JLG 2039ES Manuals

Manuals and User Guides for JLG 2039ES. We have 1 JLG 2039ES manual available for free PDF download: Service Maintenance Manual

JLG 2039ES Service Maintenance Manual

JLG 2039ES Service Maintenance Manual (212 pages)

Brand: JLG | Category: Lifting Systems | Size: 12 MB

Table of Contents

Table of Contents

5
- Hydraulic System Safety
  3
- Maintenance
  3
  - Table of Contents
    5
- Section 1 - Specifications
  
  13
  - Specifications
    13
    
    Capacities
    14
    
    Fluid Capacities
    14
    
    Batteries
    15
    
    Battery Charger
    15
    
    Motors
    15
    
    Tires
    15
    
    Lift Speed (no Load in Platform)
    16
    
    Travel Speed
    16
    
    Model Dimensions
    17
  - Torque Requirements
    18
  - Lubrication
    18
    
    Hydraulic Oil
    18
  - Limit Switches
    19
    
    High Drive Speed Cutout
    19
    
    Pressure Settings
    19
    
    Tilt Alarm
    19
  - Cylinder Specifications
    20
  - Major Component Weights
    20
  - Critical Stability Weights
    20
  - Torque Charts
    21
  - Torque Chart (SAE Fasteners - Sheet 2 of 7))
    22
  - Torque Chart (SAE Fasteners - Sheet 3 of 7)
    23
  - Torque Chart (SAE Fasteners - Sheet 4 of 7)
    24
  - Torque Chart (METRIC Fasteners - Sheet 5 of 7))
    25
  - Torque Chart (METRIC Fasteners - Sheet 6 of 7)
    26
  - Torque Chart (METRIC Fasteners - Sheet 7 of 7)
    27
- Section 2. General
  
  29
  - Machine Preparation, Inspection, and Maintenance
    29
    
    Annual Machine Inspection
    29
    
    General
    29
    
    Pre-Delivery Inspection and Frequent Inspection
    29
    
    Pre-Start Inspection
    29
    
    Preparation, Inspection, and Maintenance
    29
    
    Preventative Maintenance
    29
  - Service and Guidelines
    30
    
    Cleanliness
    30
    
    Component Disassembly and Reassembly
    30
    
    Components Removal and Installation
    30
    
    General
    30
    
    Safety and Workmanship
    30
    
    Battery
    31
    
    Bearings
    31
    
    Bolt Usage and Torque Application
    31
    
    Gaskets
    31
    
    Hydraulic Lines and Electrical Wiring
    31
    
    Hydraulic System
    31
    
    Lubrication
    31
    
    Lubrication and Servicing
    31
    
    Pressure-Fit Parts
    31
  - Lubrication and Information
    32
    
    Changing Hydraulic Oil
    32
    
    Hydraulic Oil
    32
    
    Hydraulic System
    32
    
    Lubrication Specifications
    32
  - Cylinder Drift Test
    33
    
    Cylinder Drift
    33
    
    Platform Drift
    33
  - Pins and Composite Bearing Repair Guidelines
    33
  - Preventive Maintenance and Inspection Schedule
    34
  - Preventive Maintenance and Safety Inspection
    35
- Section 3 - Chassis & Scissor Arms
  
  37
  - Diagnostic Port
    37
  - MDI Installation/Removal
    38
  - Traction System
    39
    
    Theory of Operation
    39
  - Traction Control Circuit - Sevcon Power Module
    40
  - Torque Hub
    41
    
    Leak Test
    41
    
    Oil Check/Fill Procedure
    41
    
    Roll Test
    41
    
    Manual Disengage Procedure
    42
    
    Manual Disengage Procedure
    43
    
    Manual Disengage Procedure
    44
    
    Motor and Brake Disassembly
    45
    
    Motor Disassembly
    46
    
    Drive Motor Removal
    47
    
    Main Gearbox Disassembly
    48
    
    Input Carrier Disassembly
    49
    
    Hub Disassembly
    50
    
    Spindle Disassembly
    51
    
    Spindle Sub-Assembly
    52
    
    Hub Sub-Assembly
    53
    
    Input Carrier Sub-Assembly
    54
    
    Main Gearbox Assembly
    55
    
    Motor and Brake Assembly
    57
    
    Motor Assembly
    59
    
    Motor Assembly
    60
    
    Assembly Tools
    61
    
    Tightening and Torquing Bolts
    61
  - Electric Drive Motor
    62
    
    Disassembly
    62
    
    Inspecting Motor Brushes
    62
    
    Replacing Motor Bearing
    62
    
    Replacing Motor Brushes
    62
    
    Replacing the Motor Cable
    62
    
    Reassembling the Motor
    63
    
    Motor Maintenance
    64
    
    Disassembly
    65
    
    Inspection and Service
    66
    
    Reassembly
    66
  - Terminal Tightening
    67
  - Electric Drive Motor
    68
    
    Drive Motor Disassembly
    69
    
    Drive Motor Inspection and Service
    69
    
    Drive Motor Troubleshooting
    69
    
    Drive Motor Reassembly
    70
    
    Drive Motor Servicing Guidelines
    71
  - Drive Motor Electrical Evaluation
    72
    
    Servicing Guidelines
    72
    
    Common Traction System Difficulties
    73
  - Power Module - Sevcon
    74
    
    Power Module Electrical Evaluation
    75
  - Power Module - ZAPI
    76
    
    ZAPI Power Module Electrical Evaluation
    77
  - Battery Removal
    78
    
    Battery Maintenance and Safety Practices
    79
  - Battery Charger
    79
    
    Battery Charger Maintenance
    80
    
    Battery Charger Troubleshooting
    81
  - Battery Algorithms
    83
    
    Battery Charger/Inverter (Option)
    84
    
    Battery Charger/Inverter Troubleshooting
    85
    
    Drive Motor Cable Routing
    86
    
    Limit Switch Locations - 1 of 2
    89
    
    Limit Switch Locations - 2 of 2
    90
    
    Pothole Switch Replacement
    91
    
    Pothole Switch Adjustment - 2630ES/3246ES
    92
    
    Ground Control Station
    95
    
    Printed Circuit Board (PCB) Replacement
    95
    
    Rotary Angle Sensor Replacement
    95
    
    Tilt Sensor Replacement
    96
  - Tilt Sensor Removal
    97
    
    Arms and Platform Positioning and Support
    98
    
    Platform Removal
    99
    
    Scissor Arms Removal
    99
    
    Arms and Platform Positioning and Support
    100
    
    Platform Control Station
    101
    
    Joystick Controller
    102
- Section 4 - Hydraulics
  
  103
  - Cylinders - Theory of Operation
    103
  - Valves - Theory of Operation
    103
    
    Crossover Relief Valves
    103
    
    Manual Descent Valve
    103
    
    Proportional Valve
    103
    
    Relief Valves
    103
    
    Solenoid Control Valves (Bang-Bang)
    103
  - Cylinder Checking Procedure
    104
    
    Cylinders Without Counterbalance Valves and Steer Cylinder
    104
  - Lift Pressure Setting Procedure
    104
  - Hydraulic Oil Fill
    105
    
    Oil Check Procedure
    105
    
    Slide Block Lubrication
    106
  - Lift Cylinder Removal
    106
    
    Lift Cylinder Removal
    107
  - Pump/Motor
    108
    
    Pump Motor Electrical Evaluation
    109
    
    Pump Removal
    110
    
    Motor Removal
    112
  - Cylinder Repair
    113
    
    Disassembly
    113
    
    Cleaning and Inspection
    114
    
    Steer Cylinder Piston Removal - Cyl. P/N-1684456
    114
    
    Assembly
    115
  - Piston Seal Kit Installation
    116
  - Cylinder Piston Nut Torque Specifications
    117
  - Lift Cylinder/Pump/Tank Assembly
    118
  - Lift Cylinder Assembly
    119
- Section 5 - Jlg Control System
  
  121
6.2 Dtc Index

149
- Section 6 - Diagnostic Trouble Codes
  
  149
  - Introduction
    149
  - DTC Index
    149
  - DTC Check Tables
    152
    
    Help Comments
    152
  - Error (Displayed on MDI)
    152
  - Everything Ok
    152
  - Ground Mode Ok
    152
  - Alarm Sounding - Tilted & above Elevation
    152
  - Driving at Cutback - above Elevation
    152
  - Drive & Lift up Prevented - Tilted & Elevated
    152
    
    Platform Controls
    153
    
    Power-Up
    153
  - Lift up Prevented - Max Height Zone a
    153
  - Driving at Cutback - Pothole Still Engaged
    153
  - Functions Locked out - System Powered down
    153
  - Drive Prevented - Elevated above Drive Cutout Height
    153
  - Power Cycle
    153
  - Keyswitch Faulty
    153
  - Function Problem - Horn Permanently Selected
    153
  - Function Problem - Indoor / Outdoor Permanently Selected
    154
  - Function Problem - Drive & Lift Active Together
    154
  - Function Problem - Steer Left Permanently Selected
    154
  - Function Problem - Steer Right Permanently Selected
    154
  - Accelerator Faulty - Wiper out of Range
    154
  - Steer Switches Faulty
    154
  - Function Locked out - Accelerator Not Centered
    154
  - Function Problem - Trigger Permanently Closed
    154
    
    2210 Trigger Closed too Long While in Neutral
    155
    
    2232 Function Problem - Drive & Lift both Open
    155
    
    Elev Angle Sensor Faulty - Voltage out of Range
    155
    
    Elev Angle Sensor Has Not Been Calibrated
    155
    
    Function Prevented
    155
    
    Function Problem - Brake Release Permanently Selected
    155
    
    Function Problem - Lift Permanently Selected
    155
    
    Ground Controls
    155
    
    Ground Lift up / down Active Together
    155
  - Drive Prevented - Charger Connected
    156
  - Drive & Lift up Prevented - Charger Connected
    156
  - Platform Overloaded
    156
  - Drive Prevented - Pothole Not Engaged
    156
  - Elev Prox Permanently Closed - Check Prox and Angle Adjustment
    156
  - Drive & Lift Prevented - Brakes Electrically Released for Towing
    156
    
    2510 Drive Prevented - Brakes Not Releasing
    157
    
    2511 Elev Angle Sensor Faulty - Not Mounted
    157
    
    2512 Elev Angle Sensor Not Detecting Change
    157
    
    Contactor Driver Permanently off
    157
    
    Line Contactor Miswired on or Welded
    157
    
    Line Contactor Open Circuit
    157
    
    Line Contactor Short Circuit
    157
    
    Model Changed - Hydraulics Suspended - Cycle Ems
    157
    
    Open Circuit Line Contactor
    157
    
    Brake Open Circuit
    158
    
    Brake Short to Battery
    158
    
    Contactor Driver Permanently on
    158
    
    Ground Output Driver
    158
    
    Lift Dn Open Circuit
    158
    
    Lift Dn Short to Battery
    158
    
    Lift up Open Circuit
    158
    
    Lift up Short to Battery
    158
    
    Steer Left Short to Battery
    158
  - Steer Left Open Circuit
    159
  - Steer Right Short to Battery
    159
  - 3310 Steer Right Open Circuit
    159
  - 3311 Ground Alarm Short to Battery
    159
  - 3312 Left Brake Short to Battery
    159
  - 3313 Right Brake Short to Battery
    159
  - 3314 Left Brake Open Circuit
    159
  - 3315 Right Brake Open Circuit
    159
    
    33297 Left Brake - Short to Ground
    160
    
    33298 Steer Left Valve - Short to Ground
    160
    
    33299 Line Contactor Coil - Short to Battery
    160
    
    33302 Negative Supply - Short to Battery
    160
    
    33303 Negative Supply - Short to Ground
    160
    
    33304 Right Brake - Short to Ground
    160
    
    33305 Steer Right Valve - Short to Ground
    160
    
    33406 Lift up Valve - Short to Ground
    160
    
    33407 Lift Dn Valve - Short to Ground
    160
    
    Thermal Limit (SOA)
    160
    
    4421 Logic Supply Voltage out of Range
    161
    
    Battery Supply
    161
    
    Canbus Failure - Power Module
    161
    
    Communication
    161
  - Canbus Failure - