JLG 1932RS/6RS Service And Maintenance Manual
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JLG 1932RS/6RS Service And Maintenance Manual

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Service and Maintenance Manual
Models
1932RS/6RS
3248RS/10RS
3121273
November 26, 2018 - Rev F

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Summary of Contents for JLG 1932RS/6RS

  • Page 1 Service and Maintenance Manual Models 1932RS/6RS 3248RS/10RS 3121273 November 26, 2018 - Rev F...

  • Page 3: Hydraulic System Safety

    INTRODUCTION SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- aerial platform. It is of utmost importance that mainte- TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR nance personnel pay strict attention to these warnings DEATH AND IS A SAFETY VIOLATION.
  • Page 4 INTRODUCTION REVISION LOG Original Issue A - January 30, 2012 Revised B - August 1, 2012 Revised C - January 29, 2013 Revised D - April 8, 2013 Revised E - June 29, 2018 - Revised Covers Revised F - November 26, 2018 3121273...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . A Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS Lubrication and Information ............... . 2-6 Hydraulic System .
  • Page 7 TABLE OF CONTENTS 3.14 Torque Hub Servicing ................3-26 Roll Test .
  • Page 8 SECTION 5 - JLG CONTROL SYSTEM Hand Held Analyzer ................5-1 Diagnostic Port .
  • Page 9 1932RS/6RS - Scissor Arm Assembly - Pin Configuration ....... . .
  • Page 10 LSS Pressure Sensors Location - 1932RS/6RS - (If Equipped) ....... .
  • Page 11 TABLE OF CONTENTS 7-21. Electrical Schematic - (Global) - Sheet 4 of 7 ............7-20 7-22.
  • Page 12 TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications................1-1 Platform Capacities .

  • Page 13: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 SPECIFICATIONS Table 1-1. Operating Specifications DESCRIPTION 1932RS/6RS 3248RS/10RS PLATFORM Maximum Platform Height 19 ft. (5.8 m) 32 ft. (9.75 m) DRIVING Maximum Drive Speed Stowed: 2.5 mph (4 kph) Elevated: 0.3 mph (0.5 kph) Maximum Stowed Travel Grade (Gradeability) 25% (14°)

  • Page 14: Dimensional Data

    (1.99 m) Working Height 25 ft. 38 ft. (7.62 m) (11.5 m) JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED Rail Height 40 in. 40.5 in. FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. (From platform floor) (101.6 cm)

  • Page 15: Electrical System

    MAXIMUM SPEED (PLATFORM LOWERED) UNIT OF MEASURE MODEL Sec/25 ft Sec/25 ft (Sec/7.6 m) (Sec/7.6 m) 1932RS/6RS 59 - 65 6.85 - 8.5 3246RS/10RS 57 - 65 6.85 - 8.5 Lift Speed NOTE: Maximum rated load in platform on measured lift speeds. Platform fully raised and lowered.

  • Page 16: Critical Stability Weights

    DTE 10 or Excel 15 hydraulic oil. Operating Temp — -20°F (29°C) - 200°F (392°C) Aside from JLG recommendations, it is not advisable to mix 1001102685_3 oils of different brands or types, as they may not contain the same required additives or be of comparable viscosi- Pressure Settings ties.

  • Page 17: Limit Switches

    @ TILT (SIDE TO SIDE) Assembly (964 kg) (1226 kg) BACK) ACTIVATION (± 6 IN.) 1932RS/6RS - ALL 69 in. 1.7 TORQUE REQUIREMENTS 3° 1.5° (1.75 m) Self locking fasteners, such as nylon insert and thread deform- 3248RS/10RS - 88.5 in.

  • Page 18: Torque Charts

    SECTION 1 - SPECIFICATIONS Torque Charts Figure 1-1. Torque Chart (SAE Fasteners - Sheet 1 of 5) 3121273...

  • Page 19: Torque Chart (Sae Fasteners - Sheet 2 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart (SAE Fasteners - Sheet 2 of 5) 3121273...

  • Page 20: Torque Chart (Sae Fasteners - Sheet 3 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart (SAE Fasteners - Sheet 3 of 5) 3121273...

  • Page 21: Torque Chart (Metric Fasteners - Sheet 4 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart (Metric Fasteners - Sheet 4 of 5) 3121273...

  • Page 22: Torque Chart (Metric Fasteners - Sheet 5 Of 5)

    SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart (Metric Fasteners - Sheet 5 of 5) 1-10 3121273...

  • Page 23: General

    Pre-Start degree, certificate, extensive knowledge, training, or experi- Inspection. ence, has successfully demonstrated the ability and profi- ciency to service, repair, and maintain the subject JLG product Pre-Delivery Inspection and Frequent Inspection model. Reference the Preventative Maintenance Schedule and the...

  • Page 24: Preventive Maintenance And Inspection Schedule

    19. Fully charged. tion and use of the machine. 20. No loose connections, corrosion, or abrasions. 21. Verify. JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PER- 22. Perform. FORMED IN ACCORDANCE WITH THE "ANNUAL MACHINE INSPECTION 23. Sealed properly.

  • Page 25: Preventive Maintenance & Inspection Schedule

    SECTION 2 - GENERAL Table 2-2. Preventive Maintenance & Inspection Schedule. INTERVAL PRE-DELIVERY (a) ANNUAL (c) AREA ON MACHINE OR FREQUENT (b) (YEARLY) INSPECTION INSPECTION FUNCTIONS/CONTROLS Platform Controls 5, 6, 7 5, 6, 7 Ground Controls 5, 6 5, 6, 14 Function Control Locks, Guards, or Detents Function Enable System Emergency Stop Switches (Ground &...
  • Page 26 Grease and Lubricate to Specifications 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 27: Service And Guidelines

    SECTION 2 - GENERAL SERVICE AND GUIDELINES Component Disassembly and Reassembly When disassembling or reassembling a component, complete General the procedural steps in sequence. Do not partially disassemble or assemble one part, then start on another. Always recheck The following information is provided to assist you in the use your work to assure that nothing has been overlooked.

