JLG 1930ES Operation And Safety Manual
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JLG 1930ES Operation And Safety Manual

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See also: Service Maintenance Manual , Safety and Operating Manual
Operation and Safety Manual
ANSI
Original Instructions, Keep this manual with the machine at all times.
®
Models
1930ES/
2032ES/2632ES/
2646ES/3246ES
USA Built - S/N-0200239382 to Present
China Built - S/N-B200020297 to Present
Mexico Built - S/N-M200000100 to Present
P/N - 3121655
March 7, 2016

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  • Page 1 Operation and Safety Manual Original Instructions, Keep this manual with the machine at all times. Models 1930ES/ 2032ES/2632ES/ 2646ES/3246ES USA Built - S/N-0200239382 to Present China Built - S/N-B200020297 to Present Mexico Built - S/N-M200000100 to Present ANSI P/N - 3121655 ®...
  • Page 3 IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DIS- TANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO- NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
  • Page 4 INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- WILL HAVE AN ORANGE BACKGROUND. TECTION OF PROPERTY. – JLG Lift – 3121655...
  • Page 5 Your Local JLG Office JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL (See addresses on manual rear cover) INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCI- DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR In USA:...
  • Page 6 Manual Revised ....July 22, 2015 Manual Revised ....March 7, 2016 – JLG Lift – 3121655...

  • Page 7: Table Of Contents

    Controls and Indicators ..... . 3-8 Manual Descent Control ..... 3-9 3121655 – JLG Lift –...
  • Page 8 Lower (2) & Upper Slide Pads (3) ... . 5-15 Manual Descent ......4-1 – JLG Lift – 3121655...
  • Page 9 8-2 Platform Load Sense ....5-45 9-9 Hardware ......5-46 3121655 – JLG Lift –...
  • Page 10 5-4. Decal Location - 1930ES- Sheet 1 ....5-19 5-12 Decal Location Legend ......5-25 5-5.

  • Page 11: Section 1 - Safety Precautions

    JLG Industries, Inc. (“JLG”). A maintenance program, using the information provided in this manual and the Service and Maintenance Manual,...

  • Page 12: Pre-Operation

    JLG Industries, Inc. • Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utili- zation and application of the machine.

  • Page 13: Machine Inspection

    JLG. • Check the machine for modifications to original compo- • Ensure that the ground conditions are adequate to support nents.
  • Page 14 • Fully lower platform and shut off all power before leaving machine. • Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment. – JLG Lift – 3121655...

  • Page 15: Trip And Fall Hazards

    • Prior to operation, ensure all gates and rails are fastened and secured in their proper position. • JLG Industries, Inc. recommends that all persons in the plat- form wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine.

  • Page 16: Electrocution Hazards

    50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. – JLG Lift – 3121655...

  • Page 17: Tipping Hazards

    • Never exceed the maximum work load as specified on the Over 750 KV to 1000 KV 45 (14) platform. Keep all loads within the confines of the platform, unless authorized by JLG. NOTE: This requirement shall apply except where employer, local or govern- mental regulations are more stringent.

  • Page 18: Beaufort Scale (For Reference Only)

    32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. – JLG Lift – 3121655...

  • Page 19: Crushing And Collision Hazards

    • Keep hands and limbs out of the scissor arm assembly dur- ing operation and when elevated without safety prop engaged. • Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bot- tom of platform when lifting or lowering platform. 3121655 – JLG Lift –...
  • Page 20 • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all operations. • Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, conges- tion, visibility, slope, location of personnel, and other fac- tors. 1-10 – JLG Lift – 3121655...

  • Page 21: Towing, Lifting, And Hauling

    • Ensure replacement parts or components are identical or damage to the machine or property. A maintenance program equivalent to original parts or components. 3121655 – JLG Lift – 1-11...

  • Page 22: Battery Hazards

    CLEAN WATER AND SEEK MEDICAL ATTENTION. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 1-12 – JLG Lift – 3121655...

  • Page 23: Section 2 - User Responsibilities, Machine Preparation & Inspection

    5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction. 6. The safest means to operate the machine where over- head obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs. 3121655 – JLG Lift –...

  • Page 24: Inspection And Maintenance Table

    PREPARATION, INSPECTION, AND MAINTENANCE The table below covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local reg- ulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

  • Page 25: Pre-Start Inspection

    Make sure all illegible decals and placards are cleaned or replaced. 4. Operation and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibili- 3121655 – JLG Lift –...

  • Page 26: Function Check

    Drive the machine on a grade, not to exceed the when the Emergency Stop Button is depressed. rated gradeability, and stop to ensure the brakes hold. b. Check the tilt indicator light to ensure proper operation. The light should be illuminated when tilted. – JLG Lift – 3121655...

  • Page 27: Tilt Activation Vs. Height

    2032ES 66 in. 1.7 m 18.75 (Full) 2632ES 76 in. 1.9 m 1930ES 2646ES 76 in. 1.9 m 3246ES 76 in. 1.9 m 20 (Full) 2032ES 25.4 (Full) 2632ES 26 (Full) 2646ES 31.75 (Full) 3246ES 3121655 – JLG Lift –...

  • Page 28: Daily Walk-Around Inspection - Sheet 1

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION Figure 2-1. Daily Walk-Around Inspection - Sheet 1 – JLG Lift – 3121655...
  • Page 29 Note 2. Steer Cylinder - See Inspection Note 3. Spindle, Tie Rod, Drive Motor and Steer Linkage (left front) - See Inspection Note Figure 2-2. Daily Walk-Around Inspection - Sheet 2 3121655 – JLG Lift –...

  • Page 30: Switch Locations

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION 1. Pothole Switch (Typical on oppo- site side of machine) 2. Rotary Angle Switch Figure 2-3. Switch Locations – JLG Lift – 3121655...

  • Page 31: General

    This section provides the necessary information needed to The JLG Scissor Lift has a primary operator Control Station in the understand control functions. Included in this section are the platform. From this Control Station, the operator can drive and...

  • Page 32: Operating Characteristics And

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION OPERATING CHARACTERISTICS AND LIMITATIONS Stability This machine, as originally manufactured by JLG and operated General within its rated capacity on a smooth, firm and level supporting A thorough knowledge of the operating characteristics and lim-...

  • Page 33: Location Of Machine Controls. (All Models)

    6. Platform AC Receptacle Plug 3. MDI Indicator and Brake Release Button 7. Scissor Arms - Safety Prop 4. Battery Charger AC Plug 8. Manual Storage Box Figure 3-1. Location of Machine Controls. (All Models) 3121655 – JLG Lift –...

  • Page 34: Battery Charging

    The battery charger AC plug (1) is located at the rear of the machine under the platform ladder. 3. The batteries are fully charged when green light on the ground control battery charger status panel (2), is 1. Connect the charger to a grounded outlet. illuminated. – JLG Lift – 3121655...

  • Page 35: Battery Charger Fault Codes

    30 seconds of operation. Once it has been determined that the batteries and connections are not faulty and fault 6 is again displayed after interrupting AC power for at least 10 seconds, the charger must be brought to a qualified service depot. 3121655 – JLG Lift –...

  • Page 36: Mdi (Multifunction Digital Indicator)

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION MDI (MULTIFUNCTION DIGITAL INDICATOR) 1. Right-Side Battery Compartment 2. Diagnostic Trouble Code LCD 3. Wrench Icon (Fault) 4. Fault LED 5. Battery Discharge Indicator (BDI) Figure 3-2. Multifunction Digital Indicator – JLG Lift – 3121655...

  • Page 37: Mdi Description

    • Under normal driving conditions the BDI’s will be illumi- NOTE: For DTC’s and descriptions, refer to Section 5.8, Diagnostic nated. When a DTC exists (other than 00x DTC’s) the BDI trouble codes (DTC) Check Tables Check Tables. LEDs will not be illuminated. 3121655 – JLG Lift –...

  • Page 38: Ground Control Station

    7. Battery Charge Status LEDs in the center off position, power is shut off to both 3. Emergency Stop Switch platform and ground controls. 4. Overload Indicator (If Equipped) Figure 3-3. Ground Control Station Panel – JLG Lift – 3121655...

  • Page 39: Manual Descent Control

    5. 10 Amp Fuse - Power feed to E-Stop button. 6. Hour Meter - Keeps track of number of machine hours of operation. Manual Descent - T-Handle Location 3121655 – JLG Lift –...

  • Page 40: Platform Control Station

    13. Emergency Stop Switch 14. Trigger Switch 15. Tilt Alarm Warning Horn (not shown, located on front of box) NOTE: *There is no indicator light equipped on a single capacity ANSI machine. Figure 3-4. Platform Control Station 3-10 – JLG Lift – 3121655...
  • Page 41 6. Tilt Indicator Warning Light - A red warning light on the control panel that illuminates when the chassis is on a 3121655 – JLG Lift – 3-11...
  • Page 42 (right or left). 9. Horn - This push-button switch, when activated, permits the operator to warn jobsite personnel when the machine is operating in the area. 3-12 – JLG Lift – 3121655...
  • Page 43 DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLAT- and lift functions. When released, the function being FORM IS RAISED ABOVE THE STOWED POSITION. operated will stop. 3121655 – JLG Lift – 3-13...

  • Page 44: Platform Operation

    Releasing the trigger switch will stop the func- 3. If operating from the ground controls, position the tion being operated. lift switch to up and hold until desired elevation is achieved. 3-14 – JLG Lift – 3121655...

  • Page 45: Arm Guards (If Equipped)

    Releasing the trigger will stop LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES. TO AVOID LOSS OF the function being operated. TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE 3121655 – JLG Lift – 3-15...

  • Page 46: Grade And Sideslope - Driving - Platform

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-5. Grade and Sideslope - Driving - Platform Stowed 3-16 – JLG Lift – 3121655...

  • Page 47: Soft-Touch System - (Option)

    The machine will move in the creep mode until the proximity 1. Proximity Switches 3. Lower Perimeter Bumpers switch is no longer tripped. 2. Platform Rail Bumpers Figure 3-6. Soft-Touch System 3121655 – JLG Lift – 3-17...

  • Page 48: Platform Deck Extension

    3.11 PLATFORM DECK EXTENSION The machine is equipped with a mechanically extendable deck, giving the operator better access to work areas. On the 1930ES/ 2032ES/2632ES this extension adds 3 ft. (0.9 m) and on the 2646ES and 3246ES the extension adds 4 ft. (1.2 m) to the front of the platform.

  • Page 49: Platform Rails - Fold-Down Procedure

    • Step 2 - Front deck-extension top side rail pins (2) must be removed and deck-extension top side rails slid rearward on 3121655 – JLG Lift – 3-19...

  • Page 50: Platform Rails - Fold Down Sequence

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-8. Platform Rails - Fold Down Sequence 3-20 – JLG Lift – 3121655...

  • Page 51: Parking And Stowing

    WITH THE ANTI-VANDAL COVERS CLOSED AND LOCKED IN PLACE. lock through one or more of the holes located on it’s upper mounting tabs. 3121655 – JLG Lift – 3-21...

  • Page 52: Tie Down/Lift Lugs

    LIFTING THE MACHINE FROM THE SIDES USING A FORK TRUCK IS NOT REC- OMMENDED BY JLG. IN THE EVENT THAT THE MACHINE NEEDS TO BE LIFTED FROM THE SIDES CAUTION MUST BE USED TO AVOID JAMMING THE POT HOLE PROTECTION BARS UP AGAINST THE FRAME.

  • Page 53: Lifting And Tie Down Diagram

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-10. Lifting and Tie Down Diagram 3121655 – JLG Lift – 3-23...

  • Page 54: Lifting And Tie Down Chart

    13.5 in. (34.25 cm) 2646ES 82.32 in. (209.1 cm) 43.8 in. (108.6 cm) 20.5 in. (52 cm) 3246ES 82.32 in. (209.1 cm) 43.8 in. (108.6 cm) 20.5 in. (52 cm) Figure 3-11. Lifting and Tie Down Chart 3-24 – JLG Lift – 3121655...

  • Page 55: Towing

    2. Pull the emergency stop switch out and position the keyswitch to ground mode. 3. The brake release cable hangs on a hook in the battery compartment on the opposite side of the ground con- trol panel. 3121655 – JLG Lift – 3-25...

  • Page 56: Mechanical Brake Release

    FROM THE BRAKE DISENGAGE HOLES. THE BRAKES CANNOT BE ENGAGED Figure 3-12. Manual Disengage WITH THE DISENGAGE BOLTS IN THE BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE. 3-26 – JLG Lift – 3121655...

  • Page 57: Section 4 - Emergency Procedures

    CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP BUTTON IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGI- BLE.GROUND CONTROL STATION Manual Descent - T-Handle Location 3121655 – JLG Lift –...

  • Page 58: Emergency Operation

    – JLG Lift – 3121655...

  • Page 59: Platform Caught Overhead

    It is imperative that JLG Industries, Inc. be notified immediately tures or equipment, do not continue operation of the machine of any incident involving a JLG product. Even if no injury or from either the platform or the ground until the operator and all property damage is evident, the Product Safety and Reliability personnel are safely moved to a secure location.
  • Page 60 SECTION 4 - EMERGENCY PROCEDURES NOTES: – JLG Lift – 3121655...

  • Page 61: Section 5 - General Specifications And Operator Maintenance

    Illustrated Parts Manuals: The maintenance portion of this section is intended as informa- 1930ES ............3121275 tion to assist the machine operator to perform daily mainte- 2032/2632ES ..........3121682 nance tasks only, and does not replace the more thorough 2646/3246ES ..........

  • Page 62: Operating Specifications

    3 mph 3 mph (5.6 kmh) (5.7 kmh) (5.7 kmh) (4.8 kmh) (4.8 kmh) Maximum Wind Speed 28 mph (12.5 m/s) (Depending on model, market, and indoor/outdoor selection, see Table 5-2, Platform Capacities on page 5-5) – JLG Lift – 3121655...
  • Page 63 90° 90° 90° Outside Steer Angle 69° 73° 73° 67° 67° Electrical System Voltage (DC) Approximate Gross Machine Weight - 4635 lbs (single) 2710 lbs 3610 lbs 4975 lbs 4975 lbs ANSI/CSA 4610 lbs (dual) 3121655 – JLG Lift –...
  • Page 64 2091 kg (dual) Ground Clearance with pot hole protection system up 3.5 in (8.9 cm) 5 in (12.7 cm) Ground Clearance with pot hole protection system down 1 in (2.5 cm) .75 in (1.9 cm) – JLG Lift – 3121655...

  • Page 65: Platform Capacities

    (454 kg) Zone A 3246ES to 26 ft. 1000 lb 450kg 320 kg 450 kg 320 kg (454 kg) Zone B 3246ES to 32 ft. 700 lb 320kg 320 kg 320 kg 320 kg (317 kg) 3121655 – JLG Lift –...

  • Page 66: Dimensional Data

    12.4 12.4 Platform Size - Length Platform Size - Width 0.76 Platform Extension Length Wheelbase 63 in. 160 cm 74 in. 188 cm 74 in. 188 cm 82.3 in. 209 cm 82.3 in. 209 cm – JLG Lift – 3121655...

  • Page 67: Motors

    100% Charge Indicator Green LED Fault Indicator Red LED Various LED PROTECTION Output Reverse Polarity Electronic Protection - Automatic Reset Output Short Circuit Electronic Protection - Automatic Reset AC Overload Current Limited DC Overload Current Limited — 3121655 – JLG Lift –...
  • Page 68 DC Input Voltage 21.2 to 29 VDC MECHANICAL Remote ON/OFF –40° F to + 185° F Operating Temperature CHARGER (–40° C to + 85° C) Nominal DC Output Voltage 28 VDC Housing Shock and Water Resistant Aluminum – JLG Lift – 3121655...

  • Page 69: Capacities

    1930ES 2032ES 2632ES 2646ES 3246ES Size 323mm x 100mm 406 mm x 125 mm Max Tire Load 2500 lbs (1134 kg) 4000 lbs (1814 kg) Wheel Bolt Torque 105 - 120 ft lb (142-163 Nm) 3121655 – JLG Lift –...

