JLG 1932RS/6RS, 3248RS/10RS Service And Maintenance Manual

Service and Maintenance Manual

Models

1932RS/6RS

3248RS/10RS

3121273

November 26, 2018 - Rev F

INTRODUCTION

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

GENERAL

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

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

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

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

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

HYDRAULIC SYSTEM SAFETY

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

MAINTENANCE

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

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

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

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

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

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

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

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

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

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

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

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING

SOLVENTS.

3121273 A-1

INTRODUCTION

Original Issue A - January 30, 2012

Revised B - August 1, 2012

Revised C - January 29, 2013

Revised D - April 8, 2013

Revised E - June 29, 2018 - Revised Covers

Revised F - November 26, 2018

REVISION LOG

A-2 3121273

TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

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

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

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

Maintenance and Inspection Schedule Codes:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

2.3 Service and Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Safety and Workmanship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Components Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Component Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Pressure-Fit Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Bolt Usage and Torque Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Hydraulic Lines and Electrical Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3121273 i

TABLE OF CONTENTS

2.4 Lubrication and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.5 Cylinder Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Platform Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.6 Pins and Composite Bearing Repair Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

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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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3.16 Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.17 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.18 Scissor Arms Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Removing Scissor Arm Assembly as a Complete Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Removing/Installing Scissor Arms Individually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

3.19 Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Control Station Harness Installation to Scissor Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Control Station Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Overview of Control Station Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Joystick Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

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

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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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7.8 Hydraulic Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

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LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

1-1. Torque Chart (SAE Fasteners - Sheet 1 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1-2. Torque Chart (SAE Fasteners - Sheet 2 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-3. Torque Chart (SAE Fasteners - Sheet 3 of 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1-4. Torque Chart (Metric Fasteners - Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

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

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 (Delta Q). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-5. Battery Charger (Green Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-6. Charger Decal LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

3-8. Inverter On/Off Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

3-10. Ground Control Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3-11. Main Power Contactor Relay Location (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

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

3-13. Elevation Limit Switch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-14. 1932RS/6RS - Elevation Limit Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-15. 3248RS/10RS - Elevation Limit Switch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-16. LSS - Scissor Arm Angle Sensor - Location Rear of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-17. Tilt Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-18. Tilt Sensor Switch - Bubble Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-19. Tilt Sensor Switch - Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3-20. Traction Control Circuit - ZAPI Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-21. ZAPI Power Module Location and Orientation (All models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3-22. Main Electrical Power Connections - (1001129845 - ZAPI Power Module). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3-23. Brakes - Manual Disengage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3-24. Electric Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3-25. Drive Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3-26. Drive Motor Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-27. Wire Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

3-28. Drive Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3-29. Main Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3-30. Input Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-31. Hub Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

3-32. Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

3-33. Assembly Tool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-34. Assembly Tool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-35. Assembly Tool 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

3-36. Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

3-37. Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

3-38. Input Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

3-39. Main Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

3-40. 1932RS/6RS - Steer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

3-41. 3248RS/10RS - Steer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

3-42. Arms and Platform Positioning and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

3-43. 1932RS/6RS - Scissor Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

3-44. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

3-45. 3248RS/10RS - Scissor Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

3-46. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

3-47. Platform cable (3248RS/10RS) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

3-48. Platform cable (3248RS/10RS) - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

3-49. Platform cable (3248RS/10RS) - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

3121273 v

TABLE OF CONTENTS

3-50. Platform cable (3248RS/10RS) - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

3-51. Platform cable (LSS - 3248RS/10RS) - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3-52. Platform cable (LSS - 3248RS/10RS) - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

3-53. Platform cable (LSS - 3248RS/10RS) - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

3-54. Platform cable (FTSW - 3248RS/10RS) - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

3-55. Platform cable (FTSW - 3248RS/10RS) - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

3-56. Platform cable (FTSW - 3248RS/10RS) - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

3-57. Platform cable (FTSW - 3248RS/10RS) - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

3-58. Platform Control Station Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-59. Platform Control Station Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

3-60. Platform Control Station Components - External. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-61. Platform Control Station Components - Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

3-62. Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

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 Flow Chart (Software Version P1.7) Sheet 1 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-4. Analyzer Flow Chart (Software Version P1.7) Sheet 2 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5-5. Analyzer Flow Chart (Software Version P1.7) Sheet 3 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-6. Analyzer Flow Chart (Software Version P1.7) Sheet 4 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-7. Analyzer Flow Chart (Software Version P1.7) Sheet 5 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-8. Analyzer Flow Chart (Software Version P1.7) Sheet 6 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-9. Analyzer Flow Chart (Software Version P1.7) Sheet 7 of 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. 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 - (Global) - Sheet 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

7-19. Electrical Schematic - (Global) - Sheet 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-20. Electrical Schematic - (Global) - Sheet 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

. . . . . . . . . . . . . . . . . . . . . . . . 7-7

vi 3121273

TABLE OF CONTENTS

7-21. Electrical Schematic - (Global) - Sheet 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

7-22. Electrical Schematic - (Global) - Sheet 5 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

7-23. Electrical Schematic - (Global) - Sheet 6 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

7-24. Electrical Schematic - (Global) - Sheet 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

7-25. Electrical Components Layout - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7-26. Electrical Components Layout - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

7-27. Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

3121273 vii

TABLE OF CONTENTS

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

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

1-2 Platform 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 Activation Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Preventive Maintenance & Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-3 Cylinder Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 Battery Charger Specs (Delta Q) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2 Battery Charger (Green Power). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

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

3-5 Joystick Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

3-6 Connector Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

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 (Software Version P1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

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

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

viii 3121273

SECTION 1 - SPECIFICATIONS

SECTION 1. SPECIFICATIONS

1.1 SPECIFICATIONS

Table 1-1. Operating Specifications

DESCRIPTION 1932RS/6RS 3248RS/10RS

PLATFORM

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

DRIVING

Ma x im u m D r i ve S pe e d St ow e d:

Elevated:

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:

CE:

Maximum Tire Load (per wheel) ANSI/CSA:

CE:

Ground Bearing Pressure ANSI/CSA:

CE:

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

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

1,365 lb. (620 kg)

130 PSI (9.18 kg/cm

2.5 mph (4 kph)

0.3 mph (0.5 kph)

2

)

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

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

81 PSI (5.69 kg/cm
108 PSI (7.6 kg/cm2)

2

)

Platform Capacities

Table 1-2. Platform Capacities

SPECIFICATION

ANSI/CSA/JPN

ANSI EXPORT

CE

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

MACHINE

MODEL

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

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

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

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

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

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

MAXIMUM

PLATFORM

CAPACITY

MAXIMUM CAPACITY

ALLOWED ON PLATFORM

(1)

EXTENSION

MAXIMUM PERSONS ALLOWED IN

PLATFORM

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

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

MAX. SIDE FORCE

(Platform Fully Extended

@ Max. Capacity)

OPERATING

WIND SPEED

MAXIMUM

3121273 1-1

SECTION 1 - SPECIFICATIONS

1706740A

Dimensional Data

Table 1-3. Machine Dimensions

DESCRIPTION 1932RS/6RS 3248RS/10RS

Platform Height ­Elevated

Platform Height - Stowed 79 .4 in.

Platform Heig ht - Stowed

(Rails Down)

Working Height 25 ft.

Rail Height

(From platform floor)

Rail Height

(Platform Floor to Top of Rail)

Rail Height - Folded

(Ground to Mid Rail)

Overall Machine Width 32 in.

Overall Machine Length

(w/ladder)

Platform Size - Length 71.7 in.

Platform Size - Width 26.9 in.

Wheelbase 55 in.

19 ft.

(5.8 m)

(2.02 m)

N/A

(7.62 m)

40 in.

(101.6 cm)

40 in.

(101.6 cm)

69.3 in. (176 cm)
CE ONLY

(81.28 cm)

81.5 in.

(207 cm)

(182 cm)

(68.4 cm)

(139.7 cm)

41 in. (104.3 cm) - ANSI

43.6 in. (110.7 cm) - CE

78.3 in. (198.9 cm)- ANSI

77.6 in. (197.1 cm) - CE

90 in. (2.28 m) - ANSI

94.8 in. (240.7 cm) - CE

Tires

Table 1-4. Tire Specifications

DESCRIPTION 1932RS/6RS 3248RS/10RS

Size 12.71 in. x 3.94 in.

(323 mm x 100 mm)

(406 mm x 127 mm)

32 ft.

(9.75 m)

95.8 in.

(2.43 m)

78.3 in.

(1.99 m)

38 ft.

(11.5 m)

40.5 in.

(102.9 cm)

48 in.

(122 cm)

84.7 in.

(215.1 cm)

42.5 in.

(107.9 cm)

73 in.

(185.4 cm)

16 in. x 5 in.

Batteries

Table 1-5. Battery Specifications

DESCRIPTION ALL MACHINES

Vol tag e (24V-DC System - Series) 6 V per battery

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

Reserve Capacity (Standard Battery) 447 Minutes

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

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

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

Battery Quick-Disconnect ­(If Equipped)

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

Wheel Bolt Torque 120 ft lb. (163 Nm)

1-2 3121273

Electrical System Motors

Table 1-6. Electrical System Specifications

DESCRIPTION ALL MACHINES

Electrical System Voltage (DC) 24V - DC

Battery Charger: (1001129847)

Input:

AC Input Voltage:

Nominal AC Input Voltage:

Input Frequency:

Max. AC Input Current:

Ingress Protection:

Operating Temperature:

Output:

Nominal DC Output Voltage:

Ma x . D C O ut p ut Vo l ta g e:

Max DC Output Current:

Max. Interlock Current:

Protection:

Output Reverse Polarity:

Output Short Circuit:

AC Ove rloa d:
DC Overload:

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

-22°F (-30°C) to 122°F (+50°C)

24V

33.6V
25A
1A

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

• Drive Motor

• Hydraulic Pump/Electric Motor Assembly
(All Models)

SECTION 1 - SPECIFICATIONS

Type: Shunt Wound, Sepex 24V DC

Power: 0.65 Horsepower @ 3750 rpm

Type: Series Wound Permanent Magnet 24V DC

Power: 3kW

DC t o A C I n ve r te r - Ou t pu t Ra t in g :
(OPTION)

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

Travel Speed

Table 1-7. Travel Speed

ELEVATED SPEED MAXIMUM SPEED (PLATFORM LOWERED)

MODEL

Mph

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

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

Sec/25 ft

(Sec/7.6 m)

UNIT OF MEASURE

Kph Mph

Sec/25 ft

(Sec/7.6 m)

Lift Speed

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

Table 1-8. Lift Speed

MODEL LIFT UP (SECONDS) LIFT DOWN (SECONDS)

1932RS/6RS 22 - 29 21 - 31

3246RS/10RS 55 - 65 40 - 50

Kph

3121273 1-3

SECTION 1 - SPECIFICATIONS

1.2 CRITICAL STABILITY WEIGHTS

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

Table 1-9. Critical Stability Weights

COMPON ENT 1932RS/6RS 3248RS/10RS

Wheel and Tire Assembly ­(e a ch ) F ro nt :

Wheel/Tire and
Drive Assembly (each)

Batteries (each) Standard:

AGM:

Batteries (combined)

Standard :

AGM:

Rear:

21.6 lb. (9.8 kg)

21.6 lb. (9.8 kg)

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

43 lb. (19.5 kg)

40.5 lb. (18.4 kg)

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

248 lb. (111.1 kg)

260 lb. (118 kg)

1.3 LUBRICATION

Hydraulic Oil

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

Service Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service. JLG Industries recom­mends DTE 10 or Excel 15 hydraulic oil.
Aside from JLG recommendations, it is not advisable to mix
oils of different brands or types, as they may not contain
the same required additives or be of comparable viscosi-

.

ties.

