JLG 1932RS Manuals

Manuals and User Guides for JLG 1932RS. We have 1 JLG 1932RS manual available for free PDF download: Service Maintenance Manual

JLG 1932RS Service Maintenance Manual

JLG 1932RS Service Maintenance Manual (150 pages)

Brand: JLG | Category: Scissor Lifts | Size: 7.58 MB

Table of Contents

Hydraulic System Safety
3
- Maintenance
  3
- Table of Contents
  5
Section 1 - Specifications

13
- Specifications
  13
  - Platform Capacities
    13
  - Dimensional Data
    14
  - Tires
    14
  - Batteries
    14
  - Battery Quick-Disconnect - (if Equipped)
    14
  - Electrical System
    15
  - Motors
    15
  - Travel Speed
    15
  - Lift Speed
    15
- Critical Stability Weights
  16
- Lubrication
  16
- Hydraulic Oil
  16
  - Pressure Settings
    16
- Limit Switches
  16
  - Tilt Alarm
    16
  - High Drive Speed Cutout
    17
- Cylinder Specifications
  17
- Major Component Weights
  17
- Torque Requirements
  17
  - Torque Charts
    18
- Torque Chart (SAE Fasteners - Sheet 2 of 7))
  19
- Torque Chart (SAE Fasteners - Sheet 3 of 7)
  20
- Torque Chart (SAE Fasteners - Sheet 4 of 7)
  21
- Torque Chart (METRIC Fasteners - Sheet 5 of 7))
  22
- Torque Chart (METRIC Fasteners - Sheet 6 of 7)
  23
- Torque Chart (METRIC Fasteners - Sheet 7 of 7)
  24
Section 2 - General

25
- Machine Preparation, Inspection, and Maintenance
  25
- Service and Guidelines
  29
  - General
    29
  - Safety and Workmanship
    29
  - Cleanliness
    29
  - Components Removal and Installation
    29
  - Component Disassembly and Reassembly
    29
  - Pressure-Fit Parts
    29
  - Bearings
    29
  - Gaskets
    29
  - Bolt Usage and Torque Application
    29
  - Hydraulic Lines and Electrical Wiring
    30
  - Hydraulic System
    30
  - Lubrication
    30
  - Battery
    30
- Lubrication and Information
  30
  - Hydraulic Oil
    30
  - Changing Hydraulic Oil
    31
  - Lubrication Specifications
    31
- Cylinder Drift Test
  31
  - Platform Drift
    31
  - Cylinder Drift
    31
- Pins and Composite Bearing Repair Guidelines
  32
Section 3 - Chassis & Scissor Arms

33
- Machine Component Covers
  33
- Battery Removal/Maintenance
  34
  - Battery Quick-Disconnect - (if Equipped)
    34
  - Battery Maintenance and Safety Practices
    34
- Battery Charger
  35
- Battery Charging
  36
- DC to AC Inverter (if Equipped)
  39
  - Inverter Location on Machine
    39
  - Inverter Operation
    40
  - Inverter Troubleshooting
    40
  - Inverter Specifications
    40
- Ground Control Station
  41
  - Components Location
    41
  - Removal (All Models)
    41
  - Installation
    41
- Main Power Contactor Relay
  42
- Elevation Limit Switch Assembly
  42
  - Location
    42
  - Installation
    42
  - Switch Adjustment
    43
- LSS - Scissor Arm Angle Sensor - Location
  44
- Tilt Sensor Replacement
  44
- Traction System
  46
  - Theory of Operation
    46
  - Common Traction System Difficulties
    47
- Power Control Module - ZAPI
  48
- Main Electrical Power Connections - (1001129845 - ZAPI Power Module)
  49
  - ZAPI Power Module Electrical Evaluation
    50
  - Drive Motor Servicing
    51
    
    Drive Motor Troubleshooting
    51
    
    Drive Motor Electrical Evaluation
    51
    
    Servicing Guidelines
    51
    
    Brake - Manual Disengage Procedure
    52
    
    Drive Motor Removal
    53
    
    Drive Motor Disassembly
    54
    
    Drive Motor Inspection and Service
    55
    
    Drive Motor Reassembly
    55
- Drive Motor Shaft Bearing
  56
  - Drive Motor Installation
    57
  - Torque Hub Servicing
    58
    