  • Page 70: Critical Stability Weights

    283 lbs (128 kg) Batteries: (each) 220 Amp 60 lbs (27 kg) 60 lbs (27 kg) 220 Amp (used with Inverter/Charger) 66 lbs (30 kg) 66 lbs (30 kg) 245 Amp 70 lbs (32 kg) 5-10 – JLG Lift – 3121655...

  • Page 71: Lubrication

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Lubrication NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- cosities.

  • Page 72: Operator Maintenance

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE OPERATOR MAINTENANCE 1. Hydraulic Oil 2. Lower Slide Pads 3. Upper Slide Pads 4. Scissor Arms - Safety Prop Figure 5-1. Lubrication Diagram 5-12 – JLG Lift – 3121655...

  • Page 73: Scissor Arms - Safety Prop

    ENSURE THE SCISSOR ARMS ARE PROPERLY SUPPORTED. NOTE: The 2632ES/2646ES/3246ES platforms will have to be raised higher than the 1930ES and 2032ES in order to access the oil plug. 3121655 – JLG Lift –...
  • Page 74 5. To check the oil level, lower platform so it rests on the safety prop. THERE MAY BE UP TO 10 PSI OF PRESSURE IN THE TANK. 5-14 – JLG Lift – 3121655...

  • Page 75: Lower (2) & Upper Slide Pads (3)

    2. Locate the Lower and Upper Slide Pads and remove all dirt and debris from the slide channel area (1, 2). Refer to Figure 5-2., Lower Slide Pad Channel. Figure 5-2. Lower Slide Pad Channel 3121655 – JLG Lift – 5-15...

  • Page 76: Upper Slide Pad Channel

    For Refer to Figure 5-3., Upper Slide Pad Channel. machines used in multi-shift operations and/or exposed to hostile environments or conditions, lubrication fre- quencies must be increased accordingly. Figure 5-3. Upper Slide Pad Channel 5-16 – JLG Lift – 3121655...

  • Page 77: Tires And Wheels

    RATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS 3. The tightening of the nuts should be done in stages. Fol- MATCHED TO THE CONE ANGLE OF THE WHEEL. lowing the recommended sequence, tighten nuts per wheel torque. 3121655 – JLG Lift – 5-17...

  • Page 78: Supplemental Information

    The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s2. The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s2. 5-18 – JLG Lift – 3121655...

  • Page 79: Decal Installations

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE DECAL INSTALLATIONS Figure 5-4. Decal Location - 1930ES- Sheet 1 3121655 – JLG Lift – 5-19...
  • Page 80 SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 5-5. Decal Location - 1930ES - Sheet 2 5-20 – JLG Lift – 3121655...

  • Page 81: Decal Location - 2032Es & 2632Es - Sheet 1

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 5-6. Decal Location - 2032ES & 2632ES - Sheet 1 3121655 – JLG Lift – 5-21...

  • Page 82: Decal Location - 2032Es & 2632Es - Sheet 2

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 5-7. Decal Location - 2032ES & 2632ES - Sheet 2 5-22 – JLG Lift – 3121655...

  • Page 83: Decal Location - 2646Es & 3246Es - Sheet 1

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 5-8. Decal Location - 2646ES & 3246ES - Sheet 1 3121655 – JLG Lift – 5-23...

  • Page 84: Decal Location - 2646Es & 3246Es - Sheet 2

    SECTION 5 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 5-9. Decal Location - 2646ES & 3246ES - Sheet 2 5-24 – JLG Lift – 3121655...

