Table of Contents

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Service & Maintenance Manual
Models
1930ES
2030ES
2630ES
2646ES
3246ES
3121166
June 1, 2010

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Table of Contents
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Summary of Contents for JLG 1930ES

  • Page 1 Service & Maintenance Manual Models 1930ES 2030ES 2630ES 2646ES 3246ES 3121166 June 1, 2010...
  • Page 3: Hydraulic System Safety

    • USE ONLY APPROVED, NONFLAMMABLE CLEANING direct any line pressure back into the reservoir. Pressure SOLVENTS. feed lines to system components can then be discon- nected with minimal fluid loss. 3121166 – JLG Lift –...
  • Page 4 Revised - April 27, 2007 Revised - August 27, 2007 Revised - January 11, 2008 Revised - July 30, 2008 Revised - November 4, 2008 Revised - October 8, 2009 Revised - June 1, 2010 – JLG Lift – 3121166...
  • Page 5: Table Of Contents

    Hydraulic System............2-4 3121166 – JLG Lift –...
  • Page 6 Common Traction System Difficulties ......... . 3-37 – JLG Lift –...
  • Page 7 Assembly ..............4-13 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer .
  • Page 8 Basic check ............. . 7-12 – JLG Lift –...
  • Page 9 3-43. Pothole Switch Adjustment - 1930ES/2030ES/2630ES ....... . .3-55 3-44.
  • Page 10 Hydraulic Schematic - 2792599-D ..........7-42 – JLG Lift –...
  • Page 11 Power Module - J2 (1001092456 Power Module ONLY) ....... .7-17 3121166 – JLG Lift –...
  • Page 12 TABLE OF CONTENTS This page intentionally left blank. viii – JLG Lift – 3121166...
  • Page 13: Section 1 - Specifications

    2197.7 kg 2705.7 kg 2871.2 kg CE/Australia Ground Clearance with pot hole 3.5 in (8.9 cm) protection system up Ground Clearance with pot hole 1 in (2.5 cm) 0.75 in (1.9 cm) protection system down 3121166 – JLG Lift –...
  • Page 14: Capacities

    1930ES 2030ES 2630ES 2646ES 3246ES 2 Gal 2 Gal 3 Gal Hydraulic Tank (7.6 L) (7.6 L) (11.3 L) 2.2 Gal 2.8 Gal 5.3 Gal Hydraulic System (Including Tank) (8.3 L) (10.6 L) (19.9 L) – JLG Lift – 3121166...
  • Page 15: Tires

    TERS OR JLG' S AFTERMARKET PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT Power: 3kW YOUR LOCAL JLG SUPPORT OFFICE. BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- Battery Charger PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE 20 Amp SCR DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES.
  • Page 16: Travel Speed

    1930ES 18 - 23 25 - 35 2030ES 25 - 32 35 - 45 2630ES 28 - 38 35 - 40 2646ES 38 - 45 45 - 55 3246ES 50 - 60 58 - 66 – JLG Lift – 3121166...
  • Page 17: Model Dimensions

    4.2 ft Platform Extension Length (0.9 m) 0.9 m) (0.9 m) (1.3 m) (1.3 m) 5.3 ft 6.2 ft 6.2 ft 6.9 ft 6.9 ft Wheelbase (1.6 m) (1.9 m) (1.9 m) (2.1 m) (2.1 m) 3121166 – JLG Lift –...
  • Page 18: Torque Requirements

    If use of hydraulic oil other than DTE 11M is desired, contact JLG Industries for proper recommendations. – JLG Lift –...
  • Page 19: Limit Switches

    3° 20 ft (6 m) 2000 psi +/- 50 psi 1500 psi 2646ES (138 bar ± 3.4 bar) (103 bar) 2000 psi +/- 50 psi 1500 psi 3246ES (138 bar ± 3.4 bar) (103 bar) 3121166 – JLG Lift –...
  • Page 20: Cylinder Specifications

    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) – JLG Lift – 3121166...
  • Page 21: Torque Charts

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND JLG P/N Loctite® P/N...
  • Page 22: Torque Chart (Sae Fasteners - Sheet 2 Of 7))

    1. THESE TORQUE VALUES DO NOT APPLY TO CADMIUM PLATED FASTENERS 2. ALL TORQUE VALUES ARE STATIC TORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10% 3. * ASSEMBLY USES HARDENED WASHER Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 7)) 1-10 – JLG Lift – 3121166...
  • Page 23: Torque Chart (Sae Fasteners - Sheet 3 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 7) 3121166 – JLG Lift – 1-11...
  • Page 24: Torque Chart (Sae Fasteners - Sheet 4 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-4. Torque Chart (SAE Fasteners - Sheet 4 of 7) 1-12 – JLG Lift – 3121166...
  • Page 25: Torque Chart (Metric Fasteners - Sheet 5 Of 7))

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-5. Torque Chart (METRIC Fasteners - Sheet 5 of 7)) 3121166 – JLG Lift – 1-13...
  • Page 26: Torque Chart (Metric Fasteners - Sheet 6 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-6. Torque Chart (METRIC Fasteners - Sheet 6 of 7) 1-14 – JLG Lift – 3121166...
  • Page 27: Torque Chart (Metric Fasteners - Sheet 7 Of 7)

    4. CLAMP LOAD LISTED FOR SHCS IS SAME AS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IF HIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED. Figure 1-7. Torque Chart (METRIC Fasteners - Sheet 7 of 7) 3121166 – JLG Lift – 1-15...
  • Page 28 SECTION 1 - SPECIFICATIONS This page intentionally left blank. 1-16 – JLG Lift – 3121166...
  • Page 29: Section 2. General

    Annual Machine Inspection. JLG Indus- tries, Inc. recognizes a Factory-Certified Service Techni- Preparation, Inspection, and Maintenance cian as a person who has successfully completed the JLG Service Training School for the subject JLG product It is important to establish and conform to a comprehen- model.
  • Page 30: Service And Guidelines

    At each Operator change. Service and Maintenance Pre-Delivery Prior to each sale, lease, or Qualified JLG Owner, Dealer, or User Manual and applicable JLG Inspection rental delivery. Mechanic inspection form. In service for 3 months or 150 hours, which- ever comes first; or...
  • Page 31: Pressure-Fit Parts

    3. Unless specific torque requirements are given within the text, standard torque values should be used on heat-treated bolts, studs, and steel nuts, in accor- dance with recommended shop practices. (See Torque Chart Section 1.) 3121166 – JLG Lift –...
  • Page 32: Lubrication And Information

    Hydraulic Oil 1. Refer to Section 1 for recommendations for viscosity ranges. 2. JLG recommends DTE11 hydraulic oil, which has an SAE viscosity of 10W-30 and a viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15°F (-26°C) is not recommended.
  • Page 33: Cylinder Drift Test

    NOTE: This information is based on 6 drops per minute cyl- c. Pins should be inspected to ensure it is free of inder leakage. burrs, nicks, and scratches which would dam- age the bearing during installation and opera- tion. 3121166 – JLG Lift –...
  • Page 34: Preventive Maintenance And Inspection Schedule

    SECTION 2 - GENERAL 2.6 PREVENTIVE MAINTENANCE AND NOTE: This machine requires periodic safety and mainte- nance inspections by a JLG Dealer. Notify dealer if INSPECTION SCHEDULE inspection is overdue. The preventive maintenance and inspection checks are The inspection and maintenance code numbers are as fol- listed and defined in the following table.
  • Page 35: Preventive Maintenance And Safety Inspection

