Oshkosh JLG 1930ES Service Maintenance Manual
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Oshkosh JLG 1930ES Service Maintenance Manual

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Service & Maintenance Manual
Models
1930ES
2032ES
2632ES
2646ES
3246ES
USA Built - S/N-0200239382 to Present
China Built - S/N-B200020297 to Present
Mexico Built - S/N-M200000100 to Present
Belgium Built - S/N-1200025021 to Present
3121656
July 23, 2018 - Rev H

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Summary of Contents for Oshkosh JLG 1930ES

  • Page 1 Service & Maintenance Manual Models 1930ES 2032ES 2632ES 2646ES 3246ES USA Built - S/N-0200239382 to Present China Built - S/N-B200020297 to Present Mexico Built - S/N-M200000100 to Present Belgium Built - S/N-1200025021 to Present 3121656 July 23, 2018 - Rev H...

  • Page 3: Section A. Introduction - Maintenance Safety Precautions

    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 aerial platform. It is of utmost importance that mainte- FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SEC- nance personnel pay strict attention to these warnings TION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR and precautions to avoid possible injury to themselves...
  • Page 4 INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISION LOG Original Issue A - December 11, 2014 Revised B - July 28, 2015 C - March 7, 2016 Revised Revised D - June 22, 2017 Revised E - September 11, 2017 F - October 13, 2017 Revised G - December 18, 2017 Revised...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS General ................. . a Hydraulic System Safety .
  • Page 6 TABLE OF CONTENTS Lubrication and Information ............. . 2-4 Hydraulic System .
  • Page 7 TABLE OF CONTENTS 3.12 Ground Control Station ..............3-37 Box Disassembly .
  • Page 8 TABLE OF CONTENTS SECTION 6 - DIAGNOSTIC TROUBLE CODES Introduction ................6-1 DTC Index.
  • Page 9 TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. TITLE PAGE NO. 1-1. Torque Chart - Sheet 1 of 5 - (SAE Fasteners)..........1-10 1-2.
  • Page 10 TABLE OF CONTENTS 5-1. Diagnostic Port................5-1 5-2.
  • Page 11 TABLE OF CONTENTS LIST OF TABLES TABLE NO. TITLE PAGE NO. Operating Specifications..............1-1 Platform Capacities .
  • Page 12 TABLE OF CONTENTS This page left blank intentionally viii 3121656...

  • Page 13: Section 1. Specifications

    SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS MACHINE SPECIFICATIONS Table 1-1. Operating Specifications Description 1930ES 2032ES 2632ES 2646ES 3246ES Maximum Stowed Travel Grade (Gradeability) Maximum Stowed Travel Grade 5° 5° 5° 5° 5° (Sideslope) Maximum Platform Height 18.8 ft. 20 ft. 25.4 ft.

  • Page 14: Capacities

    SECTION 1 - SPECIFICATIONS Capacities Table 1-2. Platform Capacities NOTE: All platform extension capacities are 250 lbs (120 kg) AUSTRALIAN Model ANSI/CSA CE INDOOR CE OUTDOOR AUSTRALIAN INDOOR OUTDOOR Capacity Persons Capacity Persons Capacity Persons Capacity Persons Capacity Persons 500 lbs 1930ES 230 kg 120 kg...

  • Page 15: Tires

    SECTION 1 - SPECIFICATIONS Tires Table 1-4. Tire Specifications Description 1930ES 2032ES 2632ES 2646ES 3246ES Size 323mm x 100mm 406 mm x 125 mm Max Tire Load 2500 lbs (1134 kg) 4000 lbs (1814 kg) Wheel Bolt Torque 105 - 120 ft lb (142-163 Nm) Batteries Battery Charger/AC Inverter Table 1-5.

  • Page 16: Lift Speed (No Load In Platform)

    SECTION 1 - SPECIFICATIONS Table 1-7. Battery Charger/AC Inverter Specifications Table 1-6. Battery Charger Specifications Xantrex Green Power DESCRIPTION DESCRIPTION 1001093839 1001218595 OUTPUT DC Overload Voltage Limited - Internally Controlled Nominal DC Output Voltage MECHANICAL Maximum DC Output Voltage –40° F to + 185° F Operating Temperature Maximum DC Output Current (–40°...

  • Page 17: Travel Speed

    SECTION 1 - SPECIFICATIONS Travel Speed Table 1-10. 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...

  • Page 18: 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 19: Pressure Settings

    SECTION 1 - SPECIFICATIONS Pressure Settings Table 1-15. Mobil DTE 10 Excel 15 ISO Viscosity Grade Table 1-17. Pressure Settings Density @ 59°F (15°C) 0.8375 kg/l Lift Relief Pour Point, Max -40°F (-54°C) Model Steer Relief Flash Point, Min. 330°F (182°C) USA Built China Built Viscosity...

  • Page 20: 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 21: Cylinder Specifications

    SECTION 1 - SPECIFICATIONS CYLINDER SPECIFICATIONS Table 1-20. 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...

  • Page 22: Torque Charts

    SECTION 1 - SPECIFICATIONS TORQUE CHARTS Figure 1-1. Torque Chart - Sheet 1 of 5 - (SAE Fasteners) 1-10 3121656...
  • Page 23 SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart - Sheet 2 of 5 - (SAE Fasteners) 3121656 1-11...
  • Page 24 SECTION 1 - SPECIFICATIONS Figure 1-3. Torque Chart - Sheet 3 of 5 - (SAE Fasteners) 1-12 3121656...
  • Page 25 SECTION 1 - SPECIFICATIONS Figure 1-4. Torque Chart - Sheet 4 of 5 - (METRIC Fasteners) 3121656 1-13...
  • Page 26 SECTION 1 - SPECIFICATIONS Figure 1-5. Torque Chart - Sheet 5 of 5 - (METRIC Fasteners) 1-14 3121656...

  • Page 27: Section 2 - General

    SECTION 2 - GENERAL SECTION 2. GENERAL ever comes first); out of service for a period of more than MACHINE PREPARATION, INSPECTION, 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 28: 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 29: Component Disassembly And Reassembly

    SECTION 2 - GENERAL Component Disassembly and Reassembly having the same specifications of the original, or one which is equivalent. When disassembling or reassembling a component, 3. Unless specific torque requirements are given complete the procedural steps in sequence. Do not par- within the text, standard torque values should be tially disassemble or assemble one part, then start on used on heat-treated bolts, studs, and steel nuts, in...

  • Page 30: Lubrication And Information

    SECTION 2 - GENERAL LUBRICATION AND INFORMATION Changing Hydraulic Oil 1. 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 1. The primary enemy of a hydraulic system is con- must be changed annually unless operating in tamination.

  • Page 31: 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. 1. Pinned joints should be disassembled and Platform Drift inspected if the following occurs: Measure the drift of the platform to the ground.

  • Page 32: Preventive Maintenance And Inspection Schedule

    SECTION 2 - GENERAL PREVENTIVE MAINTENANCE AND The inspection and maintenance code numbers are as follows: INSPECTION SCHEDULE 1. Check for proper and secure installation. The preventive maintenance and inspection checks are 2. Check for visible damage and legibility. listed and defined in the following table. This table is divided into two basic parts, the “AREA”...

  • Page 33: Footnotes

    SECTION 2 - GENERAL Table 2-3. 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 34 SECTION 2 - GENERAL NOTES: 3121656...

  • Page 35: Section 3 - Chassis & Scissor Arms

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

  • Page 36: Drive Motor Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS DRIVE MOTOR ELECTRICAL EVALUATION Common Traction System Difficulties Several basic electrical tests can be performed on the 1. Short-Circuit Motor Armature 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 37: Power Module Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS investigate using resistance measurement (refer to the Power Module during this analysis. Wait 60 seconds 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).

  • Page 38: 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 39: Brakes - Manual Disengage Procedure

    SECTION 3 - CHASSIS & SCISSOR ARMS Brakes - Manual Disengage Procedure 1. Brake Cover 3. Disengage Holes 2. Cover Bolts Figure 3-2. Disengage Procedure 1. Chock wheels or secure machine with tow vehicle. CAUTION 2. Ensure battery disconnect switch is in to the "OFF" AFTER THE MACHINE IS TOWED, THE DISENGAGE BOLTS MUST position.

  • Page 40: Drive Motor Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS Drive Motor Removal 1. Drive Motor 3. Washers 2. Motor Mounting Bolts 4. Motor Cable Figure 3-3. Motor Removal 3. Remove the two motor mounting bolts and wash- CAUTION ers. ENSURE THE BATTERY DISCONNECT SWITCH IS IN THE OFF 4.

  • Page 41: Main Gearbox Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Main Gearbox Disassembly 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. Cover 11. Hub Sub-Assembly 4.

  • Page 42: Input Carrier Disassembly

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

  • Page 43: Hub Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Disassembly 1. Seal 2. Hub 3. Main Bearing Figure 3-6. Hub Disassembly 1. Remove main wheel bearing. 2. 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.

  • Page 44: Spindle Disassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Disassembly 1. Spindle Sub-Assembly 5. Thrust Washer 9. O-Ring 2. Main Bushing 6. Output Planet Gear 10. Shaft Seal 3. Shaft Ball Bearing 7. Output Planet Pins 11. Snap Ring 4. Tanged Washer 8.

  • Page 45: Spindle Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Spindle Sub-Assembly 7. Place tanged thrust washer into each planet “win- dow” of the spindle. Make sure the tang sits in the 1. 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 46: Hub Sub-Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS Hub Sub-Assembly 1. Seal 2. Hub 3. Main Bearing Figure 3-8. Hub Disassembly 1. Put hub on a table with the tapped holes facing 3. Flip the hub over. down. 4. Using an appropriate pressing tool, press the main 2.

  • Page 47: Input Carrier Sub-Assembly

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

  • Page 48: Main Gearbox Assembly

    SECTION 3 - CHASSIS & SCISSOR ARMS 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. Cover 11. Hub Sub-Assembly 4.
  • Page 49 SECTION 3 - CHASSIS & SCISSOR ARMS 6. 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 counter bore of assembly.

  • Page 50: 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 1. Insert the drive motor into the back of the gear- 3. Connect the end of the Motor Cable to the Power box.

  • Page 51: 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 52: Drive Motor Cable Routing

    SECTION 3 - CHASSIS & SCISSOR ARMS DRIVE MOTOR CABLE ROUTING 4. 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 53: 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. 1. 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 54: 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 55: Servicing Guidelines

    SECTION 3 - CHASSIS & SCISSOR ARMS NOTE: Reference Figure 3-15., Drive Motor Components for b. Armature terminals and the case of the motor. part names and locations when servicing the Drive c. Field connector pins to the armature terminals. Motor.

  • Page 56: Drive Motor Reassembly

    SECTION 3 - CHASSIS & SCISSOR ARMS the Frame & Field Assembly (2) using clean, oil free, feel good, the bearing races could be “brinelled” compressed air. (races or balls deformed) and may exhibit noise and vibration problems or fail within a relatively 2.
  • Page 57 SECTION 3 - CHASSIS & SCISSOR ARMS commutator end head. Secure brake assembly to 8. Remove manual release screws from brake assem- commutator end head using three bolts. bly. Apply new Gasket (12) and affix brake cover to motor using the 2 manual release screws. 7.

  • Page 58: Power Module - Zapi

    SECTION 3 - CHASSIS & SCISSOR ARMS POWER MODULE - ZAPI MACHINE FRONT ZAPI POWER MODULE Figure 3-18. ZAPI Power Module Location 1. Turn machine power off and disconnect the bat- teries. Table 3-1. ZAPI Power Module Specs 2. Locate and remove the power module protective Operating Voltage ( B+) 14.5 to 40 VDC cover from the machine.

  • Page 59: Zapi Power Module Electrical Evaluation

    SECTION 3 - CHASSIS & SCISSOR ARMS ZAPI Power Module Electrical Evaluation "HEALTH" INTEGRATED HEALTH INDICATOR (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 60: Mdi (Multifunction Digital Indicator) And Brake Release

    SECTION 3 - CHASSIS & SCISSOR ARMS MDI (MULTIFUNCTION DIGITAL INDICATOR) Brake Release Button on the backside of the mounting bracket. AND BRAKE RELEASE NOTE: The brake release plugs have no polarity, therefore, can be connected to either post on the button. 4.
  • Page 61 SECTION 3 - CHASSIS & SCISSOR ARMS NOTICE ENSURE EMS BUTTONS ON THE CONTROL STATIONS ARE PUSHED IN TO THE OFF POSITION BEFORE DISCONNECTING THE MDI AND BRAKE RELEASE BRACKET. 1. Remove the two Screws (2) and Washers (3). 2. Disconnect Brake Release and MDI from the elec- trical harnesses.

  • Page 62: Battery Removal

    SECTION 3 - CHASSIS & SCISSOR ARMS BATTERY REMOVAL 4. Adjust the lifting device to take the weight of the battery door and remove door from under the machine. NOTICE 5. 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 63: Battery Maintenance And Safety Practices

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

  • Page 64: Battery Charger Maintenance

    SECTION 3 - CHASSIS & SCISSOR ARMS 5. 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. 6.
  • Page 65 SECTION 3 - CHASSIS & SCISSOR ARMS [2 Flashes] - Low Battery Voltage 4. Try the charger on a good battery. 5. If this fault occurs, the battery is likely in poor con- 1. Indicates either a battery failure, no battery con- dition.
  • Page 66 SECTION 3 - CHASSIS & SCISSOR ARMS Excessive Battery Watering Requirements or Strong 2. 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 67: Battery Charger/Inverter (Option)

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.10 BATTERY CHARGER/INVERTER (OPTION) Battery Charger/Inverter Troubleshooting The Battery Charger/Inverter is located on the top of The Fault LED Flash Codes are the same as the Battery the chassis at the rear of the machine. Raise and secure Charger (see Battery Charger Troubleshooting on pages scissor arms with arm prop to gain access to the charger.
  • Page 68 SECTION 3 - CHASSIS & SCISSOR ARMS 2. Disconnect Inverter/Charger control cable at the 6 Ground Module powered while key is off or similar position connector and the chassis harness at the behavior: 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 69: Limit Switch Locations

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.11 LIMIT SWITCH LOCATIONS 5. Pothole Switch (Typical on opposite side of machine) 6. Rotary Angle Switch Figure 3-26. Limit Switch Locations 3121656 3-35...

  • Page 70: Pothole Switch Replacement

    SECTION 3 - CHASSIS & SCISSOR ARMS Pothole Switch Replacement Rotary Angle Sensor Replacement Removal: 1. Lower platform to the stowed position. 2. Disable the machine and disconnect the batteries. 3. Remove the screws securing the sensor cover to the frame and remove the sensor cover. 4.

  • Page 71: Ground Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.12 GROUND CONTROL STATION NOTE: Anytime the ground control box is removed, the tilt sensor must be re-calibrated. Refer to Section 5.3, Tilt Sensor Calibration to re calibrate the tilt. Box Disassembly 5. Remove the six bolts at the back of the ground control and separate.

  • Page 72: Tilt Sensor Replacement

    SECTION 3 - CHASSIS & SCISSOR ARMS Tilt Sensor Replacement 1. Ground Control Station 2. Tilt Sensor (JLG P/N 4000021 or 1001114936) Figure 3-45. Tilt Sensor Location Tilt Sensor Removal: 1. Disconnect the batteries. 1. Tilt Sensor 2. Open the Ground Control Station to gain access to 2.

  • Page 73: Scissor Arms And Platform Positioning And Support

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.13 SCISSOR ARMS AND PLATFORM POSITIONING BEFORE INSERTING BOLTS INTO PIN. NOT APPLICABLE FOR MACHINES WITHOUT LSS. 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 3-47.).
  • Page 74 SECTION 3 - CHASSIS & SCISSOR ARMS Figure 3-47. Arms and Platform Positioning and Support 3-40 3121656...
  • Page 75 SECTION 3 - CHASSIS & SCISSOR ARMS For serial numbers - SN B200020297 For serial numbers - SN 0200241221 to Present, through B200020981 and SN M200000100 to Present and SN 0200239382 through SN B200020982 to Present 0200241220 MAF02560 Figure 3-48. Scissors Arms Assembly (2646ES and 3246ES) 3121656 3-41...

  • Page 76: Platform Control Station

    SECTION 3 - CHASSIS & SCISSOR ARMS 3.16 PLATFORM CONTROL STATION 4. Loosen and remove the four bolts that hold the bottom of the control box. Printed Circuit Board Replacement 5. Disconnect the plug from the printed circuit board. 1. Disconnect the platform control box and remove 6.

  • Page 77: Joystick Controller

    SECTION 3 - CHASSIS & SCISSOR ARMS Joystick Controller Figure 3-49. Joystick Table 3-4. Joystick Specifications Table 3-5. Connector Chart Input Voltage +5 (±0.1) VDC CONNECTOR PINOUT Current Consumption 10 mA @ 12 VDC Term Color Function HANDLE COM Output: Handle Centered 2.5 (±0.1) VDC VIOLET TRIGGER N.O.
  • Page 78 SECTION 3 - CHASSIS & SCISSOR ARMS NOTES: 3-44 3121656...

  • Page 79: Section 4 - Hydraulics

    SECTION 4 - HYDRAULICS SECTION 4. HYDRAULICS CYLINDERS - THEORY OF OPERATION thus preventing rupture of the cylinder, hydraulic line or fitting. Complete failure of the system pump is also Cylinders are of the double acting type. The Lift and avoided by relieving circuit pressure.

  • Page 80: Pump/Motor - Theory Of Operation

    SECTION 4 - HYDRAULICS 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 3-24) is essentially a "low-side" switch Pump Motor.
  • Page 81 SECTION 4 - HYDRAULICS 1. 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 4.

  • Page 82: 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 1. Using all applicable safety precautions, activate pump motor and fully extend cylinder to be checked.

  • Page 83: Hydraulic Oil Fill

    SECTION 4 - HYDRAULICS Oil Check Procedure Table 4-1. Pressure Settings 1. With the scissor lift on a flat and level surface and Lift Relief the platform empty, elevate machine and swing Model Steer Relief safety prop out of it’s stowed position. USA Built China Built 2.

  • Page 84: Slide Block Lubrication

    SECTION 4 - HYDRAULICS Slide Block Lubrication LIFT CYLINDER REMOVAL NOTE: If there is a pump failure, a crane or a forktruck can Lube - White Lithium Grease (GREDAG 741) be used to raise the platform. Refer to Figure 3-47., Interval - Every 6 months Arms and Platform Positioning and Support.
  • Page 85 SECTION 4 - HYDRAULICS 1. Battery Cables 3. Manual Descent 5. Top Cylinder Bolt (Torque 41 ft. lb.) 2. Valves 4. Steer Hoses 6. Bottom Cylinder Bolt Figure 4-2. LIft Cylinder Removal 3121656...

  • Page 86: Cylinder Repair

    SECTION 4 - HYDRAULICS CYLINDER REPAIR 7. Being careful not to mar the surface of the rod, use a punch or wooden dowel and hammer to drive the rod guide about one inch down into the cylin- NOTE: The following are general procedures that apply to der bore.

  • Page 87: Steer Cylinder Piston Removal

    SECTION 4 - HYDRAULICS 15. Remove and discard the piston o-rings, seal rings, 9. Inspect cylinder head inside diameter for scoring and backup rings. or other damage and for ovality and tapering. Replace as necessary. 16. If applicable, remove the piston spacer from the rod.

  • Page 88: Assembly

    SECTION 4 - HYDRAULICS Assembly NOTE: Prior to cylinder assembly, ensure that the proper cyl- inder seal kit is used. See your JLG Parts Manual (3121167). Apply a light film of hydraulic oil to all components prior to assembly. 1. A special tool is used to install a new rod seal into the applicable cylinder head gland groove.

  • Page 89: Cylinder Piston Nut Torque Specifications

    SECTION 4 - HYDRAULICS 7. Retorque the capscrews evenly and progressively in rotation to the specified torque value. 8. Remove the cylinder rod from the holding fixture. 9. Place new guide locks and seals in the applicable outside diameter grooves of the cylinder piston. (See Figure 4-10.) 10.
  • Page 90 SECTION 4 - HYDRAULICS 16. Push the piston onto the rod until it abuts the NOTE: Reverse the procedure Steer Cylinder Piston Removal spacer end and install the attaching nut. on page 4-9 for installing the steer cylinder piston. 17. Remove the cylinder rod from the holding fixture. Table 4-3.

  • Page 91: Pump Removal

    SECTION 4 - HYDRAULICS Pump Removal 3. If replacing filter, pull old filter off the end of the tube and push new filter onto the end of tube. 4. Thoroughly clean the tank and clean any debris from the magnet. 5.
  • Page 92 SECTION 4 - HYDRAULICS 11. Remove allen nut on the return/filter line and rotate large retainer ring to remove return/filter NOTE: Be sure to remove and discard the plastic plug at the line. oil inlet on the new pump before installing. 12.

  • Page 93: Motor Removal

    SECTION 4 - HYDRAULICS Motor Removal 2. Pull motor from valve body. 3. Once all maintenance is performed and lift cylin- der assembly is reinstalled on the machine, 1. Remove the four bolts attaching the motor to the remove fill plug and refill tank with proper grade valve body.

  • Page 94: Valve Torque Values

    SECTION 4 - HYDRAULICS T O P V IE W Figure 4-12. Lift Cylinder/Pump/Tank Assembly Table 4-4. Valve Torque Values Item Description Torque Bi-directional Relief Valve 33 ft lbs (45 Nm) Solenoid Proportional Valve 15 ft lbs (20 Nm) Check Valve 33 ft lbs (45 Nm) Blocking Valve 15 ft lbs (20 Nm)
  • Page 95 SECTION 4 - HYDRAULICS 1930ES ONLY OPPOSITE SIDE OF CYLINDER PORT BLOCK 1. Proportional Valve 7. Spring 13. Locknut 19. Wear Ring 25. Check Valve 2. Emergency Release Assy. 8. Jam Nut 14. Piston 20. Spacer 26. Dowel Pin 3. Coil 9.
  • Page 96 SECTION 4 - HYDRAULICS MAF02570 1. Barrel 5. Seal 9. Piston 13. Nut 16. Capscrew 2. Rod 6. Bearing 10. Seal 14. Bushing 17. Capscrew 3. Cylinder Head 7. O-Ring 11. Wear Ring 15. Motor/Pump/Tank 18. Extension Plug 4. Dust Seal 8.
  • Page 97 SECTION 4 - HYDRAULICS MAF02580 1. Barrel 3. Rod 5. Piston 7. Motor/Pump/Tank Assembly 2. Seal Kit 4. Cylinder Head 6. Screw 8. Bushing Lift Cylinder Assembly (1930ES) (Serta) Figure 4-15. 3121656 4-19...
  • Page 98 SECTION 4 - HYDRAULICS 1***** 5***** 4***** 7****** *Torque to 33.2-36.9 ft. lbs. (45-50 Nm) **Torque to 29.5-35.4 ft. lbs. (40-48 Nm) ***Torque to 28-33.2 ft. lbs. (38-45 Nm) ****Torque to 26.6-32.5 ft. lbs. (36-44 Nm) *****Torque to 11.8-14.8 ft. lbs. (16-20 Nm) ******Torque to 2.2-3 ft.

  • Page 99: Section 5 - Jlg Control System

    SECTION 5 - JLG CONTROL SYSTEM SECTION 5. JLG CONTROL SYSTEM DIAGNOSTIC PORT HAND HELD ANALYZER The diagnostic port is located behind the battery cover To Connect the Hand Held Analyzer: at the near the ground control station as shown below. The MDI (Multifunction Digital Indicator) and the JLG 1.

  • Page 100: Using The Analyzer

    SECTION 5 - JLG CONTROL SYSTEM Using the Analyzer: If ENTER is pressed again, the display moves to the fol- With the machine power on and the analyzer connected lowing display: properly, the analyzer will display the following: l og: ( 211) HELP: 1:STARTUP ( 2/ 1)

  • Page 101: 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 con- M ENU: figuration settings which cannot be changed until you AC C ESS LEVEL 1 enter a password to advance to a lower level.

  • Page 102: 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 personal- ity item is selected, press the UP or DOWN arrow keys to adjust its value, for example: FAILURE TO MAKE THE PROPER SETTINGS FOR THE PARTICU-...

  • Page 103: Tilt Sensor Calibration

    SECTION 5 - JLG CONTROL SYSTEM TILT SENSOR CALIBRATION Be sure that the machine is parked and stowed on level CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PER- ground. FORMANCE OF YOUR MACHINE. NOTE: Tilt Sensor Calibration can not be performed if the main contactor switch is open due to an alarm.

  • Page 104: Tilt Sensor Electrical Evaluation

    SECTION 5 - JLG CONTROL SYSTEM For the following troubleshooting steps, a bubble level TILT SENSOR ELECTRICAL EVALUATION (smaller is better) will be needed and the machine must This basic check using the JLG Analyzer can be used to be on a level surface: test the Tilt Sensor.

  • Page 105: Tilt Vs. Allowed Height Evaluation

    SECTION 5 - JLG CONTROL SYSTEM Tilt vs. Allowed Height Evaluation Table 5-1. Tilt Settings First, find a level surface (not just flat like a parking lot; Tilt Setting Tilt Setting Maximum Deck Model must be level). The surface should be a plane in which (front to back) (side to side) Elevation...

  • Page 106: Elevation Sensor Calibration

    SECTION 5 - JLG CONTROL SYSTEM ELEVATION SENSOR CALIBRATION UPDATING SOFTWARE Updating the ground module software requires a laptop NOTICE computer, connecting cable, and software update cd. MACHINE MUST BE ON LEVEL GROUND BEFORE ELEVATION SEN- Contact JLG Industries to acquire the software cd. SOR CAN BE SET.

  • Page 107: Troubleshooting

    SECTION 5 - JLG CONTROL SYSTEM TROUBLESHOOTING NOTE: It may also be helpful to do the following for inter- mittent or difficult problems: run a system test, ANA- It should be noted that there is no substitute for a thor- LYZER ->...
  • Page 108 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code While stowed, drive speed is reduced (due to lower ground clearance) since the control system detected that the pot-hole Clear the obstacle blocking the protection mechanism is deployed (failed to retraced).
  • Page 109 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The Drive - Lift selector switch indicates that both functions are selected simultaneously. In Platform Mode, the Drive and Lift Digital Inputs are Ener- Repair the wiring or switch to FUNCTION PROBLEM -- DRIVE &...
  • Page 110 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code Help messages with the 2-3 flash code indicate difficulty with the ground controls. Lift switch (up or down) in the ground control box was closed during power-up.
  • Page 111 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The Elevation Sensor’s Calibration EEPROM is set to the signa- ture implanted by the In-Circuit Test Fixture. Retained until Calibration EEPROM is over-written by a valid calibration. Platform Height assumed to be Full Elevation.
  • Page 112 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The Elevation Proximity Switch is closed to indicate that the platform is stowed, but the elevation sensor’s voltage indicates that the platform is elevated. To be conservative, the control ELEV PROX PERMANENTLY CLOSED –...
  • Page 113 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The Power Module’s Line Contactor Drive Circuitry failed to de- energize during power-up self-tests. Refer to CANbus documentation The Power Module is reporting a “Contactor Driver 1 Perma- CONTACTOR DRIVER PERMANENTLY ON for Power Module Message - nently On”...
  • Page 114 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code Current flow to the steer left solenoid was not detected during power-up. STEER LEFT OPEN CIRCUIT Left Turn INPUT driven High (momentarily) AND Left Turn STAT detected Low during power-up.
  • Page 115 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code Check for continuity through The ground board did not detect current flow to the right brake this circuit. Inspect the wiring RIGHT BRAKE OPEN CIRCUIT during normal operation.
  • Page 116 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code Help messages with the 6-6 flash code indicate vehicle communication (CANbus) problems. These faults shall not be latched. Normal operation shall resume if difficulty is resolved. The control system failed to receive messages from the Power Module.
  • Page 117 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code Cell #2’s Bridge <2Vdc, >3Vdc, or could the LSS Module could not read Cell #2’s Internal Memory. This situation indicates that the 8-2 Flash Code LSS CELL #2 ERROR sensor is unplugged, or the sen-...
  • Page 118 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The Excitation Voltage for the Load Sensors < 4.25V. 9-9 Flash Code The sensors may be excessively LSS Module Message – Status Message (0x81) is reporting loading the Excitation Supply LSS INTERNAL ERROR –...
  • Page 119 SECTION 5 - JLG CONTROL SYSTEM Table 5-2. Flash Code Listing Flash Help Message Cause Possible Resolve Code The control system has not been configured for the first time. Use the JLG Analyzer to adjust all 9-9 Flash Code FUNCTIONS LOCKED OUT – MACHINE NOT CONFIGURED Machine Setup and Personality The control system’s EEPROM flag indicates that the vehicle has settings and re-cycle power to...
  • Page 120 SECTION 5 - JLG CONTROL SYSTEM Analyzer Flow Chart 5-22 3121656...
  • Page 121 SECTION 5 - JLG CONTROL SYSTEM 3121656 5-23...
  • Page 122 SECTION 5 - JLG CONTROL SYSTEM 5-24 3121656...
  • Page 123 SECTION 5 - JLG CONTROL SYSTEM 3121656 5-25...
  • Page 124 SECTION 5 - JLG CONTROL SYSTEM 5-26 3121656...

  • Page 125: Machine Model Adjustment

    SECTION 5 - JLG CONTROL SYSTEM MACHINE MODEL ADJUSTMENT Table 5-3. Machine Model Adjustment Adjustment Adjustment Range 1930ES 2032ES 2632ES 2646ES 3246ES DRIVE ACCEL 0.1 - 5.0 (Sec) DECEL 0.1 - 1.0 (Sec) MINIMUM 0 - 25% MAXIMUM 0 -100% ELEV.

