOCK

1930ES

ONLY

7. Spring

8. Jam Nut

9. Bushing

10. Barrel

11. Wear R ing

12. Seal

1. Proportional Valve

2. Emergency Release Assy.

3. Coil

4. Relief Valve

5. Pump

6. Filter

Figure 4-13. Lift Cylinder Assembly

3121656 4-17

13. Locknut

14. Piston

15. O-ring

16. Seal

17. Head

18. O-ring

19. Wear R ing

20. Spacer

21. Wiper

22. O-ring

23. Bushing

24. Cylin der Ro d

25. Check Valve

26. Dowel Pin

27. Directional Control Valve

28. Coil

29. Directional Control Valve

Page 96

SECTION 4 - HYDRAULICS

MAF02570

1. Barrel

2. Rod

3. Cylinder Head

4. Dust Seal

5. Seal

6. Bearing

7. O-Ring

8. O-Ring

9. Piston

10. Seal

11. Wear R ing

12. O-Ring

13. Nut

14. Bushing

15. Motor/Pump/Tank

Assembly

16. Capscrew

17. Capscrew

18. Extension Plug

Figure 4-14.

Lift Cylinder Assembly (1930ES) (SH-PAC)

4-18 3121656

Page 97

SECTION 4 - HYDRAULICS

MAF02580

1. Barrel

2. Seal Kit

3. Rod

4. Cylinder Head

5. Piston

6. Screw

7. Motor/Pump/Tank Assembly

8. Bushing

Figure 4-15.

Lift Cylinder Assembly (1930ES) (Serta)

3121656 4-19

Page 98

SECTION 4 - HYDRAULICS

1*****

2**

4*****

5*****

8**

7******

9**

10**

11****

12******

13*

14****

15***

MAF02590

1. TR & TS Port

2. Relief Valve

3. Drain Plug

4. P Port

5. T Port

6. Filler Plug

7. Steer Coil Nut

8. Steer Port B

9. Steer Port A

10. Steer Relief Valve

11. Steer Solenoid Valve

12. Lift Solenoid Valve Coil Nut

13. Lift Solenoid Valve

14. Lift/Steer Check Valve

15. Descent Valve

Figure 4-16. Lift Cylinder Assembly - Motor/Pump/Tank Assembly (1930ES)

*Torque to 33.2-36.9 ft. lbs. (45-50 Nm) **Torque to 29.5-35.4 ft. lbs. (40-48 Nm) ***Torque to 28-33.2 ft. lbs. (38-45 Nm) ****Torque to 26.6-32.5 ft. lbs. (36-44 Nm) *****Torque to 11.8-14.8 ft. lbs. (16-20 Nm) ******Torque to 2.2-3 ft. lbs. (3-4 Nm)

4-20 3121656

Page 99

SECTION 5 - JLG CONTROL SYSTEM

Figure 5-1. Diagnostic Port

me n u :

PRESS ENTERHEL P:

Analyzer Display

Escape Key

To r et u rn ho m e o r

access previous menu

Enter Key

Stores and selects Top Level, Sub Level,

and item menus

Left & Right Arrow Keys

Used to move between Top Level, Sub

Level, and it em menus

Up & Down Arrow Keys

Value Selector

Figure 5-2. Hand Held Analyzer

SECTION 5. JLG CONTROL SYSTEM

5.1 DIAGNOSTIC PORT

The diagnostic port is located behind the battery cover at the near the ground control station as shown below. The MDI (Multifunction Digital Indicator) and the JLG Hand-Held Analyzer can be connected at this port..

5.2 HAND HELD ANALYZER

To Connect the Hand Held Analyzer:

1. Connect the four pin end of the cable supplied with the analyzer, to the diagnostic port (refer to Figure 5-1.) and connect the remaining end of the cable to the analyzer.

NOTE: The cable has a four pin connector at each end of the

cable; the cable cannot be connected backwards.

2. Power up the Control System by turning the lower key to the platform position and pulling both emergency stop buttons on.

3121656 5-1

Page 100

SECTION 5 - JLG CONTROL SYSTEM

ME N U : HELP: PRESS EN TER

HELP : 1:STARTUP ( 2/ 1)

l og: (211)

(machines with an MDI)

(machines with no MDI)

Using the Analyzer:

With the machine power on and the analyzer connected properly, the analyzer will display the following:

If ENTER is pressed again, the display moves to the following display:

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 selec t ed menu item, press ESC; then you will be able to scroll using the right and left arrow keys to select a different menu item.

The top level menus are as follows:

HELP DIAGNOSTICS ACCESS LEVEL PERSONALITIES MACHINE SETUP ACTIVATE TESTS CALIBRATION

If you press ENTER, at the HELP:PRESS ENTER display, and a fault is present, the analyzer display will scroll the fault across the screen. If more than one fault is present only the highest priority fault will show. The other active faults are viewable in Logged Help. If there was no fault detected, the display will read:

In platform mode,

HELP: (001) EVERYTHING OK,

In ground mode,

HELP: (002) GROUND MODE OK

LOGGED HELP

1: STARTUP (2/1): (Or last recorded fault)

LOG: (211) 1: Power Cycle (Or last recorded fault)

At this point, the analyzer will display the highest priority active fault, if any are present. You may scroll through the fault logs to view what the last fifteen faults were. Use the right and left arrow keys to scroll through the fault logs. The active faults, are listed before the first POWER CYCLE. To return to the top menu, press ESC two times.

When a top level menu is selected, a new set of menu items may be offered; If for example you choose Personalities:

DRIVE LIFT STEER GROUND

Pressing ENTER with any of the above displayed menus, will display additional sub-menus within the selected menu. In some cases the next level is the parameter or information to be changed. Refer to the flow chart for what menus are available within the top level menus. You may only view the personality settings for selected menus while in access level 2. Remember, you may always cancel a selected menu item by pressing the ESC key.

5-2 3121656

JLG 1930ES, 2032ES, 2632ES, 2646ES, 3246ES Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1. SPECIFICATIONS

1.1 MACHINE SPECIFICATIONS

Capacities

Fluid Capacities

Tires

Batteries

Battery Charger/AC Inverter

Motors

Lift Speed (No Load in Platform)

Travel Speed

Model Dimensions

1.2 TORQUE REQUIREMENTS

1.3 LUBRICATION

Hydraulic Oil

Pressure Settings

1.4 LIMIT SWITCHES

Tilt Alarm

High Drive Speed Cutout

1.5 CYLINDER SPECIFICATIONS

1.6 MAJOR COMPONENT WEIGHTS

1.7 CRITICAL STABILITY WEIGHTS

1.8 TORQUE CHARTS

SECTION 2. GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

Preparation, Inspection, and Maintenance

Pre-Start Inspection

Pre-Delivery Inspection and Frequent Inspection

Annual Machine Inspection

Preventative Maintenance

2.2 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Components Removal and Installation

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Bolt Usage and Torque Application

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

Lubrication and Servicing

2.3 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.4 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.5 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

2.6 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Footnotes:

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 TRACTION SYSTEM

Theory of Operation

3.2 DRIVE MOTOR ELECTRICAL EVALUATION

Common Traction System Difficulties

Power Module Electrical Evaluation

3.3 TORQUE HUB

Leak Test

Oil Check/Fill Procedure

Roll Test

Brakes - Manual Disengage Procedure

Drive Motor Removal

Main Gearbox Disassembly

Input Carrier Disassembly

Hub Disassembly

Spindle Disassembly

Spindle Sub-Assembly

Hub Sub-Assembly

Input Carrier Sub-Assembly

Main Gearbox Assembly