    Roll Test
    58
    
    Leak Test
    58
    
    Oil Check/Fill Procedure
    58
    
    Main Gearbox Disassembly
    59
    
    Input Carrier Disassembly
    60
    
    Hub Disassembly
    61
    
    Spindle Disassembly
    62
    
    Tightening and Torquing Bolts
    63
    
    Assembly Tools
    63
    
    Spindle Assembly
    64
    
    Hub Assembly
    65
    
    Input Carrier Assembly
    66
    
    Main Gearbox Assembly
    67
  - Steer Assembly Components
    70
- RS/10RS - Steer Assembly
  71
- RS/6RS - Scissor Arm Assembly - Pin Configuration
  75
- RS/10RS - Scissor Arm Assembly - Ref. Figure 3-45
  76
- RS/10RS - Scissor Arm Assembly - Pin Configuration
  77
  - Platform Control Station
    78
    
    Installation/Removal
    78
    
    Control Station Harness Installation to Scissor Arms
    78
    
    Control Station Disassembly
    78
    
    Overview of Control Station Components
    79
    
    Joystick Controller
    80
Section a - Introduction - Maintenance Safety Precautions

81
Section 4 - Hydraulics

81
- Cylinders - Theory of Operation
  81
- Valves - Theory of Operation
  81
  - Solenoid Control Valves (Bang-Bang)
    81
  - Relief Valves
    81
  - Crossover Relief Valves
    81
  - Proportional Valve
    81
  - Manual Descent Valve
    81
- Hydraulic System
  81
- Pump/Motor
  82
  - Pump Motor Electrical Evaluation
    82
  - Hydraulic Oil Check Procedure
    83
  - Pump/Tank Disassembly
    84
  - Pump Motor Removal
    84
  - Lubrication
    84
  - Hydraulic Oil
    85
- Lift Pressure Setting Procedure
  86
- Cylinder Checking Procedure
  86
- Lift Cylinder Removal
  87
- Cylinder Repair
  88
  - Disassembly
    88
  - Steer Cylinder Piston Removal
    89
  - Cleaning and Inspection
    89
  - Assembly
    90
- Rod Assembly Installation
  91
  - Lift Cylinder - LSS Pressure Sensor Location (if Equipped)
    92
- RS/6RS - Lift Cylinder
  93
- RS/10RS - Lift Cylinder
  94
- RS/6RS - Steer Cylinder
  95
- RS/10RS - Steer Cylinder
  96
Section 5 - Jlg Control System

97
- Hand Held Analyzer
  97
  - Diagnostic Port
    97
  - To Connect the Hand Held Analyzer
    97
  - Using the Analyzer
    98
  - Changing the Access Level of the Hand Held Analyzer
    99
  - Adjusting Parameters Using the Hand Held Analyzer
    100
  - Machine Setup
    100
  - Joystick Calibration
    101
  - Updating Software
    101
- Machine Model Adjustment
  109
- Machine Configuration Programming Information
  110
- 3121273 - JLG Lift
  111
Section 6 - Diagnostic Trouble Codes

111
- Introduction
  111
  - System Fault/Dtc Indication
    111
- Diagnostic Trouble Codes (DTC)
  111
- X-Connector References
  111
- DTC Index
  112
- DTC Check Tables
  115
Section 7 - General Electrical Information & Schematics

127
- General
  127
- Multimeter Basics
  127
  - Grounding
    127
  - Backprobing
    127
  - Min/Max
    127
  - Polarity
    127
  - Scale
    127
- Voltage Measurement (DC)
  128
- Continuity Measurement
  129
  - Continuity Measurement over Long Distances
    130
  - Requirements
    130
  - Procedure
    130
  - Applying Silicone Dielectric Compound to Amp Connectors
    131
    
    Assembly
    132
    
    Disassembly
    133
    
    Wedge Lock
    134
    
    Service - Voltage Reading
    135
  - Working with Deutsch Connectors
    136
    
    DT/DTP Series Assembly
    136
    
    DT/DTP Series Disassembly
    136
    
    HD30/HDP20 Series Assembly
    136
    
    HD30/HDP20 Series Disassembly
    137
  - Switches
    138
    
    Basic Check
    138
    
    Limit Switches
    138
    
    Automatic Switches
    139
    
    Switch Wiring - Low Side, High Side
    139
  - Circuit Boards: Inputs and Outputs
    140
  - Power Module - J2 Connector Pin Function
    141
  - Electrical Schematics and Layouts
    142
- Electrical Components Layout - Sheet 1 of 2
  146
- Hydraulic Schematic
  148

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