    15. Drive Torque Hubs 1,3,5,6 16. Steer Cylinder 5,6,13 17. Steer Components 18. Wheel Bearings 19. Scissor Arms 20. Safety Props 21. Sliding Wear Pads 8,12 22. Pivot Pins/Bolts 23. Switches, Ground Control 1,11 24. Control Tags 3121166 – JLG Lift –...
  • Page 36 SECTION 2 - GENERAL NOTES: – JLG Lift – 3121166...
  • Page 37: Section 3 - Chassis & Scissor Arms

    Module with Ground Module Software Version P1.13 Held Analyzer can be connected at this port.. or higher, or the ZAPI Power Module. Use the JLG Hand-held Analyzer to check the Sevcon software version. Plug analyzer into diagnostic port. Scroll to DIAGNOSTICS ->...
  • Page 38: Mdi Installation/Removal

    1. Remove the two Screws (2) and Washers (3). 2. Disconnect Brake Release and MDI from the electri- cal harnesses. 3. Remove Bracket. 1. MDI & Brake Release Bracket 2. Screw, M5 x 16 3. Washer, 5mm Figure 3-2. MDI Installation/Removal – JLG Lift – 3121166...
  • Page 39: Traction System

    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. 3121166 – JLG Lift –...
  • Page 40: Traction Control Circuit - Sevcon Power Module

    Figure 3-3. Traction Control Circuit - Sevcon Power Module Line Contactor Right Field Winding Armature Right Left MOSFET Armature Armature Field Shunt Left Field Winding MOSFETS Power Module Figure 3-4. Traction Control Circuit - ZAPI Power Module – JLG Lift – 3121166...
  • Page 41: Torque Hub

    However, if the unit is under warranty you should ket, the part must be replaced, and the unit rechecked. contact JLG Industries, Inc. for a replacement unit. Leak test at 10 psi for 20 minutes. The warranty will no longer be valid if the unit is dis- assembled by non-JLG personnel.
  • Page 42: Manual Disengage Procedure

    WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN THE BRAKES. FAILURE TO DO SO MAY RESULT IN INJURY OR INCLINE. EVEN DEATH. 1. Remove the 3 brake cover bolts from the back end of the motor. 2. Remove brake cover. – JLG Lift – 3121166...
  • Page 43: Manual Disengage Procedure

    5. Tighten down the bolts and the brake on that drive motor will disengage. 6. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually. 3121166 – JLG Lift –...
  • Page 44: Manual Disengage Procedure

    6. Repeat this procedure on opposite wheel drive. With both drive motor brakes now disengaged, the machine can be moved manually. 7. After towing is complete, chock wheels and remove Cover Bolts from Disengage Holes. – JLG Lift – 3121166...
  • Page 45: Motor And Brake Disassembly

    While loose. applying gentle pressure to the pry bar, tap the bot- tom of the motor housing with a rubber mallet. The 5. Remove the three spacers and the brake housing. motor should slip out. 3121166 – JLG Lift –...
  • Page 46: Motor Disassembly

    4. Remove the 2 motor mounting bolts and washers. Belgium machines built S/N 1200008481 to S/N 1200015159. 5. Gently remove the motor. 1. Make sure the E-stop button is pushed in. 2. Disconnect the cable from the power control mod- ule. 3-10 – JLG Lift – 3121166...
  • Page 47: Drive Motor Removal

    POSITION BEFORE REMOVING DRIVE MOTOR. 1. Disconnect the motor cable from the power control module. 2. Drain the oil out of the unit by removing the cover plug. Note the condition of the oil, replace if neces- sary. 3121166 – JLG Lift – 3-11...
  • Page 48: Main Gearbox Disassembly

    4. Remove input carrier sub-assembly. 7. Using a screwdriver remove spiral snap ring. 5. Remove cover o-ring. 8. Pull hub sub-assembly off of the spindle sub-assem- 6. Remove input ring gear. bly. 3-12 – JLG Lift – 3121166...
  • Page 49: Input Carrier Disassembly

    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. 3121166 – JLG Lift – 3-13...
  • Page 50: Hub Disassembly

    Try not to damage the hub of the bearing. Apply force to the push the bearing bore. out. This bearing will need to be replaced upon reas- sembly. 3-14 – JLG Lift – 3121166...
  • Page 51: Spindle Disassembly

    4. Using a screwdriver remove the shaft bearing snap ring. 5. Remove the shaft ball bearing from the center bore. 3121166 – JLG Lift – 3-15...
  • Page 52: Spindle Sub-Assembly

    16. Grease and install the motor O’ring into the groove. CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING CONTACT WITH THE BRAKE DISCS. IF THIS OCCURS IT WILL DEGRADE THE BRAKES PERFORMANCE. 3-16 – JLG Lift – 3121166...
  • Page 53: Hub Sub-Assembly

    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. 3121166 – JLG Lift – 3-17...
  • Page 54: Input Carrier Sub-Assembly

    5. Place a thrust washer on each side of the input planet gear. Line up the bores as well as you can NOTE: Do not overstress the snap ring. 3-18 – JLG Lift – 3121166...
  • Page 55: Main Gearbox Assembly

    3 stages. ring apart and work it into the groove. a. Stage 1: The hub slides together until the gear teeth of the hub hit the gear teeth of the 3 output planets. 3121166 – JLG Lift – 3-19...
  • Page 56 The grease will help keep it in the bore during assembly. NOTE: Do not use excessive pressing force because it will 11. Center the cover in the hub bore so that the “ JLG” be reacted by the main wheel bearings. logo is up. Push it into the bore.
  • Page 57: Motor And Brake Assembly

    8. Remove the disengage bolts from the brake housing 4. Install Brake disc onto splined end of motor shaft. and install them into the tapped holes in the motor end cap for storage. 3121166 – JLG Lift – 3-21...
  • Page 58 15. Reinstall the back sealing cover onto the motor end. dle. 16. Fill the gearbox with ISO grade 68 oil or oil of a simi- lar viscosity (80W gear oil or 20W engine oil). 3-22 – JLG Lift – 3121166...
  • Page 59: Motor Assembly

    NOTE: The motor may need to be rotated to line up the sun gear splines with the motor shaft splines. 3121166 – JLG Lift – 3-23...
  • Page 60: Motor Assembly

    NOTE: The motor may need to be rotated to line up the sun gear splines with the motor shaft splines. 2. Install the two motor mounting bolts and washers. Torque to 9 - 11 ft-lbs (12 - 15 Nm). 3-24 – JLG Lift – 3121166...
  • Page 61: Tightening And Torquing Bolts

    5. Using the same sequence, crisscross around the bolt circle and apply an equal torque to the remain- ing bolts. BOLT A Figure 3-22. Assembly Tool 2 BOLT B Assembly Tools Figure 3-23. Assembly Tool 3 Figure 3-21. Assembly Tool 1 3121166 – JLG Lift – 3-25...
  • Page 62: Electric Drive Motor

    7. Mark the field leads going into each splice accord- ing to the color of the cable lead. 4. Remove the screw in each of the brush holders that connects the brush wires. 8. Cut the leads going into each butt splice. 3-26 – JLG Lift – 3121166...
  • Page 63: Reassembling The Motor