Table 1-10. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0°F to +23°F (-18°C to -5°C) 10W

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

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

SAE VISCOSITY GRADE

Table 1-11. Lubrication Specifications

KEY SPECIFICATIONS

EPGL

HO

SPECIFICATION

ISO Viscosity Grade #15 #32 #32

Spec Gravity API 31.9 0.950 —

Pour Point, Max

Flash Point, Min. 330°F (166°C) 514.4 °F (268°C) 478°F (248°C)

at 40°C 15 cSt

at 100°C 4.1 cSt

at 100°F 80 SUS

at 210°F 43 SUS

cp at -30°F 3.2

Viscosity Index 140 147 189

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

Extreme Pressure Gear Lube (oil) meeting API service classifica­tion GL-5 or MIL-Spec MIL-L-2105.

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

Table 1-12. Hydraulic Oil Specifications

MOBIL
DTE 10

EXCEL 15

-40°F

(-40°C)

VISCOSITY SPECIFICATIONS

MOBIL EAL

ENVIRONSYN

H 32

-59°F

(-51°C)

33.1 cSt 32 cSt

6.36 cSt 7 cSt

——

——

——

HYDRAULIC OIL 32

MOBIL EAL

Pressure Settings

Table 1-13. Pressure Settings

MODEL MAIN RELIEF LIFT RELIEF STEER RELIEF

1932RS/6RS

3246RS/10RS

2300 psi

(158 bar)

2500 psi

(172 bar)

2300 psi

(158 bar)

2500 psi

(172 bar)

-38.2°F
(-39°C)

1001102685_3

1000 psi
(69 bar)

1000 psi
(69 bar)

Table 1-11. Lubrication Specifications

KEY SPECIFICATIONS

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

MPG

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

1-4 3121273

SECTION 1 - SPECIFICATIONS

M12 - 1.5 x 22

22

1.4 LIMIT SWITCHES

Tilt Alarm

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

Table 1-14. Tilt Activation Setting

PLATFORM

MODEL

1932RS/6RS - ALL

3248RS/10RS ­ANSI/CSA/JPN

3248RS/10RS - CE

TILT SETTING

(FRONT TO

BACK)

3° 1.5°

3° 2°

3° 1.5°

TILT SETTING

(SIDE TO SIDE)

High Drive Speed Cutout

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

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

Table 1-15. High Drive Cutout Height

MODEL

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

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

HIGH DRIVE SPEED

CUTOUT HEIGHT

DRIVE SPEED REDUCTION

ELEVATION

@ TILT

ACTI VATION (± 6

IN.)

69 in.

(1.75 m)

88.5 in.

(2.25 m)

88.5 in.

(2.25 m)

2.5 mph (4 kph) to

0.3 mph (0.5 kph)

1.6 MAJOR COMPONENT WEIGHTS

Table 1-17. Major Component Weights

COMPON ENT 1932RS/6RS 3246RS/10RS

Platform

Manual Platform Extension

Arm Assembly - (Includes Lif t Cylin­der)

Chassis w/Wheel/Tire and Drive
Assembly

240 lb.

(109 kg)

115 lb.
(52 kg)

520 lb.

(236 kg)

2,125 lb.

(964 kg)

412 lb.

(187 kg)

150 lb.

68 kg

1,806 lb.
(820 kg)

2,702 lbs

(1226 kg)

1.7 TORQUE REQUIREMENTS

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

Table 1-18. Torque Requirements

DESCRIPTION TORQUE VALUE (DRY) INTERVAL HOURS

Front Wheel Spindle Nut

Wheel Bolts

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.

30-40 ft lb

(40-54 Nm)

105 -120 ft lb

(142-163 Nm)

50

50

1.5 CYLINDER SPECIFICATIONS

Table 1-16. Cylinder Specifications

DESCRIPTION 1932RS/6RS 3246RS/10RS

Lift Cylinder Bore

Lift Cylinder Stroke

Lift Cylinder Rod Diameter

Steer Cylinder Bore

Steer Cylinder Stroke

Steer Cylinder Rod Diameter

3121273 1-5

2.48 in.

(63 mm)

43.3 in.

(1100 mm)

1.77 in.

(45 mm)

1.5 in.

(38.1 mm)

4.92 in

(125 mm)

0.75m in.

(19.05 mm)

3.93 in.

(100 mm)

48.5 in.

(1232 mm)

2.48 in.

(63 mm)

1.57 in.

(40 mm)

6.77 in.

(172 mm)

0.78 in.

(20 mm)

NOTE: 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.

SECTION 1 - SPECIFICATIONS

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

Tor q u e

To r qu e

Tor q u e

To r qu e

Torque Torque

Torque Charts

1-6 3121273

SECTION 1 - SPECIFICATIONS

Tor q u e

Tor q ue

Tor q ue

Tor qu e

To r qu e

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

3121273 1-7

SECTION 1 - SPECIFICATIONS

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

Clamp LoadTo r qu e

To r qu e

Tor q u e

Torque

Tor qu e

Tor q u e

1-8 3121273

SECTION 1 - SPECIFICATIONS

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

To r qu e

To r qu e

Torque

To r q ue

To r qu e

To r q ue

3121273 1-9

SECTION 1 - SPECIFICATIONS

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

Torq ue Torque

Tor qu e

To r qu e

To r qu e

To r q ue

1-10 3121273

SECTION 2. GENERAL

SECTION 2 - GENERAL

2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE

General

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

Preparation, Inspection, and Maintenance

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

Pre-Start Inspection

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.

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.

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 2-1

SECTION 2 - GENERAL

Table 2-1. Inspection and Maintenance Responsibilities

Type Frequency

Pre-Start

Inspection

Pre-Deliver y

Inspection

Frequent

Inspection

Annual Machine

Inspection Annually, no later than 13 months from the date of the prior inspection. Owner, Dealer, or User

Preventative Main-

tenance

In service for 3 months or 150 hours, whichever comes first; or Out of

service for a period of more than 3 months; or Purchased used.

At intervals as specified in the Service and Maintenance Manual. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

Prior to use each day; or

At each Operator change.

Prior to each sale, lease, or

rental d elivery.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or User Qualified JLG Mechanic

Owner, Dealer, or User Qualified JLG Mechanic

2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE

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

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

JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PER­FORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION
REPORT" FORM.

NOTE: This machine requires periodic safety and maintenance

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

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

Service

Qualification

Service and Maintenance Manual and

Service and Maintenance Manual and

Fac tor y-Tra ined

Service Technician

(recommended)

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.

wear dust from cover, brushes, and brush holder assem­bly.

Service and Maintenance Manual and

Reference

applicable JLG inspection form.

applicable JLG inspection form.

applicable JLG inspection form.

Maintenance and Inspection Schedule Codes:

1. Check for proper and secure installation.

2. Visual inspection for damage, cracks, distortion, or exces-

sive wear.

3. Check for proper adjustment.

4. Check for cracked or broken welds.

5. Operates properly.

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 3121273

Table 2-2. Preventive Maintenance & Inspection Schedule.

INTERVAL

SECTION 2 - GENERAL

AREA ON MACHINE

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, 10 1, 4, 10

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 & Att aching H ardware 1 1

CHASSIS ASSEMBLY

Covers Insta llati on 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

PRE-DELIVERY (a)
OR FREQUENT (b)

INSPECTION

ANNUAL (c)

(YEARLY)

INSPECTION

3121273 2-3

SECTION 2 - GENERAL

GENERAL

Operation & Safety Manual in Storage Box 21 21

ANSI & EMI Handbooks in Storage Box (ANSI ONLY) 21 21

Capacity Decals Installed, S ecure, Legi ble 21 2 1

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 an d 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

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

INTERVAL

AREA ON MACHINE

PRE-DELIVERY (a)
OR FREQUENT (b)

INSPECTION

ANNUAL (c)

(YEARLY)

INSPECTION

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

2-4 3121273

SECTION 2 - GENERAL

2.3 SERVICE AND GUIDELINES

General

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

Safety and Workmanship

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.

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

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.

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 heat­treated bolts, studs, and steel nuts, in accordance with
recommended shop practices. (See Torque Chart Sec­tion 1.)

3121273 2-5

SECTION 2 - GENERAL

Hydraulic Lines and Electrical Wiring

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

Hydraulic System

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

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

Lubrication

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

Battery

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

2.4 LUBRICATION AND INFORMATION

Hydraulic System

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

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

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

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

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

machines due to the wear-in of meshing components.

Hydraulic Oil

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

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

152.

NOTE: Start-up of hydraulic system with oil temperatures below -

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

2-6 3121273

SECTION 2 - GENERAL

Changing Hydraulic Oil

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

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

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

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

dure.

Lubrication Specifications

2.5 CYLINDER DRIFT TEST

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

Platform Drift

Measure the drift of the platform to the ground. Fully extend
the scissor arms from stowed position with the rated load in
the platform and power off. Maximum allowable drift is 2 in (5
cm) in 10 minutes. If the machine does not pass this test, pro­ceed with the following.

Cylinder Drift

Table 2-3. Cylinder Drift

CYLINDER BORE DIAMETER

inches mm inches mm

3 76.2 0.026 0.66

3.5 89 0.019 0.48

4 101.6 0.015 0.38

5 127 0.009 0.22

6 152.4 0.006 0.15

7 177.8 0.005 0.13

MAX. ACCEPTABLE DRIFT

IN 10 MINUTES

Specified lubricants, as recommended by the component
manufacturers, are always the best choice, however, multi-pur­pose greases usually have the qualities which meet a variety of
single purpose grease requirements. Should any question
arise, regarding the use of greases in maintenance stock, con­sult your local supplier for evaluation. Refer to Section 1, Table
1-11, Lubrication Specifications for an explanation of the lubri­cant key designations.

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

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

If the cylinder passes this test, it is acceptable.

NOTE:

This information is based on 6 drops per minute cyl­inder leakage.

3121273 2-7

SECTION 2 - GENERAL

2.6 PINS AND COMPOSITE BEARING REPAIR GUIDELINES

Filament wound bearings.

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

a. Excessive sloppiness in joints.

b. Noise originating from the joint during operation.

2. Filament wound bearings should be replaced if any of

the following is observed:

a. Frayed or separated fibers on the liner surface.

b. Cracked or damaged liner backing.

c. Bearings that have moved or spun in their housing.

d. Debris embedded in liner surface.

3. Pins should be replaced if any of the following is

observed (pin should be properly cleaned prior to
inspection):

a. Detectable wear in the bearing area.

b. Flaking, pealing, scoring, or scratches on the pin sur-

face.

c. Rusting of the pin in the bearing area.

4. Re-assembly of pinned joints using filament wound

bearings.

a. Housing should be blown out to remove all dirt and

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

b. Bearing / pins should be cleaned with a solvent to

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

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

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

2-8 3121273

3.1 MACHINE COMPONENT COVERS

1

2

3

2

4

SECTION 3 - CHASSIS & SCISSOR ARMS

SECTION 3. CHASSIS & SCISSOR ARMS

1. Left Side (Hydraulic) Frame Cover

2. Side Cover Release Handles

3121273 3-1

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

3. Right Side (Batteries) Frame Cover

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

SECTION 3 - CHASSIS & SCISSOR ARMS

1706740A

1

2

3

3

3.2 BATTERY REMOVAL/MAINTENANCE

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED
FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.
APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG'S
AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMARKET PRO­GRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE
CONTACT YOUR LOCAL JLG SUPPORT OFFICE.
BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH
THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO
OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. THE USE OF NON
APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFOR­MANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO
RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM THE
USE OF NON APPROVED BATTERIES.