  • Page 28: 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 viscosity index of 152. NOTE: Start-up of hydraulic system with oil temperatures below - 15°F (-26°C) is not recommended.

  • Page 29: Changing Hydraulic Oil

    10 minutes. If the machine does not pass this test, pro- ing the proper equivalent. Avoid mixing petroleum and ceed with the following. synthetic base oils. JLG Industries recommends chang- ing the hydraulic oil annually. Cylinder Drift 2. Use every precaution to keep the hydraulic oil clean. If the oil must be poured from the original container into Table 2-3.

  • Page 30: Pins And Composite Bearing Repair Guidelines

    SECTION 2 - GENERAL PINS AND COMPOSITE BEARING REPAIR 3. Pins should be replaced if any of the following is observed (pin should be properly cleaned prior to GUIDELINES inspection): Filament wound bearings. a. Detectable wear in the bearing area. b.

  • Page 31: Machine Component Covers

    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.

  • Page 32: Battery Removal/Maintenance

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.2 BATTERY REMOVAL/MAINTENANCE JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG'S AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG'S AFTERMARKET PRO- GRAMS.

  • Page 33: Battery Charger

    SECTION 3 - CHASSIS & SCISSOR ARMS Check the electrolyte level of the batteries often, adding only distilled water when required. When fully charged, battery fluid level should be 1/8" below vent tubes. (See Figure 3-3.). • DO NOT fill to bottom of vent tubes. •...

  • Page 34: Battery Charging

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.4 BATTERY CHARGING NOTE: Be sure that machine is parked in a well ventilated area before charging begins. ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED BAT- TERY TERMINAL.

  • Page 35: Battery Charger Fault (Led Flash)

    1. Check the connections to AC power. Check for AC volt- Owner’s Guide. Refer www.jlg.com for below supplement man- age between 90 and 260 VAC at the charger. 2. If the AC voltage is verified to be correct at the connec- tion to the charger, and the charger still displays no •...
  • Page 36 SECTION 3 - CHASSIS & SCISSOR ARMS 4. If this problem does not clear after the battery voltage is [5 Flashes] - Over Temperature confirmed to be higher than 1.0V per cell and all con- This fault indicates the charger has become too hot during nections are good, return the charger for service.

  • Page 37: Dc To Ac Inverter (If Equipped)

    RS Scissor models. battery pack. The most likely cause for this problem is incor- rect charge algorithm setting and/or high ambient tempera- tures. For correct charge algorithm setting, refer www.jlg.com for below supplement manual • TROUBLESHOOTING GUIDE - PN 3128829 1.

  • Page 38: Inverter Operation

    SECTION 3 - CHASSIS & SCISSOR ARMS Inverter Operation Inverter Specifications Name Description DANGER OF SHOCK OR ELECTROCUTION - TREAT INVERTER OUTPUT THE SAME DC Input 24V (20-30V) DC AS COMMERCIAL AC POWER. AC Output 110V AC If servicing remove any frame covers required to gain access to Output Waveform Modified Sine Wave (MSW) the inverter unit.

  • Page 39: Ground Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.6 GROUND CONTROL STATION DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPTING TO REMOVE THE GROUND CONTROL PANEL OR SERVICING THE ELECTRICAL SYS- TEM. FAILURE TO DO SO COULD CAUSE DAMAGE TO THE MACHINES ELECTRI- CAL COMPONENTS.

  • Page 40: Main Power Contactor Relay

    DISCONNECT MAIN POWER FROM THE BATTERIES BEFORE ATTEMPTING TO REMOVE THE MAIN POWER CONTACTOR RELAY OR SERVICING THE ELECTRI- CAL SYSTEM. FAILURE TO DO SO COULD CAUSE DAMAGE TO THE MACHINES ELECTRICAL COMPONENTS. 1932RS/6RS 3248RS/10RS Figure 3-12. Elevation Limit Switch Location 1. Limit Switch Figure 3-11.

  • Page 41: Switch Adjustment

    • Switch Reset = 13° • Switch Trip = 25° • Drive speed to be reduced before: 1932RS/6RS - 5 ft. 9 in. (1.75 m) platform height 3248RS/10Rs - 7 ft. 4 in. (2.25 m) platform height. 3248RS/10RS • The switch is to be in the trip position (25° - 70°) when the Figure 3-13.

  • Page 42: Lss - Scissor Arm Angle Sensor - Location

    SECTION 3 - CHASSIS & SCISSOR ARMS 1932RS/6RS 3248RS/10RS 1. Platform Gate 1. Elevation Limit Switch Location 2. LSS Scissor Arm Angle Sensor (rear plate shown cutaway) 2. LSS Scissor Arm Angle Switch (scissor arms shown cutaway) 3. Platform Entry Ladder 3.

  • Page 43: Tilt Sensor Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor Removal 1. Disconnect power at the batteries. 2. Remove the machine left side cover (ground control sta- tion side). 3. Unplug the tilt sensor 3-wire harness connector. 4. Remove the two (2) mounting nuts, bolts and washers attaching the sensor to the base frame.

  • Page 44: Traction System

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.11 TRACTION SYSTEM will apply as little as 14A to the fields for higher rotational speeds and better electrical efficiency. Theory of Operation The Field Windings also provide direction reversal for traction. When driving forward, MOSFET switches 1 and 4 turn On to The armatures (rotating windings) of the separately-excited apply positive potential to F2 and ground potential to F1.

