JLG 3248RS, 32410RS Service Manual

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Service & Maintenance Manual

Models

1932RS/6RS

3248RS/10RS

3121273

April 8, 2013

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A. GENERAL

This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance 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.

B. 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.

C. 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.

3121273 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - January 30, 2012

Manual Revised - August 1, 2012

Manual Revised - January 29, 2013

Manual Revised - April 8, 2013

b – JLG Lift – 3121273

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A

SECTION 1 - SPECIFICATIONS

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

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

Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.3 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

1.4 Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

High Drive Speed Cutout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.5 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.6 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.7 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

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

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

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

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

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

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

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

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

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

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TABLE OF CONTENTS

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

SECTION 3 - CHASSIS & SCISSOR ARMS

3.1 Machine Component Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Battery Removal/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Battery Maintenance and Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3.4 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Battery Charger Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 DC to AC Inverter (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Inverter Location on Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Inverter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Inverter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Inverter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.6 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Components Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Removal (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.7 Main Power Contactor Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.8 Elevation Limit Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.9 LSS - Scissor Arm Angle Sensor - location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3.10 Tilt Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Tilt Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Tilt Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Tilt Sensor Switch - Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.11 Traction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Common Traction System Difficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

3.12 Power Control Module - ZAPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

ZAPI Power Module Electrical Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.13 Drive Motor Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Drive Motor Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Drive Motor Electrical Evaluation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Servicing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Brake - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Drive Motor Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Drive Motor Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Drive Motor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.14 Torque Hub Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

Roll Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Oil Check/Fill Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Main Gearbox Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

ii – JLG Lift – 3121273

Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Hub Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Tightening and Torquing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Assembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3.15 Steer Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

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

3.17 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

3.18 Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40

Removing scissor arm assembly as a complete unit:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Removing/Installing scissor arms individually: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3.19 Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Installation/Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Control Station Harness Installation to Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Control Station Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Overview of Control Station Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

TABLE OF CONTENTS

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Pump/Tank Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Pump Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4 Lift Pressure Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.5 Cylinder Checking Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.6 Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4.7 Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

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

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

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

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

Lift Cylinder - LSS Pressure Sensor Location (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION 5 - JLG CONTROL SYSTEM

5.1 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Diagnostic Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Joystick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Updating Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.2 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5.3 Machine ConfiguRation Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

3121273 – JLG Lift – iii

TABLE OF CONTENTS

SECTION 6 - DIAGNOSTIC TROUBLE CODES

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

System Fault/DTC Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Diagnostic Trouble Codes (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 X-Connector References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.4 DTC Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.5 DTC Check Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

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

7.6 Circuit Boards: Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7.7 Electrical Schematics and Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

7.8 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

iv – JLG Lift – 3121273

TABLE OF CONTENTS

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Torque Chart (SAE Fasteners - Sheet 1 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

3-1. Machine Frame Covers (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-2. Battery Location and Hold Down Bar (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-3. Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-4. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-5. Charger Decal LED Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-6. DC to AC Inverter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-7. Inverter On/Off Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-8. Ground Control Station Component Location (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-9. Ground Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-10. Main Power Contactor Relay Location (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-11. Elevation Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-12. Elevation Limit Switch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-13. 1932RS/6RS - Elevation Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-14. 3248RS/10RS - Elevation Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-15. LSS - Scissor Arm Angle Sensor - Location Rear of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-16. Tilt Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-17. Tilt Sensor Switch - Bubble Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-18. Tilt Sensor Switch - Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-19. Traction Control Circuit - ZAPI Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

3-20. ZAPI Power Module Location and Orientation (All models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-21. Main Electrical Power Connections - (1001129845 - ZAPI Power Module) . . . . . . . . . . . . . . . . . .3-17

3-22. Brakes - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-23. Electric Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-24. Drive Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

3-25. Drive Motor Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-26. Wire Harness Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

3-27. Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

3-28. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

3-29. Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

3-30. Hub Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

3-31. Spindle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

3-32. Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-33. Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-34. Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

3-35. Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

3-36. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

3-37. Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

3-38. Main Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

3-39. 1932RS/6RS - Steer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

3-40. 3248RS/10RS - Steer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

3-41. Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

3-42. 1932RS/6RS - Scissor Arm Assembly - Ref. Figure 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

3-43. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

3-44. 3248RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44

3-45. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

3-46. Platform Control Station Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-47. Platform Control Station Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-46

3121273 – JLG Lift – v

TABLE OF CONTENTS

3-48. Platform Control Station Components - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

3-49. Platform Control Station Components - Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47

3-50. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

4-1. Hydraulic Oil Check Procedure - All Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2. Hydraulic Motor, Pump and Tank Assembly (All Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

4-11. LSS Pressure Sensors Location - 1932RS/6RS - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-12. LSS Pressure Sensors Location - 3248RS/10RS - (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . .4-12

4-13. 1932RS/6RS - Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-14. 3248RS/10RS - Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-15. 1932RS/6RS - Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-16. 3248RS/10RS - Steer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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

5-2. Diagnostic Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-3. Analyzer Menu - Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

5-4. Analyzer Menu - Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5-5. Analyzer Menu - System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-6. Analyzer Menu - Personalities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

5-7. Analyzer Menu - Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-8. Analyzer Menu - Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

5-9. Analyzer Menu - Emulation Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

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 - (ANSI) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7-19. Electrical Components Layout - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7-20. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

vi – JLG Lift – 3121273

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

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

1-3 Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-6 Electrical System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-7 Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-8 Lift Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-12 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-13 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1-14 Tilt Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-15 High Drive Cutout Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-16 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-17 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-18 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

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

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

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

3-1 Battery Charger Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2 Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3 ZAPI Power Module Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-4 Module Terminal Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-5 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

3-6 Connector Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48

4-1 Hydraulic System Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2 Lift Pressure Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3 Pressure Fitting Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

5-1 Machine Model Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5-2 Machine Configuration Programming Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

7-1 Power Module - J1 Connector Pin Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7-2 Power Module - J2 Connector Pin Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

3121273 – JLG Lift – vii

TABLE OF CONTENTS

NOTES:

viii – JLG Lift – 3121273

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

Table 1-1. Operating Specifications

DESCRIPTION 1932RS/6RS 3248RS/10RS

PLATFORM

Maximum Platform Height 19 ft. (5.8 m) 32 ft. (9.75 m)

DRIVING

M ax i mu m D ri v e S p ee d S to w ed :

Elevated:

Maximum Stowed Travel Grade (Gradeability) 25% (14°)

Inside Turning Radius 23.6 in. (60 cm) 47.9 in. (121.7 cm)

Outside Tur ning Radius 87.9 in. (221.9 cm) 125.3 in. (318.1 cm)

CHASSIS

Approximate Gross Machine Weight ANSI/CSA:

CE:

Maximum Tire Load (per wheel) ANSI/CSA:

CE:

Ground Bearing Pressure ANSI/CSA:

CE:

Ground Clearance 3.1 in. (7.8 cm) 4.1 in. (10.3 cm)

3,000 lb. (1,360 kg) 3,450 lb. (1,565 kg)

1,365 lb. (620 kg)

130 PSI (9.18 kg/cm

2.5 mph (4 kph)

0.3 mph (0.5 kph)

)

5,070 lb. (2,300 kg) 6,050 lb. (2,744 kg)

1,835 lb. (832 kg) 2,070 lb. (940 kg)

81 PSI (5.69 kg/cm 108 PSI (7.6 kg/cm

)

Platform Capacities

Table 1-2. Platform Capacities

SPECIFICATION

ANSI/CSA/JPN

ANSI EXPORT

NOTE: (1) Maximum Platform Capacity includes platform and platform extension.

MACHINE

MODEL

1932 500 Lb. (227 Kg) 250 Lb. (113 Kg) 2 100 Lb. (445 N) 28 mph

3248 705 Lb. (320 Kg) 250 Lb. (113 Kg) 2 100 Lb. (445 N) 28 mph

1932 480 Lb. (218 Kg) 240 Lb. (109 Kg) 2 100 Lb. (445 N) 28 mph

3248 683 Lb. (310 Kg) 236 Lb. (107 Kg) 2 100 Lb. (445 N) 28 mph

6RS 230 Kg 120 Kg Indoor - 2 Persons + 70 Kg 400 N 0 m/s

10RS 320 Kg 120 Kg Indoor - 2 Persons + 160 Kg 400 N 0 m/s

MAXIMUM

PLATFORM

CAPACITY

MAXIMUM CAPACITY

(1)

ALLOWED ON

PLATFORM EXTENSION

MAXIMUM PERSONS

ALLOWED IN PLATFORM

Outdoor - 1 Person + 150 Kg 200 N 12.5 m/s

Outdoor - 1 Person + 240 Kg 200 N 12.5 m/s

MAX. SIDE FORCE

(Platform Fully Extended

@ Max. Capacity)

MAXIMUM

OPERATING

WIND SPEED

3121273 – JLG Lift – 1-1

SECTION 1 - SPECIFICATIONS

NOTICE

1706740A

Dimensional Data

Table 1-3. Machine Dimensions

DESCRIPTION 1932RS/6RS 3248RS/10RS

Platform Height Elevated

Platform Height Stowed

Platform Height Stowed (Rails Down)

Working Height 25 ft.

Rail Height

(From platform floor)

Rail Height

(Platform Floor to Top of Rail)

Rail Height - Folded

(Ground to Mid Ra il)

Overall Machine Width 32 in.

Overall Machine Length

(w/ladder)

P la t fo r m Si z e - L e ng t h 7 1. 7 i n.

Platform Size - Width 26.9 in.

Wheelbase 55 in.

19 ft.

(5.8 m)

79.4 in.

(2.02 m)

N/A

(7.62 m)

40 in.

(101.6 cm)

40 in.

(101.6 cm)

69.3 in. (176 cm) CE ONLY

(81.28 cm)

81.5 in.

(207 cm)

(182 cm)

(68.4 cm)

(139.7 cm)

32 ft.

(9.75 m)

95.8 in.

(2.43 m)

78.3 in.

(1.99 m)

38 ft.

(11.5 m)

40.5 in.

(102.9 cm)

41 in. (104.3 cm) - ANSI

43.6 in. (110.7 cm) - CE

78.3 in. (198.9 cm)- ANSI

77.6 in. (197.1 cm) - CE 48 in.

(122 cm)

90 in. (2.28 m) - ANSI

94.8 in. (240.7 cm) - CE

84.7 in.

(215.1 cm)

42.5 in.

(107.9 cm)

73 in.

(185.4 cm)

Tires

Table 1-4. Tire Specifications

DESCRIPTION 1932RS/6RS 3248RS/10RS

Size 12.71 in. x 3.94 in.

(323 mm x 100 mm)

Wheel Bolt Torque 120 ft lb. (163 Nm)

16 in. x 5 in.

(406 mm x 127 mm)

Batteries

Table 1-5. Battery Specifications

DESCRIPTION ALL MACHINES

Voltage (24V-DC System - Series) 6 V per battery

Amp Hour (Standard Battery) 220 Amp Hour @ 20 HR. Rate

Reserve Capacity (Standard Battery) 447 Minutes

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

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

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.

Battery Quick-Disconnect (If Equipped)

Machines equipped with the battery quick-disconnect allow all machine power to be easily disconnected at the batteries without removing battery cables from the battery posts. To disconnect power, locate the RED quick-disconnect connector on top of the batteries inside the battery compartment and pull halves apart.

1-2 – JLG Lift – 3121273

Electrical System Motors

SECTION 1 - SPECIFICATIONS

Table 1-6. Electrical System Specifications

DESCRIPTION ALL MACHINES

Electrical System Voltage (DC) 24V - DC

Battery Charger: (1001129847)

Input:

AC Input Voltage:

Nominal AC Input Voltage:

Input Frequency:

Max. AC Input Current:

Ingress Protection:

Operating Temperature:

Output:

Nominal DC Output Voltage:

M ax . DC O u tp u t V o lt a ge :

Max DC Output Current:

Max. Interlock Current:

Protection:

Output Reverse Polarity:

Output Shor t Circuit:

AC Overload:

DC Overload:

DC to AC Inver ter - Output Rating: (OPTION)

85-265V AC 120VAC / 230VAC RMS 45 - 65Hz 12A - RMS @ 108V AC IP46 NEMA4 Type 4

-22°F (-30°C) to 122°F (+50°C)

24V

33.6V 25A 1A

Electronic Protection-Auto Reset Electronic Protection-Auto Reset Current Limited Current Limited

120V-AC, 60Hz - 7.5 Amps - 900 Watts - Modified Sinewave

•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

Power: 3kW

Travel Speed

Table 1-7. Travel Speed

ELEVATED SPEED MAXIMUM SPEED (PLATFORM LOWERED)

MODEL

Mph

1932RS/6RS 0.3 59 - 65 0.5 2.5 6.85 - 8.5 4

3246RS/10RS 0.3 57 - 65 0.5 2.5 6.85 - 8.5 4

Sec/25 ft

(Sec/7.6 m)

UNIT OF MEASURE

Kph Mph

Sec/25 ft

(Sec/7.6 m)

Lift Speed

NOTE: Maximum rated load in platform on measured lift speeds. Platform fully raised and lowered.

Table 1-8. Lift Speed

MODEL

1932RS/6RS 22 - 29 21 - 31

3246RS/10RS 55 - 65 40 - 50

LIFT UP

(SECONDS)

LIFT DOWN (SECONDS)

Kph

3121273 – JLG Lift – 1-3

SECTION 1 - SPECIFICATIONS

1.2 CRITICAL STABILITY WEIGHTS

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

Table 1-9. Critical Stability Weights

COMPONENT 1932RS/6RS 3248RS/10RS

Wheel and Tire Assembly ( ea c h) Fr o nt :

Wheel/Tire and Drive Assembly (each)

Batteries (each) Standard:

Batteries (combined)

Standard :

Rear:

AGM:

21.6 lb. (9.8 kg)

113 lb. (51.3 kg) 134 lb. (60.8 kg)

248 lb. (111.1 kg)

43 lb. (19.5 kg)

40.5 lb. (18.4 kg)

62 lb. (28.1 kg) 65 lb. (29.5 kg)

260 lb. (118 kg)

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 10 or Excel 15 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 10 or Excel 15 is desired, contact JLG Industries for proper recommendations.

Table 1-10. Hydraulic Oil

Table 1-11. Lubrication Specifications

KEY SPECIFICATIONS

Multipurpose Grease having a minimum dripping

MPG

EPGL

SPECIFICATION

ISO Viscosity

Grade

Spec Gravity API 31.9 0.950 —

Pour Point, Max

Flash Point, Min.

VISCOSITY SPECIFICATIONS

at 40°C 15 cSt

at 100°C 4.1 cSt

at 100°F 80 SUS

at 210°F 43 SUS

cp at -30°F 3.2

Viscosity Index 140 147 189

Operating Temp — -20°F (29°C) - 200°F (392°C)

point of 350°F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

Extreme Pressure Gear Lube (oil) meeting API service c la ss if ic a ti on GL- 5 or MI L-S pe c MI L-L- 21 0 5.

JLG Recommends - Mobil DTE 10, EXCEL 15 or ATF - Automatic Transmission Fluid Mobil EAL ENVIRONSYN H 32 (IN U.S.A.) Mobil EAL HYDRAULIC OIL 32 (IN EUROPE)

Table 1-12. Hydraulic Oil Specifications

MOBIL

DTE 10

EXCEL 15

#15 #32 #32

-40°F

(-40°C)

330°F

(166°C)

MOBIL EAL

ENVIRONSYN

H 32

-59°F

(-51°C)

514.4 °F (268°C)

33.1 cSt 32 cSt

6.36 cSt 7 cSt

——

MOBIL EAL

HYDRAULIC

(-39°C)

478°F (248°C)

OIL 32

-38.2°F

1001102685_3

Pressure Settings

Table 1-13. Pressure Settings

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0°F to +23°F (-18°C to -5°C) 10W

0°F to 210°F (-18°C to + 99°C) 10W-20, 10W-30

50°F to 210°F (+10°C to +210°C ) 20W-20

SAE VISCOSITY GRADE

1.4 LIMIT SWITCHES

MODEL MAIN RELIEF LIFT RELIEF

1932RS/6RS

3246RS/10RS

Illuminates a light on the platform control, sounds an alarm and cuts out lift up and drive when the machine is out of

2300 psi

(158 bar)

2500 psi

(172 bar)

2300 psi

(158 bar)

2500 psi

(172 bar)

STEER

RELIEF

1000 psi

(69 bar)

1000 psi

(69 bar)

Tilt Alarm

1-4 – JLG Lift – 3121273

SECTION 1 - SPECIFICATIONS

M12 - 1.5 x 22

level and above stowed depending on model and specifications.

Table 1-14. Tilt Activation Setting

PLATFORM ELEVATION

@ TILT

ACTIVATION

(± 6 IN.)

69 in.

(1.75 m)

88.5 in.

(2.25 m)

88.5 in.

(2.25 m)

MODEL

1932RS/6RS - ALL

3248RS/10RS ANSI/CSA/JPN

3248RS/10RS - CE

TILT

SETTING

(FRONT TO

BACK)

3° 1.5°

3° 2°

3° 1.5°

TILT SETTING (SIDE TO

SIDE)

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 1-15. High Drive Cutout Height

MODEL

1932RS/6RS 68.9 in. (1.75m)

3248RS/10RS 88.5 in. (2.25 m)

HIGH DRIVE SPEED

CUTOUT HEIGHT

DRIVE SPEED

REDUCTION

2.5 mph (4 kph) to

0.3 mph (0.5 kph)

1.6 MAJOR COMPONENT WEIGHTS

Table 1-17. Major Component Weights

COMPONENT 1932RS/6RS 3246RS/10RS

Platform

Manual Platform Extension

Arm Assembly - (Includes Lift Cylinder)

Chassis w/Wheel/Tire and Drive Assembly

240 lb.

(109 kg)

115 lb. (52 kg)

520 lb.

(236 kg)

2,125 lb. (964 kg)

412 lb.

(187 kg)

150 lb.

68 kg

1,806 lb. (820 kg)

2,702 lbs

(1226 kg)

1.7 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 1-18. Torque Requirements

DESCRIPTION

Front Wheel Spindle Nut

Wheel Bolts

TORQUE VALUE

(DRY)

30-40 ft lb

(40-54 Nm)

105 -120 ft lb

(142-163 Nm)

INTERVAL

HOURS

1.5 CYLINDER SPECIFICATIONS

Table 1-16. Cylinder Specifications

DESCRIPTION 1932RS/6RS 3246RS/10RS

Lift Cylinder Bore

Lift Cylinder Stroke

Lift Cylinder Rod Diameter

Steer Cylinder Bore

Steer Cylinder Stroke

Steer Cylinder Rod Diameter

2.48 in.

(63 mm)

43.3 in.

(1100 mm)

1.77 in.

(45 mm)

1.5 in.

(38.1 mm)

4.92 in

(125 mm)

0.75m in.

(19.05 mm)

3.93 in.

(100 mm)

48.5 in.

(1232 mm)

2.48 in.

(63 mm)

1.57 in.

(40 mm)

6.77 in.

(172 mm)

0.78 in.

(20 mm)

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.

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 the Torque Charts on page 1-6 to determine proper torque value.

3121273 – JLG Lift – 1-5

SECTION 1 - SPECIFICATIONS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

JLG P/N Loctite® P/N ND Industries P/N

Description

0100011

242

Vibra-TITE

121

Medium Strength (Blue)

0100019

271

Vibra-TITE

140

High Strength (Red)

0100071

262

Vibra-TITE

131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

NO. 5000059 REV. J

Values for Zinc Yellow Chromate Fasteners (Ref 4150707)

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

(Loctite® 262

or Vibra-

TITE

131)

Torque

Lubricated

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140)

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

Torque Charts

1-6 – JLG Lift – 3121273

Figure 1-1. Torque Chart (SAE Fasteners - Sheet 1 of 7)

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

NO. 5000059 REV. J

3. * ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000456040 553550 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120

16400 155 210 140 190 115 155

18250 170 230 155 210 130 175

20350 210 285 190 260 160 220

23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855 96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140) K=.18

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry or Loctite® 263)

K= 0.20

3121273 – JLG Lift – 1-7

Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7))

SECTION 1 - SPECIFICATIONS

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating (Ref 4150701)*

Torque

(Dry) K = .17

Torque

(Loctite® 242

or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.16

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT AP PLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

1-8 – JLG Lift – 3121273

Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note 4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

NO. 5000059 REV. J

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH

CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K = .20

Torque

(Loctite® 242TM or 271

OR Vibra-TITE

111 or

140 OR Precoat 85®

K=0.18

Zinc Yellow Chromate Fasteners (Ref 4150707)*

2. ALL TORQUE VALUES ARE STATIC TORQU E MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

SECTION 1 - SPECIFICATIONS

3121273 – JLG Lift – 1-9

Figure 1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7)

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

Torque

(Lub)

Torque

(Loctite® 262

OR Vibra-

TITE

131)

Torque

(Loctite®

242

or 271

OR Vibra-

TITE

111 or

140)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7))

1-10 – JLG Lift – 3121273

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry or Loctite®

263

)

K = 0.20

Torque

(Lub OR Loctite®

242

or 271TM OR

Vibra-TITE

111 or

140)

K= 0.18

Torque

(Loctite® 262

Vibra-TITE

131)

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

3121273 – JLG Lift – 1-11

Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7)

SECTION 1 - SPECIFICATIONS

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note 4

Torque

(Dry or Loctite®

263

)

K = .17

Torque

(Lub OR Loctite®

242

or 271

OR Vibra-TITE

111 or 140)

K = .16

Torque

(Loctite® 262

OR Vibra-TITE

131)

K = .15

Sq mm kN [N.m] [N.m] [N.m]

30.55.03

3.5 0.6 6.78

40.78.78

50.814.20

6120.1012.5 13 12 11

7128.9018.0 21 20 19

8 1.25 36.60 22.8 31 29 27 10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 AND ABOVE*

4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT

REPRESENT FULL STRENG TH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HAR DEN ED WASHER OR FASTENER IS PLAC ED AGAINST PLATED STEEL OR RAW ALUMINUM

NOTES: 1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTEN ERS

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NO. 5000059 REV. J

Magni Coating (Ref 4150701)*

Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7)

1-12 – JLG Lift – 3121273

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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

Pre-Delivery Inspection and Frequent Inspection

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

The Pre-Delivery Inspection and Frequent Inspection procedures are performed in the same manner, but at different times. The Pre-Delivery Inspection shall be performed prior to each sale, lease, or rental delivery. The Frequent Inspection shall be accomplished for each machine in service for 3 months or 150 hours (whichever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of this inspection must be increased as environment, severity and frequency of usage requires.

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.

3121273 – JLG Lift – 2-1

SECTION 2 - GENERAL

NOTICE

Table 2-1. Inspection and Maintenance Responsibilities

Ty pe Frequency

Pre-Start

Inspection

Pre-Delivery

Inspection

Frequent

Inspection

Annual Machine

Inspection

Preventative

Maintenance

In service for 3 months or 150 hours, whichever comes

first; or Out of service for a period of more than 3 months;

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

At intervals as specified in the Ser vice and Maintenance

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental deliver y.

or Purchased used.

inspection.

Manual.

2.2 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 qualified JLG mechanic. Notify JLG dealer if inspection is overdue.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or

User

Owner, Dealer, or

User

Owner, Dealer, or

User

Owner, Dealer, or

User

4. Check for cracked or broken welds.

5. Operates properly.

6. Returns to neutral or "off" position when released.

7. Clean and free of debris.

8. Interlocks function properly.

9. Check for signs of leakage.

10. Decals installed and legible.

11. Check for proper fluid level.

12. Check for chafing and proper routing.

13. Check for proper tolerances.

14. Properly lubricated.

15. Torqued to proper specification.

16. No gouges, excessive wear, or cords showing.

17. Properly inflated and seated around rim.

18. Proper and authorized components.

19. Fully charged.

20. No loose connections, corrosion, or abrasions.

21. Verify.

22. Perform.

23. Sealed properly.

24. Overrides Platform controls.

25. Remove pump motor cover and blow away any brush wear dust from cover, brushes, and brush holder assembly.

Service

Qualification

Qualified JLG

Mechanic

Qualified JLG

Mechanic

Factory-Trained

Service Technician

(recommended)

Qualified JLG

Mechanic

Reference

Service and Maintenance Man-

ual and applicable JLG inspec-

tion form.

Service and Maintenance Man-

ual and applicable JLG inspec-

tion form.

Service and Maintenance Man-

ual and applicable JLG inspec-

tion form.

Service and Maintenance Man-

ual

Footnotes:

Maintenance and Inspection Schedule Codes:

1. Check for proper and secure installation.

2. Visual inspection for damage, cracks, distortion, or excessive wear.

3. Check for proper adjustment.

(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

2-2 – JLG Lift – 3121273

SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance & Inspection Schedule.

INTERVAL

AREA ON MACHINE

PRE-DELIVERY (a) OR FREQUENT (b)

INSPECTION

FUNCTIONS/CONTROLS

Platform Controls 5, 6, 7 5, 6, 7

Ground Controls 5, 6 5, 6, 14

Function Control Locks, Guards, or Detents 5 5

Function En able Sy stem 5 5

Emergency Stop Switches (Ground & Platform) 5 5

Function Limit or Cutout Switch Systems 5 5

Manual Descent or Auxiliary Power 5 5

PLATFORM ASSEMBLY

Platform 1 1

Guard Rails 1, 2, 4 1, 2, 4

Gate 1, 5 1, 5

Floor 1, 2 1, 2

Lanyard Anchorage Point 1, 4 1, 4

SCISSOR ARMS

Scissor Arms 1, 2, 4 1, 2, 4

Arm Safety Prop 1, 5 1, 5

Cylinder Pins, Pivot Pins & Attaching Hardware 1 1

Arm Pins, Wear Pads & Attaching Hardware 1 1

CHASSIS ASSEMBLY

Covers Installation 1, 7 1, 7

Static Strap 1 1

Wheel and Tire Assemblies 2, 15 2, 15

Drive Motors 1, 7, 9 1, 7, 9

Drive Motor Brushes ** — —

POWER SYSTEM

Batteries 9 18

Battery Charger 5

HYDRAULIC/ELECTRIC SYSTEM

Hydraulic Lift/Steer Pump 1, 2, 9 1, 2, 5, 9, 25

Hydraulic Cylinders (arms and steering ) 2, 7, 9 2, 9

Steer Cylinder Attachment Pins and Pin Retainers 1, 2 1, 2

Hydraulic Hoses, Lines, and Fittings 1, 9 1, 9

Hydraulic Reservoir, Cap, and Breather 5, 7 5, 7

Hydraulic Fluid *** 11 11

Electrical Connections 20 20

Instruments, Gauges, Switches, Lights, Horn 5 5

ANNUAL (c)

(YEARLY)

INSPECTION

3121273 – JLG Lift – 2-3

SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance & Inspection Schedule. (Continued)

AREA ON MACHINE

GENERAL

Operation & Safety Manual in Storage Box 21 21

ANSI & EMI Handbooks in Storage Box (ANSI ONLY)

Capacity Decals Installed, Secure, Legible 21 21

All Decals/Placards Installed, Secure, Legible 21 21

Annual Machine Inspection Due 21

No Unauthorized Modifications or Additions 21 21

All Relevant Safety Publications Incorporated 21 21, 22

General Structural Condition and Welds 2, 4 2, 4

All Fasteners, Pins, Shields, and Covers 1, 2

Grease and Lubricate to Specifications 22 22

Function Test of All Systems 22 22

Paint and Appearance 7 7

N ot i f y J L G o f ch a n ge i n M a ch i n e O w ne r sh i p 2 2

INTERVAL

PRE-DELIVERY (a) OR FREQUENT (b)

INSPECTION

21 21

ANNUAL (c)

(YEARLY)

INSPECTION

** Replace when system performance is degraded. *** Every two years, drain and remove hydraulic oil reservoir , clean pick-up s creen, refill with fresh hydraulic fluid.

2-4 – JLG Lift – 3121273

SECTION 2 - GENERAL

2.3 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.

2. At any time when air, fuel, or oil lines are disconnected, clean adjacent areas as well as the openings and fittings themselves. As soon as a line or component is disconnected, cap or cover all openings to prevent entry of foreign matter.

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.

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.

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.

Bolt Usage and Torque Application

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

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

3. Unless specific torque requirements are given within the text, standard torque values should be used on

3121273 – JLG Lift – 2-5

SECTION 2 - GENERAL

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 a 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.

2.4 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. 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

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

2. JLG recommends DTE10 or Excel 15 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152.

NOTE: Start-up of hydraulic system with oil temperatures

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

2-6 – JLG Lift – 3121273

SECTION 2 - GENERAL

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, Table 1-11, Lubrication Specifications for an explanation of the lubricant key designations.

2.5 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 2-3. 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

3121273 – JLG Lift – 2-7

SECTION 2 - GENERAL

2.6 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 operation.

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

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their hous-

ing.

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.

2-8 – JLG Lift – 3121273

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 MACHINE COMPONENT COVERS

SECTION 3 - CHASSIS & SCISSOR ARMS

1. Left Side (Hydraulic) Frame Cover

2. Side Cover Release Handles

3121273 – JLG Lift – 3-1

Figure 3-1. Machine Frame Covers (All Models)

3. Right Side (Batteries) Frame Cover

4. Rear (Drive Motor/Charger/Control Module) Cover

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTICE

CAUTION

1706740A

3.2 BATTERY REMOVAL/MAINTENANCE

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE. 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.

Battery Quick-Disconnect (If Equipped)

BEFORE BATTERY REMOVAL CAN BEGIN, ENSURE THAT THE (+) AND (—) BATTERY CABLES HAVE BEEN PROPERLY DISCONNECTED.

1. The machine batteries are located inside the machine right side cover, remove the cover.

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

3. To remove one or more batteries from the machine, the battery hold down bar will need to be removed. (See Figure 3-2.)

4. Remove the (2) nuts and washers from each holddown anchor at the ends of the hold-down bar. Remove the bar and lay aside.

5. After battery removal and installation re-install the battery hold down bar.

6. After any maintenance on the batteries or replacement of the batteries is complete, reconnect the batteries and check for proper operation.

7. Re-install the machine right side cover.

Figure 3-2. Battery Location and Hold Down Bar

(All Models)

1. Batteries (4 - 6V)

2. Hold-Down Bar

3. Hold-Down Bar Fasteners

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 3-3.).

• 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.

• Clean terminal connections if they become corroded.

3-2 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

BATTERY

FILLER CAP

FLUID LEVEL OF FULLY

CHARGED BATTERY

VENT TUBE

PLATES

1/8 "

Figure 3-3. Battery Fluid Level

3.3 BATTERY CHARGER

The Battery Charger is located at the rear of the machine under the rear access cover, remove the cover to gain access to the charger.

Battery Charger Location

1. AC Voltage - Input Cable

3. DC Power Cable to Batteries

2. Charger Interlock Cable

Figure 3-4. Battery Charger

Table 3-1. Battery Charger Specs

BATTERY CHARGER SPECIFICATION

OUTPUT

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

INPUT

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

OPERATION

Charging Indicator Yellow LED Battery Fault Indicator Flashing Yellow LED 100% Charge Indicator Green LED Charger Fault Indicator Red LED

PROTECTION

Output Reverse Polarity

Output Short Circuit

Electronic Protection - Automatic Reset

Electronic Protection - Automatic

Reset AC Overload Current Limited DC Overload Current Limited

MECHANICAL

Operating Temperature

–22° F to +122°F

(–30°C to +50°C) Housing Shock an d Water Resistant Aluminum

3121273 – JLG Lift – 3-3

SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

GREEN (ON) Battery Fully Charged

AMBER (ON) Battery Charging

AMBER (FLASHING) Battery/System Problem

RED (FLASHING) Charger Problem

GREEN

AMBER

RED

LEDS

3.4 BATTERY CHARGING

NOTE: Be sure that machine is parked in a well ventilated

area before charging begins.

ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BATTERY TERMINAL. 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. ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR BREAKING THE (POS/NEG) CONNECTIONS TO THE BATTERY. DO NOT OPEN OR DISASSEMBLE CHARGER.

1. The battery charger AC input plug is located in an opening on the panel at the lower rear of the machine.

2. Connect the charger AC input plug to a grounded outlet using a 3 wire heavy duty extension cord. (See

Table 3-1, Battery Charger Specs, for battery charger AC input specifications.)

3. When powered up the charger will go through a short LED indicator self-test. The battery charger LED indicators on the charger (Figure 3-5.), will flash in sequence for two seconds. These LED indicators can be viewed through the opening on the rear panel where the charger AC cord is accessed.

4. The batteries are fully charged when the green light on the battery charger status panel is illuminated.

NOTE: If the charger is left plugged in, the charger will

automatically restart a complete charge cycle if the batteries voltage drops below a minimum voltage or 30 days has elapsed.

Figure 3-5. Charger Decal LED Indicators

Battery Charger Fault (LED Flash)

If a fault has occurred during battery charging, the (AMBER or RED) LED on the charger LED indicator will flash corresponding to the fault which occurred. Refer to Table 3-2 following for the flash codes and their meaning.

If required, further general and troubleshooting information about the battery charger can be found in the charger manufacturers Owner’s Guide.