Battery Quick-Disconnect ­(If Equipped)

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

Figure 3-2. Battery Location and Hold Down Bar

(All Models)

1. Batteries (4 - 6V)

2. Hold-Dow n Bar

3. Hold-Down Bar Fasteners

Battery Maintenance and Safety Practices

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

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

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

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

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

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

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

7. Re-install the machine right side cover.

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

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

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

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

3-2 3121273

Check the electrolyte level of the batteries often, adding only

BATTERY

FILLER CAP

FLUID LEVEL OF FULLY

CHARGED BATTERY

VENT TUBE

PLATES

1/8 "

Figure 3-3. Battery Fluid Level

1

2

3

distilled water when required. When fully charged, battery
fluid level should be 1/8" below vent tubes. (See Figure 3-3.).

• DO NOT fill to bottom of vent tubes.

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

• Clean terminal connections if they become corroded.

SECTION 3 - CHASSIS & SCISSOR ARMS

3.3 BATTERY CHARGER

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

Battery Charger Location

1. AC Voltage - Input Cable

3. DC Power Cable to Batteries

2. Charger Interlock Cable

Figure 3-4. Battery Charger (Delta Q)

Table 3-1. Battery Charger Specs (Delta Q)

BATTERY CHARGER SPECIFICATION

OUTPUT

Nominal DC Output Voltage 24V

Maximum DC Output Voltage 33.6V

Maximum DC Output Current 25A

Maximum Interlock Current 1A

INPUT

AC Input Voltage 85-265VAC

Nominal AC Input Voltage 120VAC - 230VAC RMS

AC Input Frequency 45-65 HZ

Maximum AC Input Current 12A RMS@108VAC

OPERATION

Charging Indicator Yellow LED

Battery Fault Indicator Flashing Yellow LED

100% Charge Indicator Green LED

Charger Fault Indicator Red LED

PROTECTION

Output Reverse Polarity Electronic Protection - Automatic Reset

Output Short Circuit Electronic Protection - Automatic Reset

AC Overload Current Limited

DC Overload Current Limited

MECHANICAL

Operating Temperature

–22° F to +122°F
(–30°C to +50°C)

Housing Shock and Water Resistant Aluminum

3121273 3-3

SECTION 3 - CHASSIS & SCISSOR ARMS

1

2

MAF03000

GREEN (ON) ­Battery Fully Charged

AMBER (ON) ­Battery Charging

AMBER (FLASHING) ­Battery/System
Problem

RED (FLASHING) ­Charger Problem

GREEN

AMBER

RED

LEDS

1. Power connector 2. Charger Interlock Cable

Figure 3-5. Battery Charger (Green Power)

3.4 BATTERY CHARGING

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

before charging begins.

ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED
OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH
NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BAT­TERY TERMINAL.
DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE
CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE
DAMAGED IN ANY WAY.
ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR BREAK­ING THE (POS/NEG) CONNECTIONS TO THE BATTERY.
DO NOT OPEN OR DISASSEMBLE CHARGER.

Table 3-2. Battery Charger (Green Power)

BATTERY CHARGER SPECIFICATION

OUTPUT

Nominal DC Output Voltage 24V

Maximum DC Output Voltage 34V

Maximum DC Output Current 30A

INPUT

AC Input Voltage 100-240V

AC Input Frequency 45-65 HZ

Maximum AC Input Current 8.5A

OPERATION

Charging Indicator Yellow LED

100% Charge Indicator Green LED

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

2. Connect the charger AC input plug to a grounded outlet
using a 3 wire heavy duty extension cord. (See Table 3-1,

Battery Charger Specs (Delta Q), for battery charger AC
input specifications.)

3. When powered up the charger will go through a short
LED indicator self-test. The battery charger LED indica­tors on the charger (Figure 3-6.), will flash in sequence for
two seconds. These LED indicators can be viewed
through the opening on the rear panel where the char­ger AC cord is accessed.

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

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

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

3-4 3121273

Figure 3-6. Charger Decal LED Indicators

SECTION 3 - CHASSIS & SCISSOR ARMS

Battery Charger Fault (LED Flash)

If a fault has occurred during battery charging, the (AMBER or
RED) LED on the charger LED indicator will flash corresponding
to the fault which occurred.

If required, general and troubleshooting information about the
battery charger can be found in the charger manufacturers
Owner’s Guide. Refer www.jlg.com for below supplement man­ual

• TROUBLESHOOTING GUIDE - PN 3128829

Battery Charger Maintenance

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

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

Battery Charger Troubleshooting

NO LIGHTS AT ALL

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

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

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

FAULT LED FLASHING

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

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

[1 Flash] - High Battery Voltage

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

ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED
OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH
NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BAT­TERY TERMINAL.
DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE
CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE
DAMAGED IN ANY WAY.
ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR BREAK­ING THE (POS/NEG) CONNECTIONS TO THE BATTERY.
DO NOT OPEN OR DISASSEMBLE CHARGER.

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

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

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

2. Check for wiring errors.

3. This fault will automatically clear and the charger will

restart charging when this problem is removed.

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

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

[2 Flashes] - Low Battery Voltage

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

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

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

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

3121273 3-5

SECTION 3 - CHASSIS & SCISSOR ARMS

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

[3 Flashes] - Charge Time-out

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

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

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

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

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

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

[4 Flashes] - Check Battery

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

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

2. Check that one or more cells in the battery are not
shorted.

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

4. Try the charger on a good battery.

5. If this fault occurs, the battery is likely in poor condition.

Try to recover the pack with a charger that can charge
the individual cells - such as an automotive charger. Be
sure to set this charger to the appropriate voltage - 6V
per 6V battery, 12V per 12V string/battery.

[5 Flashes] - Over Temperature

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

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

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

3. Confirm that dirt or mud is not blocking the cooling fins

of the charger. Clean the charger. Rinse the charger with
a low pressure hose if required. Do no use high pressure.
Do not us a pressure washer.

[6 Flashes] - Over Load/Over Temperature

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

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

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

3. This fault will occur if an internal fuse inside the charger
blows. If the green wire is shorted to ground even
momentarily, this fuse will blow. To check the fuse, mea­sure with an ohmmeter between the green and red
wires with the AC disconnected. If a short circuit is not
measured, the fuse has blown. Return unit to a service
depot to have this fuse replaced.

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

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

3-6 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

4

7

8

10

5

9

11

3

1

6

2

INVERTER

ON

OFF

1001143010A

1

2

Excessive Battery Watering Requirements or Strong
Sulphur (Rotten Egg) Smell

These symptoms indicate over-charging or high battery tem­perature. These symptoms are unlikely to be caused by too
high a charge current since the maximum charge current of
the charger will be small compared to even a moderately sized
battery pack. The most likely cause for this problem is incor­rect charge algorithm setting and/or high ambient tempera­tures. For correct charge algorithm setting, refer www.jlg.com
for below supplement manual

• TROUBLESHOOTING GUIDE - PN 3128829

3.5 DC TO AC INVERTER (IF EQUIPPED)

Inverter Location on Machine

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

1. DC to AC Inverter

2. Overload LED Indicator

3. Inverter Internal ON/OFF
Switch - Set to ON from fac­tory

4. Inverter VAC Output Cord

5. To Inverter ON/OFF Switch at
Ground Control Panel

Figure 3-7. DC to AC Inverter Components

* Items located under shield.

6. Inverter Power Relay

7. From VDC Battery POS (+)

8. To VDC Inverter POS (+) Input

9. External DC 25A Replaceable
Fuse(s )*

10. From VDC Battery NEG (–)*

11. Inverter Cooling Fan*

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

Figure 3-8. Inverter On/Off Switch Location

3121273 3-7

SECTION 3 - CHASSIS & SCISSOR ARMS

Inverter Operation

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

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

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

not lit on the inverter.)

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

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

4. Turn ON the inverter.

5. Turn on the appliance (tool).

6. Plug in any additional appliances (tools).

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

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

Inverter Specifications

Name Description

DC Input 24V (20-30V ) DC

AC Out put 1 10V AC

Output Waveform Modified Sine Wave (MSW)

Continuous Power 900 Watt

Surge Power 1800 Watt

Efficiency Aprox. 90%

Power Switc h O N/O FF Con trol

Power Switc h OF F <0. 5 ADC

Battery Low Alarm 21 ± 0.5 V DC

Battery Low Shutdown 20 ± 0.5 V DC

AC Output Sockets (2) North American Std. 7.5 Amps

External Fuses 3 x 25 Amp (Automotive Spade Type)

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

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

Net Weight 6 lbs. (2,72 Kg)

NOTE: All specifications are typical at nominal line, half load,

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

Inverter Troubleshooting

Problem: No Input Voltage

Poor contact with battery terminals. Shut down the inverter and disconnect

battery power. Clean terminals thor­oughly and reconnect.

Blown DC battery fuse(s). Turn off inverter. Replace fuse(s) with the

same type and rating.

Problem: Inverter Is In Shut Down

Battery voltage is below 20 volts. Charge or replace battery.

Inverter is too hot (thermal shut down
mode). Overload LED indicator on inverter
is lit ORANGE/RED.

Unit may be defective. See warranty and call customer service.

Problem: Low Battery Alarm On All The Time

Input voltage below 21 volts - buzzing
sound.

Poor or week battery condition. Re charge or replace battery(s).

Inadequate power being delivered to the
inverter or excessive voltage drop.

Allow inverter to cool. Check for adequate
ventilation. Reduce the load on the
inverter to rated cont inuous power.

Keep input voltage above 21 volts to main­tain regulation.

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

3-8 3121273

3.6 GROUND CONTROL STATION

1001132360A

4

5

1001146979A

3

2

1

1

1

2

3

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

Components Location

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-10. Ground Control Station Removal

1. Attach Screws and Washers

2. Brake Release Switch

3. Power Relay

Installation

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

Figure 3-9. Ground Control Station Component Location

(All Models)

1. Platform Lift/Lower Switch

2. Key Selector Switch

3. Ground Emergency StopButton

4. MDI - Indicator

5. Overload Indicator (If Equipped)

Removal (All Models)

1. Disconnect main power at the batteries.

2. Remove the machine side cover on the left side of the

machine (ground control station/pump side).

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

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

2. Insert the panel into position on the machine and align
the mounting holes in the panel with the mounting
holes in the frame.

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

4. Reconnect the main power at the batteries, power

machine up and check machine operation.

5. Install machine side cover.

3121273 3-9

SECTION 3 - CHASSIS & SCISSOR ARMS

1

2

3

4

1

1

1

2

3

4

4

3.7 MAIN POWER CONTACTOR RELAY

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

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

3.8 ELEVATION LIMIT SWITCH ASSEMBLY

Location

1932RS/6RS

3248RS/10RS

Figure 3-12. Elevation Limit Switch Location

Figure 3-11. Main Power Contactor Relay Location (All

Models)

1. Main Power Contactor Relay

2. To X14 Harness Connector -

(Power Relay and Control Module)

3. To Battery (BT03+)

4. To Control Module - (X09 B+F1)

Installation

1. Limit Switch

1932RS/6RS

Figure 3-13. Elevation Limit Switch Mounting

1. Switch Assembly

2. Scissor Arm Cam

3. Switch Lever Arm

4. Mounting Hardware

3-10 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

1

4

3

2

4

18 ft. 11 in. -

5 ft. 9 in. -

0•‹

(30•‹)

7 ft. 4 in. -

31 ft. 11 in. -

0°

(30°)

3248RS/10RS

Figure 3-13. Elevation Limit Switch Mounting

1. Switch Assembly

2. Scissor Arm Cam

3. Switch Lever Arm

4. Mounting Hardware

Switch Adjustment

Models - 1932RS/6RS (See Figure 3-13. and Figure 3-14.)

Models - 3248RS/10RS
(See Figure 3-13. and Figure 3-15.)

1. With the roller lever arm set at 30° from vertical, attach

switch to frame mount using the mounting hardware as
shown.