  • Page 45: Common Traction System Difficulties

    JLG Analyzer's HELP Menu while burned. attempting to Drive from Platform Mode. Refer to the Section 5 for explanation of the JLG Analyzer Help Mes- 5. Open-Circuit Motor Field sages. This issue will allow the vehicle to drive very slowly or not at all.

  • Page 46: Power Control Module - Zapi

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.12 POWER CONTROL MODULE - ZAPI NOTE: The power module for the RS Scissors is installed on the machine in the upside down position. This is the correct mounting position. Table 3-3. ZAPI Power Module Specifications Operating Voltage ( B+) 14.5 to 40 VDC 5.

  • Page 47: Main Electrical Power Connections - (1001129845 - Zapi Power Module)

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-22. Main Electrical Power Connections - (1001129845 - ZAPI Power Module) 1. Batteries 6. Drive Motor Armature (Brush) Cables 2. Power Module 7. To Battery Charger (+) 3. Main Power Contactor Relay 8.

  • Page 48: Zapi Power Module Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS ZAPI Power Module Electrical Evaluation INTEGRATED HEALTH INDICATOR The ZAPI Power Module provides a green STATUS LED that shines through the cover to indicate module "health" status. The LED shall be illuminated when the device is powered on. The LED blinks (2Hz) when an internal issue is detected that cannot be repaired by a technician.

  • Page 49: Drive Motor Servicing

    @ 75°F (24°C) @ 75°F (24°C) lated from the motor housing. Low resistance may be an indication of a crushed cable, a burned cable, or a burned 1932RS/6RS 0.21 Ohms 0.037 Ohms field winding. Investigate by disconnecting the drive motor 3248RS/10RS 0.127 Ohms...

  • Page 50: Brake - Manual Disengage Procedure

    SECTION 3 - CHASSIS & SCISSOR ARMS Brake - Manual Disengage Procedure Figure 3-23. Brakes - Manual Disengage Procedure 1. Cover Bolts 3. Cover Gasket 2. Brake Cover 4. Disengage Holes NOTE: The brakes may also be disengaged electrically using the 5.

  • Page 51: Drive Motor Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Removal Figure 3-24. Electric Drive Motor Removal 1. Electric Drive Motor 3. Washers 2. Motor Mounting Bolts 3. Remove the two motor mounting bolts and washers. 4. Gently remove the drive motor (1). DISCONNECT ALL POWER BY REMOVING THE POSITIVE (+) BATTERY CABLE AT THE BATTERIES BEFORE REMOVING DRIVE MOTOR.

  • Page 52: Drive Motor Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Disassembly Figure 3-25. Drive Motor Components 1. Shaft Pilot Bearing 8. Bearing 2. Frame & Field Assembly 9. Commutator End Head 3. Armature Assembly 10. Motor to Hub Mounting Screws (Qty.-2) 4.

  • Page 53: Drive Motor Inspection And Service

    SECTION 3 - CHASSIS & SCISSOR ARMS 8. Remove the screws holding the Commutator End Head 7. Visually inspect the Wire Harness (1) for frayed insula- (9) in place and remove the commutator end head from tion, loose terminals, or other damage. Replace as nec- the frame and field assembly.

  • Page 54: Drive Motor Shaft Bearing

    SECTION 3 - CHASSIS & SCISSOR ARMS 8. Remove manual release screws from brake assembly. Apply new Gasket (12) and affix brake cover to motor using the 2 manual release screws. 9. Attach terminal cover to the commutator end head using two terminal cover screws.

  • Page 55: Drive Motor Installation

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Installation Figure 3-28. Drive Motor Assembly 1. Drive Motor 3. Washers 2. Motor Mounting Bolts 1. Insert the drive motor into the back of the gearbox. The 2. Install the two motor mounting bolts and washers. drive motor will pilot on the four bosses in the gearbox.

  • Page 56: Torque Hub Servicing

    Torque-Hub unit. However, if the unit detected in a seal, o-ring or gasket, the part must be replaced, is under warranty you should contact JLG Industries, Inc. and the unit rechecked. Leak test at 10 psi for 20 minutes.

  • Page 57: Main Gearbox Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Gearbox Disassembly Figure 3-29. Main Gearbox Disassembly 1. Spindle Sub-Assembly 7. Cover 2. Spiral Snap Ring 8. Cover Snap Ring 3. Input ring Gear 9. Pipe Plug 4. Input Sun Gear 10. Input Carrier Sub-Assembly 5.

  • Page 58: Input Carrier Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Disassembly Figure 3-30. Input Carrier Disassembly 1. Planet Gears 6. Needle Bearings 2. Output Sun Gears 7. Thrust Plate 3. Input Carrier 8. Snap Ring 4. Thrust washer 9. Retaining Ring 5.

  • Page 59: Hub Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Disassembly Figure 3-31. Hub Disassembly 1. Seal 3. Main Bearing 2. Hub 1. Remove main wheel bearing. 2. Remove main lip seal. NOTE: This part is held in the hub with a press. To remove have the NOTE: This lip seal is also held in with a press fit.

  • Page 60: Spindle Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Disassembly Figure 3-32. Spindle Disassembly 1. Spindle Sub-Assembly 7. Main Bearing 2. Shaft Ball Bearing 8. O-Ring 3. Tanged Washer 9. Shaft Seal 4. Thrust Washer 10. Snap Ring 5. Output Planet Gear 11.

  • Page 61: Tightening And Torquing Bolts

    SECTION 3 - CHASSIS & SCISSOR ARMS Tightening and Torquing Bolts If an air impact wrench is used to tighten bolts, extreme care should be taken to ensure that the bolts are not tightened beyond their specified torque. The following steps describe how to tighten and torque bolts or socket head cap screws in a bolt circle.

  • Page 62: Spindle Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Assembly Figure 3-36. Spindle Assembly 1. Spindle Sub-Assembly 5. Output Planet Gear 9. Shaft Seal 2. Shaft Ball Bearing 6. Output Planet Pins 10. Snap Ring 3. Tanged Washer 7. Main Bearing 11.

  • Page 63: Hub Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Assembly Figure 3-37. Hub Assembly 1. Seal 3. Main Bearing 2. Hub 1. Put hub on a table with the tapped holes facing down. 3. Flip the hub over. 2. Using a flat plate in conjunction with a pressing tool, 4.

  • Page 64: Input Carrier Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Assembly Figure 3-38. Input Carrier Assembly 1. Planet Gears 6. Needle Bearings 2. Output Sun Gears 7. Thrust Plate 3. Input Carrier 8. Snap Ring 4. Thrust washer 9. Retaining Ring 5.

  • Page 65: Main Gearbox Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Gearbox Assembly Figure 3-39. Main Gearbox Assembly 1. Spindle Sub-Assembly 5. Cover O-Ring 9. Pipe Plug 2. Spiral Snap Ring 6. Cover Thrust Washer 10. Input Carrier Sub-Assembly 3. Input ring Gear 7.
  • Page 66 14. Test per instructions in Section 3.14, Torque Hub Servic- 11. Center the cover in the hub bore so that the “JLG” logo is ing, for proper operation and to check for any oil leaks. up. Push it into the bore.

  • Page 67: Steer Assembly Components

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.15 STEER ASSEMBLY COMPONENTS Figure 3-40. 1932RS/6RS - Steer Assembly NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-purpose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking.

  • Page 68: Rs/10Rs - Steer Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-41. 3248RS/10RS - Steer Assembly NOTE: Coat all pins with a light coat of molypaste before assembly. Pack inner and outer spindle bearings with multi-purpose grease (MPG) before assembly. Do not overtighten spindle bearing nut. Replace spindle seal if worn, damaged, or leaking. 1.

  • Page 69: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.16 ARMS AND PLATFORM POSITIONING AND 3.18 SCISSOR ARMS REMOVAL SUPPORT 1. Remove platform (refer to Section 3.17, Platform Removal). 2. Disconnect all wiring and cables attached to scissor arm NEVER WORK UNDER N ELEVATED PLAT FORM UNTIL IT HAS BEEN assembly.

  • Page 70: Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS STRAP Figure 3-42. Arms and Platform Positioning and Support 3-40 3121273...

  • Page 71: Rs/6Rs - Scissor Arm Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS MAF02440 Figure 3-43. 1932RS/6RS - Scissor Arm Assembly 3121273 3-41...

  • Page 72: Rs/6Rs - Scissor Arm Assembly - Pin Configuration

    SECTION 3 - CHASSIS & SCISSOR ARMS MAF02450 Figure 3-44. 1932RS/6RS - Scissor Arm Assembly - Pin Configuration 3-42 3121273...

  • Page 73: Rs/10Rs - Scissor Arm Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS MAF02460 Figure 3-45. 3248RS/10RS - Scissor Arm Assembly 3121273 3-43...

  • Page 74: Rs/10Rs - Scissor Arm Assembly - Pin Configuration

    SECTION 3 - CHASSIS & SCISSOR ARMS MAF02470 Figure 3-46. 3248RS/10RS - Scissor Arm Assembly - Pin Configuration 3-44 3121273...

  • Page 75: Platform Cable (3248Rs/10Rs) - Sheet 1 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS SECURE CHASSIS CONNECTOR (X11) OF PLATFORM CABLE TO CHASSIS HARNESS WITH TIE STRAP 1001196746-B MAF03360 Figure 3-47. Platform cable (3248RS/10RS) - Sheet 1 of 4 3121273 3-45...

  • Page 76: Platform Cable (3248Rs/10Rs) - Sheet 4 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS YELLOW MARKER TAPE SECURE HARNESS TO THE PLATFORM BY HOSE DO NOT ROUTE HARNESS ON CLAMP THIS ROD YELLOW MARKER TAPE ORANGE MARKER TAPE SECURE HARNESS TO THE ARMS NOTICE: USE NOTCHES TO BY INSERTING TIE STRAP, LOCATE TIE STRAPS TO CABLE THROUGH THE WELD NUTS...

  • Page 77: Platform Cable (3248Rs/10Rs) - Sheet 3 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS SEE DETAIL A ORANGE MARKER TAPE ROUTE CABLE HARNESS AND SECURE TO PLATFORM UNDERSTRUCTURE, 2X DETAIL A 1001196746-B MAF03380 Figure 3-49. Platform cable (3248RS/10RS) - Sheet 3 of 4 3121273 3-47...

  • Page 78: Platform Cable (3248Rs/10Rs) - Sheet 4 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS SEE DETAIL C SEE DETAIL B SECURE HOSE CLAMP WITH HARDWARE FACING OUTSIDE THE PLATFORM SECURE PLATFORM CONNECTOR (X12) TO CONTROL BOX AS SHOWN ROUTE CABLE HARNESS THROUGH PLATFORM OPENING, SECURE TO PLATFORM USING SEQ#1 PLATFORM CABLE IS ROUTED WITH AC CABLE THROUGH NOTICE: CABLE ROUTES THROUGH...

