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Oshkosh Corporation JLG 1930ES Service Maintenance Manual

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Service & Maintenance Manual
Models
1930ES
2032ES
2632ES
2646ES
3246ES
PVC 1910
31215074
January 8, 2020 - Rev A
AS/NZS

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  • Page 1 Service & Maintenance Manual Models 1930ES 2032ES 2632ES 2646ES 3246ES PVC 1910 31215074 January 8, 2020 - Rev A AS/NZS...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Hydraulic System Safety

    INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS GENERAL MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the mobile elevating work platform. It is of utmost impor- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- tance that maintenance personnel pay strict attention TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR to these warnings and precautions to avoid possible...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue A - January 8, 2020 31215074...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................... . 1-1 Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. Service and Guidelines ................2-2 General .
  • Page 7 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO Electric Drive Motor Service ............... . 3-22 Servicing Guidelines.
  • Page 8 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO. SECTION 5 - JLG CONTROL SYSTEM Diagnostic Port..................5-1 Hand Held Analyzer .
  • Page 9 TABLE OF CONTENTS SECTION NO. TITLE PAGE NO SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS General ................... . 7-1 Multimeter Basics .
  • Page 10 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 3-1. Traction Control Circuit - ZAPI Power Module............3-1 3-2.
  • Page 11 LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 5-1. Diagnostic Port ..................5-1 5-2.
  • Page 12 LIST OF TABLES TABLE NO. TITLE PAGE NO. Battery Charger Specifications ..............1-3 Battery Charger Specifications .
  • Page 13 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 14: Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS MACHINE SPECIFICATIONS Description 1930ES 2032ES 2632ES 2646ES 3246ES Maximum Stowed Travel Grade (Gradeability) Maximum Stowed Travel Grade (Sideslope)* 3° 3° 3° 3° 3° Maximum Operating Slope (Fully Elevated) Front to Back* 3° 3° 3°...

  • Page 15: Capacities

    SECTION 1 - SPECIFICATIONS Capacities NOTE: All platform extension capacities are 250 lb (120 kg) AUSTRALIAN Model ANSI/CSA CE INDOOR CE OUTDOOR AUSTRALIAN INDOOR OUTDOOR Capacity Persons Capacity Persons Capacity Persons Capacity Persons Capacity Persons 500 lb 1930ES 230 kg 120 kg 230 kg 120 kg...

  • Page 16: Tires

    SECTION 1 - SPECIFICATIONS Tires Description 1930ES 2032ES 2632ES 2646ES 3246ES Size 323mm x 100mm 406 mm x 125 mm Max Tire Load 2500 lb (1134 kg) 4000 lb (1814 kg) Wheel Bolt Torque 105 - 120 ft. lbs. (142-163 Nm) Batteries Battery Charger/AC Inverter Table 1-1.
  • Page 17 SECTION 1 - SPECIFICATIONS Table 1-1. Battery Charger Specifications Table 1-2. Battery Charger Specifications Delta-Q Eagle Performance DESCRIPTION DESCRIPTION 1001253952 1001177842 Charge Profile/error Display OUTPUT Nominal DC Output Voltage 'F' Code Internal Fault - Charging Stopped Maximum DC Output Voltage 31.92V 'E' Code External Fault - Charging Stopped...

  • Page 18: Lift Speed (No Load In Platform)

    SECTION 1 - SPECIFICATIONS Table 1-4. Battery Charger/AC Inverter Specifications Table 1-3. Battery Charger Specifications Xantrex DESCRIPTION Green Power 1001093839 DESCRIPTION 1001218595 DC Overload Voltage Limited - Internally Controlled OUTPUT MECHANICAL Nominal DC Output Voltage Operating Temperature –40° F to + 185° F (–40° C to + 85° C) Maximum DC Output Voltage Housing Shock and Water Resistant Aluminum...

  • Page 19: Travel Speed

    SECTION 1 - SPECIFICATIONS Travel Speed Model Elevated Speed Maximum Speed Unit of Measure Sec/25 ft Kmph Sec/7.6 m Sec/25 ft Kmph Sec/7.6 m 1930ES 28-37 33 - 38 5.6 - 7.7 5.6 - 7.7 2032ES 28-37 33 - 38 6 - 7.9 6 - 7.9 2632ES...