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

Switch Notes (All Models):

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

• Switch Reset = 13°

• Switch Trip = 25°

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

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

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

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

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

Figure 3-15. 3248RS/10RS - Elevation Limit Switch

Adjustment

Figure 3-14. 1932RS/6RS - Elevation Limit Switch

Adjustment

3121273 3-11

SECTION 3 - CHASSIS & SCISSOR ARMS







3

1

2

1

2

3

3

1932RS/6RS 3248RS/10RS

1. Platform Gate

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

3. Platform Entry Ladder

1. Elevation Limit Switch Location

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

3. Platform Entry Ladder

Figure 3-16. LSS - Scissor Arm Angle Sensor - Location Rear of Machine

3.9 LSS - SCISSOR ARM ANGLE SENSOR - LOCATION

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

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

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

3.10 TILT SENSOR REPLACEMENT

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

3-12 3121273

Figure 3-17. Tilt Sensor Installation

1. Tilt Sensor

2. Locating Hole

3. Mounting Hardware

Tilt Sensor Removal

1

2

1

1

1

2

1. Disconnect power at the batteries.

2. Remove the machine left side cover (ground control sta-

tion side).

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

4. Remove the two (2) mounting nuts, bolts and washers

attaching the sensor to the base frame.

Tilt Sensor Installation

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

2. When mounting the tilt sensor back into the base frame,
align the mounting pin on the bottom of the sensor
with the hole in the mounting plate on the base frame
(item 2 - Figure 3-17.).

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

4. Adjust per instructions following.

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-18. Tilt Sensor Switch - Bubble Level

1. Level

2. Not Level

Tilt Sensor Switch - Adjustment Procedure

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

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

NOTE: Ensure switch mounting is level and securely attached.

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

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

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

Figure 3-19. Tilt Sensor Switch - Adjustment

1. Flange Adjusting Nuts

2. Bubble Level

3121273 3-13

SECTION 3 - CHASSIS & SCISSOR ARMS

+

24V

+

+

+

Line Contactor

Right Field Winding

Left Field Winding

Power Module

Left

Armature

Right

Armature

+

+

BF1

BF2

B

+B

T

F1

F2

Field

MOSFETS

Armature

MOSFET

Shunt

3.11 TRACTION SYSTEM

Theory of Operation

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

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

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

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

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

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

It is essential that the same amount of field current is supplied
to both drive motors, or one wheel will pull the vehicle (motor
overheating and excessive tire wear would result). The vehicle
uses 12V field windings wired in series to ensure proper distri­bution of current.

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

Figure 3-20. Traction Control Circuit - ZAPI Power Module

3-14 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

Common Traction System Difficulties

1. Ground Module Interlocks

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

2. Power Module Diagnostic Issues

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

3. Open-Circuit Motor Armature

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

This situation can be detected by elevating the vehicle's
front wheels and engaging drive (platform stowed).
Under DIAGNOSTICS - TRACTION, the JLG Analyzer's
ARM CUR display (Armature Current Reading) should be
less than 50A. One wheel will rotate at full speed, while
the other will not rotate at all. The Power Module's self­diagnostics cannot detect this fault unless both arma­tures are open-circuit.

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

4. Short-Circuit Motor Armature

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

This situation can be detected by elevating the vehicle's
front wheels and engaging drive (platform stowed).
Under DIAGNOSTICS - TRACTION, the JLG Analyzer's
ARM CUR display (Armature Current Reading) will hover
around 350A. The FLD CUR display (Field Current Read­ing) will hover around 40A. Neither wheel will rotate at
normal speed, but it will be possible to rotate the drive
wheel by hand. The Power Module's self-diagnostics
cannot detect this fault since the situation appears iden­tical to climbing a steep grade.

pected drive motor leading to the Power Module's M1
and M2 Terminals. Re-test the traction function. If the
remaining drive motor is able to reach full speed (and
Armature Current is less than 50A), the drive motor that
has been disconnected is fault. Investigate for crushed
and burned cables. Check if the drive motor smells
burned.

5. Open-Circuit Motor Field

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

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

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

6. Short-Circuit Brake Release

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

This situation can be detected by elevating the vehicle's
front wheels and engaging drive (platform stowed).
Under DIAGNOSTICS - TRACTION, the JLG Analyzer's
ARM CUR display (Armature Current Reading) will hover
around 350A. The FLD CUR display (Field Current Read­ing) will hover around 40A. Neither wheel will rotate,
and it will be impossible to rotate either drive wheel by
hand. The Ground Module cannot detect this fault dur­ing power-up or self-test since energizing the brakes
could pose a hazard. However, it may detect this issue
during Drive (investigate using JLG Analyzer).

To find the source of the difficulty, disconnect main
power at the batteries and disconnect the Armature Wir­ing (heavy red and black conductors) from the sus-

3121273 3-15

SECTION 3 - CHASSIS & SCISSOR ARMS

3.12 POWER CONTROL MODULE - ZAPI

Tab l e 3-3. Z API Power Module Specifications

Operating Voltage ( B+) 14.5 to 40 VDC

Maximum Current Limits:
Ar m at u re
Fi e ld
Pu m p
In t eg r al M ai n Fu s e

Standby Current 150 mA

Temperature Range:
Op e ra t in g
St o ra g e
Thermal Limit

Switching Frequency 16 kHz

The power module is located inside rear machine cover at the
left rear of the machine, as shown in Figure 3-21., ZAPI Power
Module Location and Orientation (All models). Use the
following instructions when replacing the power module.

1. Turn machine power off and disconnect the batteries.

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

3. Tag and note the wire terminal locations before remov-

ing the power module, also see Figure 3-22.

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

300 A

40 A
180 A
250 A

-40°C to 75°C

-40°C to 125°C
75°C to 90°C

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

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

5. When installing the power module, be sure that the ter­minals are oriented as shown in Figure 3-21.

6. After installing the new power module, begin connect­ing the wire connectors/cables to the module. (See
Table 3-4 and Figure 3-22.)

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

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

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

10. Re-install the rear machine cover.

Table 3-4. Module Terminal Functions

+ BF1 Controller to Main Power Contactor

+ BF2 Left and Right Positive Armature

+ B Positive Pump Connection

– B Controller to Battery Negative

– T Left and Right Negative Armature

– P Negative Pump Connection

F1 To Motor Fields Wired in Series

F2 To Motor Fields Wired in Series

Figure 3-21. ZAPI Power Module Location and Orientation (All models)

3-16 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

A1

A1

3

A2

A2

2

1

4

6

7

8

9

5

10

Figure 3-22. Main Electrical Power Connections - (1001129845 - ZAPI Power Module)

1. Batteries

2. Power Module

3. Main Power Contactor Relay

4. Hydraulic Pump Motor

5. Drive Motor Stator Field Wires

6. Drive Motor Armature (Brush) Cables

7. To Battery Charger (+)

8. To Battery Charger (–)

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

10. Battery Quick-Disconnect (OPTION)

3121273 3-17

SECTION 3 - CHASSIS & SCISSOR ARMS

P/N - 1001139845

ZAPI Power Module Electrical Evaluation

INTEGRATED HEALTH INDICATOR

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

ZAPI Power Module - "HEALTH" (Status LED)

3-18 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

3.13 DRIVE MOTOR SERVICING

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

Drive Motor Troubleshooting

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

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

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

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

Model

1932RS/6RS 0.21 Ohms 0.037 Ohms

3248RS/10RS 0.127 Ohms 0.051 Ohms

Field Resistance

@ 75°F (24°C)

Armature Resistance

@ 75°F (24°C)

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

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

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

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

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

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

b. Armature terminals and the case of the motor.

c. Field connector pins to the armature terminals.

6. Verify continuity in 2 pin brake connector (yellow and

brown wires). Measure the brake resistance and verify
that it is between 18 and 22 Ohms.

Drive Motor Electrical Evaluation

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

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

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

• Resistance < 2 Ohms Blue to Orange Field Wires. The
blue and orange conductors are connected to the motor's

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

Servicing Guidelines

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

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

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

a. Dusty or dirty locations like cement plants, lumber

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

b. High temperature areas like steel mills, foundries,

etc.

c. Environments with sudden temperature change,

such as in refrigeration plant, etc.

3121273 3-19

SECTION 3 - CHASSIS & SCISSOR ARMS

1

2

4

3

Brake - Manual Disengage Procedure

Figure 3-23. Brakes - Manual Disengage Procedure

1. Cover Bolts

2. Brake Cover

NOTE: The brakes may also be disengaged electrically using the

brake release switch, see procedure in Operation Manual.

CHOCK WHEELS OR SECURE MACHINE WITH TOW VEHICLE.

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

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

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

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

3. Cover Gasket

4. Disengage Holes

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

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

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

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

3-20 3121273

Drive Motor Removal

1

3

2

3

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-24. Electric Drive Motor Removal

1. Electric Drive Motor

2. Motor Mounting Bolts

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

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

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

3. Washers

3. Remove the two motor mounting bolts and washers.

4. Gently remove the drive motor (1).

NOTE: Reference Figure 3-25., Drive Motor Components for part

names and locations when servicing the Drive Motor.

Periodic maintenance consisting of inspections of motors, bat­teries and wiring circuitry is recommended, see Section 2,
Table 2-2, Preventive Maintenance & Inspection Schedule..

ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE OPERATION.

3121273 3-21

SECTION 3 - CHASSIS & SCISSOR ARMS

2

3

4

5

6

7

8

9

11

10

14

1

13

12

Drive Motor Disassembly

NOTE: Refer to Figure 3-25.

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

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

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

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

Figure 3-25. Drive Motor Components

1. Shaft Pilot Bearing

2. Frame & Fie ld Assembly

3. Armature Assembly

4. Brush Spring (4)

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

6. Brush Box Assembly

7. Retaining Ring

8. Bearing

9. Commutator End Head

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

11. Brake Assembly

12. Cover Gasket

13. Brake Cover

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

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

6. Install the two Brake Cover Mounting Screws (15) into
the threaded holes in the brake assembly and tighten to
manually release the brake (see Figure 3-24.).

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

3-22 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

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

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

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

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

Drive Motor Inspection and Service

NOTE: Refer to Figure 3-25.

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

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

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

4. Visually inspect the frame and field assembly for over­heating or other signs of damage. Check all wiring to
ensure that the insulation is in good condition. Verify
that pole screws are torqued to 250 - 300 in-lb (28.2 -

33.9 Nm). Verify field resistance using a suitable ohmme­ter per the appropriate motor specification. Verify that
the field is electrically isolated from the frame using a
dielectric tester. Replace as necessary.

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

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

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

Drive Motor Reassembly

NOTE: Refer to Figure 3-25.

1. After inspection and servicing, reassemble the wiring in
the Commutator End Head (9) as originally found.
Ensure the wiring does not contact metal parts and that
it allows the brushes to move unrestricted in the hold­ers. Motor terminals must be assembled as shown Fig­ure 3-27. Torque bottom terminal nut to 110 - 140 in-lb
(12.4 - 15.8 Nm).

2. After the motor has been disassembled, it is recom­mended that new bearings be installed because bear­ings may have been damaged during removal. Although
the bearings may appear and feel good, the bearing
races could be “brinelled” (races or balls deformed) and
may exhibit noise and vibration problems or fail within a
relatively short period of service. Press a new bearing
into the commutator end head, pressing on the outer
race only. See Figure 3-26.. Replace the Retaining Ring
(7) in the retaining ring groove.

3. Press the Armature (3) commutator end into the com­mutator end head and bearing assembly, carefully sup­porting the inner-race of the bearing. See Figure 3-26.

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

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

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

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

Always secure the bottom nut with a wrench as you
tighten the top nut. Torque top nut to 90 - 110 in-lb

(10.2 - 12.4 Nm).

3121273 3-23

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-27. Wire Harness Connections

8. Remove manual release screws from brake assembly.

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

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

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

Figure 3-26. Drive Motor Shaft Bearing

1. Press Fixture must press against Outer Race

2. Bearing

3. End Head (held stationary)

4. Armature Assembly

5. Assembled End Head, Bearing, and Retaining Ring

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

3-24 3121273

Drive Motor Installation

1

3

2

3

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-28. Drive Motor Assembly

1. Drive Motor

2. Motor Mounting Bolts

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

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

splines with the motor shaft splines.

3. Washers

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

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

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

3121273 3-25

SECTION 3 - CHASSIS & SCISSOR ARMS

3.14 TORQUE HUB SERVICING

THE PROCEDURES WITHIN THIS SECTION APPLY TO ALL MACHINES AND

TORQUE HUBS. PROCEDURES THAT APPLY TO SPECIFIC MACHINES AND

TORQUE HUBS WILL BE SO NOTED BY PROPER SERIAL NUMBERS.

NOTE: These instructions will cover how to completely assemble

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

TORQUE HUB UNITS SHOULD ALWAYS BE ROLL AND LEAK TESTED BEFORE DIS-

ASSEMBLY AND AFTER ASSEMBLY TO MAKE SURE THAT THE UNIT’S GEARS

AND SEALANTS ARE WORKING PROPERLY.

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

IF THE MACHINE IS ON ANY INCLINE, THE WHEELS MUST BE ADEQUATELY

BLOCKED PRIOR TO MANUALLY DISENGAGING THE BRAKES. FAILURE TO DO

SO MAY RESULT IN INJURY OR EVEN DEATH.

Leak Test

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

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

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

Oil Check/Fill Procedure

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

In the event of servicing, fill the unit with ISO grade 68 hydrau­lic oil.

NOTE: The gearbox capacity is 10 oz of oil.

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

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

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

NOTE: The brake must be released before performing the roll test.

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

RE-ENGAGE BRAKES BEFORE RETURNING TO NORMAL OPERATION.

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

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

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

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

Roll Test

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

3-26 3121273

Main Gearbox Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-29. Main Gearbox Disassembly

1. Spindle Sub-Assembly

2. Spiral Snap Ring

3. Input ring Gear

4. Input Sun Gear

5. Cover O-Ring

6. Cover Thrust Washer

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

2. Remove cover. Cover Thrust washer should be in the

inner counter bore of the cover.

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

inserted into the pipe plug holes.

3. Remove input sun gear.

4. Remove input carrier sub-assembly.

5. Remove cover o-ring.

6. Remove input ring gear.

7. Cover

8. Cover Snap Ring

9. Pipe Plug

10. Input Carrier Sub-Assembly

11. Hub Sub-Assembly

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

diameter. Insert jacking screws (1/4-20UNC grade 8) with
at least 1.5 inches of thread length into each of the three
tapped holes to force the ring gear out. Be sure and alter­nate between the jacking screws to keep the ring gear from
becoming misaligned in the bore. The screws will push
against the outer race of the main bearing. This bearing
will have to be replaced afterwards.

7. Using a screwdriver remove spiral snap ring.

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

3121273 3-27

SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Disassembly

Figure 3-30. Input Carrier Disassembly

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

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

NOTE: Do not overstress these retaining rings when removing

them.

2. Remove thrust plate.

3. Remove a thrust washer from each planet shaft.

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

5. Remove 22 needle bearings from the bore of each

planet gear.

6. Remove the thrust washer from each planet gear.

7. Remove retaining ring from output sun gear.

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

carrier.

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining Ring

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

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

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

3-28 3121273

Hub Disassembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-31. Hub Disassembly

1. Seal

2. Hub

1. Remove main wheel bearing.

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

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

3. Main Bearing

2. Remove main lip seal.

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

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

3121273 3-29

SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Disassembly

Figure 3-32. Spindle Disassembly

1. Spindle Sub-Assembly

2. Shaft Ball Bearing

3. Tanged Washer

4. Thrust Washer

5. Output Planet Gear

6. Output Planet Pins

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

2. Remove 3 output planet shafts.

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

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

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

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

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

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

7. Main Bearing

8. O-Ring

9. Shaft Seal

10. Snap Ring

11. Needle Roller Bearings

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

7. Remove the main bearing from the outside diameter of

the spindle.

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

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

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

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

3-30 3121273

Tightening and Torquing Bolts

BOLT A

BOLT B

Figure 3-33. Assembly Tool 1

Figure 3-34. Assembly Tool 2
Figure 3-35. Assembly Tool 3

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

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

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

2. Go to the opposite side of the bolt circle and tighten

bolt "B" until equally snug.

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

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

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

SECTION 3 - CHASSIS & SCISSOR ARMS

Assembly Tools

3121273 3-31

SECTION 3 - CHASSIS & SCISSOR ARMS

Spindle Assembly

Figure 3-36. Spindle Assembly

1. Spindle Sub-Assembly

2. Shaft Ball Bearing

3. Tanged Washer

4. Thrust Washer

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

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

3. Retain the bearing with the spiral retaining ring.

4. Line the bore of the output planet gear with 22 needle

rollers. Use grease to retain the needle rollers in the
bore.

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

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

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

5. Output Planet Gear

6. Output Planet Pins

7. Main Bearing

8. O-Ring

9. Shaft Seal

10. Snap Ring

11. Needle Roller Bearings

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

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

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

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

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

13. Using a flat plate or rod, press the motor shaft seal into

the center bore so that it is flush with the face of the
spindle.

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

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

3-32 3121273

Hub Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-37. Hub Assembly

1. Seal

2. Hub

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

2. Using a flat plate in conjunction with a pressing tool,

press in the seal so it is flush with the edge of the hub.

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

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

3. Main Bearing

3. Flip the hub over.

4. Using an appropriate pressing tool, press the main bear-

ing into the bore until it bottoms out.

3121273 3-33

SECTION 3 - CHASSIS & SCISSOR ARMS

Input Carrier Assembly

Figure 3-38. Input Carrier Assembly

1. Planet Gears

2. Output Sun Gears

3. Input Carrier

4. Thrust washer

5. Input Planet Gear

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

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

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

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

5. Place a thrust washer on each side of the input planet
gear. Line up the bores as well as you can visually. Addi­tional grease may help hold everything together.

6. Needle Bearings

7. Thrust Plate

8. Snap Ring

9. Retaining Ring

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

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

8. Put the thrust plate onto the three input planet shafts.

Use the 3 holes on the innermost bolt circle. The other 3
holes are for a different gear ratio.

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

NOTE: Do not overstress the snap ring.

3-34 3121273

Main Gearbox Assembly

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-39. Main Gearbox Assembly

1. Spindle Sub-Assembly

2. Spiral Snap Ring

3. Input ring Gear

4. Input Sun Gear

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

2. Apply a coating of grease to the lip seal of the hub sub­assembly.

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

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

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

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

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

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

5. Cover O-Ring

6. Cover Thrust Washer

7. Cover

8. Cover Snap Ring

9. Pipe Plug

10. Input Carrier Sub-Assembly

11. Hub Sub-Assembly

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

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

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

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

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

reacted by the main wheel bearings.

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

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

3121273 3-35

SECTION 3 - CHASSIS & SCISSOR ARMS

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

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

to avoid pinching or shearing when the cover is assembled.

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

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

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

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

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

13. Re-install drive motor to torque hub per instructions

Drive Motor Installation - page 3-25, install on machine.

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

3-36 3121273

3.15 STEER ASSEMBLY COMPONENTS

1

1

2

3

2

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-40. 1932RS/6RS - Steer Assembly

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

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

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

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

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

3121273 3-37

SECTION 3 - CHASSIS & SCISSOR ARMS

1

1

Figure 3-41. 3248RS/10RS - Steer Assembly

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

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

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

3-38 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

3.16 ARMS AND PLATFORM POSITIONING AND SUPPORT

NEVER WORK UNDER N ELEVATED PLATFORM UNTIL IT HAS BEEN

RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVER­HEAD SLING.

The arm stack can be supported by using an overhead
crane,(See Figure 3-42.). If an overhead crane is not available
the stack may also be lifted by using a fork-truck using the fol­lowing instructions:

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

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

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

4. At this point the lift cylinder removal may begin. (Refer
to Section 4.6, Lift Cylinder Removal)

3.18 SCISSOR ARMS REMOVAL

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

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

3. The scissor arms can be removed as a complete unit or
individually.

Removing Scissor Arm Assembly as a Complete Unit

1. Remove the pin attaching the bottom scissor arms to
the rear of the frame by removing the bolt.

2. Place two straps around each end of the entire scissor
arm assembly. Using an overhead crane, slowly and
carefully move the arm stack forwards so that slide
blocks at front of machine slide out the front of the slide
channel on the frame.

NOTE: Overhead crane and straps must be capable of lifting at

least 2000 lbs (907 kg).

3. Once slide blocks are clear of machine, the scissor stack
can be moved to a more desirable location for further
arm disassembly.

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

3.17 PLATFORM REMOVAL

1. Support the platform using an overhead crane with
straps capable of lifting at least 500 lbs (227 kg) (See Fig­ure 3-42.). Refer to Section 3.16, Arms and Platform Posi­tioning and Support.

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

3. Remove the bolts attaching the pins and slide blocks at
each corner to the arm stack. Carefully remove the four
pins attaching the platform to the arm stack.

4. Lift the platform from the arm stack and set aside.

NOTE: When attaching platform back onto scissor arm assembly,

follow removal procedures in reverse order.

Removing/Installing Scissor Arms Individually

See Figure 3-43., Figure 3-44., Figure 3-45. and Figure 3-46.

1. With the platform removed, start with the top arms
(closest to platform).

2. Secure each arm section being removed using an over­head crane with suitable lifting straps.

3. Remove the bolts securing the connecting pins in place.

4. Remove the pins from the arms.

5. Remove the arm section from the machine using the

overhead crane.

6. Repeat previous steps for remaining arm sections.

NOTE: When attaching scissor arm assembly back onto frame,

follow removal procedures in reverse order.

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

3121273 3-39

SECTION 3 - CHASSIS & SCISSOR ARMS

STRAP

Figure 3-42. Arms and Platform Positioning and Support

3-40 3121273

MAF02440

E

D

A

C

B

G

C

E

D

F

J

H

C

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

SECTION 3 - CHASSIS & SCISSOR ARMS

3121273 3-41

SECTION 3 - CHASSIS & SCISSOR ARMS

MAF02450

G

H

F

D

E

C

A

B

J

Figure 3-44. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration

3-42 3121273

MAF02460

A

C

B

M

B

E

E

E

E

L

E

H

E

E

K

E

E

K

E

E

D

G

C

F

F

J

C

C

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

SECTION 3 - CHASSIS & SCISSOR ARMS

3121273 3-43

SECTION 3 - CHASSIS & SCISSOR ARMS

MAF02470

E

F

H

G

J

L

A

C

M

B

D

Figure 3-46. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration

3-44 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

1001196746-B

MAF03360

SECURE CHASSIS CONNECTOR (X11) OF PLATFORM CABLE
TO CHASSIS HARNESS WITH TIE STRAP

Figure 3-47. Platform cable (3248RS/10RS) - Sheet 1 of 4

3121273 3-45

SECTION 3 - CHASSIS & SCISSOR ARMS

APPROXIMATELY 236MM
ORANGE TAPE MARK

SECURE CABLE HARNESS
ALONG SIDE OF CYLINDER
UNTIL REACHING THE
ORANGE MARKER TAPE

YELLOW MARKER TAPE
SECURE HARNESS TO THE

ARMS BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, 3X

ORANGE MARKER TAPE
NOTICE: USE NOTCHES TO
LOCATE TIE STRAPS TO CABLE
CARRIER, 4X

YELLOW MARKER TAPE

SECURE HARNESS TO THE ARMS
BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, 5X