Table 3-2. Battery Charger Fault (LED Flash)

FLASHING LED FAULT REMEDY

AMBER Batter y High Voltage

AMBER Battery Low Voltage

AMBER Failed Trickle to min V

Upon battery voltage >2.5V per cell @ star tup, charger shall flash amber LED and not allow charging - Battery or System problem.

Upon battery voltage <0.17V per cell @ star tup, charger shall flash amber LED and not allow charging - Battery or System problem.

Should battery fail to reach 1.75V per cell charge shall flash an amber LED until charger is power cycled - Battery or System problem.

RED Charger Internal Fault Signals a hardware fault of the charger and shall in dicate flashing red LED.

3-4 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

Battery Charger Maintenance

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.

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

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

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

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

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.

[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.

3121273 – JLG Lift – 3-5

SECTION 3 - CHASSIS & SCISSOR ARMS

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 not 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, complete the following steps.

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

2. 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.

3. 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.

4. If this fault occurs after battery charging has started, confirm that AC power was not interrupted and that all battery connections are good.

5. If all battery connections are good, an internal fault has been detected and the charger must be brought to a qualified service depot.

3-6 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

INVERTER

OFF

1001143010A

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. If the output voltage of the charger seems excessive, return the charger for service. Contact JLG to get the expected battery voltage settings for the charger in question. Be sure to have the charger’s serial number and charge algorithm setting available when calling.

3.5 DC TO AC INVERTER (IF EQUIPPED)

Inverter Location on Machine

The inverter is located to the right rear of the machine in the battery side compartment on all RS Scissor models.

1. DC to AC Inverter

2. Overload LED Indicator

3. Inverter Internal ON/OFF

Switch - Set to ON from factory

4. Inverter VAC Output Cord

5. To Inverter ON/OFF Switch

at Ground Control Panel

Figure 3-6. DC to AC Inverter Components

* Items located under shield.

6. Inverter Power Relay

7. From VDC Battery POS (+)

8. To VDC Inverter POS (+)

Input

9. External DC 15A Fuse(s)*

10. From VDC Battery NEG (–)*

11. Inverter Cooling Fan*

1. Inverter On/Off Switch 2. Ground Control Panel

Figure 3-7. Inverter On/Off Switch Location

3121273 – JLG Lift – 3-7

SECTION 3 - CHASSIS & SCISSOR ARMS

DANGER

Inverter Operation

DANGER OF SHOCK OR ELECTROCUTION - TREAT INVERTER OUTPUT THE SAME AS COMMERCIAL AC POWER.

If servicing remove any frame covers required to gain access to the inverter unit.

1. Turn ON the inverter at the ground control station inverter ON/OFF switch. (Make certain the overload

LED is not lit on the inverter.)

2. Turn OFF the inverter. The overload LED may briefly "blink" and the audible alarm may also sound a short "chirp". This is normal.

3. When you have confirmed that the appliance (tool) to be operated is turned off, plug the appliance cord into the inverter AC output cord.

4. Turn ON the inverter.

5. Turn on the appliance (tool).

6. Plug in any additional appliances (tools).

NOTE: The audible alarm may make a momentary "chirp"

when the inverter is turned OFF. This same alarm may also sound when the inverter is being connected to or disconnected from the 24 volt battery bank.

Inverter Troubleshooting

Problem: No Input Voltage

Poor contact with battery terminals.

Shut down the inver ter and disconnect battery power. Clean terminals thoroughly and reconnect.

Poor or week battery condition. Recharge or replace battery(s).

Inadequate power being delivered to the inver ter or excessive voltage drop.

Use lower gauge (heavier) cable. Keep cable length as short as possible.

Inverter Specifications

Name Description

Input 24V (20-30V) DC

Output 110V AC

Output Waveform Modified Sine Wave (MSW)

Continuous Power 900 Watt

Surge Power 1800 Watt

Efficiency Aprox. 90%

Power Switch ON/OFF Control

Power Switch OFF <0.5 ADC

Battery Low Alarm 21 ± 0.5 V DC

Battery Low Shutdown 20 ± 0.5 V DC

AC Output Sockets (2) Nor th American Standard 15 Amps

External Fuses 3 x 15 Amp (Automotive Spade Type)

Dimensions 5 in. (W) x 2.75 in. (H) x 10.5 in. (D)

(12,7cm x 7cm x 26,67cm)

Net Weight 6 lbs. (2,72 Kg)

NOTE: All specifications are typical at nominal line, half

load, and 77° F (25° C) unless otherwise specified. Specifications are subject to change without notice.

Blown DC battery fuse(s). Turn off inver ter. Replace fuse(s)

with the same type and rating.

Problem: Inverter Is In Shut Down

Battery voltage is below 20 volts. Charge or replace batter y.

Inver ter is too hot (thermal shut down mode). Overload LED indicator on inver ter is lit ORANGE/ RED.

Unit may be defective. See warranty and call customer

Problem: Low Battery Alarm On All The Time

Input voltage below 21 volts buzzing sound.

Allow inver ter to cool. Check for adequate ventilation. Reduce the load on the inver ter to rated continuous power.

service.

Keep input voltage above 21 volts to maintain regulation.

3-8 – JLG Lift – 3121273

3.6 GROUND CONTROL STATION

NOTICE

1001132360A

1001146979A

DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPTING TO REMOVE THE GROUND CONTROL PANEL OR SERVICING THE ELECTRICAL SYSTEM. FAILURE TO DO SO COULD CAUSE DAMAGE TO THE MACHINES ELECTRICAL COMPONENTS.

Components Location

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-9. Ground Control Station Removal

1. Attach Screws and Washers

2. Brake Release Switch

3. Power Relay

Installation

1. Check that all components are installed into the panel and connected to the wiring harness.

2. Insert the panel into position on the machine and

Figure 3-8. Ground Control Station Component Location

(All Models)

1. Platform Lift/Lower Switch

2. Key Selector Switch

3. Ground Emergency Stop-

Button

4. MDI - Indicator

5. Overload Indicator (If

Equipped)

align the mounting holes in the panel with the mounting holes in the frame.

3. Attach using the (4) mounting screws and washers.

4. Reconnect the main power at the batteries, power machine up and check machine operation.

5. Install machine side cover.

Removal (All Models)

1. Disconnect main power at the batteries.

2. Remove the machine side cover on the left side of the machine (ground control station/pump side).

3. Remove the (4) screws and washers attaching the ground control panel to the frame.

4. When panel is released, rotate and position to unplug or disconnect the desired connectors and components on the back of the panel.

3121273 – JLG Lift – 3-9

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTICE

3.7 MAIN POWER CONTACTOR RELAY

The main power relay is located under the rear cover next to the battery charger.

DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPTING TO REMOVE THE MAIN POWER CONTACTOR RELAY OR SERVICING THE ELECTRICAL SYSTEM. FAILURE TO DO SO COULD CAUSE DAMAGE TO THE MACHINES ELECTRICAL COMPONENTS.

3.8 ELEVATION LIMIT SWITCH ASSEMBLY

Location

1932RS/6RS

3248RS/10RS

Figure 3-11. Elevation Limit Switch Location

1. Limit Switch

Figure 3-10. Main Power Contactor Relay Location (All

Models)

1. Main Power Contactor Relay

2. To X14 Harness Connector -

( Power Relay and Control Module)

3. To Battery (BT03+)

4. To Control Module -

(X09 B+F1)

Installation

Figure 3-12. Elevation Limit Switch Mounting

1932RS/6RS

1. Switch Assembly

2. Scissor Arm Cam

3. Switch Lever Arm

4. Mounting Hardware

3-10 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

18 ft. 11 in. -

5 ft. 9 in. -

0•‹

(30•‹)

7 ft. 4 in. -

31 ft. 11 in. -

0°

(30°)

3248RS/10RS

Figure 3-12. Elevation Limit Switch Mounting

1. Switch Assembly

2. Scissor Arm Cam

3. Switch Lever Arm

4. Mounting Hardware

Switch Adjustment

Models - 3248RS/10RS (See Figure 3-12. and Figure 3-14.)

1. With the roller lever arm set at 30° from vertical, attach switch to frame mount using the mounting hardware as shown.

2. With the scissor arms in the stowed position, adjust the switch up or down in the vertical mounting slots in the frame, so that the roller contacts both surfaces of the scissor arm cam, then tighten.

Switch Notes (All Models):

• The lever arm angle is to be pre-set to 30° from vertical.

• Switch Reset = 13°

•Switch Trip = 25°

• Drive speed to be reduced before: 1932RS/6RS - 5 ft. 9 in. (1.75 m) platform height 3248RS/10Rs - 7 ft. 4 in. (2.25 m) platform height.

• The switch is to be in the trip position (25° - 70°) when the machine platform height is above: 1932RS/6RS - 5 ft. 9 in. (1.75 m) platform height 3248RS/10Rs - 7 ft. 4 in. (2.25 m) platform height.

• The switch is to be in the reset position (0° - 13°) when the machine is stowed.

Models - 1932RS/6RS (See Figure 3-12. and Figure 3-13.)

1. With the roller lever arm set at 30° from vertical, attach switch to frame mount using the mounting hardware as shown.

2. With the scissor arms in the stowed position, adjust the switch fore or aft in the horizontal mounting slots in the frame, so that the roller contacts both surfaces of the scissor arm cam, then tighten.

Figure 3-14. 3248RS/10RS - Elevation Limit Switch

Adjustment

Figure 3-13. 1932RS/6RS - Elevation Limit Switch

Adjustment

3121273 – JLG Lift – 3-11

SECTION 3 - CHASSIS & SCISSOR ARMS













1932RS/6RS 3248RS/10RS

1. Platform Gate

2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway)

3. Platform Entry Ladder

Figure 3-15. LSS - Scissor Arm Angle Sensor - Location Rear of Machine

1. Elevation Limit Switch Location

2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway)

3. Platform Entry Ladder

3.9 LSS - SCISSOR ARM ANGLE SENSOR LOCATION

RS Scissor machines equipped with the Load Sensing System (LSS) are equipped with a separate scissor arm angle sensor switch besides the standard elevation limit switch. This switch communicates with the power control module in tandem with the lift cylinder pressure switches to accurately determine platform load for any given platform height.

There is no adjustment to the angle sensor switch and arm assembly, just install in the proper orientation.

See the LSS Service Manual (3124288) for complete service information for the RS Scissors - LSS system.

3.10 TILT SENSOR REPLACEMENT

The tilt sensor is located inside the left side machine cover (ground control station side).

3-12 – JLG Lift – 3121273

Figure 3-16. Tilt Sensor Installation

1. Tilt Sensor

2. Locating Hole

3. Mounting Hardware

Tilt Sensor Removal

NOTICE

1. Disconnect power at the batteries.

2. Remove the machine left side cover (ground control station side).

3. Unplug the tilt sensor 3-wire harness connector.

4. Remove the two (2) mounting nuts, bolts and washers attaching the sensor to the base frame.

Tilt Sensor Installation

1. Before mounting the tilt sensor to the base frame, check the mating surfaces of the sensor and the mounting plate, be certain there is no debris or burrs to prevent a flush mount.

2. When mounting the tilt sensor back into the base frame, align the mounting pin on the bottom of the sensor with the hole in the mounting plate on the base frame (item 2 - Figure 3-16.).