    16. Install the connector for the brake onto the yellow no load for approximately 10 minutes to seat the and brown leads. The leads can go with either of the brushes, if the brushes have been replaced. connector pins. 3121166 – JLG Lift – 3-27...
  • Page 64: Motor Maintenance

    3. Brush and Terminal Assembly 11. Brake Assembly 4. Brush Spring 12. Cover Plate 5. Brush Box Assembly 13. O-Ring 6. Retaining Ring 14. Strain Relief Bushing 7. Bearing 15. Cover 8. Wire Harness Figure 3-24. Drive Motor 3-28 – JLG Lift – 3121166...
  • Page 65: Disassembly

    8. Use an arbor press or a bearing puller to remove the armature from the commutator end head assembly. 9. Remove the snap ring (6) and bearing (7) from the commutator end head. Discard the bearing. 3121166 – JLG Lift – 3-29...
  • Page 66: Inspection And Service

    Press Fixture must press against Inner Race (held sta- tionary) Figure 3-27. Bearing Pressure Guidelines 3. Press the armature (2) commutator end into the commutator end head and bearing assembly, care- fully supporting the inner-race of the bearing. See Figure 3. 3-30 – JLG Lift – 3121166...
  • Page 67: Terminal Tightening

    10. Align cover plate (12) with groove in frame and field and affix using 2 screws. MOTOR CABLE SECURING NUT STUD TERMINAL SECURING NUT CABLE LUG TERMINAL FLAT WASHER SECURE NUT WHILE INSULATING WASHER APPLYING TORQUE MOTOR HOUSING Figure 3-28. Terminal Tightening 3121166 – JLG Lift – 3-31...
  • Page 68: Electric Drive Motor

    15. Brake Cover Mounting Screws 4. Brush Spring 10. Grommet 16. Terminal Cover Mounting Screws 5. Brush & Terminal Assembly 11. Brake Assembly 6. Brush Box Assembly 12. Gasket Seal Kit Figure 3-29. Drive Motor Components 3-32 – JLG Lift – 3121166...
  • Page 69: Drive Motor Troubleshooting

    3. Remove the two Terminal Cover Mounting Screws the commutator end head. Replace brush box (16). Slide the strain relief of the Wire Harness (1) assemblies in the commutator end head if they are 3121166 – JLG Lift – 3-33...
  • Page 70: Drive Motor Reassembly

    See Figure 3-27. 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. 3-34 – JLG Lift – 3121166...
  • Page 71: Drive Motor Servicing Guidelines

    Dusty or dirty locations like cement plants, lum- ber and flour mills, coal mining, stone quarries, etc. b. High temperature areas like steel mills, found- ries, etc. c. Environments with sudden temperature change, such as in refrigeration plant, etc. 3121166 – JLG Lift – 3-35...
  • Page 72: Drive Motor Electrical Evaluation

    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). 3-36 – JLG Lift – 3121166...
  • Page 73: Common Traction System Difficulties

    (heavy red and black conductors) from the sus- the brakes could pose a hazard. However, it may pected drive motor leading to the Power Module's detect this issue during Drive (investigate using JLG M1 and M2 Terminals. Re-test the traction function. Analyzer).
  • Page 74: Power Module - Sevcon

    The Power Module is located at the front of the machine as shown in Figure 3-32., Sevcon Power Module Location. 7. After all connections to the Power Module are made, the battery can be reconnected. 3-38 – JLG Lift – 3121166...
  • Page 75: Power Module Electrical Evaluation

    Field Terminals (F1 & F2) and +B. Internally, there are MOSFET transistors between these terminals that should be high-impedance when the module is un-powered. Place the Black meter lead on +B and the Red meter lead on F1 / F1. 3121166 – JLG Lift – 3-39...
  • Page 76: Power Module - Zapi

    8. After all connections to the power module are made, Power Module Location. Use the following instructions the batteries can be reconnected. when replacing the power module. 9. Reinstall the power module cover, then check for normal machine operation. 3-40 – JLG Lift – 3121166...
  • Page 77: Zapi Power Module Electrical Evaluation

    The LED blinks (2Hz) when an internal issue is detected that cannot be repaired by a technician. It should be noted that this will trigger replacement of the device. P/N - 1001092456 ZAPI Power Module - "HEALTH" (Status LED) 3121166 – JLG Lift – 3-41...
  • Page 78: Battery Removal

    8. Reconnect batteries and check for proper operation. WITH PROPER BATTERY REPLACEMENT, PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE. BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES.
  • Page 79: Battery Maintenance And Safety Practices

    VENT TUBE 1/8 " PLATES 1. AC Voltage - Input Cable 3. DC Power Cable to Batteries 2. Charger Interlock Cable 4. LED Indicator Cable Figure 3-34. Battery Fluid Level Figure 3-36. Battery Charger 3121166 – JLG Lift – 3-43...
  • Page 80: Battery Charger Maintenance

    Follow the safety instructions recommended by the battery manufacturer. 2. Make sure charger connections to battery terminals are tight and clean. 3. Do not expose charger to oil or to direct heavy water spraying when cleaning vehicle. 3-44 – JLG Lift – 3121166...
  • Page 81: Battery Charger Troubleshooting

    Be sure to set this charger to the appropri- 3. This fault will clear automatically when the low bat- ate voltage - 6V per 6V battery, 12V per 12V string/ tery voltage problem is rectified. battery. 3121166 – JLG Lift – 3-45...
  • Page 82 4. If the output voltage of the charger seems excessive, started charging normally, be sure to make a note of it. return the charger for service. Contact JLG to get the 1. Remove excessive AC loads from inverter if expected battery voltage settings for the charger in installed.
  • Page 83: Battery Algorithms

    The charger is pre-loaded with programming algorithms rithm by repeating the above steps 1 and 3. for the specific batteries detailed in Table 3-4, Battery Algorithms. Contact JLG if your specific battery model is not listed. Table 3-4. Battery Algorithms...
  • Page 84: Battery Charger/Inverter (Option)

    Shock and Water Resistant Aluminum 1. AC Output Connector 4. External DC Fuse Location 2. AC Input Connector 5. DC (+) Connection 3. Remote On/Off Switch Cable 6. DC (-) Connection Figure 3-38. Battery Charger/Inverter 3-48 – JLG Lift – 3121166...
  • Page 85: Battery Charger/Inverter Troubleshooting

    Inverter/Charger manual. First, go through the trou- 3. If wiring is found to be good, the LED printed circuit bleshooting in the Owner’s Guide (JLG part number card is likely to be bad. 3128406), then use the procedures below. For control of...
  • Page 86: Drive Motor Cable Routing

    Belgium Built Machines Prior to S/N 1200015159: CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING. Figure 3-40. Motor Cable Routing (2030ES/2630ES) Figure 3-39. Motor Cable Routing (1930ES) 3-50 – JLG Lift – 3121166...
  • Page 87 15. Place the Green Clamp on the clamping rings as Belgium Built Machines S/N 1200015159 to Present: shown below. NOTE: The below procedures (1 - 19) apply to 1930ES only. CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING.
  • Page 88 5. Tuck all wires into the power module compartment and install cover. 6. Reconnect battery cable plug. Power up machine and operate the drive function to ensure drive motors operate properly. 1. Bolt, Washers, and Nut 2. Cable Clamp 3-52 – JLG Lift – 3121166...
  • Page 89: Limit Switch Locations - 1 Of 2