ORANGE MARKER TAPE
NOTICE: USE NOTCHES TO
LOCATE TIE STRAPS TO CABLE
CARRIER, 4X

YELLOW MARKER TAPE
SECURE HARNESS TO THE ARMS
BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, 3X

ORANGE MARKER TAPE

NOTICE: USE NOTCHES TO
LOCATE TIE STRAPS TO CABLE
CARRIER, 4X

YELLOW MARKER TAPE

SECURE HARNESS TO THE ARMS
BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, 6X

YELLOW MARKER TAPE
SECURE HARNESS TO THE
PLATFORM BY HOSE
CLAMP

DO NOT ROUTE HARNESS ON
THIS ROD

1001196746-B

MAF03370

NOTES:

4. ADDITIONAL TIE STRAPS SHOULD BE USED TO FIRMLY ATTACH THE HARNESS TO THE MACHINE.

3. AT EVERY ORANGE MARKER, SECURE THE HARNESS TO THE CABLE CARRIER USING WIRE TIE STRAP.

2. AT EVERY YELLOW MARKER, SECURE THE HARNESS TO THE NUTS WELDED ON THE ARMS USING TIE STRAP.
UNLESS OTHERWISE SPECIFIED

1. ORANGE AND YELLOW MARKER TAPE STRIPS ARE LOCATED ON PLATFORM HARNESS TO ASSIST IN INSTALLATION.

ROUTE CABLE THROUGH
THE ROD AND SECURE TIE STRAP

ROUTE CABLE AROUND
CROSS TUBE
NOTICE: ROUTE IN A
CLOCKWISE DIRECTION

ROUTE CABLE THROUGH
FRAME AND TOP SHIELD
OPENING

FIRST ORANGE TAPE MARK
(BEGINS ON THIRD HOOK)

ROUTE CABLE AROUND
ARM STACK TO CYLINDER
NOTICE: ROUTE FROM
OUTSIDE TO INSDIE OF ARM
STACK

Figure 3-48. Platform cable (3248RS/10RS) - Sheet 2 of 4

3-46 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

SEE DETAIL A

DETAIL A

ORANGE MARKER TAPE
ROUTE CABLE HARNESS AND SECURE TO
PLATFORM UNDERSTRUCTURE, 2X

1001196746-B

MAF03380

Figure 3-49. Platform cable (3248RS/10RS) - Sheet 3 of 4

3121273 3-47

SECTION 3 - CHASSIS & SCISSOR ARMS

1001196746-B

MAF03390

SEE DETAIL B

SEE DETAIL C

DETAIL B

NOTICE: CABLE ROUTES THROUGH
PLATFORM USING THE PLATFORM
CABLE SUPPORT ENTRY POINT

SECURE HOSE CLAMP WITH
HARDWARE FACING OUTSIDE
THE PLATFORM

ROUTE CABLE HARNESS THROUGH
PLATFORM OPENING, SECURE TO
PLATFORM USING SEQ#1

DETAIL C

PLATFORM CABLE IS ROUTED
WITH AC CABLE THROUGH
CLAMP

TIGHTEN UNTIL CABLES
ARE SECURE

NOTICE: CABLE ROUTES
THROUGH PLATFORM
USING THE PLATFORM
CABLE SUPPORT EXIT POINT

SECURE PLATFORM CONNECTOR

(X12) TO CONTROL BOX AS SHOWN

Figure 3-50. Platform cable (3248RS/10RS) - Sheet 4 of 4

3-48 3121273

NOTES:

1. ORANGE AND YELLOW MARKER TAPE STRIPS ARE LOCATED ON PLATFORM CABLE HARNESS TO ASSIST IN INSTALLATION.

2. AT EVERY YELLOW MARKER TAPE, SECURE THE HARNESS TO THE NUTS WELDED ON THE ARMS USING WIRE TIE STRAP.

3. AT EVERY ORANGE MARKER TAPE, SECURE THE HARNESS TO THE CABLE CARRIER USING WIRE TIE STRAP.

4. ADDITIONAL TIES SHOULD BE USED TO FIRMLY ATTACH THE HARNESS TO THE MACHINE.

1001147239-E

MAF02430

APPROXIMATELY 230 MM
ORANGE TAPE MARK

SECURE CABLE HARNESS
ALONG SIDE OF CYLINDER
UNTIL REACHING THE ORANGE
MARKER TAPE

DO NOT ROUTE HARNESS
ON THIS ROD

YELLOW MARKER TAPE

ORANGE MARKER TAPE
NOTICE: USE NOTCHES TO
LOCATE TIE STRAPS
TO CABLE CARRIER, -2X

YELLOW MARKER TAPE

ORANGE MARKER TAPE
NOTICE: USE NOTCHES TO

LOCATE TIE STRAPS
TO CABLE CARRIER, -2X

YELLOW MARKER TAPE

SECURE HARNESS TO THE
ARMS BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, -3X

ORANGE MARKER TAPE
NOTICE: USE NOTCHES
TO LOCATE TIE STRAPS TO
CABLE CARRIER, -2X

YELLOW MARKER TAPE

SECURE HARNESS TO THE
ARMS BY INSERTING TIE
STRAP, THROUGH THE WELD
NUTS ALONG THE ARM TACK, 0X

YELLOW MARKER TAPE
SECURE HARNESS TO THE
PLATFORM BY HOSE CLAMP

SECURE HARNESS TO THE
ARMS BY INSERTING TIE STRAP,
THROUGH THE WELD NUTS
ALONG THE ARM STACK, -1X

SECURE HARNESS TO THE
ARMS BY INSERTING TIE
STRAP, THROUGH THE
WELD NUTS ALONG THE
ARM STACK, -3X

Figure 3-51. Platform cable (LSS - 3248RS/10RS) - Sheet 1 of 3

SECTION 3 - CHASSIS & SCISSOR ARMS

3121273 3-49

SECTION 3 - CHASSIS & SCISSOR ARMS

1001147249-E

MAF02600

SEE DETAIL A

ORANGE MARKER TAPE
ROUTE CABLE HARNESS AND SECURE TO

PLATFORM UNDERSTRUCTURE, 3X

DETAIL A

Figure 3-52. Platform cable (LSS - 3248RS/10RS) - Sheet 2 of 3

3-50 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

1001147249-E

MAF02610

SEE DETAIL B

SEE DETAIL C

DETAIL B

ROUTE CABLE HARNESS THROUGH
PLATFORM OPENING, SECURE TO
PLATFORM USING HOSE CLAMP

SECURE HOSE CLAMP WITH
HARDWARE FACING OUTSIDE
THE PLATFORM

NOTICE: CABLE ROUTES THROUGH
PLATFORM USING THE PLATFORM
CABLE SUPPORT

ENTRY POINT

DETAIL C

PLATFORM CABLE IS ROUTED
WITH AC CABLE THROUGH
CLAMP

TIGHTEN UNTIL CABLES
ARE SECURE

SECURE PLATFORM CONNECTOR (X8)

TO RAIL WELDMENT AS SHOWN

NOTICE: CABLE ROUTES THROUGH
PLATFORM USING THE PLATFORM
CABLE SUPPORT

EXIT POINT

Figure 3-53. Platform cable (LSS - 3248RS/10RS) - Sheet 3 of 3

3121273 3-51

SECTION 3 - CHASSIS & SCISSOR ARMS

NOTES:

1. ORANGE AND YELLOW MARKER TAPE STRIPS ARE LOCATED ON
PLATFORM CABLE HARNESS TO ASSIST IN INSTALLATION.

2. AT EVERY YELLOW MARKER TAPE, SECURE THE HARNESS TO THE
NUTS WELDED ON THE ARMS USING WIRE TIE STRAP.

3. AT EVERY ORANGE MARKER TAPE, SECURE THE HARNESS TO THE
CABLE CARRIER USING WIRE TIE STRAP.

4. ADDITIONAL WIRE TIES SHOULD BE USED TO FIRMLY ATTACH THE
HARNESS TO THE MACHINE.

SEE NOTE REGARDING
ASECUREMENT OF HARNESS

1001196745-B

MAF02960

TIE STRAP THE FIRST TAPE MARK
ON THE PLATFORM CABLE TO THE
ROD ON THE LOWER INBOARD AS SHOWN.

Figure 3-54. Platform cable (FTSW - 3248RS/10RS) - Sheet 1 of 4

3-52 3121273

SECTION 3 - CHASSIS & SCISSOR ARMS

1001196745-B

MAF02970

SECURE HARNESS TO TUBE ON

CYLINDER WITH TIE STRAP

AT EVERY ORANGE TAPE

Figure 3-55. Platform cable (FTSW - 3248RS/10RS) - Sheet 2 of 4

3121273 3-53

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-56. Platform cable (FTSW - 3248RS/10RS) - Sheet 3 of 4

1001196745-B

MAF02980

SEE DETAIL B

DETAIL B

USE TIE STRAP TO SECURE CABLE
TO THE PLATFORM CROSS MEMBER

DETAIL A

SECURE HARNESS BY
WRAPPING TIE WRAP

AROUND CABLE CARRIER

SEE DETAIL A

SECURE CABLE TO THE
ARMS BY INSERTING WIRE
TIE STRAP THROUGH NUTS
WELDED TO ARMS

3-54 3121273

1001196745-B

MAF02990

DETAIL C

USE SUPPORT FROM
PLATFORM INSTALLATION
TO SECURE CABLE IN
CHANNEL

CABLE ROUTES
THROUGH CLAMP

RAIL AND BRACKET ASHOWN IN

PHANTOM FOR CLARITY

SECURE PLATFORM CONNECTOR (X12)

TO PLATFORM BOX AS SHOWN

SEE DETAIL C

Figure 3-57. Platform cable (FTSW - 3248RS/10RS) - Sheet 4 of 4

SECTION 3 - CHASSIS & SCISSOR ARMS

3121273 3-55

SECTION 3 - CHASSIS & SCISSOR ARMS

1

2

3

1

1

2

3.19 PLATFORM CONTROL STATION

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

Installation/Removal

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

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

Control Station Harness Installation to Scissor Arms

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

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

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

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

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

Control Station Disassembly

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

2. Remove the main body from the mount, by removing
the long through bolt, cap-nut and washers (item 1) and
the two (2) bolts and nuts (item 2) along the rear edge.

Figure 3-58. Platform Control Station Installation

1. Harness Connector

2. Mounting Pin

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

3. Lift and Remove

Figure 3-59. Platform Control Station Disassembly

1. Through Bolt, Cap-nut and
Was her s

2. Rear Edge Bolts and Nuts

3-56 3121273

Overview of Control Station Components

1001132362 B

1

3

4

8

9

10

2

5

1

2

6

7

11

FRONT

3

4

1

2

5

9

7

6

8

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-60. Platform Control Station Components -

External

1. Steer Control Switch

2. Drive and Lift Joystick Control

3. Trigger Switch

4. Forward/Reverse/Lift/Lower
Direction Decal

5. Alarm

6. Overload Indicator (If Equipped)

7. Machine Tilt Indicator

8. Emergency Stop Switch

9. Horn Button

10. Drive and Lift Select Switch

11. Low Battery Charge/System
Fault Ind icator

Figure 3-61. Platform Control Station Components - Internal

1. Drive and Lift Joystick Control

2. Low Battery Charge/System
Fault Indicator

3. Drive and Lift Select Switch

4. Emergency Stop Switch

NOTE: (1) Zip-tie item-6 (Harness Splice Connector) to item-5

(Horn Button Switch), to prevent any possible interference
with the joystick path.

5. Horn Button Switch

6. Harness Splice Connector

7. Machine Tilt Indicator

8. Overload Indicator
(If Equipped)

9. Alarm

(1)

3121273 3-57

SECTION 3 - CHASSIS & SCISSOR ARMS

Figure 3-62. Joystick

Joystick Controller

Table 3-5. Joystick Specifications

Input Voltage +5 (±0.1) VDC

Current Consumption 10 mA @ 12 VDC

Output: Handle Centered 2.5 (±0.1) VDC

Output: Full Positive (Reverse) Deflection 4 (±0.1) VDC

Output: Full Negative (Forward) Deflec tion 1 (±0.1) VDC

NOTE: For joystick calibration procedure see Joystick Calibration -

page 5-5.