  • Page 20: Torque Requirements

    SECTION 1 - SPECIFICATIONS TORQUE REQUIREMENTS LUBRICATION Self locking fasteners, such as nylon insert and thread Hydraulic Oil deforming locknuts, are not intended to be reinstalled after removal. Always use new replacement hardware NOTE: Hydraulic oils must have anti-wear qualities at least when installing locking fasteners.

  • Page 21: Pressure Settings

    SECTION 1 - SPECIFICATIONS Pressure Settings Table 1-10. Mobil DTE 10 Excel 15 ISO Viscosity Grade Lift Relief Density @ 59°F (15°C) 0.8375 kg/l Model Steer Relief Pour Point, Max -65.2°F (-54°C) USA Built China Built Flash Point, Min. 360°F (182°C) 1800 psi ±...

  • Page 22: Limit Switches

    SECTION 1 - SPECIFICATIONS LIMIT SWITCHES High Drive Speed Cutout High drive speed is cut out when the platform is raised Tilt Alarm above the preset height per model as follows: Illuminates a light on the platform, sounds an alarm and NOTE: These figures are given with a tolerance of ±...

  • Page 23: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS CYLINDER SPECIFICATIONS Description 1930ES 2032ES 2632ES 2646ES 3246ES Lift Cylinder Bore 2.8 in 3.1 in 3.1 in 3.9 in 3.9 in (7.1 cm) (7.9 cm) (7.9 cm) (9.9 cm) (9.9 cm) Lift Cylinder Stroke 43.2 in 48 in 48 in 44.9 in...

  • Page 24: Thread Locking Compound

    SECTION 1 - SPECIFICATIONS THREAD LOCKING COMPOUND JLG PN Loctite® ND Industries Description 0100011 242™ Vibra-TITE™ 121 Medium Strength (Blue) 1001095650 243™ Vibra-TITE™ 122 Medium Strength (Blue) 0100019 271™ High Strength (Red) Vibra-TITE™ 140 0100071 262™ Vibra-TITE™ 131 Medium - High Strength (Red) NOTE: Loctite®...

  • Page 25: Torque Charts

    SECTION 1 - SPECIFICATIONS TORQUE CHARTS SAE Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque (Loctite® 242™ or 271™ Tensile Clamp Torque Torque Size Bolt Dia (Loctite® 262™ or Stress Area Load (Dry)

  • Page 26: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Vibra- Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load...
  • Page 27 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry) Area...
  • Page 28 SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Torque Torque Torque (Loctite® 242™ or 271™ or Tensile Stress (Loctite® 262™ or Size Bolt Dia Clamp Load (Dry or Loctite®...

  • Page 29: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Magni Coating Fasteners (Ref 4150701) SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 30: Sae Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS SAE Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* SOCKET HEAD CAPSCREWS Torque Torque (Loctite® 242™ or 271™ or Tensile Stress Clamp Load Torque (Loctite® 262™ or Size Bolt Dia Area See Note 4 (Dry) K=0.17 Vibra-TITE™...

  • Page 31: Metric Fastener Torque Chart

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® 242™ or (Loctite® 262™ or 271™ Tensile Stress Clamp Load Torque Size Pitch Torque (Lube)

  • Page 32: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Zinc Yellow Chromate Fasteners (Ref 4150707)* CLASS 10.9 METRIC (HEX HEAD) BOLTS, CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAPSCREWS M3 - M5* Torque Torque (Lube or Loctite® 242™ or Torque Tensile Clamp Load...
  • Page 33 SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 8.8 METRIC (HEX/SOCKET HEAD) BOLTS CLASS 8 METRIC NUTS Torque Torque (Loctite® 262™ or Torque (Lube or Loctite® 242™ or Tensile Clamp Load Size Pitch (Dry or Loctite®...

  • Page 34: Metric Fastener Torque Chart (Continued)

    SECTION 1 - SPECIFICATIONS Metric Fastener Torque Chart (Continued) Values for Magni Coated Fasteners (Ref 4150701)* CLASS 10.9 METRIC (HEX HEAD) BOLTS CLASS 10 METRIC NUTS, CLASS 12.9 SOCKET HEAD CAPSCREWS M6 AND ABOVE* Torque Torque (Lube or Loctite® 242™ or Clamp Torque Tensile...

  • Page 35: General

    SECTION 2 - GENERAL SECTION 2. GENERAL MACHINE PREPARATION, INSPECTION, ever comes first); out of service for a period of more than 3 months; or when purchased used. The frequency of AND MAINTENANCE this inspection must be increased as environment, severity and frequency of usage requires.