    SECTION 3 - CHASSIS & SCISSOR ARMS NOTE: Item 1 shows configuration for machines prior to S/N’s: 1930ES - USA built - S/N 0200150266 - Belgium built - S/N 1200007882 2030ES/2630ES - USA built - S/N 0200152825 - Belgium built - S/N 1200008481...
  • Page 90: Limit Switch Locations - 2 Of 2

    SECTION 3 - CHASSIS & SCISSOR ARMS NOTE: Item 1 shows configuration for machine from S/N to present: 1930ES - USA built - S/N 0200151266 - Belgium built - S/N 1200007882 2030ES/2630ES - USA built - S/N 0200152825 - Belgium built - S/N 1200008481...
  • Page 91: Pothole Switch Replacement

    Switch Link Machines from S/N’s to present: Machines prior to S/N’s: 1930ES - USA built - S/N 0200151266 1930ES - USA built - S/N 0200150266 - Belgium built - S/N 1200007882 - Belgium built - S/N 1200007882 2030ES/2630ES - USA built - S/N 0200152825...
  • Page 92: Pothole Switch Adjustment - 2630Es/3246Es

    5. Repeat this procedure on the opposite side. 6. Raise and lower the machine from the ground con- trol several times to ensure that the switch is func- tioning properly. 3-56 – JLG Lift – 3121166...
  • Page 93 HONEYWELL TELEMECHANIQUE IF EXISTING SWITCH IS 13 & 14 3 & 4 NEW CONNECTOR SHOULD 1 & 4 WIRED TO PINS: BE LOADED TO PINS: 21 & 22 1 & 2 2 & 3 3121166 – JLG Lift – 3-57...
  • Page 94 6. Mount the new switch assembly to the machine using the supplied (10mm) bolts, nuts and washers. 8. Repeat this procedure on the opposite side pothole switch. 9. Power up machine and operate lift and drive to ensure proper function. 3-58 – JLG Lift – 3121166...
  • Page 95: Rotary Angle Sensor Replacement

    Installation: sensor must be re-calibrated. Refer to Section 5, 1. Connect the wiring harness to the new rotary angle JLG Control System to re calibrate the tilt. sensor. Printed Circuit Board (PCB) Replacement 2. Position and connect rotary angle sensor to the arm pin as shown below.
  • Page 96: Tilt Sensor Replacement

    5. Remove the six bolts at the back of the ground con- trol and separate. 1. Ground Control Station 6. Pull the pin connectors from the printed circuit 2. Tilt Sensor (JLG PN 4000006) board. Figure 3-45. Tilt Sensor Location Tilt Sensor Removal: NOTE: Refer to Figure 3-44., Tilt Sensor Removal for num-...
  • Page 97: Tilt Sensor Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor, JLG P/N 4000021 and 1001114936: 1. Ground Control Station 2. Tilt Sensor (JLG P/N 4000021 or 1001114936) 1. Tilt Sensor (JLG P/N 4000006) 2. Screw, 3.5 x 0.6 x 16 LG Figure 3-45.
  • Page 98: Arms And Platform Positioning And Support

    4. At this point the lift cylinder removal may begin. (Refer to Section 4.6, Lift Cylinder Removal) If removal of the platform becomes necessary use the above procedure to stabilize the platform for pin and plat- 1. Tilt Sensor (JLG P/N 4000021 or form removal. 1001114936) 2. Sensor Mount 3.
  • Page 99: Platform 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. 3121166 – JLG Lift – 3-63...
  • Page 100: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH SAFETY PROPS, BLOCKING OR OVERHEAD SLING. STRAP Figure 3-47. Arms and Platform Positioning and Support 3-64 – JLG Lift – 3121166...
  • Page 101: Platform Control Station

    NOTE: You may have to only loosen the two power bolts and remove the two closest the top in order to get to the printed circuit board located in the top of the control box where the drive/lift select switch is located. 3121166 – JLG Lift – 3-65...
  • Page 102: Joystick Controller

    VIOLET TRIGGER N.O. Output: Full Positive (Reverse) Deflection 4 (±0.1) VDC SPARE Output: Full Negative (Forward) Deflection 1 (±0.1) VDC YELLOW ROCKER RT GREEN ROCKER LT SPARE WHITE/RED +5VDC WHITE/BLACK GROUND BROWN SIG OUTPUT 3-66 – JLG Lift – 3121166...
  • Page 103: Section 4 - Hydraulics

    3121166 – JLG Lift –...
  • Page 104: Cylinder Checking Procedure

    5. Remove plug from P port (3) and install a pressure gauge. 6. Raise the platform and take a pressure reading. 7. Adjust the Pressure Setting Screw to reach the proper lift pressure per model as listed in Table 4-1. – JLG Lift – 3121166...
  • Page 105: Hydraulic Oil Fill

    NOTE: The 2630ES/2646ES/ 3246ES platforms will have to 1800 psi ± 50 psi 1500 psi 1930ES be raised higher than the 1930ES and 2030ES in (124 bar ± 3.5 bar) (103.4 bar) order to access the oil plug. 1800 psi ± 50 psi...
  • Page 106: Slide Block Lubrication

    7. Remove the 4 bolts that attach the pump/motor assembly to the lift cylinder. 8. Remove the bolt from the bracket that attaches the hydraulic reservoir to the lift cylinder. 9. Separate the cylinder from the pump/motor assem- bly. Upper Slide Pad Channel – JLG Lift – 3121166...
  • Page 107: Lift Cylinder Removal

    SECTION 4 - HYDRAULICS 1. Battery Cables 3. Manual Descent 5. Top Cylinder Bolt (Torque 41 ft. lb.) 2. Valves 4. Steer Hoses 6. Bottom Cylinder Bolt Figure 4-2. LIft Cylinder Removal 3121166 – JLG Lift –...
  • Page 108: Pump/Motor

    The P Terminal will be approxi- mately at +1V (referenced to -B) when the pump is run- ning at full speed (Lift Up from Ground Mode). Line Contactor Series DC Pump Motor Power Module – JLG Lift – 3121166...
  • Page 109: Pump Motor Electrical Evaluation

    Motor will not operate. Under DIAGNOSTICS - aged. PUMP , the JLG Analyzer will show PUMP PWM 100% and PUMP CUR 0.0A when Lift Up is operated from Ground Mode.
  • Page 110: Pump Removal

    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. – JLG Lift – 3121166...
  • Page 111 13. Loosen and remove the two hexhead nuts from the pump and block. 9. 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. 10. Replace the o-rings if necessary. 3121166 – JLG Lift –...
  • Page 112: Motor Removal

    Fill until oil weeps out of opening. 4. Replace plug and torque to 40 ft. lbs. 4-10 – JLG Lift – 3121166...
  • Page 113: Cylinder Repair

    Loosen the cylinder head set- outer piece of the tapered bushing. Progressively screw. tighten the cap screw(s) until the bushing is loose NOTE: Steps 6 and 7 apply only to the steer cylinder. on the piston. 3121166 – JLG Lift – 4-11...
  • Page 114: Steer Cylinder Piston Removal - Cyl. P/N-1684456