Ter m Color Function

1RED HANDLE COM

2 VIOLET TRIGGER N.O.

3-- SPARE

4 YELLOW ROCKER RT

5 GREEN ROCKER LT

6-- SPARE

7 WHITE/RED +5VDC

8 WHITE/BLACK GROUND

9 BROWN SIG OUTPUT

Table 3-6. Connector Chart

CONNECTOR PINOUT

3-58 3121273

SECTION 4. HYDRAULICS

SECTION 4 - HYDRAULICS

4.1 CYLINDERS - THEORY OF OPERATION

Cylinders are of the double acting type. The Lift and Steer sys­tems incorporate double acting cylinders. A double acting cyl­inder is one that requires oil flow to operate the cylinder rod in
both directions. Directing oil (by actuating the corresponding
control valve to the piston side of the cylinder) forces the pis­ton to travel toward the rod end of the barrel, extending the
cylinder rod (piston attached to rod). When the oil flow is
stopped, movement of the rod will stop. By directing oil to the
rod side of the cylinder, the piston will be forced in the oppo­site direction and the cylinder rod will retract.

NOTE: The lift cylinder is a single acting cylinder which takes

hydraulic pressure to extend and gravity to retract.

A holding valve is used in the hydraulic lift circuit to prevent
motion unintended by the operator in the event of a hydraulic
line failure.

4.2 VALVES - THEORY OF OPERATION

Solenoid Control Valves (Bang-Bang)

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

Relief Valves

Main relief valves are installed at various points within the
hydraulic system to protect associated systems and compo­nents against excessive pressure. Excessive pressure can be
developed when a cylinder reaches its limit of travel and the
flow of pressurized fluid continues from the system control.
The relief valve provides an alternate path for the continuing
flow from the pump, thus preventing rupture of the cylinder,
hydraulic line or fitting. Complete failure of the system pump
is also avoided by relieving circuit pressure. The relief valve is
installed in the circuit between the pump outlet (pressure line)
and the cylinder of the circuit, generally as an integral part of
the system valve bank. Relief pressures are set slightly higher
than the load requirement, with the valve diverting excess
pump delivery back to the reservoir when operating pressure
of the component is reached.

Crossover Relief Valves

Crossover relief valves are used in circuits where the actuator
requires an operating pressure lower than that supplied to the
system. When the circuit is activated and the required pressure
at the actuator is developed, the crossover relief diverts excess
pump flow to the reservoir. Individual, integral relief’s are pro­vided for each side of the circuit.

Proportional Valve

Flow is proportional to the amount of voltage supplied to the
valve coil. Voltage is gained by the machine controller and
determined by the position of the joystick.

Manual Descent Valve

The manual descent valve is located on the top of the holding
valve on the lift cylinder. The holding valve is a normally closed
solenoid valve, and holds the platform in place when raised.
When activated, the valve opens to permit lift down. The hold­ing valve is connected to the manual descent valve, which is
connected to a cable which, when pulled, manually opens the
lift down port of the valve and allows the platform to be low­ered in the event hydraulic and/or electric power is lost.

3121273 4-1

SECTION 4 - HYDRAULICS

4.3 PUMP/MOTOR

Theory of Operation

The Power Module (see Section 3.12, Power Control Module ­ZAPI) is essentially a "low-side" switch for the pump motor.
The positive terminal of the pump is tied to Battery Positive
after the Line Contactor. The negative terminal of the pump
connects to the P Terminal of the Power Module, which
switches current through MOSFET transistors to the Battery
Negative.

For variable speed pump operation, the MOSFET transistors
switch On and Off at high frequencies (16kHz). The Duty Cycle
is varied to control the voltage applied to the pump motor.
When the MOSFET's spend 50% of the period On and 50% Off,
approximately ½ of the available Battery Voltage will be
applied to the pump motor. Similarly, the MOSFET are On con­tinuously (100% Duty Cycle) to apply all available Battery Volt­age to the pump motor (as in Lift Up at full speed).

When the Control System is energized, the voltage at the P Ter­minal will be approximately +24V (referenced to -B) when the
pump is static. The P Terminal will be approximately at +1V
(referenced to -B) when the pump is running at full speed (Lift
Up from Ground Mode).

Pump Motor Electrical Evaluation

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

Refer to Figure 7-2., Resistance Measurement. Make all mea­surements with a voltmeter set to resistance scale (Ohms). Dis­connect main power at the batteries and all pump motor
cables during this analysis.

• Resistance < 5 Ohms between Motor Terminals.
The internal windings are very low impedance and should
appear to be a short-circuit for an ordinary voltmeter
(other tests can determine if the windings are truly
shorted). High resistance can signal worn brushes, a faulty
commutator, or open windings.

• Resistance > 1 Mega-Ohms between Motor Terminals
and Motor Housing. The internal windings should be
electrically isolated from the motor housing. Low resis­tance may be an indication of a broken motor terminal,
damaged brush, faulty commutator, or burned winding.

COMMON DIFFICULTIES

The following difficulties can be examined using the JLG Ana­lyzer, a voltmeter, and simple hand tools. Unless otherwise
noted, the Control System shall be energized in Ground Mode
during testing. For a convenient Ground Reference, place the
black meter lead on the negative post of the left battery in the
left-side batter compartment. The vehicle should be placed
on a smooth, firm, and level surface for all analysis.

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

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

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

2. Open-Circuit between Pump Motor Negative Terminal
and P Terminal

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

After ensuring there is not an Open-Circuit between the
+B Terminal and Pump Motor Positive Terminal, check
that the voltage measured between the Pump Motor
Negative Terminal and Ground Reference is 24V. If not,
examine the issues within Open-Circuit Pump Motor.
This voltage should ramp to approximately 0V when Lift
Up is operated from Ground Mode. If not, examine the
cable between the terminal and the Power Module com­partment (P Terminal). Inspect crimps for corrosion and
ensure that bolted connections are tight. Ensure that
the cable is not crushed where it passes between the
frame side sheets and the cylinder assembly.

3. Open-Circuit Pump Motor

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

Disconnect main power at the batteries to completely
de-energize the Control System. Next, detach the cable
from Pump Motor Positive Terminal. Using a voltmeter
set for resistance measurement (Ohms), ensure that the
resistance between the Pump Motor Positive and Nega­tive Terminals is less than 2 Ohms. If not, examine the
pump motor for worn brushes or broken terminals. After
examination, re-connect the Pump Motor Positive Ter­minal and main power at the batteries.

4-2 3121273

SECTION 4 - HYDRAULICS

-B

P

+B

Series DC

Pump Motor

24V

Line Contactor

Power Module

4. Short-Circuit between Pump Motor Positive and Nega­tive Terminals

This issue will allow the vehicle to drive, but Lift Up and
Steer Functionality will be lost and the Pump Motor will
not operate. Under DIAGNOSTICS - PUMP, the JLG Ana­lyzer will show an erratic reading for PUMP PWM % and
PUMP CUR will hover around 150A when Lift Up is oper­ated from Ground Mode.

Disconnect main power at the batteries to completely
de-energize the Control System. Next, detach both
Pump Motor Terminals and insulate them indepen­dently. Re-connect main power at the batteries and re­try Lift Up. If the same symptoms persist (erratic PUMP
PWM%, PUMP CUR around 150A), examine the cabling
between the Pump Motor and Power Module compart­ment for a short-circuit (most likely near area where cyl­inder retracts between frame side sheets or near pot­hole mechanism, if equipped). If the symptoms change,
suspect a short-circuited (or mechanically frozen) pump
motor.

A clamp-on ammeter (set for 200A DC) can be placed on
either Pump Motor Cable for verification. During Lift Up,
the ammeter will read approximately 150A.

Hydraulic Oil Check Procedure

Lube Point(s) - Hydraulic Reservoir

Lube - Hydraulic Oil

Interval - Check Daily

Table 4-1. Hydraulic System Capacities

COMPONE NT 1932RS/6RS 3248RS/10RS

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

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

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

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

1. On the left side of the machine, remove the side access
door on the base frame. Locate the hydraulic oil reser­voir (1) on the pump unit (2). Check the oil level in the
hydraulic reservoir by looking at the markings on the
side of the tank. The reservoir is marked with a MAX
(maximum) marking (3). The oil level must be kept at or
within one (1) inch of this marking to operate properly.

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

NOTE: Care should be taken not to introduce any impurities

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

3121273 4-3

SECTION 4 - HYDRAULICS

1

2

3

4

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

NOTE: Recommended lubricating intervals are based on

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

oil by using a funnel. Fill until oil is up to the MAX
level indicator on the side of the tank.

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

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

outlet.

5. Replace the o-rings if necessary.

6. Remove allen nut on the return/filter line and rotate

large retainer ring to remove return/filter line.

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

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

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

inlet on the new pump before installing.

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

Pump/Tank Disassembly

(See Figure 4-2.)

1. Place the pump/motor assembly on a clean workbench.

NOTE: Drain the hydraulic oil by carefully removing the oil fill plug

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

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

a. Slowly loosen and remove the four bolts that hold

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

b. Carefully remove the tank from the valve taking care

not to damage internal pickup tube or o-ring gasket
on tank.

c. Place tank on a suitable work bench or work area.

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

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

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

a. Thoroughly clean the tank and clean any debris

from the magnet.

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

not to introduce debris or dirt.

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

(8.5-10 Nm).

d. If only replacing the oil filter and maintenance is

complete, reinstall tank assembly on machine,
remove fill cap and refill tank with proper grade of

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

Pump Motor Removal

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

2. Pull motor from valve.

3. Once all maintenance is performed, reinstall tank assem-

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

4-4 3121273

Torque: 15 - 18 ft. lb.

Torque: 15 - 18 ft. lb.

Torque: 29 - 37 ft. lb.

Torque: 18 - 22 ft. lb.

Torque: 37 - 44 ft. lb.

Torque: 24 - 29 ft.lb.

Torque: 6 - 7 ft. lb.

20

5

4

8.5-10 Nm

25 - 30 Nm

40 - 50 Nm

20 - 25 Nm

20 - 25 Nm

20 - 25 Nm

32 - 40 Nm

50 - 60 Nm

1

23

7

Torque: 3.5 - 4.5 ft.lb.

5 - 6 Nm

Torque: 15 - 18 ft. lb.

44

6

17

16

12

19

13

18

14

11

21

9

22

8

3

2

10

15

SECTION 4 - HYDRAULICS

1. Main Valve Body

2. Pump Electric Motor

3. Motor to Valve Body Adapter

4. Hydraulic Oil Tank

5. Tank to Valve Body Attachment Ring

6. Tank to Valve Body - O-Ring

7. Auxiliary Pressure (M) Port

8. Suction Pipe

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

9. Suction Filter

10. Modular to Main Valve Body Screw

11. Solenoid Valve

12. Lift Relief Valve

13. Steer Relief Valves

14. Valve Coil for Steer Cylinder

15. Gear Pump

17. Return Filter Pipe

18. 1/4" JIC/BSPP Adapter

19. 3/8" JIC/BSPP - 90° Adapter

20. Product ID Plate

21. Valve Coil for Lift Up/Down

22. M Port - 1/4" BSPP

23. P1 Port - 3/8" BSPP

16. Return Filter w/Bypass

3121273 4-5

SECTION 4 - HYDRAULICS

4.4 LIFT PRESSURE SETTING PROCEDURE

1. Place 120% of the rated load of the machine on the plat­form.

2. Increase lift pressure to raise the platform to full height.

3. Adjust the pressure setting screw on lift relief valve to

reach the proper lift pressure per model as listed in Table

4-2.