  • Page 79: Platform Cable (Lss - 3248Rs/10Rs) - Sheet 1 Of 3

    SECTION 3 - CHASSIS & SCISSOR ARMS YELLOW MARKER TAPE SECURE HARNESS TO THE PLATFORM BY HOSE CLAMP DO NOT ROUTE HARNESS YELLOW MARKER TAPE ON THIS ROD SECURE HARNESS TO THE ORANGE MARKER TAPE ARMS BY INSERTING TIE NOTICE: USE NOTCHES STRAP, THROUGH THE WELD TO LOCATE TIE STRAPS TO NUTS ALONG THE ARM TACK, 0X...
  • Page 80 SECTION 3 - CHASSIS & SCISSOR ARMS SEE DETAIL A ORANGE MARKER TAPE ROUTE CABLE HARNESS AND SECURE TO PLATFORM UNDERSTRUCTURE, 3X DETAIL A 1001147249-E MAF02600 Figure 3-52. Platform cable (LSS - 3248RS/10RS) - Sheet 2 of 3 3-50 3121273...
  • Page 81 SECTION 3 - CHASSIS & SCISSOR ARMS SEE DETAIL C SEE DETAIL B SECURE HOSE CLAMP WITH HARDWARE FACING OUTSIDE THE PLATFORM SECURE PLATFORM CONNECTOR (X8) TO RAIL WELDMENT AS SHOWN NOTICE: CABLE ROUTES THROUGH PLATFORM CABLE IS ROUTED PLATFORM USING THE PLATFORM WITH AC CABLE THROUGH CABLE SUPPORT CLAMP...

  • Page 82: Platform Cable (Ftsw - 3248Rs/10Rs) - Sheet 1 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS TIE STRAP THE FIRST TAPE MARK ON THE PLATFORM CABLE TO THE ROD ON THE LOWER INBOARD AS SHOWN. SEE NOTE REGARDING ASECUREMENT OF HARNESS NOTES: 1. ORANGE AND YELLOW MARKER TAPE STRIPS ARE LOCATED ON PLATFORM CABLE HARNESS TO ASSIST IN INSTALLATION.

  • Page 83: Platform Cable (Ftsw - 3248Rs/10Rs) - Sheet 2 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS SECURE HARNESS TO TUBE ON CYLINDER WITH TIE STRAP AT EVERY ORANGE TAPE 1001196745-B MAF02970 Figure 3-55. Platform cable (FTSW - 3248RS/10RS) - Sheet 2 of 4 3121273 3-53...

  • Page 84: Platform Cable (Ftsw - 3248Rs/10Rs) - Sheet 3 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS USE TIE STRAP TO SECURE CABLE TO THE PLATFORM CROSS MEMBER SEE DETAIL B DETAIL B SEE DETAIL A SECURE HARNESS BY WRAPPING TIE WRAP DETAIL A AROUND CABLE CARRIER SECURE CABLE TO THE ARMS BY INSERTING WIRE TIE STRAP THROUGH NUTS WELDED TO ARMS...

  • Page 85: Platform Cable (Ftsw - 3248Rs/10Rs) - Sheet 4 Of 4

    SECTION 3 - CHASSIS & SCISSOR ARMS SEE DETAIL C RAIL AND BRACKET ASHOWN IN PHANTOM FOR CLARITY SECURE PLATFORM CONNECTOR (X12) TO PLATFORM BOX AS SHOWN USE SUPPORT FROM PLATFORM INSTALLATION CABLE ROUTES TO SECURE CABLE IN DETAIL C THROUGH CLAMP CHANNEL 1001196745-B...

  • Page 86: Platform Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.19 PLATFORM CONTROL STATION Control Station Harness Installation to Scissor Arms Below are a few notes for positioning and securing the platform control station harness to the scissor arms when POWER MACHINE DOWN AT THE GROUND CONTROL STATION BEFORE DISCON- installing or removing the harness on the machine.

  • Page 87: Overview Of Control Station Components

    SECTION 3 - CHASSIS & SCISSOR ARMS Overview of Control Station Components Figure 3-60. Platform Control Station Components - Figure 3-61. Platform Control Station Components - Internal External 1. Drive and Lift Joystick Control 5. Horn Button Switch 1. Steer Control Switch 7.

  • Page 88: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS Joystick Controller Figure 3-62. Joystick Table 3-5. Joystick Specifications Table 3-6. Connector Chart CONNECTOR PINOUT Input Voltage +5 (±0.1) VDC Term Color Function Current Consumption 10 mA @ 12 VDC HANDLE COM Output: Handle Centered 2.5 (±0.1) VDC VIOLET TRIGGER N.O.

  • Page 89: Cylinders - Theory Of Operation

    SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS 4.1 CYLINDERS - THEORY OF OPERATION Relief Valves Cylinders are of the double acting type. The Lift and Steer sys- Main relief valves are installed at various points within the tems incorporate double acting cylinders. A double acting cyl- hydraulic system to protect associated systems and compo- inder is one that requires oil flow to operate the cylinder rod in nents against excessive pressure.

  • Page 90: Pump/Motor

    Terminals is less than 2 Ohms. If not, examine the COMMON DIFFICULTIES pump motor for worn brushes or broken terminals. After The following difficulties can be examined using the JLG Ana- examination, re-connect the Pump Motor Positive Ter- lyzer, a voltmeter, and simple hand tools. Unless otherwise minal and main power at the batteries.

  • Page 91: Hydraulic Oil Check Procedure

    This issue will allow the vehicle to drive, but Lift Up and Steer Functionality will be lost and the Pump Motor will Lube - Hydraulic Oil not operate. Under DIAGNOSTICS - PUMP, the JLG Ana- lyzer will show an erratic reading for PUMP PWM % and Interval - Check Daily PUMP CUR will hover around 150A when Lift Up is oper- ated from Ground Mode.

  • Page 92: Pump/Tank Disassembly

    SECTION 4 - HYDRAULICS oil by using a funnel. Fill until oil is up to the MAX level indicator on the side of the tank. 4. To remove the oil pickup line, squeeze retainer and slide outward. NOTE: There are two o-rings located in the valve for the pump outlet.

  • Page 93: Hydraulic Motor, Pump And Tank Assembly (All Machines)

    SECTION 4 - HYDRAULICS 32 - 40 Nm Torque: 24 - 29 ft.lb. Torque: 37 - 44 ft. lb. 50 - 60 Nm Torque: 15 - 18 ft. lb. 20 - 25 Nm Torque: 3.5 - 4.5 ft.lb. 5 - 6 Nm Torque: 15 - 18 ft.

  • Page 94: Lift Pressure Setting Procedure

    6. Activate pump motor and retract cylinder. Check extend Table 4-3. Pressure Fitting Adapter port for leakage. PORT JLG PART # 7. If extend port leakage is less than 6-8 drops per minute, 300057 - JIC carefully reconnect hose to extend port, than activate...

  • Page 95: Lift Cylinder Removal

    SECTION 4 - HYDRAULICS 4.6 LIFT CYLINDER REMOVAL 3. Remove the valve connector, the two hoses and the manual decent cable from the cylinder. NOTE: If there is a pump failure, a crane or a forktruck can be used NOTE: To avoid having to readjust the manual descent, remove to raise the platform.

  • Page 96: Cylinder Repair

    SECTION 4 - HYDRAULICS 4.7 CYLINDER REPAIR 7. Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end, as applicable. NOTE: The following are general procedures that apply to the cyl- inders on this machine. Procedures that apply to a specific cylinder will be so noted.

  • Page 97: Steer Cylinder Piston Removal

    SECTION 4 - HYDRAULICS Steer Cylinder Piston Removal 10. Inspect threaded portion of head for damage. Dress threads as necessary. 1. Using the spanner holes, rotate the piston until the end 11. Inspect seal and o-ring grooves in head for burrs and of the retaining ring can be seen through the cross- sharp edges.

  • Page 98: 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 99: Rod Assembly Installation

    13. Retorque the capscrews evenly and progressively in cable. (See Figure 4-13., 1932RS/6RS - Lift Cylinder or rotation to the specified torque value. Figure 4-14., 3248RS/10RS - Lift Cylinder).

  • Page 100: Lift Cylinder - Lss Pressure Sensor Location (If Equipped)

    29. If applicable, install the cartridge-type holding valve and fittings in the port block using new o-rings as applica- ble. Refer to Figure 4-13., 1932RS/6RS - Lift Cylinder on page 4-13. or Figure 4-14., 3248RS/10RS - Lift Cylinder on page 4-14...

  • Page 101: 1932Rs/6Rs - Lift Cylinder

    ***Torque to 25-30 lbf. ft (33.9-40.67 Nm) ****Torque to 34 ft. lbs. (46 Nm) *****Torque to 384.3-496.7 lbf. ft (521-673.43 Nm) ******Torque to 546.3-667.7 ft. lbs. (740-905.27 Nm) MAF02480 Figure 4-13. 1932RS/6RS - Lift Cylinder 1. Cylinder Barrel 9. O-Ring 17. Bushing 2. Cylinder Rod 10.

  • Page 102: Rs/10Rs - Lift Cylinder

    SECTION 4 - HYDRAULICS 22**** 18*** 21** 22**** 15***** 3****** *Torque to 15.5-17.1 lbf. ft (21-23.2 Nm) **Torque to 14.4 ft. lbs. (19.5 Nm) ***Torque to 25-30 lbf. ft (33.9-40.67 Nm) ****Torque to 34-37.4 ft. lbs. (46-50.70 Nm) *****Torque to 240.3-293.7 lbf. ft (325.8-398.20 Nm) ******Torque to 358.2-437.8 ft.

  • Page 103: 1932Rs/6Rs - Steer Cylinder

    131 - 161 Nm Torque: 97 - 119 ft. lb. Torque: 306 - 374 ft. lb. 415 - 507 Nm Figure 4-15. 1932RS/6RS - Steer Cylinder 1. Cylinder Barrel 6. Wear Ring 11. Piston Seal 2. Cylinder Rod 7.

  • Page 104: 3248Rs/10Rs - Steer Cylinder

    SECTION 4 - HYDRAULICS Torque: 13 ft. lb. 17.6 Nm (Apply Loctite #262 to threads before assembly.) 131 - 161 Nm Torque: 97 - 119 ft. lb. Torque: 306 - 374 ft. lb. 415 - 507 Nm Figure 4-16. 3248RS/10RS - Steer Cylinder 1.

  • Page 105: Hand Held Analyzer

    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 Level, To return home or access previ-...

  • Page 106: 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 prop- In ground mode, erly, the analyzer will display the following: HELP: (002) GROUND MODE OK...

  • Page 107: 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 M ENU: 2 which enables you to only view most configuration settings AC C ESS LEVEL 1 which cannot be changed until you enter a password to advance to a lower level.

  • Page 108: 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 Once you have gained access to level 1, and a personality item arrow keys to adjust its value, for example:...

  • Page 109: Joystick Calibration

    Con- stop switches must be pulled out (reset) and the ground con- tact JLG Industries to acquire the software cd. trol keyswitch set on platform mode. Before updating the software, use the Hand-held Analyzer to 1.
  • Page 110 SECTION 5 - JLG CONTROL SYSTEM 3121273...
  • Page 111 SECTION 5 - JLG CONTROL SYSTEM 3121273...
  • Page 112 SECTION 5 - JLG CONTROL SYSTEM 3121273...
  • Page 113 SECTION 5 - JLG CONTROL SYSTEM 3121273...
  • Page 114 SECTION 5 - JLG CONTROL SYSTEM 5-10 3121273...
  • Page 115 SECTION 5 - JLG CONTROL SYSTEM 3121273 5-11...
  • Page 116 SECTION 5 - JLG CONTROL SYSTEM 5-12 3121273...