    6. Inspect piston surface for damage and scoring and for distortion. Dress piston surface or replace piston 16. Inspect the oil ports for blockage or the presence of as necessary. dirt or other foreign material. Repair as necessary. 4-12 – JLG Lift – 3121166...
  • Page 115: Assembly

    17. If applicable, inspect piston rings for cracks or other damage. Replace as necessary. Assembly NOTE: Prior to cylinder assembly, ensure that the proper cylinder seal kit is used. See your JLG Parts Manual (3121167). Apply a light film of hydraulic oil to all components prior to assembly.
  • Page 116: Piston Seal Kit Installation

    4. Assemble the tapered bushing loosely into the pis- ton and insert JLG capscrews (not vendor cap- screws) through the drilled holes in the bushing and into the tapped holes in the piston.
  • Page 117: Cylinder Piston Nut Torque Specifications

    Refer to Table 4-3, Holding Valve Torque WHEN REBUILDING THE CYLINDERS, APPLY LOCTITE #242 TO Specifications. THE PISTON NUT AND SETSCREW, THEN TORQUE PISTON NUT. REFER TO TABLE 4-2, CYLINDER PISTON NUT TORQUE SPECIFI- CATIONS. 3121166 – JLG Lift – 4-15...
  • Page 118: Lift Cylinder/Pump/Tank Assembly

    Proportional Valve 15 ft lbs (20 Nm) Check Valve 33 ft lbs (45 Nm) Blocking Valve 15 ft lbs (20 Nm) 4 Way Directional Valve 15 ft lbs (20 Nm) Extend Port Retract Port 4-16 – JLG Lift – 3121166...
  • Page 119: Lift Cylinder Assembly

    10. Barrel 16. Seal 22. O-ring 28. Coil 5. Pump 11. Wear Ring 17. Head 23. Bushing 29. Directional Control Valve 6. Filter 12. Seal 18. O-ring 24. Cylinder Rod Figure 4-13. Lift Cylinder Assembly 3121166 – JLG Lift – 4-17...
  • Page 120 SECTION 4 - HYDRAULICS NOTES: 4-18 – JLG Lift – 3121166...
  • Page 121: Section 5 - Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM 5.1 HAND HELD ANALYZER m en u: Analyzer Display HELP: PRESS ENTER Enter Key Escape Key Stores and selects Top Level, Sub To return home or access Level, and item menus previous menu Left &...
  • Page 122: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: In platform mode, HELP: (001) EVERYTHING OK, With the machine power on and the analyzer connected In ground mode, properly, the analyzer will display the following: HELP: (002) GROUND MODE OK...
  • Page 123: Changing The Access Level Of The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM while in access level 2. Remember, you may always can- cel a selected menu item by pressing the ESC key. Changing the Access Level of the Hand Held Analyzer: M ENU: AC C ESS LEVEL 1...
  • Page 124: Adjusting Parameters Using The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Adjusting Parameters Using the Hand Held Machine Setup Analyzer When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value, for example: Once you have gained access to level 1, and a personality...
  • Page 125: Tilt Sensor Calibration

    SECTION 5 - JLG CONTROL SYSTEM 5.2 TILT SENSOR CALIBRATION NOTE: Refer to Table 5-3, Machine Model Adjustment (Machines with Sevcon - 1600346 Power Module Only), and Table 5-5, Machine Configuration Pro- Be sure that the machine is parked and stowed on level gramming Information (Machines with Sevcon - ground.
  • Page 126: Failure Troubleshooting For The Field

    Ground Control box electrically connected. Level one This basic check using the JLG Analyzer can be used to axis of the tilt sensor and observe the raw read- test the Tilt Sensor.
  • Page 127: Tilt Vs. Allowed Height Evaluation

    Elevation Sensor. must assume that the sensor output has drifted. There- fore, replace the sensor and return to JLG with a detailed troubleshooting description. NOTE: There is a rare case in which an attempted calibra- tion will be unsuccessful for machines with Ground module software version P1.5 or earlier.
  • Page 128: Elevation Sensor Calibration

    NOTICE computer, connecting cable, and software update cd. MACHINE MUST BE ON LEVEL GROUND BEFORE ELEVATION Contact JLG Industries to acquire the software cd. SENSOR CAN BE SET. Before updating the software, use the Hand-held Analyzer to view the machine’s settings (MACHINE SETUP and 1.
  • Page 129: Troubleshooting

    SECTION 5 - JLG CONTROL SYSTEM 5.7 TROUBLESHOOTING It should be noted that there is no substitute for a thorough knowledge of the equipment and related systems. It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electri- cal systems.
  • Page 130 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 0 DRIVING AT CUTBACK -- POTHOLE STILL While stowed, drive speed is reduced (due to lower ground Clear the obstacle blocking ENGAGED...
  • Page 131 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 2 FUNCTION PROBLEM -- DRIVE & LIFT ACTIVE The Drive - Lift selector switch indicates that both functions Repair the wiring or switch to TOGETHER are selected simultaneously.
  • Page 132 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 2 TRIGGER CLOSED TOO LONG WHILE IN NEU- Trigger switch in the platform control box was closed for Release switch or repair the...
  • Page 133 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE Help messages with the 2-5 flash code indicate that a function is prevented due to a cutout. 5 ELEV ANGLE SENSOR FAULTY – NOT MOUNTED...
  • Page 134 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 5 ELEV PROX PERMANENTLY CLOSED – CHECK The Elevation Proximity Switch is closed to indicate that the Check elevation switches. PROX AND ANGLE ADJUSTMENT platform is stowed, but the elevation sensor’s voltage indi-...
  • Page 135 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 2 CONTACTOR DRIVER PERMANENTLY ON The Power Module’s Line Contactor Drive Circuitry failed Refer to CANbus documenta- to de-energize during power-up self-tests.
  • Page 136 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 3 STEER RIGHT SHORT TO BATTERY Voltage was detected on the steer right solenoid when the output driver was commanded off during power-up.
  • Page 137 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE Help messages with the 4-2 flash code indicate a thermal problem. 2 POWER MODULE TOO HOT – PLEASE WAIT The Power Module for drive, steer, and lift up has reached thermal cutout.
  • Page 138 1 from an Accessory Module, but failed to receive another within 1000mS. Retained until power is re-cycled. No motion interlocks. Help messages with the 6-7 flash code indicate JLG accessory problems. These faults shall not be latched. Normal operation shall resume if difficulty is resolved. 7 ACCESSORY FAULT...
  • Page 139 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE Help messages with the 8-x flash codes indicate problems with the platform load sensing system. The second digit of the flash code is used to indicated channel.
  • Page 140 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 3 LSS HAS NOT BEEN CALIBRATED 9-3 Flash Code Calibrate the Load Sensing The Load Sensing System’s Calibration EEPROM for System using the calibration...
  • Page 141 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing FLASH HELP MESSAGE CAUSE POSSIBLE RESOLVE CODE 9 POWER MODULE FAILURE: SYSTEM MONITOR The ground board detected armature, field, or pump cur- Refer to Drive Motor Electrical rent while function was not commanded.
  • Page 142 SECTION 5 - JLG CONTROL SYSTEM Analyzer Flow Chart 5-22 – JLG Lift– 3121166...
  • Page 143 SECTION 5 - JLG CONTROL SYSTEM 3121166 – JLG Lift – 5-23...
  • Page 144 SECTION 5 - JLG CONTROL SYSTEM 5-24 – JLG Lift– 3121166...
  • Page 145: Machine Model Adjustment - Sevcon - 1600346 Power Module