  • Page 126: Machine Configuration Programming Information

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

  • Page 127: Section 6 - Diagnostic Trouble Codes

    SECTION 6 - DIAGNOSTIC TROUBLE CODES SECTION 6. DIAGNOSTIC TROUBLE CODES 6.1 INTRODUCTION This section provides a reference for Diagnostic Trouble Codes (DTC) read from the Multifunction Digital Indicator (MDI). This section should only be used for machines equipped with a MDI and SEVCON Power Module-(ground board software version P1.13 or higher) or ZAPI Power Module-(ground board software version P1.0 or higher).
  • Page 128 SECTION 6 - DIAGNOSTIC TROUBLE CODES 2511 ELEV ANGLE SENSOR FAULTY - NOT MOUNTED ............................6-10 2512 ELEV ANGLE SENSOR NOT DETECTING CHANGE .............................6-10 311 OPEN CIRCUIT LINE CONTACTOR ..................................6-11 312 CONTACTOR DRIVER PERMANENTLY OFF ..............................6-11 321 LINE CONTACTOR MISWIRED ON OR WELDED ............................6-11 322 CONTACTOR DRIVER PERMANENTLY ON ................................6-11...
  • Page 129 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9911 FUNCTION LOCKED OUT - LSS MODULE SOFTWARE VERSION IMPROPER ................6-22 9912 POWER MODULE FAILURE - SYSTEM MONITOR ............................6-22 9924 FUNCTIONS LOCKED OUT - MACHINE NOT CONFIGURED ......................... 6-22 3121656...

  • Page 130: Dtc Check Tables

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 6.3 DTC CHECK TABLES 0-0 Help Comments FAULT MESSAGE DESCRIPTION CHECK Error (Displayed on MDI) The MDI is powered, but cannot • Check the MDI connector. communicate with the control • Check the diagnostic connector. system.

  • Page 131: Drive & Lift Up Prevented - Tilted & Elevated

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 0-0 Help Comments FAULT MESSAGE DESCRIPTION CHECK 005 DRIVE & LIFT UP PRE- Driving is not possible since the • Check that the machine is tilted. If so, lower the plat- VENTED - TILTED & ELE- platform is elevated and the form and reposition the machine to a level surface.

  • Page 132: Power-Up

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 0-0 Help Comments FAULT MESSAGE DESCRIPTION CHECK 009 DRIVE PREVENTED - ELE- The platform is elevated above • Check that the elevation angle sensor is securely VATED ABOVE DRIVE the calibrated cutout height. mounted. CUTOUT HEIGHT •...

  • Page 133: Function Problem - Steer Left Permanently Selected

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-2 Platform Controls FAULT MESSAGE DESCRIPTION CHECK 224 FUNCTION PROBLEM - The steer left switch was closed • Check if the steer left switch is obstructed or jammed. STEER LEFT PERMA- during power-up in platform •...

  • Page 134: Ground Controls

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-2 Platform Controls FAULT MESSAGE DESCRIPTION CHECK 2210 TRIGGER CLOSED TOO The trigger switch was closed for • Check if the trigger switch is obstructed or jammed. LONG WHILE IN NEU- more than five seconds while •...

  • Page 135: Function Prevented

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-5 Function Prevented FAULT MESSAGE DESCRIPTION CHECK 251 ELEV ANGLE SENSOR The elevation angle sensor • Check that the platform elevation sensor is securely FAULTY - VOLTAGE OUT input voltage is outside the mounted and undamaged. OF RANGE acceptable range of 0.10V - •...

  • Page 136: Drive Prevented - Pothole Not Engaged

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 2-5 Function Prevented FAULT MESSAGE DESCRIPTION CHECK 256 DRIVE PREVENTED - Driving is not possible while ele- • Check for obstructions or mechanical problems POTHOLE NOT vated since the pot-hole protec- around the pot-hole protection mechanisms. ENGAGED tion system failed to deploy.

  • Page 137: Line Contactor Open Circuit

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-1 Line Contactor Open Circuit FAULT MESSAGE DESCRIPTION CHECK 311 OPEN CIRCUIT LINE The power modules line contac- • Check contactor main contact wiring to battery (+) CONTACTOR tor did not close when ener- terminal and power controller terminal B+.

  • Page 138: Ground Output Driver

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver FAULT MESSAGE DESCRIPTION CHECK 331 BRAKE SHORT TO BAT- The ground board detected • Ensure ANALYZER -> MACHINE SETUP -> ELEV PROX is TERY voltage while the brake sole- set to NOT INSTALLED. noid was commanded off.

  • Page 139: Steer Right Short To Battery

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver FAULT MESSAGE DESCRIPTION CHECK 339 STEER RIGHT SHORT TO The ground board detected • Check for continuity through this circuit. Steer right BATTERY voltage while the steer right solenoid resistance should measure about 30 Ohms. solenoid was commanded off.
  • Page 140 SECTION 6 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver FAULT MESSAGE DESCRIPTION CHECK 33298 STEER LEFT VALVE - Drive, Steer and Lift Up Pre- • Excessive current flow to the steer left solenoid SHORT TO GROUND vented detected (J2-9 NLV). •...

  • Page 141: Thermal Limit (Soa)

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 4-2 Thermal Limit (SOA) FAULT MESSAGE DESCRIPTION CHECK 421 POWER MODULE TOO The power module has reached • Power down and allow to cool. HOT - PLEASE WAIT thermal cutout. • Do not operate in ambients over 140° F (60° C). •...

  • Page 142: Communication

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 4-4 Battery Supply FAULT MESSAGE DESCRIPTION CHECK 4422 LOGIC SUPPLY VOLTAGE The system module logic supply • This may be caused by a loose battery terminal, OUT OF RANGE voltage was measured by the severely discharged batteries, damaged battery, or an power PCB to be less than 11V improper wire harness connection.
  • Page 143 SECTION 6 - DIAGNOSTIC TROUBLE CODES 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK 662 CANBUS FAILURE - PLAT- In platform mode, the control • Turn on machine in ground mode. If DTC 661 is not FORM MODULE system failed to receive mes- present check for 24V between platform box connec- sages from the platform board.

  • Page 144: Accessory

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 6-6 Communication FAULT MESSAGE DESCRIPTION CHECK CANBUS FAILURE - PLAT- In platform mode, the control • Disconnect platform box connector. Open platform (Cont. FORM MODULE system failed to receive mes- box. Disconnect platform board connector. Platform (Continued) sages from the platform board.
  • Page 145 SECTION 6 - DIAGNOSTIC TROUBLE CODES 7-7 Electric Motor FAULT MESSAGE DESCRIPTION CHECK 773 CAPACITOR BANK Drive, Steer, and Lift Prevented • There is an internal or external fault that prevents the FAULT - CHECK POWER System Module’s capacitor bank from charging. CIRCUITS •...

  • Page 146: Tilt Sensor

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 7-7 Electric Motor FAULT MESSAGE DESCRIPTION CHECK 7710 PUMP P HIGH - CHECK Drive, Steer, and Lift Prevented • While steering or lifting up, the voltage measured at POWER CIRCUITS the System Module’s P terminal did not agree with the predicted value for at least 240mS.

  • Page 147: Hardware

    SECTION 6 - DIAGNOSTIC TROUBLE CODES 8-2 Platform Load Sense FAULT MESSAGE DESCRIPTION CHECK 824 LSS CELL #4 ERROR A problem has been detected • Refer to Section 2.3: Troubleshooting in the LSS man- with the load sense system. ual, 3124288. 825 LSS HAS NOT BEEN CAL- The load sensing system mod- •...
  • Page 148 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK 9911 FUNCTION LOCKED The load sensing system mod- • Replace LSS module to clear fault. OUT - LSS MODULE ule software version is not com- SOFTWARE VERSION patible with the rest of the IMPROPER system.
  • Page 149 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK 9956 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module’s field current control or MOS- URE - INTERNAL ERROR FET’s are malfunctioning. • Cycle machine, if error still exists, replace System Module.
  • Page 150 SECTION 6 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware FAULT MESSAGE DESCRIPTION CHECK 9970 POWER MODULE FAIL- Drive, Steer, & Lift Prevented • The System Module detected a mismatch in the URE - INTERNAL ERROR redundant RAM information stored in the interface PCB.

  • Page 151: Section 7 - General Electrical Information & Schematics

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 7. GENERAL ELECTRICAL INFORMATION & SCHEMATICS GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
  • Page 152 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 • First test meter and leads by touching leads range (See multimeter’s operation manual) together.
  • Page 153 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 • Set up the meter for the expected current range enable audible continuity testing •...

  • Page 154: 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 condi- tion of a particular wire in the harness.

  • Page 155: Applying Silicone Dielectric Compound To Amp Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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 156: 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 follows: Figure 7-6. Connector Assembly (1 of 4) 1.

  • Page 157: 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 (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6.

  • Page 158: 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 159: Service - Voltage Reading

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Service - Voltage Reading CAUTION 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 sys- tem.

  • Page 160: Working With Deutsch Connectors

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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.

  • Page 161: Hd30/Hdp20 Series Disassembly

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 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. HD/HDP Contact Removal 11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed. 12.

  • Page 162: Switches

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SWITCHES Basic check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected.

  • Page 163: 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.

  • Page 164: Electrical Schematics And Layouts

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ELECTRICAL SCHEMATICS AND LAYOUTS Figure 7-18. Electrical Schematic 7-14 3121656...
  • Page 165 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001166759_E - Sht. 1 of 4 Figure 7-18., Electrical Schematic 3121656 7-15...
  • Page 166 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18., Electrical Schematic 7-16 3121656...
  • Page 167 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001166759_E - Sht. 2 of 4 Figure 7-18., Electrical Schematic 3121656 7-17...
  • Page 168 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18., Electrical Schematic 7-18 3121656...
  • Page 169 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001166759_E - Sht. 3 of 4 Figure 7-18., Electrical Schematic 3121656 7-19...
  • Page 170 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-18., Electrical Schematic 7-20 3121656...
  • Page 171 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001166759_E - Sht. 4 of 4 Figure 7-18., Electrical Schematic 3121656 7-21...
  • Page 172 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19. Electrical Components Layout 7-22 3121656...
  • Page 173 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-19., Electrical Components Layout 3121656 7-23...

  • Page 174: Hydraulic Schematic

    SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS HYDRAULIC SCHEMATIC Figure 7-20. Hydraulic Schematic - USA Manufactured 7-24 3121656...
  • Page 175 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-20., Hydraulic Schematic - USA Manufactured 3121656 7-25...
  • Page 176 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21. Hydraulic Schematic - China Manufactured 7-26 3121656...
  • Page 177 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 7-21., Hydraulic Schematic - China Manufactured 3121656 7-27...
  • Page 178 SECTION 7 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS NOTES: 7-28 3121656...
  • Page 180 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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