  • Page 117: 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 118: 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 119 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Machine Configuration Programming Information (Software Version P1.7) Market Default Setting Configuration Digit Setting Description NO - Vehicle is not configured for the beacon option, beacon only operates in descent limiter zone YES - Vehicle has the beacon option, beacon works inside descent limit zone and outside descent...
  • Page 120 SECTION 5 - JLG CONTROL SYSTEM NOTES: 5-16 3121273...

  • Page 121: Introduction

    For example: a “2-1 Power-Up” on page 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 diagnos- tic analyzer.

  • Page 122: Dtc Index

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 6.4 DTC INDEX 0-0 Help Comments ..............6-5 EVERYTHING OK .
  • Page 123 SECTION 6 - DIAGNOSTIC TROUBLE CODES LIFT DOWN VALVE - SHORT TO BATTERY ..........6-9 LIFT DOWN VALVE - OPEN CIRCUIT .
  • Page 124 SECTION 6 - DIAGNOSTIC TROUBLE CODES 8-2 LSS - Load Sensing System (See 3124288 - LSS Manual) ......6-13 8212 LSS PRESSURE SENSOR - DISAGREEMENT .

  • Page 125: Dtc Check Tables

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 6.5 DTC CHECK TABLES 0-0 Help Comments FAULT MESSAGE DESCRIPTION CHECK EVERYTHING OK The normal help message in platform mode. Dis- • HEALTH (Status LED) - ON plays on the analyzer only. GROUND MODE OK The normal help message in ground mode.
  • Page 126 SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-2 Platform Controls FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - HORN PERMA- The horn switch was closed during power-up in • Check if the horn switch is damaged, obstructed or jammed. NENTLY SELECTED platform mode. •...
  • Page 127 SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-3 Ground Controls FAULT MESSAGE DESCRIPTION CHECK FUNCTION PROBLEM - LIFT PERMA- Lift Switch (Up or Down) in the Ground Control • Release or repair the switch to clear the message. NENTLY SELECTED Box was closed during power-up. •...
  • Page 128 MODEL CHANGED - HYDRAULICS SUS- The user changed the Model Selection using the • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER. PENDED - CYCLE EMS JLG Analyzer. • Cycle Emergency Stop Switch. • Replace ground board. • HEALTH (Status LED) - ON...
  • Page 129 SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver FAULT MESSAGE DESCRIPTION CHECK LIFT UP VALVE - SHORT TO BATTERY Voltage from an external source was detected on • Check for continuity through this circuit. The lift up solenoid resistance should the Lift Up Solenoid (J2-17 NUV).
  • Page 130 SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver FAULT MESSAGE DESCRIPTION CHECK 3312 LEFT BRAKE - SHORT TO BATTERY Voltage from an external source was detected on • Check for continuity through this circuit. The left brake is powered with 24V from the Left Brake Solenoid (J1-34 NLB).
  • Page 131 SECTION 6 - DIAGNOSTIC TROUBLE CODES 4-2 Thermal Limit (SOA) FAULT MESSAGE DESCRIPTION CHECK POWER MODULE TOO HOT - PLEASE The System Module's internal temperature is • Power down and allow to cool. WAIT excessive (>+75° C). Allow to cool by powering •...
  • Page 132 SECTION 6 - DIAGNOSTIC TROUBLE CODES 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK CANBUS FAILURE - POWER MODULE The control system failed to receive messages • This may occur if re-programming was interrupted. from the power microprocessor. • Alternately, this may be an internal fault. •...
  • Page 133 SECTION 6 - DIAGNOSTIC TROUBLE CODES 7-7 Electric Motor FAULT MESSAGE DESCRIPTION CHECK 7741 ARMATURE BRAKING CURRENT TOO The System Module detected excessive braking • This can be caused by transporting an excessive load on a steep grade. Alter- HIGH current.
  • Page 134 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK POWER MODULE FAILURE - PERSON- The power module detected an out-of-range or • Record all personality settings in ANALYZER -> PERSONALITIES and ANALYZER -> ALITY RANGE ERROR corrupt personality setting MACHINE SETUP.
  • Page 135 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK 9971 POWER MODULE FAILURE - INTER- • Cycle machine, if error still exists, replace System Module. NAL ERROR • HEALTH (Status LED) - FLASHING 99143 POWER MODULE FAILURE - INTER- •...
  • Page 136 SECTION 6 - DIAGNOSTIC TROUBLE CODES NOTES: 6-16 3121273...

  • Page 137: General

    IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CON- TAINING 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 138: Voltage Measurement (Dc)

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 7-1. Voltage Measurement (DC) Figure 7-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range • First test meter and leads by touching leads together. (See multimeter’s operation manual) Resistance should read a short circuit (very low resis- tance)

  • Page 139: Continuity Measurement

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 7-3. Continuity Measurement Figure 7-4. Current Measurement (DC) • Some meters require a separate button press to enable • Set up the meter for the expected current range audible continuity testing •...

  • Page 140: Continuity Measurement Over Long Distances

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness.

  • Page 141: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.3 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. •...

  • Page 142: Assembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Figure 7-6. Connector Assembly (1 of 4)). Proceed as fol- lows: Figure 7-6. Connector Assembly (1 of 4) 1.

  • Page 143: Disassembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-8. Connector Assembly (3 of 4) Figure 7-9. Connector Assembly (4 of 4) Disassembly 5. Insert a 4.8 mm (m3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6.

  • Page 144: Wedge Lock

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-10. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts. 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.

  • Page 145: Service - Voltage Reading

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading DO NOT PIERCE WIRE INSULATION TO TAKE VOLTAGE READINGS. It has been common practice in electrical troubleshooting to probe wires by piercing the insulation with a sharp point. This practice should be discouraged when dealing with the AMPSEAL plug assembly, or any other sealed connector system.

  • Page 146: Working With Deutsch Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.4 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 7-12. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4.

  • Page 147: Hd30/Hdp20 Series Disassembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 7-15. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 7-16.

  • Page 148: 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 149: Automatic Switches

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. Connect instrumentation to monitor and/or control the parameter the switch is measuring.

  • Page 150: Circuit Boards: Inputs And Outputs

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.6 CIRCUIT BOARDS: INPUTS AND OUTPUTS Table 7-1. Power Module - J1 Connector Pin Function Function Type Spare - Analog Input - EAME - LSS Pressure Switch - 1 Analog Input Spare - Analog Input - EAME - LSS Pressure Switch - 2 Analog Input Control for Ground Alarm (PWM)

  • Page 151: Power Module - J2 Connector Pin Function

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 7-2. Power Module - J2 Connector Pin Function Function Type Positive Lift/Steer Relays - (Connect to +BATT) Power Output Positive Lift Down Valve (High-Side Driver) Power Output Lift Select - Platform Switch Digital Input Steer Left - Joystick Controller...
  • Page 152 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS This page left blank intentionally 7-16 3121273...

  • Page 153: Electrical Schematics And Layouts

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.7 ELECTRICAL SCHEMATICS AND LAYOUTS 3248RS/10RS, 1932RS/6RS/R6 LSS EQUIPPED MACHINE SHEET 2: CHASSIS HARNESS MDI JUMPER LIFT DOWN JUMPER SHEET 3: POWER CABLES PLATFORM CABLE PLATFORM CONTROL BOX BATTERY DISCONNECT SHEET 4: CAN TILT SENSOR...

  • Page 154: Electrical Schematic - (Global) - Sheet 2 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS TELEMATICS SN108 WHT 2-34 SLPH SYSTEM MODULE CO09-J1 CO09-J2 WHT 14 GND ALARM S123 WHT 21 12V IGN YEL 2-36 IGN YEL 2-3 GND MODE YEL 3-1-6 TILT IGN CANL YEL 3-1-7 GND ALARM IGN SN109 WHT 2-35 SRPH WHT 13 TILT SIG...

  • Page 155: Electrical Schematic - (Global) - Sheet 3 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS FOR DIAGNOSTICS MS35-1 WHT 40 5V JOY WHT 39 JOYSTICK MS35-3 WHT 41 GND JOY WHT 41 GND JOY SYSTEM MODULE WHT 39 JOYSTICK CO09-J1 CO09-J2 WHT 14 GND ALARM YEL 3-1-8 IGN WHT 40 5V JOY WHT 21 12V IGN WHT 20 P LIFT DN...

  • Page 156: Electrical Schematic - (Global) - Sheet 4 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BLK/RED BLK/RED BLK/RED 18AWG TFFN BRN/BLK BRN/BLK BRN/BLK 18AWG TFFN BLU/RED BLU/RED BLU/RED 18AWG TFFN YEL 18AWG TFFN PLATFORM CABLE BLU/BLK BLU/BLK BLU/BLK 18AWG TFFN BRN 18AWG TFFN CONNECTS YEL/BLK YEL/BLK YEL/BLK 18AWG TFFN RED 18AWG TFFN TO X28 BLK 18AWG TFFN...

  • Page 157: Electrical Schematic - (Global) - Sheet 5 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BLK/RED 18AWG TFFN BLK/RED 18AWG TFFN BRN/BLK 18AWG TFFN YEL 3-9 IGN BLU/RED 18AWG TFFN RED 18AWG TFFN YEL 18AWG TFFN SW16 BLU/BLK 18AWG TFFN BRN 18AWG TFFN YEL/BLK 18AWG TFFN ORN/BLK 18AWG TFFN RED 18AWG TFFN SW38-1 BLK 18AWG TFFN...

  • Page 158: Electrical Schematic - (Global) - Sheet 6 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS CO09-J2 BLK 50 GND WHT 26 CANL YEL 51 PWR WHT 25 CANH WHT 25 CANH WHT 26 CANL WHT 27 CANS YEL 3-7 IGN BLK 57 GND WHT 56 INV ON RL74 WHT 27 CANS RED 6AWG...

  • Page 159: Electrical Schematic - (Global) - Sheet 7 Of 7

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS RED 6AWG INVERTER OPTION - ANSI ONLY BLK 6AWG BLK 57 GND INVERTER WHT 56 INV ON RED 6AWG RL74 RED 6AWG RL74-2 RED 6AWG RL74-1 SW75 AC CABLE WHT 56 INV ON YEL 55 IGN FULL CONNECTOR ON SHEET 2 SHEET 4...

  • Page 160: Electrical Components Layout - Sheet 1 Of 2

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS PLATFORM LSS LIFT CYLINDER RECEPTACLE 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 7-25. Electrical Components Layout - Sheet 1 of 2 7-24 3121273...

  • Page 161: Electrical Components Layout - Sheet 2 Of 2

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BATTERIES ALARM BATTERY CHARGER BATTERY QUICK- DISCONNECT CONTACTOR (OPTION) RELAY DRIVE MODULE –T PUMP/ MOTOR/ RESERVOIR +BF2 –B –P BEACON LIGHT (REAR) BEACON LIGHT LEFT DRIVE RIGHT DRIVE (FRONT) MOTOR MOTOR Figure 7-26. Electrical Components Layout - Sheet 2 of 2 3121273 7-25...

  • Page 162: Hydraulic Schematic

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 7.8 HYDRAULIC SCHEMATIC 1001131095_E Figure 7-27. Hydraulic Schematic 7-26 3121273...
  • Page 164 3121273 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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