  • Page 85: Decal Location Legend

    1704277 1704277 1704277 1704277 1704277 1704277 1704277 1703819 1703819 1703819 1703819 1703819 1703819 1703819 1703819 1703819 1703822 1703822 1703822 1703822 1703822 1703822 1703822 1703822 1703822 1705692 1705692 1705692 1705692 1705692 1705692 1705692 1705692 1705692 3121655 – JLG Lift – 5-25...
  • Page 86 1705894 1705680 1705680 1705679 1705679 1705679 1705727 1705679 1705679 1705681 1705681 1705681 1705721 1705681 1705681 1703813 1705670 1705670 1704340 1704339 1704341 1704344 1707022 1705670 (1930ES) 1001099919 (2032ES) 1001178302 (2632ES) 1001178304 (2646ES) 1001099922 (3246ES) 1001099923 5-26 – JLG Lift – 3121655...
  • Page 87 All Models 1001104865 1001104866 1001126868 1001104865 1001104865 1001104865 1001104865 1001104865 1001104866 CHINA - MANUFACTURED All Models 1001115695 1001115696 1001127512 1001115695 1001115695 1001115695 1001115695 1001115695 1001115696 0272870 0272870 0272870 0272870 0272870 0272870 0272870 0272870 0272870 3121655 – JLG Lift – 5-27...
  • Page 88 1701499 1701499 1701499 1701499 1701499 1701499 (1930ES) 1001092071 1001092497 1001092497 1001092580 1001120629 1001120623 1001120622 1001120621 1001092497 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001094359 1001146794 1001146795 1001146795 1001146794 1001146794 1001146794 1001146794 1001146794 1001146795 5-28 – JLG Lift – 3121655...

  • Page 89: Diagnostic Trouble Codes (Dtc)

    DTCs are sorted in groups by the first two digits, which is also the system distress lamp flash code. To troubleshoot multiple DTCs, start with the DTC with the higher first two digits. If a correction is made during a check, conclude the check by cycling the machine power, using the emergency stop switch. 3121655 – JLG Lift – 5-29...

  • Page 90: Diagnostic Trouble Codes (Dtc)

    The MDI is powered, but cannot communi- • Check the MDI connector. cate with the control system. • Check the diagnostic connector. Refer problem to a qualified JLG mechanic. 001 EVERYTHING OK The normal help message in platform mode. Displays on the analyzer only.
  • Page 91 • Check that the elevation angle sensor is securely mounted. • Check that the pothole protection switches are securely mounted. Refer problem to a qualified JLG mechanic. 005 DRIVE & LIFT UP PREVENTED - TILTED Driving is not possible since the platform is •...

  • Page 92: Power-Up

    • Check that the PHP switches are securely mounted. hole protection mechanism failed to Refer problem to a qualified JLG mechanic. retract. 008 FUNCTIONS LOCKED OUT - SYSTEM After 2 hours without activity, the control •...

  • Page 93: Platform Controls

    • Check if the horn switch is damaged, obstructed or jammed. NENTLY SELECTED up in platform mode. Refer problem to a qualified JLG mechanic. 222 FUNCTION PROBLEM - INDOOR / OUT- The indoor / outdoor (zone A / zone B) •...

  • Page 94: Ground Controls

    • Check if the trigger switch is obstructed or jammed. NEUTRAL than five seconds while the joystick was Refer problem to a qualified JLG mechanic. centered. 2232 FUNCTION PROBLEM - DRIVE & LIFT The drive and lift inputs are both de-ener- •...

  • Page 95: Function Prevented

    • Check that the platform elevation sensor is securely mounted and AGE OUT OF RANGE angle sensor input. undamaged. Refer problem to a qualified JLG mechanic. 252 ELEV ANGLE SENSOR HAS NOT BEEN The elevation angle sensor has not been Refer problem to a qualified JLG mechanic.
  • Page 96 DESCRIPTION CHECK 257 ELEV PROX PERMANENTLY CLOSED - The elevation proximity switch shows the Refer problem to a qualified JLG mechanic. CHECK PROX AND ANGLE ADJUST- platform to be stowed, while the elevation MENT angle sensor shows the platform to be raised.