  • Page 36: Service And Guidelines

    SECTION 2 - GENERAL Table 2-1. Inspection and Maintenance Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Prior to use each day; or User or Operator User or Operator Operator and Safety Manual Inspection At each Operator change. Service and Maintenance Man- Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User...

  • Page 37: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly Bolt Usage and Torque Application When disassembling or reassembling a component, Self locking fasteners, such as nylon insert and complete the procedural steps in sequence. Do not par- thread deforming locknuts, are not intended to be tially disassemble or assemble one part, then start on reinstalled after removal.

  • Page 38: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Changing Hydraulic Oil Use of any of the recommended crankcase or Hydraulic System hydraulic oils eliminates the need for changing the oil on a regular basis. However, filter elements The primary enemy of a hydraulic system is con- must be changed annually unless operating in tamination.

  • Page 39: Cylinder Drift Test

    SECTION 2 - GENERAL CYLINDER DRIFT TEST PINS AND COMPOSITE BEARING REPAIR GUIDELINES Maximum acceptable cylinder drift is to be measured using the following methods. Filament wound bearings. Pinned joints should be disassembled and Platform Drift inspected if the following occurs: Measure the drift of the platform to the ground.

  • Page 40: Preventive Maintenance And Inspection Schedule

    SECTION 2 - GENERAL PREVENTIVE MAINTENANCE AND The inspection and maintenance code numbers are as follows: INSPECTION SCHEDULE Check for proper and secure installation. The preventive maintenance and inspection checks are Check for visible damage and legibility. listed and defined in the following table. This table is divided into two basic parts, the “AREA”...

  • Page 41: Footnotes

    SECTION 2 - GENERAL Table 2-2. Preventive Maintenance and Safety Inspection AREA Interval PRE-DELIVERY (a) ANNUAL (c) OR FREQUENT (b) (YEARLY) INSPECTION INSPECTION PLATFORM Controller 1,11 1,11 Switches 1,11 1,11 Placards and Decals Control Tags Hoses and Cables Wear Pads 8,12 8,12 Handrails and Chains...
  • Page 42 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 43: Chassis & Scissor Arms

    SECTION 3 - CHASSIS & SCISSOR ARMS SECTION 3. CHASSIS & SCISSOR ARMS TRACTION SYSTEM will apply as little as 14A to the fields for higher rota- tional speeds and better electrical efficiency. Theory of Operation The Field Windings also provide direction reversal for traction.

  • Page 44: Pump/Motor - Theory Of Operation

    SECTION 3 - CHASSIS & SCISSOR ARMS PUMP/MOTOR - THEORY OF OPERATION Pump Motor Electrical Evaluation The Power Module (see Figure 3-18., ZAPI Power Module Several basic electrical tests can be performed on the Location on page 3-26) is essentially a "low-side" switch Pump Motor.
  • Page 45 SECTION 3 - CHASSIS & SCISSOR ARMS Open-Circuit between +B Terminal and Pump brushes or broken terminals. After examination, Motor Positive Terminal re-connect the Pump Motor Positive Terminal and the Main Battery Disconnect. This issue will allow the vehicle to drive, but Lift Up and Steer Functionality will be lost and the Pump Short-Circuit between Pump Motor Positive and Negative Terminals...

  • Page 46: Drive Motor Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS DRIVE MOTOR ELECTRICAL EVALUATION Common Traction System Difficulties Short-Circuit Motor Armature Several basic electrical tests can be performed on the Drive Motors. Failure of one of these evaluations is sig- This issue will allow the vehicle to drive very slowly nificant and may indicate that the device is physically or not at all.

  • Page 47: Power Module Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Electrical Evaluation). Suspect dam- after power is disconnected to allow internal charge to aged cabling, burned cabling, or faulty brake dissipate (risk of hazard, improper readings otherwise). release solenoids. Trace the brake release cabling •...

  • Page 48: Torque Hub

    SECTION 3 - CHASSIS & SCISSOR ARMS TORQUE HUB Leak Test The purpose of a leak test is to make sure the unit is air NOTICE tight. You can tell if your unit has a leak if the pressure THE PROCEDURES WITHIN THIS SEC TION APPLY TO ALL gauge reading on your leak checking fitting starts to fall MACHINES AND TORQUE HUBS.

  • Page 49: Brakes - Manual Disengage Procedure

    SECTION 3 - CHASSIS & SCISSOR ARMS Brakes - Manual Disengage Procedure Brake Cover Disengage Holes Cover Bolts Figure 3-2. Disengage Procedure Chock wheels or secure machine with tow vehicle. CAUTION Ensure battery disconnect switch is in to the "OFF" AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST position.

  • Page 50: Drive Motor Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Removal Drive Motor Washers Motor Mounting Bolts Motor Cable Figure 3-3. Motor Removal Remove the two motor mounting bolts and wash- CAUTION ers. ENSURE THE BATTERY DISCONNECT SWITCH IS IN THE OFF Gently remove the drive motor (1).

  • Page 51: Main Gearbox Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Gearbox Disassembly Spindle Sub-Assembly Cover O-Ring Pipe Plug Spiral Snap Ring Cover Thrust Washer 10. Input Carrier Sub-Assembly Input ring Gear Cover 11. Hub Sub-Assembly Input Sun Gear Cover Snap Ring Figure 3-4. Main Gearbox Disassembly Using a screwdriver, pry off the cover snap ring.

  • Page 52: Input Carrier Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Disassembly Planet Gears Thrust washer Thrust Plate Output Sun Gears Input Planet Gear Snap Ring Input Carrier Needle Bearings Retaining Ring Figure 3-5. Input Carrier Disassembly NOTE: The planet pins are held in with a press fit. To avoid Remove retaining rings from each of the 3 planet shafts.

  • Page 53: Hub Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Disassembly Seal Main Bearing Figure 3-6. Hub Disassembly Remove main wheel bearing. Remove main lip seal. NOTE: This part is held in the hub with a press. To remove NOTE: This lip seal is also held in with a press fit. Remove have the hub sitting seal side up.

  • Page 54: Spindle Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Disassembly Spindle Sub-Assembly Thrust Washer O-Ring Main Bushing Output Planet Gear Shaft Seal Shaft Ball Bearing Output Planet Pins Snap Ring Tanged Washer Main Bearing Needle Roller Bearings Figure 3-7. Spindle DIsassembly Place unit on bench with planet gears facing up.

  • Page 55: Spindle Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Sub-Assembly Place tanged thrust washer into each planet “win- dow” of the spindle. Make sure the tang sits in the Using an appropriate pressing tool, press in the 2 cast groove on the inside of the window. main bushings in the upper bore of the spindle.

  • Page 56: Hub Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Sub-Assembly Seal Main Bearing Figure 3-8. Hub Disassembly Put hub on a table with the tapped holes facing Flip the hub over. down. Using an appropriate pressing tool, press the main Using a flat plate in conjunction with a pressing bearing into the bore until it bottoms out.

  • Page 57: Input Carrier Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Input Carrier Sub-Assembly Planet Gears Thrust washer Thrust Plate Output Sun Gears Input Planet Gear Snap Ring Input Carrier Needle Bearings Retaining Ring Figure 3-9. Input Carrier Disassembly Press 3 input planet shafts into the 3 holes of the visually.

  • Page 58: Main Gearbox Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Gearbox Assembly Spindle Sub-Assembly Cover O-Ring Pipe Plug Spiral Snap Ring Cover Thrust Washer 10. Input Carrier Sub-Assembly Input ring Gear Cover 11. Hub Sub-Assembly Input Sun Gear Cover Snap Ring Figure 3-10. Main Gearbox Disassembly Inspect seal surface of spindle.
  • Page 59 SECTION 3 - CHASSIS & SCISSOR ARMS Using an appropriate pressing tool, press the Input 10. Apply a heavy coating of grease to the cover thrust Ring gear (recessed side down) into the hub sub- washer and place it in the center counterbore of assembly.

  • Page 60: Motor And Brake Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Motor and Brake Assembly 1. Drive Motor 3. Washers 2. Motor Mounting Bolts 4. Motor Cable Figure 3-11. Drive Motor Assembly Insert the drive motor into the back of the gear- Connect the end of the Motor Cable to the Power box.

  • 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 capscrews in a bolt circle.

  • Page 62: Drive Motor Cable Routing

    SECTION 3 - CHASSIS & SCISSOR ARMS DRIVE MOTOR CABLE ROUTING Place the Green Clamp on the clamping rings as shown below. 1930ES Only CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING.

  • Page 63: 2032Es/2632Es/2646Es/3246Es Only

    SECTION 3 - CHASSIS & SCISSOR ARMS 2032ES/2632ES/2646ES/3246ES Only CAUTION BE SURE TO PULL THE BATTERY DISCONNECT ANYTIME WORK IS BEING PERFORMED ON THE DRIVE MOTORS OR DRIVE MOTOR CABLING. Orient the drive cables going back towards the rear of the machine. Loop the cables forward towards the front of the machine then up and back.

  • Page 64: Electric Drive Motor Service

    SECTION 3 - CHASSIS & SCISSOR ARMS ELECTRIC DRIVE MOTOR SERVICE 1. Wire Harness 7. Retaining Ring 13. Cover Plate Kit 2. Frame & Field Assembly 8. Bearing 14. Cover Plate Mounting Screws 3. Armature Assembly 9. Commutator End Head 15.

  • Page 65: Servicing Guidelines

    SECTION 3 - CHASSIS & SCISSOR ARMS NOTE: Reference Figure 3-15., Drive Motor Components for Using a dielectric tester, verify that there are no part names and locations when servicing the Drive shorts between the following items: Motor. a. Field connector pins and the case of the motor. Periodic maintenance consisting of inspections of b.

  • Page 66: Drive Motor Inspection And Service

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Inspection and Service Drive Motor Reassembly NOTE: Refer to Figure 3-15. NOTE: Refer to Figure 3-15. Carefully blow out any accumulated carbon dust After inspection and servicing, reassemble the wir- and dirt from the Commutator End Head (9) and ing in the Commutator End Head (9) as originally the Frame &...
  • Page 67 SECTION 3 - CHASSIS & SCISSOR ARMS Assemble the commutator end head to the Frame Install Wire Harness (1) to motor by connecting the & Field Assembly (2) and tighten the screws to 120 brake connectors and securing the armature ter- - 140 in-lb (13.6 - 15.8 Nm).

  • Page 68: Power Module - Zapi

    SECTION 3 - CHASSIS & SCISSOR ARMS POWER MODULE - ZAPI MACHINE FRONT ZAPI POWER MODULE Figure 3-18. ZAPI Power Module Location Turn machine power off and disconnect the bat- teries. Table 3-1. ZAPI Power Module Specs Locate and remove the power module protective Operating Voltage ( B+) 14.5 to 40 VDC cover from the machine.

  • Page 69: Zapi Power Module Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS ZAPI Power Module Electrical Evaluation INTEGRATED HEALTH INDICATOR "HEALTH" (STATUS LED) 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.

  • Page 70: Mdi (Multifunction Digital Indicator) And Brake Release

    SECTION 3 - CHASSIS & SCISSOR ARMS MDI (MULTIFUNCTION DIGITAL INDICATOR) Apply di-electric grease to the two Brake Release Plugs. Connect the Brake Release Plugs to the AND BRAKE RELEASE Brake Release Button on the backside of the mounting bracket. NOTE: The brake release plugs have no polarity, therefore, can be connected to either post on the button.

  • Page 71: Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Using a 5/32" allen wrench, mount the MDI and Using zip ties, tie back cables and wires to prevent Brake Release Bracket onto the wall of the battery damage to the cables and wires. compartment.

  • Page 72: Battery Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS BATTERY REMOVAL Adjust the lifting device to take the weight of the battery door and remove door from under the machine. NOTICE Once the battery door is removed from the JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS machine, battery replacement/maintenance can ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FAC- begin.

  • Page 73: Battery Maintenance And Safety Practices

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 BATTERY CHARGER Battery Maintenance and Safety Practices The Battery Charger is located on the top of the chassis CAUTION at the rear of the machine. Raise and secure scissor arms ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT with arm prop to gain access to the charger.