3. Secure to the base frame with the mounting hardware.

4. Adjust per instructions following.

Tilt Sensor Switch - Adjustment Procedure

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-17. Tilt Sensor Switch - Bubble Level

1. Level

2. Not Level

PERFORM TILT SWITCH LEVELING PROCEDURE A MINIMUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH.

1. Park the machine on a smooth, firm, and level surface. Be sure it is as level as possible.

NOTE: Ensure switch mounting is level and securely

attached.

2. Tighten the three flange nuts with a socket wrench. Each nut should be tightened approximately onequarter of its spring’s travel.

3. Using bubble level on top of indicator, Tighten or loosen the three flange nuts until indicator is level.

4. Individually push down on one corner at a time. There should be enough travel to cause the indicator to trip. If the indicator does not trip in all three tests, the flange nuts have been tightened too far.

Figure 3-18. Tilt Sensor Switch - Adjustment

1. Flange Adjusting Nuts

2. Bubble Level

3121273 – JLG Lift – 3-13

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

3.11 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 (pulsewidth modulation; 16kHz). The Duty Cycle (On & Off time) is varied to control the voltage applied to the Armatures. When the MOSFET's spend 50% of the period On and 50% Off, approximately ½ of the available Battery Voltage will be applied to the Armatures. Similarly, the MOSFET are On continuously (100% Duty Cycle) to apply all available Battery Voltage to the Armatures (as in Driving at Full Speed).

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

force. On level terrain, the Power Module will apply as little as 14A to the fields for higher rotational speeds and better electrical efficiency.

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). 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 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.

Figure 3-19. Traction Control Circuit - ZAPI Power Module

3-14 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Common Traction System Difficulties

1. Ground Module Interlocks

There are a variety of interlocks that prevent Drive due to system events. Before investigating Traction System issues, examine the JLG Analyzer's HELP Menu while attempting to Drive from Platform Mode. Refer to the Section 5 for explanation of the JLG Analyzer Help Messages.

2. Power Module Diagnostic Issues

The Power Module executes a self-test during every power-up to ensure proper functionality. If a Diagnostic Issue is detected, the Power Module will not energize the Main Power Contactor. Instead, it will flash the Green LED, please refer to ZAPI Power Module Electrical Evaluation - page 3-18.

3. Open-Circuit Motor Armature

This issue will allow the vehicle to drive, but one motor will handle the entire traction load. Motor overheating and excessive tire wear will result, along with a lack of traction control.

This 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) should be less than 50A. One wheel will rotate at full speed, while the other will not rotate at all. The Power Module's self-diagnostics cannot detect this fault unless both armatures are open-circuit.

To find the source of the difficulty, disconnect main power at the batteries and investigate the wiring pathways from the Power Controller's M1 and M2 terminals to the armature on the motor that does not rotate. Investigate for issues like improper crimps, loose terminals, and corrosion.

4. 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 hover around 350A. 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, disconnect main power at the batteries 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. Check if the drive motor smells burned.

5. Open-Circuit Motor Field

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

This situation can be detected by elevating the vehicle's front wheels and engaging drive (platform stowed). Under DIAGNOSTICS - TRACTION, the JLG Analyzer's ARM CUR display (Armature Current Reading) will hover around 350A. The FLD CUR display (Field Current Reading) will be erratic or low (less than 10A). Neither wheel will rotate at normal speed, but it will be possible to rotate the drive wheel by hand.

To find the source of the difficulty, pull the Main Battery Disconnect and disconnect the Field Wiring (two blue wires leading to F1 and F2 Terminals) from the Power Module. Using a voltmeter set for resistance scale (Ohms), investigate if there is a short-circuit (less than 5 Ohms) between the two blue wires (this is normal). If not, investigate for improper crimps, burned cables, damaged cables, or damaged field windings.

6. 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 hover around 350A. The FLD CUR display (Field Current Reading) will hover around 40A. Neither wheel will rotate, and it will be impossible to rotate either drive wheel by hand. The Ground Module cannot detect this fault during power-up or selftest since energizing the brakes could pose a hazard. However, it may detect this issue during Drive (investigate using JLG Analyzer).

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SECTION 3 - CHASSIS & SCISSOR ARMS

3.12 POWER CONTROL MODULE - ZAPI

Table 3-3. ZAPI Power Module Specifications

Operating Voltage ( B+) 14.5 to 40 VDC

Maximum Current Limits: A r ma t ur e F ie l d P um p I nt eg r al Ma i n F us e

Standby Current 150 mA

Temperature Range: O pe r a ti n g S to r a ge Thermal Limit

Switching Frequency 16 kHz

The power module is located inside rear machine cover at the left rear of the machine, as shown in Figure 3-20., ZAPI Power Module Location and Orientation (All models). Use the following instructions when replacing the power module.

1. Turn machine power off and disconnect the batteries.

2. Locate and remove the rear cover from the machine.

3. Tag and note the wire terminal locations before removing the power module, also see Figure 3-21.

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

300 A

40 A 180 A 250 A

-40°C to 75°C

-40°C to 125°C 75°C to 90°C

NOTE: The power module for the RS Scissors is installed on

the machine in the upside down position. This is the correct mounting position.

5. When installing the power module, be sure that the terminals are oriented as shown in Figure 3-20.

6. After installing the new power module, begin connecting the wire connectors/cables to the module. (See Table 3-4 and Figure 3-21.)

7. Torque all terminal bolts to torque specifications as shown on the front of the module. Overtightening could damage the module.

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

9. Power up machine and check for normal machine operation.

10. Re-install the rear machine cover.

Table 3-4. Module Terminal Functions

+ BF1 Controller to Main Power Contactor

+ BF2 Left and Right Positive Armature

+ B Positive Pump Connection

– B Controller to Batter y Negative

– T Lef t and Right Negative Armature

– P Negative Pump Connection

F1 To Motor Fields Wired in Series

F2 To Motor Fields Wired in Series

Figure 3-20. ZAPI Power Module Location and Orientation (All models)

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SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-21. Main Electrical Power Connections - (1001129845 - ZAPI Power Module)

1. Batteries

2. Power Module

3. Main Power Contactor Relay

4. Hydraulic Pump Motor

5. Drive Motor Stator Field Wires

6. Drive Motor Armature (Brush) Cables

7. To Battery Charger (+)

8. To Battery Charger (–)

9. To Pin 13 and Pin 32 - J1 Connector on Power Module

10. Battery Quick-Disconnect (OPTION)

3121273 – JLG Lift – 3-17

SECTION 3 - CHASSIS & SCISSOR ARMS

P/N - 1001139845

ZAPI Power Module Electrical Evaluation

INTEGRATED HEALTH INDICATOR

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

ZAPI Power Module - "HEALTH" (Status LED)

3-18 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

3.13 DRIVE MOTOR SERVICING

The drive motors are located at the rear of the machine, inside the machine rear cover, remove the machine rear cover, see Figure 3-1.

Drive Motor Troubleshooting

1. Turn off power to unit, remove side cover and disconnect main battery power.

2. Disconnect drive motor connections from the Power Module inside rear cover.

3. 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.

4. 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

1932RS/6RS 0.21 Ohms 0.037 Ohms

3248RS/10RS 0.127 Ohms 0.051 Ohms

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

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

b. Armature terminals and the case of the motor.

c. Field connector pins to the armature terminals.

6. 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.

Field Resistance

@ 75°F (24°C)

Armature Resistance

@ 75°F (24°C)

Drive Motor Electrical Evaluation

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

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

• Resistance < 2 Ohms Red to Black Armature Wires.

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

• Resistance < 2 Ohms Blue to Orange Field Wires.

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

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

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

Servicing Guidelines

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

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

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

a. Dusty or dirty locations like cement plants, lum-

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

b. High temperature areas like steel mills, found-

ries, etc.

c. Environments with sudden temperature change,

such as in refrigeration plant, etc.

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SECTION 3 - CHASSIS & SCISSOR ARMS

CAUTION

Brake - Manual Disengage Procedure

Figure 3-22. Brakes - Manual Disengage Procedure

1. Cover Bolts

2. Brake Cover

NOTE: The brakes may also be disengaged electrically

using the brake release switch, see procedure in Operation Manual.

CHOCK WHEELS OR SECURE MACHINE WITH TOW VEHICLE.

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

2. Start with either of the drive motors and remove the two cover bolts and brake cover.

3. Thread the cover bolts into the two disengage holes in the brake housing.

4. Tighten down the cover bolts so the brake on that drive motor will disengage.

3. Cover Gasket

4. Disengage Holes

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

6. After towing is complete, chock wheels and remove cover bolts from disengage holes.

7. Reinstall brake cover, replace cover gasket if damaged.

AFTER THE MACHINE IS TOWED, THE COVER 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.

3-20 – JLG Lift – 3121273

Drive Motor Removal

NOTICE

CAUTION

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-23. Electric Drive Motor Removal

1. Electric Drive Motor

2. Motor Mounting Bolts

DISCONNECT ALL POWER BY REMOVING THE POSITIVE (+) BATTERY CABLE AT THE BATTERIES BEFORE REMOVING DRIVE MOTOR.

1. Disconnect the power cables, brake and field power connectors from the drive motor.

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

3. Washers

3. Remove the two motor mounting bolts and washers.

4. Gently remove the drive motor (1).

NOTE: Reference Figure 3-24., 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, see Section 2, Table 2-2, Preventive Maintenance & Inspection Schedule..

ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE OPERATION.

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SECTION 3 - CHASSIS & SCISSOR ARMS

Drive Motor Disassembly

NOTE: Refer to Figure 3-24.

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.

1. Shaft Pilot Bearing

2. Frame & Field Assembly

3. Armature Assembly

4. Brush Spring (4)

5. Brush & Terminal Assembly (Qty.-2)

6. Brush Box Assembly

7. Retaining Ring

Figure 3-24. Drive Motor Components

8. Bearing

9. Commutator End Head

10. Motor to Hub Mounting Screws (Qty.-2)

11. Brake Assembly

12. Cover Gasket

13. Brake Cover

14. Brake Cover Mounting Screws (Qty.-2)

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-

23.).

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 Arma-

3-22 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

ture (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.

Drive Motor Inspection and Service

NOTE: Refer to Figure 3-24.

1. Carefully blow out any accumulated carbon dust and dirt from the Commutator End Head (9) and the Frame & Field Assembly (2) using clean, oil free, compressed air.

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

3. Make sure the Brush Box Assembly (6) is tight on the commutator end head. Replace brush box assemblies in the commutator end head if they are 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 3-24.

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 3-26. 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 3-25.. 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 3-25.

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.

5. Assemble the commutator end head to the Frame & Field Assembly (2) and tighten the screws to 120 140 in-lb (13.6 - 15.8 Nm). Make sure to align the field connection with the notch in the commutator end head. Seal wires where they exit from commutator end head with the Grommet (10).

6. Place the Gasket Seal (12) in the bottom of the notch in the commutator end head. Align wires from the Brake Assembly (11) into the notch in the commutator end head. Secure brake assembly to commutator end head using three bolts.

7. Install Wire Harness (1) to motor by connecting the brake connectors and securing the armature terminals to the terminal studs. Crimp the field connection (red/orange to orange and blue to blue) together and heat shrink. Motor terminals must be assembled as shown in Always secure the bottom nut with a wrench as you tighten the top nut. Torque top nut to 90 - 110 in-lb (10.2 - 12.4 Nm).

3121273 – JLG Lift – 3-23

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-26. Wire Harness Connections

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

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

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

Figure 3-25. Drive Motor Shaft Bearing

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)

3-24 – JLG Lift – 3121273

Drive Motor Installation

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-27. Drive Motor Assembly

1. Drive Motor

2. Motor Mounting Bolts

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. Washers

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.

3121273 – JLG Lift – 3-25

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTICE

CAUTION

3.14 TORQUE HUB SERVICING

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.

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.

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.

RE-ENGAGE BRAKES BEFORE RETURNING TO NORMAL OPERATION.

Roll Test

The purpose of the roll test is to determine if the unit's gears are rotating freely and properly. You 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.

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).

3-26 – JLG Lift – 3121273

Main Gearbox Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-28. 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

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 each of the three tapped holes to force the ring gear out. Be sure and alternate between the jacking screws to keep the ring gear from becoming mis-

7. Cover

8. Cover Snap Ring

9. Pipe Plug

10. Input Carrier Sub-Assembly

11. Hub Sub-Assembly

aligned 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 sub-assembly.

3121273 – JLG Lift – 3-27

SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Disassembly

Figure 3-29. Input Carrier Disassembly

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

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.

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining Ring

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.

3-28 – JLG Lift – 3121273

Hub Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-30. Hub Disassembly

1. Seal

2. Hub

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.

3. Main Bearing

2. Remove main lip seal.

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

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

3121273 – JLG Lift – 3-29

SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Disassembly

Figure 3-31. Spindle Disassembly

1. Spindle Sub-Assembly

2. Shaft Ball Bearing

3. Tanged Washer

4. Thrust Washer

5. Output Planet Gear

6. Output Planet Pins

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.

7. Main Bearing

8. O-Ring

9. Shaft Seal

10. Snap Ring

11. Needle Roller Bearings

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. Remove the motor o-ring from the groove on side opposite from the carrier side.

3-30 – JLG Lift – 3121273

Tightening and Torquing Bolts

BOLT A

BOLT B

Figure 3-32. Assembly Tool 1

Figure 3-33. Assembly Tool 2

Figure 3-34. 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

3121273 – JLG Lift – 3-31

SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Assembly

Figure 3-35. Spindle Assembly

1. Spindle Sub-Assembly

2. Shaft Ball Bearing

3. Tanged Washer

4. Thrust Washer

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

2. 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.

3. Retain the bearing with the spiral retaining ring.

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

5. 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.

6. 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.

5. Output Planet Gear

6. Output Planet Pins

7. Main Bearing

8. O-Ring

9. Shaft Seal

10. Snap Ring

11. Needle Roller Bearings

8. 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.

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

10. 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.

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

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

13. 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.

14. Grease and install the motor o-ring into the groove.

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

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

3-32 – JLG Lift – 3121273

Hub Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-36. Hub Assembly

1. Seal

2. Hub

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

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

3. Main Bearing

3. Flip the hub over.

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

3121273 – JLG Lift – 3-33

SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Assembly

Figure 3-37. Input Carrier Assembly

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

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

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining 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.

NOTE: Do not overstress the snap ring.

3-34 – JLG Lift – 3121273

Main Gearbox Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-38. Main Gearbox Assembly

1. Spindle Sub-Assembly

2. Spiral Snap Ring

3. Input ring Gear

4. Input Sun Gear

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.

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.

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

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 outside diameter 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.

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.

3121273 – JLG Lift – 3-35

SECTION 3 - CHASSIS & SCISSOR ARMS

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.

13. Re-install drive motor to torque hub per instructions Drive Motor Installation - page 3-25, install on machine.

14. Test per instructions in Section 3.14, Torque Hub Servicing, for proper operation and to check for any oil leaks.

3-36 – JLG Lift – 3121273

NOTES:

SECTION 3 - CHASSIS & SCISSOR ARMS

3121273 – JLG Lift – 3-37

SECTION 3 - CHASSIS & SCISSOR ARMS

3.15 STEER ASSEMBLY COMPONENTS

Figure 3-39. 1932RS/6RS - Steer Assembly

NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-pur-

pose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking.

1. Install the bearing with the flange surface on top of the spindle arm.

2. Assemble the spindle kingpin attach, banjo pin hardware, in the frame hole towards the front of the machine.

3. Install cylinder to frame attach pin with cotter pin hole on top.

3-38 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-40. 3248RS/10RS - Steer Assembly

NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-pur-

pose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking.

1. Install the bearing with the flange surface on top of the spindle arm.

3121273 – JLG Lift – 3-39

SECTION 3 - CHASSIS & SCISSOR ARMS

3.16 ARMS AND PLATFORM POSITIONING AND SUPPORT

NEVER WORK UNDER N ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING.

The arm stack can be supported by using an overhead crane,(See Figure 3-41.). If an overhead crane is not available the stack may also be lifted by using a fork-truck using the following instructions:

1. With the forks on the fork-truck slid close together, enter from the front of the machine and place the forks on the cross tube of the second arm assembly below the platform.

2. Slowly lift the arm stack with the fork-truck while the manual descent valve is being engaged (this allows the oil to drain back into the tank).

3. Place machine on safety prop and leave the fork truck in place.

4. At this point the lift cylinder removal may begin.

(Refer to Section 4.6, Lift Cylinder Removal)

If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and platform removal.

3.17 PLATFORM REMOVAL

1. Support the platform using an overhead crane with straps capable of lifting at least 500 lbs (227 kg) (See Figure 3-41.). Refer to Section 3.16, Arms and Platform Positioning and Support.

2. Disconnect and remove the platform control station and wiring harness at the platform. Disconnect AC receptacle cable if applicable. Route the cables out through the hole at the right-rear of the platform to free platform of any constraints when lifting.

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 arm stack and set aside.

NOTE: When attaching platform back onto scissor arm

assembly, follow removal procedures in reverse order.

3.18 SCISSOR ARMS REMOVAL

1. Remove platform (refer to Section 3.17, Platform Removal).

2. Disconnect all wiring and cables attached to scissor arm assembly.

3. 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 2000 lbs (907 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/Installing scissor arms individually:

See Figure 3-42., Figure 3-43., Figure 3-44. and Figure 3-

45.

1. With the platform removed, 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.

3-40 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-41. Arms and Platform Positioning and Support

3121273 – JLG Lift – 3-41

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-42. 1932RS/6RS - Scissor Arm Assembly - Ref. Figure 3-43.

3-42 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-43. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration

3121273 – JLG Lift – 3-43

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-44. 3248RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45.

3-44 – JLG Lift – 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-45. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration

3121273 – JLG Lift – 3-45

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTICE

3.19 PLATFORM CONTROL STATION

POWER MACHINE DOWN AT THE GROUND CONTROL STATION BEFORE DISCONNECTING THE PLATFORM CONTROL STATION.

Installation/Removal

1. Disconnect the platform control station harness at the connector below the control station mount.

2. Remove the pin securing the control station to the platform station mount, swing and lift to remove control station from the machine.

Control Station Harness Installation to Scissor Arms

Below are a few notes for positioning and securing the platform control station harness to the scissor arms when installing or removing the harness on the machine.

• Orange and yellow marker tape strips are located on the platform harness to assist in installation.

• At every yellow marker tape, secure the harness to the nuts welded on the arms using wire ties.

• At every orange marker tape, secure the harness to the cable carrier using wire ties.

• If necessary, additional wire ties should be used to firmly attach the harness to the machine.

Control Station Disassembly

1. Place the platform control station assembly on a suitable work bench.

2. Remove the main body from the mount, by removing the long through bolt, cap-nut and washers (item

1) and the two (2) bolts and nuts (item 2) along the rear edge.

Figure 3-46. Platform Control Station Installation

1. Harness Connector

2. Mounting Pin

3. To install, reverse steps 1 and 2 above.

3. Lift and Remove

Figure 3-47. Platform Control Station Disassembly

1. Through Bolt, Cap-nut and Washers

2. Rear Edge Bolts and Nuts

3-46 – JLG Lift – 3121273

Overview of Control Station Components

1001132362 B

FRONT

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-48. Platform Control Station Components -

External

1. Steer Control Switch

2. Drive and Lift Joystick Control

3. Trigger Switch

4. Forward/Reverse/Lift/Lower

Direction Decal

5. Alarm

6. Overload Indicator (If Equipped)

7. Machine Tilt Indicator

8. Emergency Stop Switch

9. Horn Button

10. Drive and Lift Select

Switch

11. Low Battery Charge/System Fault Indicator

Figure 3-49. Platform Control Station Components -

Internal

1. Drive and Lift Joystick Control

2. Low Battery Charge/System

Fault Indicator

3. Drive and Lift Select Switch

4. Emergency Stop Switch

NOTE: (1) Zip-tie item-6 - Harness Splice Connector - to

item- 5 - Horn Switch, to prevent any possible interference with the joystick path.

5. Horn Button

6. Harness Splice Connector

7. Machine Tilt Indicator

8. Overload Indicator

(If Equipped)

9. Alarm

(1)

3121273 – JLG Lift – 3-47

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-50. Joystick

Joystick Controller

Table 3-5. 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

NOTE: For joystick calibration procedure see Joystick Cali-

bration - page 5-5.

Term Color Function

1RED HANDLE COM

2 VIOLET TRIGGER N.O.

3-- SPARE

4YELLOW ROCKER RT

5 GREEN ROCKER LT

6-- SPARE

7WHITE/RED +5VDC

8 WHITE/BLACK GROUND

9BROWN SIG OUTPUT

Table 3-6. Connector Chart

CONNECTOR PINOUT

3-48 – JLG Lift – 3121273

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 hydraulic lift circuit to prevent motion unintended by the operator in the event of a hydraulic line failure.

4.2 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

Control valves used are four-way, three-position solenoid valves of the sliding spool design. When a circuit is activated and the control valve solenoid energizes, the spool is shifted and the corresponding work port opens to permit oil flow to the component in the selected circuit, with the opposite work port opening to reservoir. Once the circuit is deactivated (control returned to neutral), the valve spool returns to neutral (center) and oil flow is then directed through the valve body and returns to reservoir. A typical control valve consists of the valve body, sliding spool, and two solenoid assemblies. The spool is machine fitted in the bore of the valve body. Lands on the spool divide the bore into various chambers, which, when the spool is shifted, align with corresponding ports in the valve body open to common flow. At the same time other ports would be blocked to flow. The spool is springloaded to center position, therefore when the control is released, the spool automatically returns to neutral, prohibiting any flow through the circuit.

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, 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 the 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 and/or electric power is lost.

3121273 – JLG Lift – 4-1

SECTION 4 - HYDRAULICS

4.3 PUMP/MOTOR

Theory of Operation

The Power Module (see Section 3.12, Power Control Module - ZAPI) 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 main power at the batteries and all pump motor cables during this analysis.

• Resistance < 5 Ohms between Motor Terminals. 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 Mega-Ohms 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 batter compartment. The vehicle should be placed on a smooth, firm, and level surface for all analysis.