    SECTION 5 - JLG CONTROL SYSTEM 5.8 MACHINE MODEL ADJUSTMENT - SEVCON - 1600346 POWER MODULE Table 5-3. Machine Model Adjustment (Machines with Sevcon - 1600346 Power Module Only) Adjustment Adjustment Range 1930ES 2030ES 2630ES 2646ES 3246ES DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 1.0 (Sec)
  • Page 146: Machine Model Adjustment - Zapi - 1001092456 Power Module

    SECTION 5 - JLG CONTROL SYSTEM 5.9 MACHINE MODEL ADJUSTMENT - ZAPI - 1001092456 POWER MODULE Table 5-4. Machine Model Adjustment (Machines with ZAPI - 1001092456 Power Module Only) Adjustment Adjustment Range 1930ES 2030ES 2630ES 2646ES 3246ES DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 1.0 (Sec)
  • Page 147: Machine Configuration Programming Information - Sevcon - 1600346

    SECTION 5 - JLG CONTROL SYSTEM 5.10 MACHINE CONFIGURATION PROGRAMMING INFORMATION - SEVCON - 1600346 NOTE: When configuring an ES scissors machine, the machine configuration must be completed before any personality set- tings can be changed. Changing the personality settings first and then changing the model number of the machine con- figuration will cause the personality settings to return to default.
  • Page 148: Machine Configuration Programming Information - Zapi - 1001092456

    SECTION 5 - JLG CONTROL SYSTEM 5.11 MACHINE CONFIGURATION PROGRAMMING INFORMATION - ZAPI - 1001092456 NOTE: When configuring an ES scissors machine, the machine configuration must be completed before any personality set- tings can be changed. Changing the personality settings first and then changing the model number of the machine con- figuration will cause the personality settings to return to default.
  • Page 149: Section 6 - Diagnostic Trouble Codes

    257 ELEV PROX PERMANENTLY CLOSED - CHECK PROX AND ANGLE ADJUSTMENT ..........6-8 258 DRIVE & LIFT PREVENTED - BRAKES ELECTRICALLY RELEASED FOR TOWING ........... 6-8 259 MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS ................6-8 3121166 – JLG Lift –...
  • Page 150 6635 CANBUS FAILURE - CHASSIS TILT SENSOR ......................6-15 671 ACCESSORY FAULT ..............................6-15 771 OPEN CIRCUIT DRIVE MOTOR WIRING........................7-15 772 STALLED TRACTION MOTOR OR POWER WIRING ERROR ..................7-16 773 CAPACITOR BANK FAULT - CHECK POWER CIRCUITS ...................7-16 774 SHORT CIRCUIT FIELD WIRING ..........................7-16 – JLG Lift – 3121166...
  • Page 151 99146 POWER MODULE FAILURE - INTERNAL ERROR ....................9-21 99147 POWER MODULE FAILURE - INTERNAL ERROR ....................9-21 99148 POWER MODULE FAILURE - INTERNAL ERROR ....................9-21 99149 POWER MODULE FAILURE - INTERNAL ERROR ....................9-21 3121166 – JLG Lift –...
  • Page 152: Dtc Check Tables

    • Backprobing ground board J1-18 should show about 0 volts. • Backprobing ground board J1-10 should show about 0 volts. • Calibrate the elevation sensor, see Section 5.5. • Calibrate the tilt sensor, see Section 5.2. – JLG Lift – 3121166...
  • Page 153: Power-Up

    • Disconnect the horn switch ribbon cable on the platform board. If DTC still present, replace the platform board. If DTC 221 is no SELECTED longer present, replace the horn switch or platform board. 3121166 – JLG Lift –...
  • Page 154: Function Problem - Indoor / Outdoor Permanently Selected

    • Check the trigger switch signal and wiring to the platform board. TRIGGER PERMANENTLY power-up in platform mode. CLOSED The trigger input (24V) is from platform board terminal J1-1, and its output (24V when closed) is to platform board terminal J1-8. • Replace platform board. – JLG Lift – 3121166...
  • Page 155: Ground Controls

    J1-15, and its ground is to ground board terminal J1-16. • Replace the ground board. • Calibrate the elevation angle sensor to clear fault. See Section 5.5. ELEV ANGLE SENSOR HAS The elevation angle sensor has not been NOT BEEN CALIBRATED calibrated. 3121166 – JLG Lift –...
  • Page 156: Drive Prevented - Charger Connected

    • Check the brake release switch signal and wiring to the ground sible. board. The switch input (24V) is from ground board terminal J1- 19, and its output (24V when closed) is to ground board terminal J1-20. • Replace ground board. – JLG Lift – 3121166...
  • Page 157: Line Contactor Open Circuit

    • Check continuity between contactor connector pin 2 and power module 12 position connector terminal 8. • Measure voltage between power model B+ and B- terminals. If 24V is present, replace line contactor. • Replace power module. 3121166 – JLG Lift –...
  • Page 158: Ground Output Driver

    30 Ohms. The steer left solenoid is off at power up. powered with 24V from ground board J1-21, and its ground is to ground board J1-30, 37. • Inspect the wiring for physical damage. • Replace ground board. 6-10 – JLG Lift – 3121166...
  • Page 159: Steer Left Open Circuit

    24V from ground board J1-24, and its ground is to ground board J1-30, 37. • Inspect the wiring for physical damage. • Replace ground board. 3121166 – JLG Lift – 6-11...
  • Page 160: Thermal Limit (Soa)

    • Check for jammed or obstructed drive motors. POWER MODULE CURRENT has reached thermal limit. • Check for excessively high traction current consumption, ANA- LIMIT LYZER -> DIAGNOSTICS -> TRACTION -> ARM CUR over 120 Amps while driving on the level. 6-12 – JLG Lift – 3121166...
  • Page 161: Battery Supply

    10 should have continuity. Ground board socket J1-32 to power module connector socket 11 should have continuity. • Turn on machine in platform mode. If DTC 662 is present, trouble- shoot that DTC before continuing. 3121166 – JLG Lift – 6-13...
  • Page 162: Canbus Failure - Platform Module

    F should measure open circuit. Platform box pin E to pin G should measure open circuit. Platform box pin F to pin G should measure open circuit. If these checks are OK replace platform board. 6-14 – JLG Lift – 3121166...
  • Page 163: Accessory

    However, an external short circuit was detected when current was applied to F1 / F2. This situation is caused by improper field wiring or a damaged motor. • ZAPI - HEALTH (Status LED) - ON 3121166 – JLG Lift – 6-15...
  • Page 164: Open Circuit Field Wiring

    • The System Module detected excessive braking current for more RENT TOO HIGH than 5000mS. This can be caused by transporting an excessive load on a steep grade. Alternately, this may indicate an internal fault. • ZAPI - HEALTH (Status LED) - ON 6-16 – JLG Lift – 3121166...
  • Page 165: Tilt Sensor

    ANALYZER -> MACHINE SETUP . Reset control system per- ERROR sonalities to default settings by selecting a different model than indicated, cycle power then select proper model. Then, enter per- sonality settings recorded above. 3121166 – JLG Lift – 6-17...
  • Page 166: Power Module Failure - Internal Error

