JLG 3248RS, 32410RS Service Manual

Service & Maintenance Manual

Models

1932RS/6RS

3248RS/10RS

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

SECTION A. INTRODUCTION - MAINTENANCE SAFETY

PRECAUTIONS

A. GENERAL

C. MAINTENANCE

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.

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

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

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

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

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

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

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

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

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

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

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

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

•USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS.

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INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

REVISION LOG

Original Issue - January 30, 2012

Manual Revised - August 1, 2012

Manual Revised - January 29, 2013

Manual Revised - April 8, 2013

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TABLE OF CONTENTS

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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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

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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

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

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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

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	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

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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

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	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

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SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1SPECIFICATIONS

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
Maximum Drive Speed	Stowed:			2.5 mph (4 kph)
	Elevated:		0.3 mph (0.5 kph)
Maximum Stowed Travel Grade (Gradeability)				25% (14°)
Inside Turning Radius		23.6 in. (60 cm)			47.9 in. (121.7 cm)
Outside Turning Radius		87.9 in. (221.9 cm)			125.3 in. (318.1 cm)
CHASSIS
Approximate Gross Machine Weight	ANSI/CSA:	3,000 lb. (1,360 kg)			5,070 lb. (2,300 kg)
	CE:	3,450 lb. (1,565 kg)			6,050 lb. (2,744 kg)
Maximum Tire Load (per wheel)	ANSI/CSA:	1,365 lb. (620 kg)			1,835 lb. (832 kg)
	CE:				2,070 lb. (940 kg)
Ground Bearing Pressure	ANSI/CSA:	130 PSI (9.18 kg/cm2)			81 PSI (5.69 kg/cm2)
	CE:				108 PSI (7.6 kg/cm2)
Ground Clearance		3.1 in. (7.8 cm)			4.1 in. (10.3 cm)

Platform Capacities

Table 1-2. Platform Capacities

		MACHINE	MAXIMUM	MAXIMUM CAPACITY	MAXIMUM PERSONS	MAX. SIDE FORCE	MAXIMUM
	SPECIFICATION		PLATFORM	ALLOWED ON		(Platform Fully Extended	OPERATING
		MODEL			ALLOWED IN PLATFORM
			CAPACITY (1)	PLATFORM EXTENSION		@ Max. Capacity)	WIND SPEED
	ANSI/CSA/JPN	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
	ANSI EXPORT	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
	CE	6RS	230 Kg	120 Kg	Indoor - 2 Persons + 70 Kg	400 N	0 m/s
					Outdoor - 1 Person + 150 Kg	200 N	12.5 m/s
		10RS	320 Kg	120 Kg	Indoor - 2 Persons + 160 Kg	400 N	0 m/s
					Outdoor - 1 Person + 240 Kg	200 N	12.5 m/s
	NOTE: (1) Maximum Platform Capacity includes platform and platform extension.

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Dimensional Data

Table 1-3. Machine Dimensions

	DESCRIPTION	1932RS/6RS	3248RS/10RS
	Platform Height -	19 ft.	32 ft.
	Elevated	(5.8 m)	(9.75 m)
	Platform Height -	79.4 in.	95.8 in.
	Stowed	(2.02 m)	(2.43 m)
	Platform Height -	N/A	78.3 in.
	Stowed (Rails Down)		(1.99 m)
	Working Height	25 ft.	38 ft.
		(7.62 m)	(11.5 m)
	Rail Height	40 in.	40.5 in.
	(From platform floor)	(101.6 cm)	(102.9 cm)
	Rail Height	40 in.	41 in. (104.3 cm) - ANSI
	(Platform Floor to Top of
		(101.6 cm)	43.6 in. (110.7 cm) - CE
	Rail)
	Rail Height - Folded	69.3 in. (176 cm)	78.3 in. (198.9 cm)- ANSI
	(Ground to Mid Rail)	CE ONLY	77.6 in. (197.1 cm) - CE
	Overall Machine Width	32 in.	48 in.
		(81.28 cm)	(122 cm)
	Overall Machine Length	81.5 in.	90 in. (2.28 m) - ANSI
	(w/ladder)	(207 cm)	94.8 in. (240.7 cm) - CE
	Platform Size - Length	71.7 in.	84.7 in.
		(182 cm)	(215.1 cm)
	Platform Size - Width	26.9 in.	42.5 in.
		(68.4 cm)	(107.9 cm)
	Wheelbase	55 in.	73 in.
		(139.7 cm)	(185.4 cm)