  • Page 74: Battery Charger Maintenance

    SECTION 3 - CHASSIS & SCISSOR ARMS For flooded lead-acid batteries, regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer. Follow the safety instruc- tions recommended by the battery manufacturer. Make sure charger connections to battery termi- nals are tight and clean.
  • Page 75 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-2. Diagnostic Trouble Codes (Delta Q Battery Charger) Fault Solution Check the battery voltage and cable connections. Check battery size and condition. E-0-0-1 Battery high voltage E-0-2-1 This error will automatically clear once the condition has been corrected. E-0-0-2 Check the battery voltage and cable connections.
  • Page 76 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-3. Fault Codes (Green Power) Flash Code Cause Solution 1) Check battery connection is correct. Connection Issue 2) Check charger connection is correct. 3) Check each battery is good. 1) Check AC input cord is connected between charger and AC outlet. Abnormal AC Power Input (Voltage) 2) Make sure AC plug is tightly secured into AC outlet.
  • Page 77 SECTION 3 - CHASSIS & SCISSOR ARMS Table 3-4. Fault Codes (Eagle Battery Charger) LED Indications Fault Solution This indication occurs whenever the charger circuitry cannot detect a bat- tery. The charger circuitry will not allow charge current to flow under this 30% RED LED NO BATTERY DETECTED condition.
  • Page 78 SECTION 3 - CHASSIS & SCISSOR ARMS Excessive Battery Watering Requirements or Strong To change the algorithm, touch the connector to Sulphur (Rotten Egg) Smell the battery’s positive terminal for 3 seconds during the 11 second display period and then remove. These symptoms indicate over-charging or high battery The Algorithm # will advance after 3 seconds.

  • Page 79: Battery Charger/Inverter (Option)

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.11 BATTERY CHARGER/INVERTER (OPTION) Battery Charger/Inverter Troubleshooting The Battery Charger/Inverter is located on the top of the The Fault LED Flash Codes are the same as the Battery chassis at the rear of the machine. Raise and secure scis- Charger (see Battery Charger Troubleshooting on pages sor arms with arm prop to gain access to the charger.
  • Page 80 SECTION 3 - CHASSIS & SCISSOR ARMS Ground Module powered while key is off or similar Disconnect Inverter/Charger control cable at the 6 behavior: position connector and the chassis harness at the 4 position connector at the Ground Box. There This condition can be caused by various ground module should be continuity between the following: outputs getting shorted to battery.

  • Page 81: 3.12 Limit Switch Locations

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.12 LIMIT SWITCH LOCATIONS Pothole Switch (Typical on opposite side of machine) Rotary Angle Switch Figure 3-26. Limit Switch Locations 3-39 31215074...

  • Page 82: Pothole Switch Replacement

    SECTION 3 - CHASSIS & SCISSOR ARMS Pothole Switch Replacement POTHOLE SWITCH LINK SEE DETAIL A DETAIL A For 1930ES, 2032ES and 2632ES POTHOLE SWITCH LINK SEE DETAIL B DETAIL B For 2646ES and 3264ES MAF21000 Figure 3-27. Pothole Switch Adjustment With the machine in the stowed position and the Raise and lower the machine from the ground con- battery door open, remove the old pothole switch.

  • Page 83: Rotary Angle Sensor Replacement

    SECTION 3 - CHASSIS & SCISSOR ARMS Rotary Angle Sensor Replacement 3.13 GROUND CONTROL STATION Removal: NOTE: Anytime the ground control box is removed, the tilt sensor must be re-calibrated. Refer to Section 5.3, Tilt Lower platform to the stowed position. Sensor Calibration to re calibrate the tilt.

  • Page 84: Tilt Sensor Replacement

    SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor Replacement Remove the six bolts at the back of the ground control and separate. Ground Control Station Tilt Sensor (JLG PN 4000021 or 1001114936) Figure 3-28. Tilt Sensor Location Tilt Sensor Removal: Disconnect the batteries.
  • Page 85 SECTION 3 - CHASSIS & SCISSOR ARMS 3.14 SCISSOR ARMS AND PLATFORM POSITIONING AND SUPPORT CAUTION PLATFORM IS HEAVY AND PRESENTS A CRUSHING HAZARD. TAKE GREAT CARE WHEN REMOVING PLATFORM OR SCISSOR ARM ASSEMBLY The arm stack can be supported by using an overhead crane,(See Figure 3-30.).