1. Open-Circuit between +B Terminal and Pump Motor Positive Terminal

This issue will allow the vehicle to drive, but Lift Up and Steer Functionality will be lost and the Pump Motor will not operate. Under DIAGNOSTICS PUMP, the JLG Analyzer will show PUMP PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.

As shown in the diagram, the voltage measured between the Pump Motor Positive Terminal and Ground Reference should be 24V. If it is not, examine the cable between the terminal and the Power Module compartment. Inspect crimps for corrosion and ensure that bolted connections are tight. Ensure that the cable is not crushed where it passes between the frame side sheets and the cylinder assembly.

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.

3. Open-Circuit Pump Motor

Disconnect main power at the batteries 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

4-2 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

-B

Series DC

Pump Motor

24V

Line Contactor

Power Module

the Pump Motor Positive and Negative Terminals is less than 2 Ohms. If not, examine the pump motor for worn brushes or broken terminals. After examination, re-connect the Pump Motor Positive Terminal and main power at the batteries.

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.

Disconnect main power at the batteries to completely de-energize the Control System. Next, detach both Pump Motor Terminals and insulate them independently. Re-connect main power at the batteries 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 shortcircuit (most likely near area where cylinder retracts between frame side sheets or near pot-hole mechanism, if equipped). 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.

Hydraulic Oil Check Procedure

Lube Point(s) - Hydraulic Reservoir

Lube - Hydraulic Oil

Interval - Check Daily

Table 4-1. Hydraulic System Capacities

COMPONENT 1932RS/6RS 3248RS/10RS

Hydraulic Tank 1.32 Gal. (5 L) 2.38 Gal. (9 L)

Hydraulic System 1.85 Gal. (7 L) 3.96 Gal. (15 L)

NOTE: Check the hydraulic oil level with the platform in the

stowed position ONLY. Be certain the hydraulic oil has warmed to operating temperature before checking the oil level in the reservoir.

1. On the left side of the machine, remove the side access door on the base frame. Locate the hydraulic oil reservoir (1) on the pump unit (2).

Check the oil level in the hydraulic reservoir by looking at the markings on the side of the tank. The reservoir is marked with a MAX (maximum) marking (3). The oil level must be kept at or within one (1) inch of this marking to operate properly.

2. If additional oil is required, wipe all dirt and debris from the filler/breather cap (4) area, add proper grade of oil. Fill until oil level is close to the MAX marking (3), but not over the MAX marking.

NOTE: Care should be taken not to introduce any impurities

(dirt, water, etc.) while cap is removed.

3121273 – JLG Lift – 4-3

SECTION 4 - HYDRAULICS

NOTICE

Figure 4-1. Hydraulic Oil Check Procedure - All

Machines

c. Replace the tank. Torque mounting bolts to 6-7

ft-lb. (8.5-10 Nm).

d. If only replacing the oil filter and maintenance is

complete, reinstall tank assembly on machine, remove fill cap and refill tank with proper grade of oil by using a funnel. Fill until oil is up to the MAX level indicator on the side of the tank.

4. To remove the oil pickup line, squeeze retainer and slide outward.

NOTE: There are two o-rings located in the valve for the pump out-

let.

5. Replace the o-rings if necessary.

6. Remove allen nut on the return/filter line and rotate large retainer ring to remove return/filter line.

NOTE: Recommended lubricating intervals are based on

machine operations under normal conditions. For machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.

Pump/Tank Disassembly

(See Figure 4-2.)

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 hydraulic reservoir and tilting the assembly up allowing oil to drain into a clean container.

2. Remove the oil tank from the pump as follows:

a. Slowly loosen and remove the four bolts that

hold the tank to valve body attachment ring on to the valve body.

b. Carefully remove the tank from the valve taking

care not to damage internal pickup tube or oring gasket on tank.

c. Place tank on a suitable work bench or work

area.

7. With the return line and the pickup tube removed, the pump can be removed.

8. Loosen and remove the two hexhead nuts from the pump and block.

NOTE: Be sure to remove and discard the plastic plug at the oil inlet

on the new pump before installing.

9. Check o-ring on valve block and replace if necessary before installing the new pump.

NOTE TORQUE VALUES IN FIGURE 4-2. FOR THE VARIOUS FASTENERS AND VALVES INSTALLED ON THE VALVE BODY. DO NOT OVERTIGHTEN OR DAMAGE COULD OCCUR.

Pump Motor Removal

1. Remove the four bolts attaching the motor to the valve adapter assembly.

2. Pull motor from valve.

3. Once all maintenance is performed, reinstall tank assembly on machine, remove fill cap and refill tank with proper grade of oil by using a funnel. Fill until oil is up to the MAX level indicator on the side of the tank.

NOTE: The filter and bypass are located on the pickup tube inside

the tank. The filter should be changed once a year.

3. If replacing filter, pull old filter off the end of the tube and push new filter onto the end of tube.

a. Thoroughly clean the tank and clean any debris

from the magnet.

b. Wipe out tank with clean, lint free rag, taking

care not to introduce debris or dirt.

4-4 – JLG Lift – 3121273

Torque: 15 - 18 ft. lb.

Torque: 29 - 37 ft. lb.

Torque: 18 - 22 ft. lb.

Torque: 37 - 44 ft. lb.

Torque: 24 - 29 ft.lb.

Torque: 6 - 7 ft. lb.

8.5-10 Nm

25 - 30 Nm

40 - 50 Nm

20 - 25 Nm

32 - 40 Nm

50 - 60 Nm

Torque: 3.5 - 4.5 ft.lb.

5 - 6 Nm

Torque: 15 - 18 ft. lb.

SECTION 4 - HYDRAULICS

Figure 4-2. Hydraulic Motor, Pump and Tank Assembly (All Machines)

1. Main Valve Body

2. Pump Electric Motor

3. Motor to Valve Body Adapter

4. Hydraulic Oil Tank

5. Tank to Valve Body Attachment Ring

6. Tan k to Valv e Bo d y - O -Ring

7. Auxiliary Pressure (M) Port

8. Suction Pipe

9. Suction Filter

10. Modular to Main Valve Body Screw

11. Solenoid Valve

12. Lift Relief Valve

13. Steer Relief Valves

14. Valve Coil for Steer Cylinder

15. Gear Pump

16. Return Filter w/Bypass

17. Return Filter Pipe

18. 1/4" JIC/BSPP Adapter

19. 3/8" JIC/BSPP - 90° Adapter

20. Product ID Plate

21. Valve Coil for Lift Up/Down

22. M Port - 1/4" BSPP

23. P1 Por t - 3/8" BSPP

3121273 – JLG Lift – 4-5

SECTION 4 - HYDRAULICS

4.4 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 to full height.

3. Adjust the pressure setting screw on lift relief valve to reach the proper lift pressure per model as listed

in Table 4-2.

Model Lift Relief Steer Relief

1932RS/6RS

3248RS/10RS

Alternate Lift Pressure Setting Procedure (if 120% load or high ceiling is not available):

1. Install adapter from table into M-port or P1-port on pump (see Figure 4-2.) and attach pressure gauge.

Table 4-3. Pressure Fitting Adapter

2. Remove the solenoid from the lift valve.

3. Activate the lift function from the ground or platform and adjust the pressure setting screw on lift relief valve to reach the proper lift pressure per model as listed in Table 4-2.

Table 4-2. Lift Pressure Settings

2300 psi ± 50 psi

(159 bar ± 3.5 bar)

2500 psi ± 50 psi

(172 bar ± 3.5 bar)

PORT JLG PART #

300057 - JIC

300017 - JIC

2221222 - Quick Disconnect

1000 psi

(69 bar)

1000 psi

(69 bar)

4.5 CYLINDER CHECKING PROCEDURE

NOTE: Cylinder check must be performed anytime a system compo-

nent is replaced or when improper system operation is suspected.

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.

NOTE: Steps 5 through 7 for Steer Cylinder Only.

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. Remove the pressure gauge from port M or P1 and replace plug.

5. Replace the solenoid on the lift valve.

4-6 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

NOTICE

4.6 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 3.15, Scissor Arms Removal.

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 use an overhead crane or fork truck to secure the platform and scissor arms before lift cylinder removal begins. (See Figure 3-

41.)

2. Cut any wire ties that attach any cables or hoses to the lift cylinder.

DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER ASSEMBLY.

3. Remove the valve connector, the two hoses and the manual decent cable from the cylinder.

NOTE: To avoid having to readjust the manual descent, remove the

large nut located behind the manual descent bracket as shown. Also see Figures 3-42., 3-43., 3-44., for lift cylinder mounting hardware configurations.

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 from the lower cylinder pin and have someone assist you in lifting the cylinder from the scissor arms.

6. Place the cylinder on a clean workbench.

3121273 – JLG Lift – 4-7

SECTION 4 - HYDRAULICS

NOTICE

Figure 4-3. Cylinder Barrel Support

Figure 4-4. Cylinder Rod Support

4.7 CYLINDER REPAIR

NOTE: The following are general procedures that apply to the cylin-

ders 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.

removing again. If still no release, tap barrel with hammer in threaded area, and try again. Repeat if necessary, until head is completely removed.

7. 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.

8. With the barrel clamped securely, apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel.

9. 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.

10. Loosen and remove the cap screw(s), if applicable, which attach the tapered bushing to the piston.

11. 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.

12. Remove the bushing from the piston.

5. Mark cylinder head and barrel with a center punch for easy realignment. Loosen the cylinder head setscrew.

6. Using the proper wrench, loosen the cylinder head and remove head from cylinder barrel. When removing cylinder head do not force if binding occurs. Reverse rotation a couple times and try

13. Screw the piston CCW, by hand, and remove the piston from cylinder rod.

14. Remove and discard the piston o-rings, seal rings, and backup rings.

15. If applicable, remove the piston spacer from the rod.

16. Remove the rod from the holding fixture. Remove the cylinder head gland and retainer plate, if applica-

4-8 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

STEEL

BUSHING

GAR-MAX BUSHING

ARBOR

Figure 4-5. Gar-Max Bearing Installation

ble. 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.

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 damage.

If steel bushing is worn or damaged, rod/barrel must be replaced.

c. Lubricate inside of steel bushing with WD40

prior to bearing installation.

d. Using an arbor of the correct size, carefully

press the bearing into steel bushing.

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.

9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace 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.

3121273 – JLG Lift – 4-9

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 cylinder

seal kit is used. See your JLG Parts Manual for these machine models.

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. If applicable, correctly place new o-ring in the inner piston diameter groove. (The backup ring side facing the O-ring is grooved.)

6. 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.

7. Using suitable protection, clamp the cylinder rod in a vise or similar holding fixture as close to piston as possible.

4-10 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

NOTICE

Head Gland

Piston Asssembly

Barrel Asssembly

Cylinder Rod

Figure 4-10. Rod Assembly Installation

8. Carefully thread the piston on the cylinder rod hand tight, ensuring that the o-ring and back-up rings are not damaged or dislodged.

9. 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.

10. 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.

11. Tighten the capscrews evenly and progressively in rotation to the specified torque value.

12. 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.

13. Retorque the capscrews evenly and progressively in rotation to the specified torque value.

14. Remove the cylinder rod from the holding fixture.

15. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston.

