JLG 1936RS Service Maintenance Manual
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JLG 1936RS Service Maintenance Manual

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Service & Maintenance Manual
Models
1932RS/6RS
3248RS/10RS
3121273
April 8, 2013

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Summary of Contents for JLG 1936RS

  • Page 1 Service & Maintenance Manual Models 1932RS/6RS 3248RS/10RS 3121273 April 8, 2013...

  • Page 3: Hydraulic System Safety

    • USE ONLY APPROVED, NONFLAMMABLE CLEANING sures. Every effort should be made to relieve any system SOLVENTS. pressure prior to disconnecting or removing any portion of the system. 3121273 – JLG Lift –...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue - January 30, 2012 Manual Revised - August 1, 2012 Manual Revised - January 29, 2013 Manual Revised - April 8, 2013 – JLG Lift – 3121273...

  • Page 5: Table Of Contents

    Hydraulic Oil ............. 2-4 3121273 – JLG Lift –...
  • Page 6 Main Gearbox Disassembly..........3-27 – JLG Lift –...
  • Page 7 Lift Cylinder - LSS Pressure Sensor Location (If Equipped) ......4-12 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer .
  • Page 8 Hydraulic Schematic ............7-22 – JLG Lift –...
  • Page 9 Platform Control Station Disassembly ..........3-46 3121273 – JLG Lift –...
  • Page 10 Hydraulic Schematic ............7-22 – JLG Lift –...
  • Page 11 Power Module - J2 Connector Pin Function ......... .7-15 3121273 – JLG Lift –...
  • Page 12 TABLE OF CONTENTS NOTES: viii – JLG Lift – 3121273...

  • Page 13: Section 1 - Specifications

    320 Kg 120 Kg Indoor - 2 Persons + 160 Kg 400 N 0 m/s Outdoor - 1 Person + 240 Kg 200 N 12.5 m/s NOTE: (1) Maximum Platform Capacity includes platform and platform extension. 3121273 – JLG Lift –...

  • Page 14: Dimensional Data

    LOCAL JLG SUPPORT OFFICE. Overall Machine Width 32 in. 48 in. (81.28 cm) (122 cm) BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COM- Overall Machine Length 81.5 in. 90 in. (2.28 m) - ANSI PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE (w/ladder) (207 cm) 94.8 in.

  • Page 15: Electrical System

    NOTE: Maximum rated load in platform on measured lift speeds. Platform fully raised and lowered. Table 1-8. Lift Speed LIFT UP LIFT DOWN MODEL (SECONDS) (SECONDS) 1932RS/6RS 22 - 29 21 - 31 3246RS/10RS 55 - 65 40 - 50 3121273 – JLG Lift –...

  • Page 16: Critical Stability Weights

    -20°F (29°C) - 200°F (392°C) not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other 1001102685_3 than DTE 10 or Excel 15 is desired, contact JLG Industries for proper recommendations. Pressure Settings Table 1-13. Pressure Settings Table 1-10.

  • Page 17: High Drive Speed Cutout

    When maintenance becomes necessary or a fas- tener has loosened, refer to the Torque Charts on page 1-6 to determine proper torque value. 3121273 – JLG Lift –...

  • Page 18: 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 19: 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)) 3121273 – JLG Lift –...

  • Page 20: 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) – JLG Lift – 3121273...

  • Page 21: 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) 3121273 – JLG Lift –...

  • Page 22: 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)) 1-10 – JLG Lift – 3121273...

  • Page 23: 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) 3121273 – JLG Lift – 1-11...

  • Page 24: 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) 1-12 – JLG Lift – 3121273...

  • Page 25: Section 2 - General

    Inc. recognizes a Factory-Trained Service Technician Preparation, Inspection, and Maintenance as a person who has successfully completed the JLG Ser- vice Training School for the subject JLG product model. It is important to establish and conform to a comprehen- Reference the machine Service and Maintenance Manual sive inspection and preventive maintenance program.
  • Page 26 21. Verify. NOTICE 22. Perform. 23. Sealed properly. JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE 24. Overrides Platform controls. "ANNUAL MACHINE INSPECTION REPORT" FORM. 25. Remove pump motor cover and blow away any...
  • Page 27 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 *** Electrical Connections Instruments, Gauges, Switches, Lights, Horn 3121273 – JLG Lift –...
  • Page 28 Function Test of All Systems Paint and Appearance Notify JLG of change in Machine Ownership Replace when system performance is degraded. *** Every two years, drain and remove hydraulic oil reservoir , clean pick-up screen, refill with fresh hydraulic fluid.