    • Refer to Power Module Electrical Evaluation in Section 3.6. 9924 FUNCTIONS LOCKED OUT - The control system' s memory indicates • Use the JLG analyzer to adjust all machine setup and personality settings, refer to 5.7 Machine Configuration Programming Infor- MACHINE NOT CONFIG-...
  • Page 167: 9956 Power Module Failure - Internal Error

    • The System Module’s MC feedback from the interface PCB dis- INTERNAL ERROR agrees with the feedback from the power PCB. • Cycle machine, if error still exists, replace System Module. • ZAPI - HEALTH (Status LED) - FLASHING 3121166 – JLG Lift – 6-19...
  • Page 168: 99145 Power Module Failure - Internal Error

    Drive, Steer, & Lift Prevented • The System Module encountered an unexpected software issue. INTERNAL ERROR • Cycle machine, if error still exists, replace System Module. • ZAPI - HEALTH (Status LED) - FLASHING 6-20 – JLG Lift – 3121166...
  • Page 169: Section 7 - General Electrical Information & Schematics

    = kilo = 1,000 * (Displayed Number) m = milli = (Displayed Number) / 1,000 µ = micro = (Displayed Number) / 1,000,000 Example: 1.2 k = 1200  Example: 50 mA = 0.05 A 3121166 – JLG Lift –...
  • Page 170: Voltage Measurement (Dc)

    • Circuit power must be turned OFF before testing resistance • Disconnect component from circuit before testing • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • Use firm contact with meter leads – JLG Lift – 3121166...
  • Page 171: Continuity Measurement

    (See multi meter’s operation manual) • Use firm contact with meter leads • Use firm contact with meter leads • First test meter and leads by touching leads together. Meter should produce an audible alarm, indicating continuity 3121166 – JLG Lift –...
  • Page 172: Continuity Measurement Over Long Distances

    One can find the continuity of two wires, here #1 and #2, at once by following steps 1 through 4. If there is a problem the third wire is used to troubleshoot the other wires. To find the problem, start at step 1 and use the entire procedure. – JLG Lift – 3121166...
  • Page 173: Applying Silicone Dielectric Compound To Amp Connectors

    2. Pierce one of the unused wire seals to allow the trapped air inside the housing to escape. 3. Install a hole plug into this and/or any unused wire seal that has silicone dielectric compound escaping from it. Figure 7-5. AMP Connector 3121166 – JLG Lift –...
  • Page 174: Assembly

    (See Figure 7-8. Connector Assembly (3 of 4)). 4. Slide the wedge lock into the housing until it is flush with the housing (See Figure 7-9. Connector Assembly (4 of 4)). Figure 7-7. Connector Assembly (2 of 4) – JLG Lift – 3121166...
  • Page 175: Disassembly

    6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. 3121166 – JLG Lift –...
  • Page 176: Wedge Lock

    The wedge lock has slotted openings in the forward, or mating end. These slots accommodate circuit testing in the field, by using a flat probe such as a pocket knife. DO NOT use a sharp point such as an ice pick. – JLG Lift – 3121166...
  • Page 177: Service - Voltage Reading

    This nullifies the effectiveness of the connector seals and could result in system failure. Figure 7-11. Connector Installation 3121166 – JLG Lift –...
  • Page 178: Working With Deutsch Connectors

    7. Hold the rear seal in place, as removing the contact may displace the seal. HD30/HDP20 Series Assembly Figure 7-14. HD/HDP Contact Installation 8. Grasp contact about 25mm behind the contact crimp barrel. 9. Hold connector with rear grommet facing you. 7-10 – JLG Lift – 3121166...
  • Page 179: Hd30/Hdp20 Series Disassembly

    12. Slide tool along into the insert cavity until it engages contact and resistance is felt. 13. Pull contact-wire assembly out of connector. Figure 7-17. HD/HDP Unlocking Contacts NOTE: Do Not twist or insert tool at an angle. 3121166 – JLG Lift – 7-11...
  • Page 180: Switches

    Another type of limit switch used by JLG is the inductive proximity switch, also referred to as a "prox switch". Inductive proximity switches are actuated only by ferrous metal (metal that contains Iron, such as steel) near the switch. They do not require contact, and must be energized to actuate.
  • Page 181: Switch Wiring - Low Side, High Side

    25 Lift Up Coil Output Vbatt 26 Lift Down Coil Output 27 Ground Power Output 28 Ground Alarm Output 29 Charger Interlock Input Vbatt 30 Ground Power Output 31 CAN Bus High Input/Output Comm 3121166 – JLG Lift – 7-13...
  • Page 182: Ground Board J2

    Power Output 12 Platform Alarm (Active Low) Output Vbatt 13 Indoor/Outdoor Select Swtich Power Output Vbatt 14 Horn Switch Power Output Vbatt 15 Steer Left Switch Input Vbatt 16 Steer Right Switch Input Vbatt 7-14 – JLG Lift – 3121166...
  • Page 183: Platform Board J3

    Vbatt Not Used Not Used Not Used Not Used Not Used Not Used Line Contactor High Side Power Output Vbatt Not Used CAN Bus High Input/Output Comm CAN Bus Low Input/Output Comm Not Used 3121166 – JLG Lift – 7-15...
  • Page 184: Power Module - J1 (1001092456 Power Module Only)

    32 Negative Main Line Contactor (Low-Side Driver) Digital Output 33 Negative Right Brake Solenoid (Low-Side Driver) Digital Output 34 Negative Left Brake Solenoid (Low-Side Driver) Digital Output 35 Spare Digital Output (Low-Side Driver) / Digital Input (High-Sensing) Digital Output 7-16 – JLG Lift – 3121166...
  • Page 185: Power Module - J2 (1001092456 Power Module Only)

    Spare Analog Input (0-5V) Analog Input Spare Digital Output (Low-Side Driver) Digital Output Spare Digital Output (Low-Side Driver) Digital Output Negative for Overload Lamp (Low-Side Driver) Digital Output Negative for Hourmeter (Low-Side Driver) Digital Output 3121166 – JLG Lift – 7-17...
  • Page 186: Electrical Schematics And Layouts

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.7 ELECTRICAL SCHEMATICS AND LAYOUTS Electrical Schematic - 1870164G - Sheet 1 of 2 Figure 7-18. Electrical Schematic - 1870164 G - Sheet 1 of 2 7-18 – JLG Lift – 3121166...
  • Page 187: Electrical Schematic - 1870164 G - Sheet 2 Of 2

    Electrical Schematic - 1870164G - Sheet 2 of 2 1930ES USA Built Machines Prior to S/N 0200150266 1930ES Belgium Built Machines Prior to S/N 1200007882 2030ES/2630ES USA Built Machines Prior to S/N 0200152825 2030ES/2630ES Belgium Built Machines Prior to S/N 1200008481...
  • Page 188: Electrical Schematic - 187205 B - Sheet 1 Of 2

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic - 1870205B - Sheet 1 of 2 Figure 7-20. Electrical Schematic - 187205 B - Sheet 1 of 2 7-20 – JLG Lift – 3121166...
  • Page 189: Electrical Schematic - 187205 B - Sheet 2 Of 2