  • Page 97: Line Contactor Open Circuit

    DESCRIPTION CHECK 311 OPEN CIRCUIT LINE CONTACTOR There is a problem with the line contactor. Refer problem to a qualified JLG mechanic. 312 CONTACTOR DRIVER PERMANENTLY There is a problem with the power module Refer problem to a qualified JLG mechanic.
  • Page 98 DESCRIPTION CHECK 332 BRAKE OPEN CIRCUIT A problem has been detected in this func- Refer problem to a qualified JLG mechanic. tion. 333 LIFT UP SHORT TO BATTERY A problem has been detected in this func- Refer problem to a qualified JLG mechanic.
  • Page 99 DESCRIPTION CHECK 3312 LEFT BRAKE SHORT TO BATTERY A problem has been detected in this func- Refer problem to a qualified JLG mechanic. tion. 3313 RIGHT BRAKE SHORT TO BATTERY A problem has been detected in this func- Refer problem to a qualified JLG mechanic.

  • Page 100: Thermal Limit (Soa)

    DESCRIPTION CHECK 33305 STEER RIGHT VALVE - SHORT TO A problem has been detected in this func- Refer problem to a qualified JLG mechanic. GROUND tion. 33406 LIFT UP VALVE - SHORT TO GROUND A problem has been detected in this func- Refer problem to a qualified JLG mechanic.

  • Page 101: Battery Supply

    • Check for severely discharged battery, loose cables or for damaged bat- was measured to be out of normal operat- tery; otherwise; 4421 ing range. • Refer problem to a qualified JLG mechanic. 4422 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK...

  • Page 102: Communication

    DESCRIPTION CHECK 662 CANBUS FAILURE - PLATFORM MOD- In platform mode, the control system Refer problem to a qualified JLG mechanic. failed to receive messages from the plat- form board. 663 CANBUS FAILURE - LOAD SENSING With load sensing system enabled, the Refer problem to a qualified JLG mechanic.

  • Page 103: Electric Motor

    DESCRIPTION CHECK 771 OPEN CIRCUIT DRIVE MOTOR WIRING The power module detected a problem in Refer problem to a qualified JLG mechanic. the drive motors' power circuit wiring. 772 STALLED TRACTION MOTOR OR POWER The power module detected a problem in Refer problem to a qualified JLG mechanic.

  • Page 104: Tilt Sensor

    DESCRIPTION CHECK 7710 PUMP P HIGH - CHECK POWER CIR- The power module detected a problem in Refer problem to a qualified JLG mechanic. CUITS the drive motors' power circuit wiring. 7711 PUMP P LOW - CHECK POWER CIR- The power module detected a problem in Refer problem to a qualified JLG mechanic.

  • Page 105: Platform Load Sense

    DESCRIPTION CHECK 821 LSS CELL #1 ERROR A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system. 822 LSS CELL #2 ERROR A problem has been detected with the load Refer problem to a qualified JLG mechanic.

  • Page 106: Hardware

    DESCRIPTION CHECK 991 LSS WATCHDOG RESET A problem has been detected with the load Refer problem to a qualified JLG mechanic. sense system. 992 LSS EEPROM ERROR A problem has been detected with the load Refer problem to a qualified JLG mechanic.
  • Page 107 DESCRIPTION CHECK 9910 FUNCTION LOCKED OUT - PLATFORM The platform board software version is not Refer problem to a qualified JLG mechanic. MODULE SOFTWARE VERSION compatible with the rest of the system. IMPROPER 9911 FUNCTION LOCKED OUT - LSS MODULE The load sensing system module software Refer problem to a qualified JLG mechanic.
  • Page 108 POWER MODULE FAILURE - INTERNAL A problem has been detected with the Cycle machine power on /off a few times if this doesn’t clear the DTC, 9951 ERROR power module. refer problem to a qualified JLG mechanic. 9952 9953 9954 9955 9956...

  • Page 109: Inspection And Repair Log

    SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Machine Serial Number____________________________________ Table 6-1. Inspection and Repair Log Date Comments 3121655 – JLG Lift –...
  • Page 110 SECTION 6 - INSPECTION AND REPAIR LOG Table 6-1. Inspection and Repair Log Date Comments – JLG Lift – 3121655...
  • Page 114 +33 (0) 553 84 85 74 +(852) 2639 5797 Email:german-parts@jlg.com Email: pieces@jlg.com Email: emeaservice@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & Services JLG Industries Via Po. 22 Polaris Avenue 63 2B Fisher Cresent Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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