  • Page 29: Service And Guidelines

    3. If a part resists removal, check to see whether all nuts, bolts, cables, brackets, wiring, etc., have been 3. Unless specific torque requirements are given within removed and that no adjacent parts are interfering. the text, standard torque values should be used on 3121273 – JLG Lift –...

  • Page 30: Hydraulic Lines And Electrical Wiring

    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 viscos- ity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below -15°F (-26°C) is not recommended.

  • Page 31: Changing Hydraulic Oil

    Avoid mixing petroleum and syn- Cylinder Drift thetic base oils. JLG Industries recommends chang- ing the hydraulic oil annually. Table 2-3. Cylinder Drift 2. Use every precaution to keep the hydraulic oil clean.

  • Page 32: Pins And Composite Bearing Repair Guidelines

    Debris embedded in liner surface. c. Pins should be inspected to ensure it is free of burrs, nicks, and scratches which would dam- age the bearing during installation and opera- tion. – JLG Lift – 3121273...

  • Page 33: Section 3 - Chassis & Scissor Arms

    SECTION 3. CHASSIS & SCISSOR ARMS 3.1 MACHINE COMPONENT COVERS Figure 3-1. Machine Frame Covers (All Models) 1. Left Side (Hydraulic) Frame Cover 3. Right Side (Batteries) Frame Cover 2. Side Cover Release Handles 4. Rear (Drive Motor/Charger/Control Module) Cover 3121273 – JLG Lift –...

  • Page 34: Battery Removal/Maintenance

    TERS 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 COM- PATIBILITY WITH THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES.

  • Page 35: Battery Charger

    Battery Charger Location Electronic Protection - Automatic Output Short Circuit Reset AC Overload Current Limited DC Overload Current Limited MECHANICAL –22° F to +122°F Operating Temperature (–30°C to +50°C) Housing Shock and Water Resistant Aluminum 3121273 – JLG Lift –...

  • Page 36: Battery Charging

    Should battery fail to reach 1.75V per cell charge shall flash an amber LED until charger is AMBER Failed Trickle to min V power cycled - Battery or System problem. Charger Internal Fault Signals a hardware fault of the charger and shall indicate flashing red LED. – JLG Lift – 3121273...

  • Page 37: Battery Charger Maintenance

    Confirm that a nomi- nal battery voltage is the same as the charger volt- age. 3. This fault will clear automatically when the low bat- tery voltage problem is rectified. 3121273 – JLG Lift –...
  • Page 38 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 appropri- ate voltage - 6V per 6V battery, 12V per 12V string/ battery. – JLG Lift – 3121273...

  • Page 39: Dc To Ac Inverter (If Equipped)

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

  • Page 40: Inverter Operation

    Unit may be defective. See warranty and call customer service. Problem: Low Battery Alarm On All The Time Input voltage below 21 volts - Keep input voltage above 21 volts buzzing sound. to maintain regulation. – JLG Lift – 3121273...

  • Page 41: Ground Control Station

    3. Remove the (4) screws and washers attaching the ground control panel to the frame. 4. When panel is released, rotate and position to unplug or disconnect the desired connectors and components on the back of the panel. 3121273 – JLG Lift –...

  • Page 42: Main Power Contactor Relay

    4. To Control Module - ( Power Relay and Control Module) (X09 B+F1) 1932RS/6RS Figure 3-12. Elevation Limit Switch Mounting 1. Switch Assembly 3. Switch Lever Arm 2. Scissor Arm Cam 4. Mounting Hardware 3-10 – JLG Lift – 3121273...

  • Page 43: Switch Adjustment

    18 ft. 11 in. - (30•‹) 0•‹ 5 ft. 9 in. - Figure 3-14. 3248RS/10RS - Elevation Limit Switch Adjustment Figure 3-13. 1932RS/6RS - Elevation Limit Switch Adjustment 3121273 – JLG Lift – 3-11...

  • Page 44: Lss - Scissor Arm Angle Sensor - Location

    See the LSS Service Manual (3124288) for complete ser- vice information for the RS Scissors - LSS system. Figure 3-16. Tilt Sensor Installation 1. Tilt Sensor 3. Mounting Hardware 2. Locating Hole 3-12 – JLG Lift – 3121273...

  • Page 45: Tilt Sensor Removal

    If the indicator does not trip in all three tests, the flange nuts have been tightened too far. Figure 3-18. Tilt Sensor Switch - Adjustment 1. Flange Adjusting Nuts 2. Bubble Level 3121273 – JLG Lift – 3-13...

  • Page 46: Traction System

    40A to the field windings for more electro-motive Line Contactor Right Field Winding Armature Right Left MOSFET Armature Armature Field Shunt Left Field Winding MOSFETS Power Module Figure 3-19. Traction Control Circuit - ZAPI Power Module 3-14 – JLG Lift – 3121273...

  • Page 47: Common Traction System Difficulties

    (and Armature Current is less than 50A), the Menu while attempting to Drive from Platform Mode. drive motor that has been disconnected is fault. Refer to the Section 5 for explanation of the JLG Investigate for crushed and burned cables. Check if Analyzer Help Messages.

  • Page 48: Power Control Module - Zapi

    4. Disconnect all wire connectors and cables from the To Motor Fields Wired in Series power module and remove it from the machine. To Motor Fields Wired in Series Figure 3-20. ZAPI Power Module Location and Orientation (All models) 3-16 – JLG Lift – 3121273...

  • Page 49: Main Electrical Power Connections - (1001129845 - Zapi Power Module)

    3. Main Power Contactor Relay 8. To Battery Charger (–) 4. Hydraulic Pump Motor 9. To Pin 13 and Pin 32 - J1 Connector on Power Module 5. Drive Motor Stator Field Wires 10. Battery Quick-Disconnect (OPTION) 3121273 – JLG Lift – 3-17...

  • Page 50: 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 require replacement of the device. P/N - 1001139845 ZAPI Power Module - "HEALTH" (Status LED) 3-18 – JLG Lift – 3121273...

  • Page 51: Drive Motor Servicing

    High resistance can signal corro- ries, etc. sion, improper crimps, damaged cabling, worn c. Environments with sudden temperature change, brushes, a faulty commutator, or an open armature such as in refrigeration plant, etc. winding. 3121273 – JLG Lift – 3-19...

  • Page 52: Brake - Manual Disengage Procedure

    BRAKE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE in the brake housing. TO ROLL WHEN PARKED ON AN INCLINE. 4. Tighten down the cover bolts so the brake on that drive motor will disengage. 3-20 – JLG Lift – 3121273...

  • Page 53: Drive Motor Removal

    2. Drain the oil out of the unit by removing the cover tion 2, Table 2-2, Preventive Maintenance & Inspection plug. Note the condition of the oil, replace if neces- Schedule.. sary. CAUTION ALWAYS WEAR EYE PROTECTION DURING ANY MAINTENANCE OPERATION. 3121273 – JLG Lift – 3-21...

  • Page 54: Drive Motor Disassembly

    4. Discard the Gasket (12) that was located under the 8. Remove the screws holding the Commutator End brake and terminal covers. Head (9) in place and remove the commutator end head from the frame and field assembly. The Arma- 3-22 – JLG Lift – 3121273...

  • Page 55: Drive Motor Inspection And Service

    Torque top nut sive wear and overheating. Replace as necessary. to 90 - 110 in-lb (10.2 - 12.4 Nm). 6. Visually inspect the brake surfaces for excessive wear. Replace Brake Assembly (11) if necessary. 3121273 – JLG Lift – 3-23...

  • Page 56: 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) Figure 3-26. Wire Harness Connections 3-24 – JLG Lift – 3121273...

  • Page 57: Drive Motor Installation

    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). 3121273 – JLG Lift – 3-25...