Tires

Table 1-4. Tire Specifications

DESCRIPTION	1932RS/6RS	3248RS/10RS
Size	12.71 in. x 3.94 in.	16 in. x 5 in.
	(323 mm x 100 mm)	(406 mm x 127 mm)
Wheel Bolt Torque	120 ft lb. (163 Nm)

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

NOTICE

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	1706740A
power to be easily disconnected at

the batteries without removing bat-

tery 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.

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Electrical System

Motors

Table 1-6. Electrical System Specifications

• Drive Motor

Type: Shunt Wound, Sepex 24V DC

DESCRIPTION

ALL MACHINES

Power: 0.65 Horsepower @ 3750 rpm

Electrical System Voltage (DC)

24V - DC

• Hydraulic Pump/Electric Motor Assembly

Battery Charger: (1001129847)

(All Models)

Input:

Type: Series Wound Permanent Magnet 24V DC

AC Input Voltage:

85-265V AC

Power: 3kW

Nominal AC Input Voltage:

120VAC / 230VAC RMS

Input Frequency:

45 - 65Hz

Max. AC Input Current:

12A - RMS @ 108V AC

Ingress Protection:

IP46 NEMA4 Type 4

Operating Temperature:

-22°F (-30°C) to 122°F (+50°C)

Output:

Nominal DC Output Voltage:

24V

Max. DC Output Voltage:

33.6V

Max DC Output Current:

25A

Max. Interlock Current:

1A

Protection:

Output Reverse Polarity:

Electronic Protection-Auto Reset

Output Short Circuit:

Electronic Protection-Auto Reset

AC Overload:

Current Limited

DC Overload:

Current Limited

DC to AC Inverter - Output Rating:

120V-AC, 60Hz - 7.5 Amps - 900

(OPTION)

Watts - Modified Sinewave

Travel Speed

Table 1-7. Travel Speed

ELEVATED SPEED

MAXIMUM SPEED (PLATFORM LOWERED)

MODEL

UNIT OF MEASURE

Mph

Sec/25 ft

Kph

Mph

Sec/25 ft

Kph

(Sec/7.6 m)

(Sec/7.6 m)

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

Lift Speed

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

Table 1-8. Lift Speed

	MODEL	LIFT UP	LIFT DOWN
		(SECONDS)	(SECONDS)
	1932RS/6RS	22 - 29	21 - 31
	3246RS/10RS	55 - 65	40 - 50

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1.2CRITICAL 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 -
	(each)	Front:	21.6 lb. (9.8 kg)	43 lb. (19.5 kg)
		Rear:	21.6 lb. (9.8 kg)	40.5 lb. (18.4 kg)
	Wheel/Tire and		113 lb. (51.3 kg)	134 lb. (60.8 kg)
	Drive Assembly (each)
	Batteries (each)	Standard:	62 lb. (28.1 kg)
		AGM:	65 lb. (29.5 kg)
	Batteries (combined)
		Standard :	248 lb. (111.1 kg)
		AGM:	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

	HYDRAULIC SYSTEM OPERATING	SAE VISCOSITY GRADE
	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

1.4 LIMIT SWITCHES

Tilt Alarm

Table 1-11. Lubrication Specifications

	KEY	SPECIFICATIONS
		Multipurpose Grease having a minimum dripping
	MPG	point of 350°F. Excellent water resistance and adhe-
		sive qualities, and being of extreme pressure type.
		(Timken OK 40 pounds minimum.)
	EPGL	Extreme Pressure Gear Lube (oil) meetingAPI service
		classification GL-5 or MIL-Spec MIL-L-2105.
		JLG Recommends - Mobil DTE 10, EXCEL 15 or
	HO	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	MOBIL EAL	MOBIL EAL
	SPECIFICATION	DTE 10	ENVIRONSYN	HYDRAULIC
		EXCEL 15	H 32	OIL 32
	ISO Viscosity	#15	#32	#32
	Grade
	Spec Gravity API	31.9	0.950	—
	Pour Point, Max	-40°F	-59°F	-38.2°F
		(-40°C)	(-51°C)	(-39°C)
	Flash Point, Min.	330°F	514.4 °F	478°F (248°C)
		(166°C)	(268°C)
	VISCOSITY SPECIFICATIONS
	at 40°C	15 cSt	33.1 cSt	32 cSt
	at 100°C	4.1 cSt	6.36 cSt	7 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)

1001102685_3

Pressure Settings

Table 1-13. Pressure Settings

	MODEL	MAIN RELIEF	LIFT RELIEF	STEER
				RELIEF
	1932RS/6RS	2300 psi	2300 psi	1000 psi
		(158 bar)	(158 bar)	(69 bar)
	3246RS/10RS	2500 psi	2500 psi	1000 psi
		(172 bar)	(172 bar)	(69 bar)

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

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level and above stowed depending on model and specifications.

Table 1-14. Tilt Activation Setting

		TILT	TILT	PLATFORM
				ELEVATION
		SETTING	SETTING
	MODEL			@ TILT
		(FRONT TO	(SIDE TO
				ACTIVATION
		BACK)	SIDE)
				(± 6 IN.)
	1932RS/6RS - ALL	3°	1.5°	69 in.
				(1.75 m)
	3248RS/10RS -	3°	2°	88.5 in.
	ANSI/CSA/JPN			(2.25 m)
	3248RS/10RS - CE	3°	1.5°	88.5 in.
				(2.25 m)

High Drive Speed Cutout

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

NOTE: These figures are given with a tolerance of ± 6 in. (0.15 m).

Table 1-15. High Drive Cutout Height

	MODEL	HIGH DRIVE SPEED	DRIVE SPEED
		CUTOUT HEIGHT	REDUCTION
	1932RS/6RS	68.9 in. (1.75m)	2.5 mph (4 kph) to
	3248RS/10RS	88.5 in. (2.25 m)	0.3 mph (0.5 kph)

1.5CYLINDER SPECIFICATIONS

Table 1-16. Cylinder Specifications

	DESCRIPTION	1932RS/6RS	3246RS/10RS
	Lift Cylinder Bore	2.48 in.	3.93 in.
		(63 mm)	(100 mm)
	Lift Cylinder Stroke	43.3 in.	48.5 in.
		(1100 mm)	(1232 mm)
	Lift Cylinder Rod Diameter	1.77 in.	2.48 in.
		(45 mm)	(63 mm)
	Steer Cylinder Bore	1.5 in.	1.57 in.
		(38.1 mm)	(40 mm)
	Steer Cylinder Stroke	4.92 in	6.77 in.
		(125 mm)	(172 mm)
	Steer Cylinder Rod Diame-	0.75m in.	0.78 in.
	ter	(19.05 mm)	(20 mm)

1.6MAJOR COMPONENT WEIGHTS

Table 1-17. Major Component Weights

	COMPONENT	1932RS/6RS	3246RS/10RS
	Platform	240 lb.	412 lb.
		(109 kg)	(187 kg)
	Manual Platform Extension	115 lb.	150 lb.
		(52 kg)	68 kg
	Arm Assembly - (Includes	520 lb.	1,806 lb.
	Lift Cylinder)	(236 kg)	(820 kg)
	Chassis w/Wheel/Tire and	2,125 lb.	2,702 lbs
	Drive Assembly	(964 kg)	(1226 kg)

1.7TORQUE 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	TORQUE VALUE	INTERVAL
		(DRY)	HOURS
	Front Wheel Spindle Nut	30-40 ft lb	50
		(40-54 Nm)
	Wheel Bolts	105 -120 ft lb	50
		(142-163 Nm)

NOTE: Anytime a wheel bolt is replaced, be sure one of the same length is used. Use bolt shown below on wheels that use the 1/4" (6.4mm) ring.

22

M12 - 1.5 x 22

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.

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SECTION 1 - SPECIFICATIONS

Torque Charts

				Values for Zinc Yellow Chromate Fasteners (Ref 4150707)
						SAE GRADE 5 BOLTS & GRADE 2 NUTS
											Torque				Torque
			Tensile		Torque			Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia		Clamp Load												TM	or Vibra-
			Stress Area			(Dry)		Lubricated			OR Vibra-TITE		TM	111 or	(Loctite® 262
															TITETM 131)
											140)
		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
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS														NO. 5000059		REV. J

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

3.* ASSEMBLY USES HARDENED WASHER

	REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND
JLG P/N	Loctite® P/N		ND Industries P/N	Description
0100011	242TM		Vibra-TITETM 121	Medium Strength (Blue)
0100019	271TM		Vibra-TITETM 140	High Strength (Red)
0100071	262TM		Vibra-TITETM 131	Medium - High Strength (Red)

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

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				SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*
						Torque			Torque			Torque
			Tensile						(Loctite® 242TM or 271TM			(Loctite® 262TM or Vibra-
Size	TPI	Bolt Dia	Stress Area	Clamp Load		(Dry or Loctite® 263)			OR Vibra-TITETM 111 or			TITETM 131)
						K= 0.20			140)		K=.18	K=0.15
		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	1320		43		5
10	24	0.1900	0.01750	1580		60		7
	32	0.1900	0.02000	1800		68		8
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	770		1045	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
NOTES:	1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS											NO. 5000059		REV. J

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

3.* ASSEMBLY USES HARDENED WASHER

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

3121273

– JLG Lift –

1-7

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
					Magni Coating (Ref 4150701)*
							Torque			Torque
							(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load	Torque					(Loctite® 262TM
			Stress Area	See Note 4	(Dry)	K = .17	OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
							140 OR Precoat 85®
										K=0.15
							K=0.16
		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

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

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

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

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

1-8

– JLG Lift –

3121273

NO. 5000059 REV. J

SECTION 1 - SPECIFICATIONS

					SOCKET HEAD CAP SCREWS
				Zinc Yellow Chromate Fasteners (Ref 4150707)*
								Torque			Torque
					Torque			(Loctite® 242TM or 271TM
Size	TPI	Bolt Dia	Tensile	Clamp Load							(Loctite® 262TM
			Stress Area	See Note 4	(Dry)			OR Vibra-TITETM 111 or			or Vibra-TITE		TM	131)
					K = .20			140 OR Precoat 85®
											K=0.15
								K=0.18
		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

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

2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% *3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED STEEL OR RAW ALUMINUM

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

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

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

3121273

– JLG Lift –

1-9

SECTION 1 - SPECIFICATIONS

					CLASS 8.8 METRIC BOLTS
					CLASS 8 METRIC NUTS
								Torque	Torque
		Tensile			Torque				(Loctite®
Size	PITCH		Clamp				Torque	(Loctite® 262TM	242TM or 271TM
		Stress	Load		(Dry or Loctite®		(Lub)	OR Vibra-	OR Vibra-
		Area			TM
					263 )			TITETM 131)	TITETM 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
								NO. 5000059 REV. J

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

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

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

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

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

1-10

– JLG Lift –

3121273

SECTION 1 - SPECIFICATIONS

					CLASS 10.9 METRIC BOLTS
					CLASS 10 METRIC NUTS
			CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*
							Torque
		Tensile			Torque		(Lub OR Loctite®	Torque
Size	PITCH		Clamp		(Dry or Loctite®		242TM or 271TM OR	(Loctite® 262TM OR
		Stress	Load		263TM)		Vibra-TITETM 111 or	Vibra-TITETM 131)
		Area
					K = 0.20		140)	K=0.15
							K= 0.18
		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
							NO. 5000059 REV. J

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

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

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

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

ADDITIONAL TESTING IS REQUIRED.