16. 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.

17. With the barrel clamped securely, and while adequately supporting the rod, insert the piston end into the barrel cylinder. Ensure that the piston loading oring and seal ring are not damaged or dislodged.

18. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

19. Secure the cylinder head gland using the washer ring and socket head bolts.

20. 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.

21. If applicable, install the cartridge-type holding valve and fittings in the rod port block, using new o-rings as applicable. (See Figure 4-13., 1932RS/6RS - Lift Cylinder or Figure 4-14., 3248RS/10RS - Lift Cylinder).

22. Push the piston onto the rod until it abuts the spacer end and install the attaching nut.

WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #262 TO THE PISTON NUT, THEN TORQUE PISTON NUT. REFER TO APPLICABLE CYLINDER ILLUSTRATION FOR TORQUE REQUIREMENT.

NOTE: Reverse the procedure Steer Cylinder Piston Removal on

page 4-9 for installing the steer cylinder piston.

23. Remove the cylinder rod from the holding fixture.

24. 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.

3121273 – JLG Lift – 4-11

SECTION 4 - HYDRAULICS

25. 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.

26. Continue pushing the rod into the barrel until the cylinder head gland can be inserted into the barrel cylinder.

27. If applicable, secure the cylinder head retainer using a suitable chain wrench.

28. 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.

29. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applicable. Refer to Figure 4-13., 1932RS/6RS - Lift Cylinder on page 4-13. or Figure 4-14., 3248RS/ 10RS - Lift Cylinder on page 4-14

Lift Cylinder - LSS Pressure Sensor Location (If Equipped)

Lift cylinders on machines with the Load Sensing System (LSS) are equipped with two pressure sensing transducers installed. These sensors, two are used in case one should fail, are wired in parallel directly to the machine control module as part of the LSS system.

Figure 4-12. LSS Pressure Sensors Location -

3248RS/10RS - (If Equipped)

1. Ports On Bottom of Cylinder

2. Pressure Sensors

3. Harness Connectors

Figure 4-11. LSS Pressure Sensors Location -

1. Ports On Barrel of Cyl-

2. Pressure Sensors

1932RS/6RS - (If Equipped)

3. Harness Connectors

inder

4-12 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

Torque: 240 - 294 ft. lb.

Torque: 25 - 30 ft. lb.

325 - 398 Nm

33 - 40 Nm

Torque: 29 - 38 ft. lb.

39 - 51 Nm

Torque: 358 - 438 ft. lb.

485 - 593 Nm

(Apply Loctite #262 to threads

before assembly.)

1. Cylinder Barrel

2. Cylinder Rod

3. Bushing

4. Proportional Valve w/Manual

Release

5. Check Valve

Figure 4-13. 1932RS/6RS - Lift Cylinder

6. Extend/Retract - Block Fittings

7. Head

8. Seal

9. Seal w/Backing Ring

10. O-Rings

11. Wear Ring

12. Rod Piston

13. D-Ring

14. Seal

15. Wear Ring

16. O-Ring

17. Piston Nut

3121273 – JLG Lift – 4-13

SECTION 4 - HYDRAULICS

Torque: 406 - 448 ft. lb.

Torque: 25 - 30 ft. lb.

634 - 700 Nm

33 - 40 Nm

Torque: 29 - 38 ft. lb.

39 - 51 Nm

Torque: 577 - 637 ft. lb.

782 - 863 Nm

(Apply Loctite #262 to threads

before assembly.)

1. Cylinder Barrel

2. Cylinder Rod

3. Bushing

4. Proportional Valve and Coil, w/

Manual Release

5. Check Valve

Figure 4-14. 3248RS/10RS - Lift Cylinder

6. Pressure/Tank - Block Fittings

7. Head

8. Seal

9. Seal w/Backing Ring

10. O-Rings

11. Wear Ring

12. Rod Piston

13. D-Ring

14. Seal

15. Wear Ring

16. O-Ring

17. Piston Nut

4-14 – JLG Lift – 3121273

SECTION 4 - HYDRAULICS

Torque: 97 - 119 ft. lb.

Torque: 13 ft. lb.

131 - 161 Nm

17.6 Nm

Torque: 306 - 374 ft. lb.

415 - 507 Nm

(Apply Loctite #262 to threads

before assembly.)

Figure 4-15. 1932RS/6RS - Steer Cylinder

1. Cylinder Barrel

2. Cylinder Rod

3. Head

4. Wiper Seal

5. Rod Seal

6. Wear Ring

7. O-Ring

8. O-Ring

9. Piston

10. Rod O-Ring

11. Piston Seal

12. Wear Ring

13. Nut

14. Hose Fittings

15. O-Ring

3121273 – JLG Lift – 4-15

SECTION 4 - HYDRAULICS

Torque: 97 - 119 ft. lb.

Torque: 13 ft. lb.

131 - 161 Nm

17.6 Nm

Torque: 306 - 374 ft. lb.

415 - 507 Nm

(Apply Loctite #262 to threads

before assembly.)

1. Cylinder Barrel

2. Cylinder Rod

3. Head

4. Wiper Seal

5. Rod Seal

Figure 4-16. 3248RS/10RS - Steer Cylinder

6. O-Ring

7. Wear Ring

8. O-Ring

9. Piston

10. Piston O-Ring

11. Piston Seal

12. Wear Ring

13. Nut

14. Hose Fittings

15. O-Ring

4-16 – JLG Lift – 3121273

5.1 HAND HELD ANALYZER

me n u :

PRESS ENTERHELP:

Analyzer Display

Escape Key

To return home or 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 item menus

Up & Down Arrow Keys

Value Selector

Figure 5-1. Hand Held Analyzer

SECTION 5 - JLG CONTROL SYSTEM

SECTION 5. JLG CONTROL SYSTEM

Diagnostic Port

The diagnostic port to connect the Hand Held Analyzer is located behind the hydraulic cover (machine left side) at or near the ground control station as shown in Figure 5-2.

To Connect the Hand Held Analyzer:

1. Connect the four pin end of the cable supplied with

NOTE: The cable has a four pin connector at each end of

the analyzer, to the diagnostic port and connect the remaining end of the cable to the analyzer.

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.

Figure 5-2. Diagnostic Port Location

3121273 – JLG Lift – 5-1

SECTION 5 - JLG CONTROL SYSTEM

MENU: HEL P: P RES S EN T E R

l og: (211)

Using the Analyzer:

With the machine power on and the analyzer connected properly, the analyzer will display the following:

In platform mode,

HELP: (001) EVERYTHING OK,

In ground mode,

HELP: (002) GROUND MODE OK

If ENTER is pressed again, the display moves to the following display:

HELP: PRESS ENTER

At this point, using the RIGHT and LEFT arrow keys, you can move between the top level menu items. To select a displayed menu item, press ENTER. To cancel a selected menu item, press ESC; then you will be able to scroll using the right and left arrow keys to select a different menu item.

The top level menus are as follows:

HELP DIAGNOSTICS SYSTEM TEST ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATION EMULATION MODE

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:

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 – JLG Lift– 3121273

Changing the Access Level of the Hand Held

MENU: ACCESS LEVEL 2

MENU: ACCESS LEVEL 1

Analyzer:

When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration settings which cannot be changed until you enter a password to advance to a lower level. This ensures that a setting cannot be accidentally altered. To change the access level, the correct password must be entered. To enter the password, scroll to the ACCESS LEVEL menu.

For example:

SECTION 5 - JLG CONTROL SYSTEM

Press ENTER to select the ACCESS LEVEL menu.

Using the UP or DOWN arrow keys, enter the first digit of the password, 3.

Then using the RIGHT arrow key, position the cursor to the right one space to enter the second digit of the password.

Use the UP or DOWN arrow key to enter the second digit of the password which is 3.

Repeat this process until you have entered all five digits of the password which is 33271.

Once the correct password is displayed, press ENTER. The access level should display the following, if the password was entered correctly:

MENU:

ACCESS LEVEL 1

Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings:

MENU:

ACCESS LEVEL 2

3121273 – JLG Lift – 5-3

SECTION 5 - JLG CONTROL SYSTEM

PER SO NALITIES: DRIVE A CCEL 0 .7s

GROUND ALARM: 1=DESCENT

Adjusting Parameters Using the Hand Held Analyzer

Once you have gained access to level 1, and a personality item is selected, press the UP or DOWN arrow keys to adjust its value, for example:

Machine Setup

When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example:

FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICULAR MACHINE CAN RESULT IN IMPROPER OPERATION.

PERSONALITIES: DRIVE ACCEL 0.7s

There will be a minimum and maximum for the value to ensure efficient operation. The Value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular personality. If the value does not change when pressing the up and down arrows, check the access level to ensure you are at access level 1.

GROUND ALARM:

1=DESCENT

The effect of the machine digit value is displayed along with its value. The above display would be selected if the machine was equipped with a ground alarm and you wanted it to sound when driving. There are certain settings allowed to install optional features or select the machine model.

When selecting the machine model to match the size of the machine, the personality settings will return to default settings.

NOTE: Refer to Table 5-1, Machine Model Adjustment and

Figure 5-2, Machine Configuration Programming Information for the default settings.

Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings.

CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE.

5-4 – JLG Lift– 3121273

JLG 3248RS, 32410RS Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Service & Maintenance Manual

A. GENERAL

B. HYDRAULIC SYSTEM SAFETY

C. MAINTENANCE

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

Platform Capacities

Dimensional Data

Tires

Batteries

Electrical System Motors

Travel Speed

Lift Speed

1.2 CRITICAL STABILITY WEIGHTS

1.3 LUBRICATION

Hydraulic Oil

Pressure Settings

1.4 LIMIT SWITCHES

Tilt Alarm

High Drive Speed Cutout

1.6 MAJOR COMPONENT WEIGHTS

1.7 TORQUE REQUIREMENTS

1.5 CYLINDER SPECIFICATIONS

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 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

Footnotes:

Maintenance and Inspection Schedule Codes:

2.3 SERVICE AND GUIDELINES

General

Safety and Workmanship

Cleanliness

Component Disassembly and Reassembly

Pressure-Fit Parts

Bearings

Gaskets

Components Removal and Installation

Bolt Usage and Torque Application

Hydraulic Lines and Electrical Wiring

Hydraulic System

Lubrication

Battery

2.4 LUBRICATION AND INFORMATION

Hydraulic System

Hydraulic Oil

Changing Hydraulic Oil

Lubrication Specifications

2.5 CYLINDER DRIFT TEST

Platform Drift

Cylinder Drift

2.6 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

SECTION 3. CHASSIS & SCISSOR ARMS

3.1 MACHINE COMPONENT COVERS

3.2 BATTERY REMOVAL/MAINTENANCE

Battery Maintenance and Safety Practices

3.3 BATTERY CHARGER

3.4 BATTERY CHARGING

Battery Charger Fault (LED Flash)

Battery Charger Maintenance

Battery Charger Troubleshooting

3.5 DC TO AC INVERTER (IF EQUIPPED)

Inverter Location on Machine

Inverter Operation

Inverter Troubleshooting

Inverter Specifications

3.6 GROUND CONTROL STATION

Components Location

Installation

Removal (All Models)