  • Page 58: Torque Hub Servicing

    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 59: Main Gearbox Disassembly

    8) with at least 1.5 inches of thread length into each of the three tapped holes to force the ring gear out. Be sure and alternate between the jacking screws to keep the ring gear from becoming mis- 3121273 – JLG Lift – 3-27...

  • Page 60: Input Carrier Disassembly

    6. Remove the thrust washer from each planet gear. 7. Remove retaining ring from output sun gear. 8. Slide output sun gear out from the center of the input carrier. 9. Remove the three planet shafts from the input car- rier. 3-28 – JLG Lift – 3121273...

  • Page 61: Hub Disassembly

    The lip seal will most likely become dam- of the bearing. Apply force to the push the bearing aged during removal. Try not to damage the hub out. This bearing will need to be replaced upon reas- bore. sembly. 3121273 – JLG Lift – 3-29...

  • Page 62: Spindle Disassembly

    NOTE: The output planet gears are a very similar size to the input planet gears, tag or label the planet gears to avoid confusion. 4. Using a screwdriver remove the shaft bearing snap ring. 5. Remove the shaft ball bearing from the center bore. 3-30 – JLG Lift – 3121273...

  • Page 63: Tightening And Torquing Bolts

    BOL T A Figure 3-33. Assembly Tool 2 BO L T B Assembly Tools Figure 3-34. Assembly Tool 3 Figure 3-32. Assembly Tool 1 3121273 – JLG Lift – 3-31...

  • Page 64: Spindle Assembly

    7. Slide the planet gear into the window with the tanged washer until the bores line up. CARE SHOULD BE TAKEN TO PREVENT ANY OIL FROM MAKING CONTACT WITH THE BRAKE DISCS. IF THIS OCCURS IT WILL DEGRADE THE BRAKES PERFORMANCE. 3-32 – JLG Lift – 3121273...

  • Page 65: Hub 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. 3121273 – JLG Lift – 3-33...

  • Page 66: Input Carrier Assembly

    NOTE: Do not overstress the snap ring. 5. Place a thrust washer on each side of the input planet gear. Line up the bores as well as you can 3-34 – JLG Lift – 3121273...

  • Page 67: Main Gearbox Assembly

    3121273 – JLG Lift – 3-35...
  • Page 68 14. Test per instructions in Section 3.14, Torque Hub assembly. Servicing, for proper operation and to check for any 11. Center the cover in the hub bore so that the “ JLG” oil leaks. logo is up. Push it into the bore.
  • Page 69 SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3121273 – JLG Lift – 3-37...

  • Page 70: Steer Assembly Components

    1. Install the bearing with the flange surface on top of the spindle arm. 2. Assemble the spindle kingpin attach, banjo pin hardware, in the frame hole towards the front of the machine. 3. Install cylinder to frame attach pin with cotter pin hole on top. 3-38 – JLG Lift – 3121273...

  • Page 71: Rs/10Rs - Steer Assembly

    (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, dam- aged, or leaking. 1. Install the bearing with the flange surface on top of the spindle arm. 3121273 – JLG Lift – 3-39...

  • Page 72: Arms And Platform Positioning And Support

    NOTE: When attaching platform back onto scissor arm deforming locknuts, are not intended to be reinstalled assembly, follow removal procedures in reverse after removal. Always use new replacement hardware order. when installing locking fasteners. 3-40 – JLG Lift – 3121273...

  • Page 73: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-41. Arms and Platform Positioning and Support 3121273 – JLG Lift – 3-41...

  • Page 74: Rs/6Rs - Scissor Arm Assembly - Ref. Figure 3-43

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-42. 1932RS/6RS - Scissor Arm Assembly - Ref. Figure 3-43. 3-42 – JLG Lift – 3121273...

  • Page 75: Rs/6Rs - Scissor Arm Assembly - Pin Configuration

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-43. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration 3121273 – JLG Lift – 3-43...

  • Page 76: Rs/10Rs - Scissor Arm Assembly - Ref. Figure 3-45

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-44. 3248RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45. 3-44 – JLG Lift – 3121273...

  • Page 77: Rs/10Rs - Scissor Arm Assembly - Pin Configuration

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-45. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration 3121273 – JLG Lift – 3-45...

  • Page 78: Platform Control Station

    3. Lift and Remove 2. Mounting Pin 3. To install, reverse steps 1 and 2 above. Figure 3-47. Platform Control Station Disassembly 1. Through Bolt, Cap-nut 2. Rear Edge Bolts and Nuts and Washers 3-46 – JLG Lift – 3121273...

  • Page 79: Overview Of Control Station Components

    9. Alarm 6. Overload Indicator (If Equipped) tem Fault Indicator NOTE: (1) Zip-tie item-6 - Harness Splice Connector - to item- 5 - Horn Switch, to prevent any possible inter- ference with the joystick path. 3121273 – JLG Lift – 3-47...

  • Page 80: Joystick Controller

    Output: Full Negative (Forward) Deflection 1 (±0.1) VDC YELLOW ROCKER RT GREEN ROCKER LT NOTE: For joystick calibration procedure see Joystick Cali- bration - page 5-5. SPARE WHITE/RED +5VDC WHITE/BLACK GROUND BROWN SIG OUTPUT 3-48 – JLG Lift – 3121273...

  • Page 81: Section 4 - Hydraulics

    3121273 – JLG Lift –...

  • Page 82: Pump/Motor

    P Terminal of the Power Mod- Motor will not operate. Under DIAGNOSTICS - ule, which switches current through MOSFET transistors PUMP , the JLG Analyzer will show PUMP PWM 100% to the Battery Negative. and PUMP CUR 0.0A when Lift Up is operated from For variable speed pump operation, the MOSFET transis- Ground Mode.

  • Page 83: Hydraulic Oil Check Procedure

    Hydraulic System 1.85 Gal. (7 L) 3.96 Gal. (15 L) PUMP , the JLG Analyzer will show an erratic reading for PUMP PWM % and PUMP CUR will hover around NOTE: Check the hydraulic oil level with the platform in the 150A when Lift Up is operated from Ground Mode.

  • Page 84: Pump/Tank Disassembly

    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. – JLG Lift – 3121273...

  • Page 85: Hydraulic Oil

    6. Tank to Valve Body - O-Ring 14. Valve Coil for Steer Cylinder 22. M Port - 1/4" BSPP 7. Auxiliary Pressure (M) Port 15. Gear Pump 23. P1 Port - 3/8" BSPP 8. Suction Pipe 16. Return Filter w/Bypass 3121273 – JLG Lift –...

  • Page 86: Lift Pressure Setting Procedure

    Table 4-2. 4. Remove the pressure gauge from port M or P1 and replace plug. 5. Replace the solenoid on the lift valve. – JLG Lift – 3121273...

  • Page 87: Lift Cylinder Removal

    2. Cut any wire ties that attach any cables or hoses to the scissor arms. the lift cylinder. 6. Place the cylinder on a clean workbench. NOTICE DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE REMOVING ANY COMPONENTS FROM THE LIFT CYLINDER ASSEMBLY. 3121273 – JLG Lift –...

  • Page 88: Cylinder Repair

    When removing cylinder head do not force if binding 16. Remove the rod from the holding fixture. Remove occurs. Reverse rotation a couple times and try the cylinder head gland and retainer plate, if applica- – JLG Lift – 3121273...

  • Page 89: Steer Cylinder Piston Removal

    17. If applicable, inspect piston rings for cracks or other and sharp edges. Dress applicable surfaces as nec- damage. Replace as necessary. essary. 9. Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering. Replace as necessary. 3121273 – JLG Lift –...

  • Page 90: Assembly

    SECTION 4 - HYDRAULICS 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.

  • Page 91: Rod Assembly Installation

    10. Assemble the tapered bushing loosely into the pis- Cylinder Rod 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 92: Lift Cylinder - Lss Pressure Sensor Location (If Equipped)

    LSS system. Figure 4-11. LSS Pressure Sensors Location - 1932RS/6RS - (If Equipped) 1. Ports On Barrel of Cyl- 3. Harness Connectors inder 2. Pressure Sensors 4-12 – JLG Lift – 3121273...