Table 4-2. Lift Pressure Settings

Model Lift Relief Steer Relief

1932RS/6RS

3248RS/10RS

2300 psi ± 50 psi

(159 bar ± 3.5 bar)

2500 psi ± 50 psi

(172 bar ± 3.5 bar)

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

1. Install adapter from table into M-port or P1-port on

pump (see Figure 4-2.) and attach pressure gauge.

Table 4-3. Pressure Fitting Adapter

PORT JLG PART #

P1

M

2. Remove the solenoid from the lift valve.

3. Activate the lift function from the ground or platform

and adjust the pressure setting screw on lift relief valve
to reach the proper lift pressure per model as listed in
Table 4-2.

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

5. Replace the solenoid on the lift valve.

300057 - JIC

300017 - JIC

2221222 - Quick Disconnect

1000 psi

(69 bar)

1000 psi

(69 bar)

4.5 CYLINDER CHECKING PROCEDURE

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

ponent is replaced or when improper system operation is
suspected.

1. Using all applicable safety precautions, activate pump
motor and fully extend cylinder to be checked.

2. Carefully disconnect hydraulic hoses from retract port of
cylinder. There will be some initial weeping of hydraulic
fluid which can be caught in a suitable container. After
the initial discharge, there should be no further drainage
from the retract port.

3. Activate pump motor and extend cylinder.

4. If cylinder retract port leakage is less than 6-8 drops per

minute, carefully reconnect hose to port and retract cyl­inder. If leakage continues at a rate of 6-8 drops per min­ute or more, cylinder repair must be made.

NOTE: Steps 5 through 7 for Steer Cylinder Only.

5. With cylinder fully retracted, shut down machine power
and carefully disconnect hydraulic hose from cylinder
extend port.

6. Activate pump motor and retract cylinder. Check extend
port for leakage.

7. If extend port leakage is less than 6-8 drops per minute,
carefully reconnect hose to extend port, than activate
cylinder through one complete cycle and check for
leaks. If leakage continues at a rate of 6-8 drops per min­ute or more, cylinder repairs must be made.

4-6 3121273

SECTION 4 - HYDRAULICS

4.6 LIFT CYLINDER REMOVAL

NOTE: If there is a pump failure, a crane or a forktruck can be used

to raise the platform. Refer to Figure 3.15, Scissor Arms
Removal.

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

1. Raise the platform and use an overhead crane or fork
truck to secure the platform and scissor arms before lift
cylinder removal begins. (See Figure 3-42.)

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

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

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

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

the large nut located behind the manual descent bracket
as shown.
Also see Figures 3-43., 3-44., 3-45., for lift cylinder mount­ing hardware configurations.

4. Ensuring that the deck and scissor arms are properly
secure, remove the top lift cylinder pin and rest the top
of the cylinder on the arm cross tube directly below the
cylinder.

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

6. Place the cylinder on a clean workbench.

3121273 4-7

SECTION 4 - HYDRAULICS

Figure 4-3. Cylinder Barrel Support

Figure 4-4. Cylinder Rod Support

4.7 CYLINDER REPAIR

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

inders on this machine. Procedures that apply to a specific
cylinder will be so noted.

Disassembly

DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK
SURFACE IN A DIRT FREE WORK AREA.

1. Connect a suitable auxiliary hydraulic power source to
the port block fitting in the manifold located on the cyl­inder.

DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE. RETRACT CYLINDER
SLIGHTLY TO AVOID TRAPPING PRESSURE.

2. Operate the hydraulic power source and extend the cyl­inder. Shut down and disconnect the power source.
Adequately support the cylinder rod, if applicable.

3. If applicable, remove the cartridge-type holding valve
and fittings from the cylinder port block. Discard o­rings.

7. Attach a suitable pulling device to the cylinder rod port
block end or cylinder rod end, as applicable.

EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

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

4. Place the cylinder barrel into a suitable holding fixture.

5. Mark cylinder head and barrel with a center punch for

easy realignment. Loosen the cylinder head setscrew.

6. Using the proper wrench, loosen the cylinder head and
remove head from cylinder barrel.
When removing cylinder head do not force if binding
occurs. Reverse rotation a couple times and try remov­ing again. If still no release, tap barrel with hammer in
threaded area, and try again. Repeat if necessary, until
head is completely removed.

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

NOTE: For steer cylinder piston removal, see Steer Cylinder Piston

Removal on page 4-9 following.

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

11. Insert the cap screw(s) in the threaded holes in the outer
piece of the tapered bushing. Progressively tighten the
cap screw(s) until the bushing is loose on the piston.

12. Remove the bushing from the piston.

13. Screw the piston CCW, by hand, and remove the piston

from cylinder rod.

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

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

16. Remove the rod from the holding fixture. Remove the

cylinder head gland and retainer plate, if applicable. Dis­card the o-rings, back-up rings, rod seals, and wiper
seals.

4-8 3121273

SECTION 4 - HYDRAULICS

STEEL

BUSHING

GAR-MAX
BUSHING

ARBOR

Figure 4-5. Gar-Max Bearing Installation

Steer Cylinder Piston Removal

1. Using the spanner holes, rotate the piston until the end
of the retaining ring can be seen through the cross­drilled retaining ring hole.

2. Insert a flathead screwdriver (or similar tool) into the
cross-drilled retaining ring hole.

3. Using the screwdriver, guide the retaining ring into the
cross-drilled retaining ring hole while turning the pis­ton.

4. Continue turning the piston approximately one (1) full
turn until the start of the retaining ring is again aligned
with the cross-drilled retaining ring hole.

5. Lift up on the retaining ring so that the hook on the start
of the retaining ring releases from the hole in the rod.

6. Pull the retraining ring all the way out of the cross­drilled retraining ring hole.

7. Slide the piston over the rod in the direction of the span­ner holes to remove.

10. Inspect threaded portion of head for damage. Dress
threads as necessary.

11. Inspect seal and o-ring grooves in head for burrs and
sharp edges. Dress applicable surfaces as necessary.

12. Inspect cylinder head outside diameter for scoring or
other damage and ovality and tapering. Replace as nec­essary.

13. If applicable, inspect rod and barrel bearings for signs of
correct excessive wear or damage. Replace as necessary.

a. Thoroughly clean hole, (steel bushing) of burrs, dirt

etc. to facilitate bearing installation.

b. Inspect steel bushing for wear or other damage. If

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

c. Lubricate inside of steel bushing with WD40 prior to

bearing installation.

d. Using an arbor of the correct size, carefully press the

bearing into steel bushing.

NOTE: Install pin into the Gar-Max bearing dry. Lubrication is not

required with nickel plated pins and bearings.

Cleaning and Inspection

1. Clean all parts thoroughly in an approved cleaning sol­vent.

2. Inspect the cylinder rod for scoring, tapering, ovality, or
other damage. If necessary, dress rod with Scotch Brite
or equivalent. Replace rod if necessary.

3. Inspect threaded portion of rod for excessive damage.
Dress threads as necessary.

4. Inspect inner surface of cylinder barrel tube for scoring
or other damage. Check inside diameter for tapering or
ovality. Replace if necessary.

5. Inspect threaded portion of barrel for damage. Dress
threads as necessary.

6. Inspect piston surface for damage and scoring and for
distortion. Dress piston surface or replace piston as nec­essary.

7. Inspect threaded portion of piston for damage. Dress
threads as necessary.

8. Inspect seal and o-ring grooves in piston for burrs and
sharp edges. Dress applicable surfaces as necessary.

14. Inspect travel limiting collar or spacer for burrs and
sharp edges. If necessary, dress inside diameter surface
with Scotch Brite or equivalent.

15. If applicable, inspect port block fittings and holding
valve. Replace as necessary.

16. Inspect the oil ports for blockage or the presence of dirt
or other foreign material. Repair as necessary.

17. If applicable, inspect piston rings for cracks or other
damage. Replace as necessary.

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

3121273 4-9

SECTION 4 - HYDRAULICS

Figure 4-6. Rod Seal Installation

Figure 4-7. Poly-Pak Piston Seal Installation

Figure 4-8. Wiper Seal Installation

Figure 4-9. Installation of Head Seal Kit

Assembly

NOTE: Prior to cylinder assembly, ensure that the proper cylinder

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

Apply a light film of hydraulic oil to all components prior to
assembly.

1. A special tool is used to install a new rod seal into the
applicable cylinder head gland groove.

3. Place a new “O-ring and back-up seal in the applicable
outside diameter groove of the cylinder head.

WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE SEALS ARE INSTALLED
PROPERLY. REFER TO WIPER SEAL INSTALLATION FOR CORRECT SEAL ORIEN­TATION. IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAK­AGE AND IMPROPER CYLINDER OPERATION.

2. Use a soft mallet to tap a new wiper seal into the appli­cable cylinder head gland groove. Install a new wear
ring into the applicable cylinder head gland-groove.

4. Install washer ring onto rod, carefully install the head
gland on the rod, ensuring that the wiper and rod seals
are not damaged or dislodged. Push the head along the
rod to the rod end, as applicable.

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

6. If applicable, correctly place new seals and guide lock
rings in the outer piston diameter groove. (A tube, with
I.D. slightly larger than the O.D. of the piston is recom­mended to install the solid seal.)

NOTE: The backup rings for the solid seal have a radius on one

side. This side faces the solid seal.(See magnified insert in
Figure 4-9. The split of seals and backup rings are to be
positioned so as not to be in alignment with each other.

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

4-10 3121273

SECTION 4 - HYDRAULICS

Head Gland

Piston Asssembly

Barrel Asssembly

Cylinder Rod

Figure 4-10. Rod Assembly Installation

8. Carefully thread the piston on the cylinder rod hand

tight, ensuring that the o-ring and back-up rings are not
damaged or dislodged.

9. Thread the piston onto the rod until it abuts the spacer
end and install the tapered bushing.

NOTE: When installing the tapered bushing, piston and mating

end of rod must be free of oil.

10. Assemble the tapered bushing loosely into the piston
and insert JLG capscrews (not vendor capscrews)
through the drilled holes in the bushing and into the
tapped holes in the piston.

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

12. After the screws have been torqued, tap the tapered
bushing with a hammer (16 to 24 oz.) and brass shaft
(approximately 3/4" in diameter) as follows;

a. Place the shaft against the cylinder rod and in con-

tact with the bushing in the spaces between the
capscrews.

b. Tap each space once; this means the tapered bush-

ing is tapped 3 times as there are 3 spaces between
the capscrews.

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

14. Remove the cylinder rod from the holding fixture.

15. Place new guide locks and seals in the applicable out-

side diameter grooves of the cylinder piston.

16. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

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

20. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
reinstallation of any holding valve or valves.

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

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

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

NOTE: Reverse the procedure Steer Cylinder Piston Removal on

page 4-9 for installing the steer cylinder piston.

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

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

3121273 4-11

23. Remove the cylinder rod from the holding fixture.

24. Position the cylinder barrel in a suitable holding fixture.

EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD,
HEAD, AND PISTON. AVOID PULLING THE ROD OFF-CENTER, WHICH COULD
CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.

SECTION 4 - HYDRAULICS

1

2

3

1

2

3

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

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

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

28. After the cylinder has been reassembled, the rod should
be pushed all the way in (fully retracted) prior to the
reinstallation of any holding valve or valves.

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

Lift Cylinder - LSS Pressure Sensor Location (If equipped)

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

Figure 4-12. LSS Pressure Sensors Location -

3248RS/10RS - (If Equipped)

1. Ports On Bottom of Cylinder

2. Pressure Sensors

3. Harness Connectors

Figure 4-11. LSS Pressure Sensors Location -

1932RS/6RS - (If Equipped)

1. Ports On Barrel of Cylinder

2. Pressure Sensors

3. Harness Connectors

4-12 3121273