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Schematic - 1870205B - Sheet 2 of 2 1930ES USA Built Machines S/N 0200150266 to Present 1930ES Belgium Built Machines S/N 1200007882 to Present 2030ES/2630ES USA Built Machines S/N 0200152825 to Present 2030ES/2630ES Belgium Built Machines S/N 1200008481...
  • Page 190: Electrical Schematic - Sheet 1 Of 2 (Machines With Mdi)

    X018 WITH A BUTT SPLICE OR JUMPER HARNESS ORN/RED 49-4 X090 X091 YEL/RED 2-5-9 X021 X093 X097 X096 X094 BLACK YELLOW BROWN Figure 7-22. Electrical Schematic - Sheet 1 of 2 (Machines with MDI) 7-22 – JLG Lift – 3121166...
  • Page 191: Electrical Schematic - Sheet 2 Of 2 (Machines With Mdi)

    MOUNTED IN FRONT COMPARTMENT OF CHASSIS BETWEEN DRIVE MOTORS; COMPARTMENT IS COVERED, DRIVE MOTOR CABLES ENTER COMPARTMENT; 1870205 B OPTIONAL EQUIPMENT CONNECTION Figure 7-23. Electrical Schematic - Sheet 2 of 2 (Machines with MDI) 3121166 – JLG Lift – 7-23...
  • Page 192: Battery Inverter/Charger Schematic

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Inverter/Charger Schematic Figure 7-24. Battery Inverter/Charger Schematic 7-24 – JLG Lift – 3121166...
  • Page 193 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121166 – JLG Lift – 7-25...
  • Page 194: Electrical Schematic - (Machines With 1001092456 Power Module) - Sheet 1 Of 3

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO S42 CONNECTOR TO PROX. SWTCH. TO X18 CONN. Figure 7-25. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3 7-26 – JLG Lift – 3121166...
  • Page 195: Electrical Schematic - (Machines With 1001092456 Power Module) - Sheet 1 Of 3

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TO S42 CONNECTOR TO S42 CONN. 1001114879_C-1 Figure 7-26. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 1 of 3 3121166 – JLG Lift – 7-27...
  • Page 196: Electrical Schematic - (Machines With 1001092456 Power Module) - Sheet 2 Of 3

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-27. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3 7-28 – JLG Lift – 3121166...
  • Page 197: Electrical Schematic - (Machines With 1001092456 Power Module) - Sheet 2 Of 3

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_C-2 Figure 7-28. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 2 of 3 3121166 – JLG Lift – 7-29...
  • Page 198: Electrical Schematic - (Machines With 1001092456 Power Module) - Sheet 3 Of 3

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_C-3 Figure 7-29. Electrical Schematic - (Machines with 1001092456 Power Module) - Sheet 3 of 3 7-30 – JLG Lift – 3121166...
  • Page 199 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 3121166 – JLG Lift – 7-31...
  • Page 200: Electrical Components - Sheet 1 Of 2

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Electrical Components - Sheet 1 of 2 Figure 7-30. Electrical Components - Sheet 1 of 2 NOTE: (USA Built Machines Prior to S/N 0200135154) (Belgium Built Machines Prior to S/N 1200004293) 7-32 – JLG Lift – 3121166...
  • Page 201: Electrical Components - Sheet 2 Of 2

    NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED. Figure 7-31. Electrical Components - Sheet 2 of 2 NOTE: (USA Built Machines Prior to S/N 0200135154) (Belgium Built Machines Prior to S/N 1200004293) 3121166 – JLG Lift – 7-33...
  • Page 202: Electrical Components - Sheet 1 Of 2

    Figure 7-32. Electrical Components - Sheet 1 of 2 NOTE: 1930ES: USA Built Machines S/N 0200135154 to S/N 0200151266, Belgium Built Machines S/N 1200004293 to SN 1200007882; 2030ES/2630ES: USA Built Machines S/N 0200135154 to S/N 0200152528, Belgium Built Machines S/ N 1200004293 to S/N 1200008481;...
  • Page 203: Electrical Components - Sheet 2 Of 2

    Figure 7-33. Electrical Components - Sheet 2 of 2 NOTE: 1930ES: USA Built Machines S/N 0200135154 to S/N 0200151266, Belgium Built Machines S/N 1200004293 to SN 1200007882; 2030ES/2630ES: USA Built Machines S/N 0200135154 to S/N 0200152528, Belgium Built Machines S/ N 1200004293 to S/N 1200008481;...
  • Page 204: Electrical Components - Sheet 1 Of 2

    MOTORS Figure 7-34. Electrical Components - Sheet 1 of 2 NOTE: 1930ES: USA Built Machines S/N 0200151266 to Present, Belgium Built Machines SN 1200007882 to Present; 2030ES/2630ES: USA Built Machines S/N 0200152528 to Present, Belgium Built Machines S/N 1200008481 to Present;...
  • Page 205: Electrical Components - Sheet 2 Of 2

    NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED. Figure 7-35. Electrical Components - Sheet 2 of 2 NOTE: 1930ES: USA Built Machines S/N 0200151266 to Present, Belgium Built Machines SN 1200007882 to Present; 2030ES/2630ES: USA Built Machines S/N 0200152528 to Present, Belgium Built Machines S/N 1200008481 to Present;...
  • Page 206: Electrical Components - Sheet 1 Of 2 (Machines With Mdi)

    X029 X097 X096 X030 X099 X098 X035 X036 X037 X038 X039 GROUND X040 DRIVE CONTROL X095 X092 MOTORS X091 X090 X093 X094 Figure 7-36. Electrical Components - Sheet 1 of 2 (Machines with MDI) 7-38 – JLG Lift – 3121166...
  • Page 207: Electrical Components - Sheet 2 Of 2 (Machines With Mdi)

    CHARGER X064 X063 X112 X027 X067 X066 X085 *NOTE: THIS CONNECTION USED ONLY WHEN FOOTSWITCH OR BATTERY CHARGER INTERLOCK OPTIONS ARE REQUIRED Figure 7-37. Electrical Components - Sheet 2 of 2 (Machines with MDI) 3121166 – JLG Lift – 7-39...
  • Page 208: Electrical Components - (Machines With 1001092456 Power Module) - Sheet 1 Of 2

    BLOCK PLATFORM RECEPTACLE DIAGNOSTIC ANALYZER ROTARY ANGLE SENSOR MDI/HOUR RELAY METER GROUND CONTROL RIGHT DRIVE LEFT DRIVE MOTOR MOTOR Figure 7-38. Electrical Components - (Machines with 1001092456 Power Module) - Sheet 1 of 2 7-40 – JLG Lift – 3121166...
  • Page 209: Electrical Components - (Machines With 1001092456 Power Module) - Sheet 2 Of 2

    BEACON LIGHT BATTERY CHARGER/ INVERTER CONTACTOR (POWER) RELAY PUMP/MOTOR/ RESERVOIR POWER MODULE 1001092456 –T +BF2 BATTERY CHARGER –P F1 F2 Figure 7-39. Electrical Components - (Machines with 1001092456 Power Module) - Sheet 2 of 2 3121166 – JLG Lift – 7-41...
  • Page 210: Hydraulic Schematic

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.8 HYDRAULIC SCHEMATIC Hydraulic Schematic - 2792599C 2792599-D Figure 7-40. Hydraulic Schematic - 2792599-D 7-42 – JLG Lift – 3121166...
  • Page 211 CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm. WASH HANDS AFTER HANDLING!
  • Page 212 JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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