  • Page 93: Rs/6Rs - Lift Cylinder

    7. Head 13. D-Ring 3. Bushing 8. Seal 14. Seal 4. Proportional Valve w/Manual 9. Seal w/Backing Ring 15. Wear Ring Release 10. O-Rings 16. O-Ring 5. Check Valve 11. Wear Ring 17. Piston Nut 3121273 – JLG Lift – 4-13...

  • Page 94: Rs/10Rs - Lift Cylinder

    3. Bushing 8. Seal 14. Seal 4. Proportional Valve and Coil, w/ 9. Seal w/Backing Ring 15. Wear Ring Manual Release 10. O-Rings 16. O-Ring 5. Check Valve 11. Wear Ring 17. Piston Nut 4-14 – JLG Lift – 3121273...

  • Page 95: Rs/6Rs - Steer Cylinder

    6. Wear Ring 11. Piston Seal 2. Cylinder Rod 7. O-Ring 12. Wear Ring 3. Head 8. O-Ring 13. Nut 4. Wiper Seal 9. Piston 14. Hose Fittings 5. Rod Seal 10. Rod O-Ring 15. O-Ring 3121273 – JLG Lift – 4-15...

  • Page 96: Rs/10Rs - Steer Cylinder

    11. Piston Seal 2. Cylinder Rod 7. Wear Ring 12. Wear Ring 3. Head 8. O-Ring 13. Nut 4. Wiper Seal 9. Piston 14. Hose Fittings 5. Rod Seal 10. Piston O-Ring 15. O-Ring 4-16 – JLG Lift – 3121273...

  • Page 97: 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 98: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: In platform mode, HELP: (001) With the machine power on and the analyzer connected EVERYTHING OK, properly, the analyzer will display the following: In ground mode, HELP: (002) GROUND MODE OK...

  • Page 99: Changing The Access Level Of The Hand Held Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Changing the Access Level of the Hand Held Analyzer: When the analyzer is first connected, you will be in access level 2 which enables you to only view most configuration M ENU: settings which cannot be changed until you enter a pass- AC C ESS LEVEL 1 word to advance to a lower level.

  • Page 100: 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 101: Joystick Calibration

    (reset) and the cd. Contact JLG Industries to acquire the software cd. ground control keyswitch set on platform mode. Before updating the software, use the Hand-held Analyzer 1.
  • Page 102 SECTION 5 - JLG CONTROL SYSTEM – JLG Lift– 3121273...
  • Page 103 SECTION 5 - JLG CONTROL SYSTEM 3121273 – JLG Lift –...
  • Page 104 SECTION 5 - JLG CONTROL SYSTEM – JLG Lift– 3121273...
  • Page 105 SECTION 5 - JLG CONTROL SYSTEM 3121273 – JLG Lift –...
  • Page 106 SECTION 5 - JLG CONTROL SYSTEM 5-10 – JLG Lift– 3121273...
  • Page 107 SECTION 5 - JLG CONTROL SYSTEM 3121273 – JLG Lift – 5-11...
  • Page 108 SECTION 5 - JLG CONTROL SYSTEM 5-12 – JLG Lift– 3121273...

  • Page 109: Machine Model Adjustment

    SECTION 5 - JLG CONTROL SYSTEM 5.2 MACHINE MODEL ADJUSTMENT Table 5-1. Machine Model Adjustment Adjustment Adjustment Range 10RS 1932RS 3248RS DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 1.0 (Sec) MINIMUM 0 - 25% MAXIMUM 0 -100% ELEV. MAX.

  • Page 110: Machine Configuration Programming Information

    SECTION 5 - JLG CONTROL SYSTEM 5.3 MACHINE CONFIGURATION PROGRAMMING INFORMATION NOTE: 1. When configuring an RS scissors machine, the machine configuration must be completed before any personality settings can be changed. Changing the personality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default.

  • Page 111: 3121273 - Jlg Lift

    For example: a “2-1 Power-Up” on page 6-5 would be indicated by 2 flashes, a pause, then 1 flash, a pause, then would keep repeating until the fault is cleared. The more detailed three digit code numbers in the DTC column of the following tables are only indicated on a JLG handheld diagnostic analyzer.

  • Page 112: Dtc Index

    LIFT UP VALVE - OPEN CIRCUIT ..........6-9 – JLG Lift –...
  • Page 113 FIELD VOLTAGE IMPROPER ........... .6-14 3121273 – JLG Lift –...
  • Page 114 POWER MODULE FAILURE - INTERNAL ERROR ........6-16 – JLG Lift –...

  • Page 115: Dtc Check Tables

    DESCRIPTION CHECK FUNCTION PROBLEM - The horn switch was closed during • Check if the horn switch is damaged, obstructed or jammed. HORN PERMANENTLY power-up in platform mode. • HEALTH (Status LED) - ON SELECTED 3121273 – JLG Lift –...
  • Page 116 • Repair the wiring or switch to clear the message. DRIVE & LIFT BOTH OPEN tor Switch indicates that neither func- • Check if either function is active, if Yes; tion is selected. • HEALTH (Status LED) - ON – JLG Lift – 3121273...
  • Page 117 • Check that charger's red (positive) battery wire connector termi- nal is receiving power (24V) from batteries. • Check signal from charger interlock connector terminal 2 to ground board terminal J1-26, where 0VDC indicates charging in process. • HEALTH (Status LED) - ON 3121273 – JLG Lift –...
  • Page 118 MODEL CHANGED - The user changed the Model Selection • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER. HYDRAULICS SUSPENDED - using the JLG Analyzer. • Cycle Emergency Stop Switch. CYCLE EMS • Replace ground board. • HEALTH (Status LED) - ON...
  • Page 119 20 Ohms. The lift down sole- noid is powered (PWM) by ground board J2-2, and its ground is to ground board J2-16. • Inspect the wiring for physical damage. • Replace ground board. • HEALTH (Status LED) - ON 3121273 – JLG Lift –...
  • Page 120 20 Ohms. The right brake is powered (J1-33 NRB). with 24V from ground board J1-30, and its ground is to ground board J1-33. • Inspect the wiring for physical damage. • Replace ground board. 6-10 – JLG Lift – 3121273...
  • Page 121 • HEALTH (Status LED) - ON GROUND Solenoid was detected (J2-17 NUV). 33407 LIFT DN VALVE - SHORT TO Excessive current flow to the Lift Down • HEALTH (Status LED) - ON GROUND Solenoid was detected (J2-16 NDV). 3121273 – JLG Lift – 6-11...
  • Page 122 PCB to charged batteries, damaged battery, or an improper wire harness be more than 34V for 10uS. connection. • Drive, Steer, and Lift Prevented • HEALTH (Status LED) - ON 6-12 – JLG Lift – 3121273...
  • Page 123 • This issue may be caused by a power wiring error or an internal POWER CIRCUITS the System Module’s T-terminal did not fault. agree with the predicted value. • HEALTH (Status LED) - ON 3121273 – JLG Lift – 6-13...
  • Page 124 • Calibrate the Angle Sensor using the CALIBRATION: ANGLE sub- NOT BEEN CALIBRATED brated and the control system assumes menu to clear the message. that the platform is overloaded. • HEALTH (Status LED) - ON 6-14 – JLG Lift – 3121273...
  • Page 125 • Cycle machine, if error still exists, replace System Module. INTERNAL ERROR • HEALTH (Status LED) - FLASHING 9957 POWER MODULE FAILURE - • Cycle machine, if error still exists, replace System Module. INTERNAL ERROR • HEALTH (Status LED) - FLASHING 3121273 – JLG Lift – 6-15...
  • Page 126 • Cycle machine, if error still exists, replace System Module. INTERNAL ERROR • HEALTH (Status LED) - FLASHING 99149 POWER MODULE FAILURE - • Cycle machine, if error still exists, replace System Module. INTERNAL ERROR • HEALTH (Status LED) - FLASHING 6-16 – JLG Lift – 3121273...

  • Page 127: Section 7 - General Electrical Information & Schematics

    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 DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.

  • Page 128: 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 – 3121273...