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

3121273

– JLG Lift –

1-11

SECTION 1 - SPECIFICATIONS

			Magni Coating (Ref 4150701)*
			CLASS 12.9 SOCKET HEAD CAP SCREWS
				M6 AND ABOVE*
					Torque	Torque
				Torque	(Lub OR Loctite®
		Tensile				(Loctite® 262TM
Size	PITCH		Clamp Load	(Dry or Loctite®	242TM or 271TM
		Stress	See Note 4	263TM)	OR Vibra-TITETM	OR Vibra-TITE	TM
		Area
				K = .17	111 or 140)	131)
						K = .15
					K = .16
		Sq mm	kN	[N.m]	[N.m]	[N.m]
3	0.5	5.03
3.5	0.6	6.78
4	0.7	8.78
5	0.8	14.20
6	1	20.10	12.5	13	12	11
7	1	28.90	18.0	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
					NO. 5000059 REV. J

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

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

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

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

ADDITIONAL TESTING IS REQUIRED.

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

1-12

– JLG Lift –

3121273

SECTION 2 - GENERAL

SECTION 2. GENERAL

2.1MACHINE 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

Table 2-1. Inspection and Maintenance Responsibilities

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start	Prior to use each day; or	User or Operator	User or Operator	Operation and Safety Manual
	Inspection	At each Operator change.
	Pre-Delivery	Prior to each sale, lease, or	Owner, Dealer, or	Qualified JLG	Service and Maintenance Man-
					ual and applicable JLG inspec-
	Inspection	rental delivery.	User	Mechanic
					tion form.
	Frequent	In service for 3 months or 150 hours, whichever comes	Owner, Dealer, or	Qualified JLG	Service and Maintenance Man-
		first; or Out of service for a period of more than 3 months;			ual and applicable JLG inspec-
	Inspection	or Purchased used.	User	Mechanic	tion form.
	AnnualMachine	Annually, no later than 13 months from the date of the prior	Owner, Dealer, or	Factory-Trained	Service and Maintenance Man-
				Service Technician	ual and applicable JLG inspec-
	Inspection	inspection.	User
				(recommended)	tion form.
	Preventative	At intervals as specified in the Service and Maintenance	Owner, Dealer, or	Qualified JLG	Service and Maintenance Man-
	Maintenance	Manual.	User	Mechanic	ual

2.2PREVENTIVE 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.

NOTICE

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 maintenance inspections by a qualified JLG mechanic. Notify JLG dealer if inspection is overdue.

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.

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.

Footnotes:

(a)Prior to each sale, lease, or delivery

(b)In service for 3 months; or Out of service for 3 months or more; or Purchased used

(c)Annually, no later than 13 months from the date of the prior inspection

2-2

– JLG Lift –

3121273

SECTION 2 - GENERAL

Table 2-2. Preventive Maintenance & Inspection Schedule.

		INTERVAL
AREA ON MACHINE	PRE-DELIVERY (a)		ANNUAL (c)
	OR FREQUENT (b)		(YEARLY)
	INSPECTION		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 Enable System	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

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

INTERVAL

AREA ON MACHINE	PRE-DELIVERY (a)	ANNUAL (c)
	OR FREQUENT (b)	(YEARLY)
	INSPECTION	INSPECTION
GENERAL
Operation & Safety Manual in Storage Box	21	21
ANSI & EMI Handbooks in Storage Box (ANSI	21	21
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
Notify JLG of change in Machine Ownership		22

**Replace when system performance is degraded.

***Every two years, drain and remove hydraulic oil reservoir , clean pick-up screen, refill with fresh hydraulic fluid.

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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

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

Cleanliness

1.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.

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.

Component Disassembly and Reassembly

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

Pressure-Fit Parts

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

Bearings

1.When a bearing is removed, cover it to keep out dirt and abrasives. Clean bearings in nonflammable cleaning solvent and allow to drip dry. Compressed air can be used but do not spin the bearing.

2.Discard bearings if the races and balls (or rollers) are pitted, scored, or burned.

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

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

Gaskets

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

Bolt Usage and Torque Application

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

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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).

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