  • Page 86: Scissor Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.15 PLATFORM REMOVAL 3.16 SCISSOR ARMS REMOVAL Remove platform (refer to Section 3.15, Platform Support the platform using an overhead crane Removal). with straps capable of lifting at least 439 lb (199 kg) (See Figure 3-30.). Refer to Section 3.14, Disconnect all wiring and cables attached to scis- Scissor Arms and Platform Positioning and Sup- sor arm assembly.
  • Page 87 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-30. Arms and Platform Positioning and Support 3-45 31215074...
  • Page 88 SECTION 3 - CHASSIS & SCISSOR ARMS 1001131004-D MAF21010D 1. Arm Assembly 5. Arm Pivot Pin 9. Cable 2. Capscrew 6. Angle Sensor Switch 10. Lock Nut 3. Lock Nut 7. Agle Sensor Mount 11. Spring 4. Lower Side Pad 8.
  • Page 89 SECTION 3 - CHASSIS & SCISSOR ARMS LIFT CYLINDER VIEW SHOWN HERE FOR CLARITY 1001131005-D MAF21020D 1. Arm Assembly 5. Lock Nut 9. Spring 2. Capscrew 6. Lock Nut 10. Capscrew 3. Cable 7. Lower Side Pad 11. Angle Sensor Switch 4.
  • Page 90 SECTION 3 - CHASSIS & SCISSOR ARMS LIFT CYLINDER VIEW SHOWN HERE FOR CLARITY 1001190904-A MAF21030A 1. Capscrew 5. Lock Nut 9. Capscrew 2. Cable 6. Lower Side Pad 10. Angle Sensor Switch 3. Angle Sensor Mount 7. Arm Pivot Pin 11.
  • Page 91 SECTION 3 - CHASSIS & SCISSOR ARMS 12 3 LIFT CYLINDER VIEW SHOWN HERE FOR CLARITY 1001191063-B 1001191064-B MAF21040B 1. Capscrew 6. Lower Side Pad 11. Tape 2. Cable 7. Arm Pivot Pin 12. Angle Sensor Switch 3. Angle Sensor Mount 8.

  • Page 92: 3.17 Platform Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.17 PLATFORM CONTROL STATION Loosen and remove the four bolts that hold the bottom of the control box. Printed Circuit Board Replacement Disconnect the plug from the printed circuit board. Disconnect the platform control box and remove Remove the bolts attaching the printed circuit from the machine.

  • Page 93: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS Joystick Controller Figure 3-35. Joystick Table 3-7. Joystick Specifications Table 3-8. Connector Chart Input Voltage +5 (±0.1) VDC CONNECTOR PINOUT Term Color Function Current Consumption 10 mA @ 12 VDC HANDLE COM Output: Handle Centered 2.5 (±0.1) VDC VIOLET TRIGGER N.O.
  • Page 94 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 95: Hydraulics

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

  • Page 96: Cylinder Checking Procedure

    SECTION 4 - HYDRAULICS CYLINDER CHECKING PROCEDURE LIFT PRESSURE SETTING PROCEDURE NOTE: Cylinder check must be performed anytime a system component is replaced or when improper system operation is suspected. Cylinders Without Counterbalance Valves and Steer Cylinder Using all applicable safety precautions, activate pump motor and fully extend cylinder to be checked.

  • Page 97: Hydraulic Oil Fill

    SECTION 4 - HYDRAULICS HYDRAULIC OIL FILL Table 4-1. Pressure Settings NOTE: The hydraulic oil level should be checked every 6 Lift Relief months. Always check the oil level any time any Model Steer Relief maintenance is performed that would effect the USA Built China Built hydraulic oil level.

  • Page 98: Slide Block Lubrication

    SECTION 4 - HYDRAULICS NOTE: Care should be taken not to introduce any impurities Apply a layer of grease along the inside and top of (dirt, water etc.) while plug is removed. the upper slide channel (2) on both sides of the machine.

  • Page 99: Lift Cylinder Removal

    SECTION 4 - HYDRAULICS LIFT CYLINDER REMOVAL NOTE: If there is a pump failure, a crane or a forktruck can be used to raise the platform. Refer to Figure 3-47., Arms and Platform Positioning and Support. Self locking fasteners, such as nylon insert and thread deforming locknuts, are not intended to be reinstalled after removal.
  • Page 100 SECTION 4 - HYDRAULICS 1. Battery Cables 3. Manual Descent 5. Top Cylinder Bolt (Torque 41 ft. lbs.) 2. Valves 4. Steer Hoses 6. Bottom Cylinder Bolt Figure 4-2. LIft Cylinder Removal 31215074...
  • Page 101 SECTION 4 - HYDRAULICS CYLINDER REPAIR Being careful not to mark the surface of the rod, use a punch or wooden dowel and hammer to NOTE: The following are general procedures that apply to drive the rod guide about one inch down into the cylinder bore.

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