  • Page 129: 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 3121273 – JLG Lift –...

  • Page 130: 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 – 3121273...

  • Page 131: 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 3121273 – JLG Lift –...

  • Page 132: 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 – 3121273...

  • Page 133: 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. 3121273 – JLG Lift –...

  • Page 134: 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 – 3121273...

  • Page 135: Service - Voltage Reading

    This nullifies the effectiveness of the connector seals and could result in system failure. Figure 7-11. Connector Installation 3121273 – JLG Lift –...

  • Page 136: 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 – 3121273...

  • Page 137: 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. 3121273 – JLG Lift – 7-11...

  • Page 138: 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 139: Automatic Switches

    Also, the technician can mea- sure the voltage at both power terminals with respect to battery ground. The difference between those two measure- ments is the voltage applied to the load. 3121273 – JLG Lift – 7-13...

  • Page 140: Circuit Boards: Inputs And Outputs

    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) 7-14 – JLG Lift – 3121273...

  • Page 141: Power Module - J2 Connector Pin Function

    19 Joystick Analog Input (0-5V) Analog Input 20 Alarm - Platform Box Digital Output 21 Yellow Lamp - Platform Box Digital Output 22 Spare Digital Output 23 Red Lamp - Platform Box Digital Output 3121273 – JLG Lift – 7-15...

  • Page 142: Electrical Schematics And Layouts

    YEL 3-16 IGN LB24+ EAME MACHINE ONLY CONNECT TO CONTACTOR RL14 ON SHEET 3 A3 ATTACH SPLICE GROUND ALARM 1001129844_D - Sht. 2 ELEVATION POWER RELAY BEACON TILT SENSOR Figure 7-18. Electrical Schematic - (Global) 7-16 – JLG Lift – 3121273...
  • Page 143 THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES,INC. AND CONTAINS PROPRIETARY AND CONFIDENTIAL 1001129844_D - Sht. 2 INFORMATION OF JLG. IT MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG'S WRITTEN CONSENT AND IS PROVIDED FOR THE LIMITED PURPOSE OF REVIEW AND EVALUATION.
  • Page 144 BLK 4AWG RL14-2 BLK 2/0AWG RL14-1 CONNECT TO X08 SHEET 2 B8 INTERLOCK AC PLUG BATTERY CHARGER 1001129844_D - Sht. 3 6V BATTERY 6V BATTERY 6V BATTERY 6V BATTERY Figure 7-18. Electrical Schematic - (Global) 7-18 – JLG Lift – 3121273...
  • Page 145 THIS PRINT IS THE PROPERTY OF JLG INDUSTRIES,INC. 1001129844_D - Sht. 3 AND CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION OF JLG. IT MAY NOT BE COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT JLG'S WRITTEN CONSENT AND IS PROVIDED FOR THE Note: Sheet 1 of this Schematic was a table of contents and is not shown.

  • Page 146: Electrical Components Layout - Sheet 1 Of 2

    TRANSDUCERS LIFT CYLINDER VALVE BLOCK PLATFORM CONTROL BOX ANGLE SENSOR (CE SPEC) BRAKE RELEASE RELAY ELEVATION SENSOR LIMIT SWITCH GROUND CONTROL PANEL TILT SENSOR Figure 7-19. Electrical Components Layout - Sheet 1 of 2 7-20 – JLG Lift – 3121273...
  • Page 147 DISCONNECT (OPTION) CONTACTOR RELAY DRIVE MODULE –T PUMP/ MOTOR/ RESERVOIR +BF2 –B –P BEACON LIGHT (REAR) BEACON LIGHT LEFT DRIVE RIGHT DRIVE (FRONT) MOTOR MOTOR Figure 7-19. Electrical Layout - Sheet 2 of 2 3121273 – JLG Lift – 7-21...

  • Page 148: Hydraulic Schematic

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.8 HYDRAULIC SCHEMATIC Hydraulic Schematic - 2792599C 1001131095_E Figure 7-20. Hydraulic Schematic 7-22 – JLG Lift – 3121273...
  • Page 149 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 150 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797 Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & JLG Industries Via Po. 22 Polaris Avenue 63 Services Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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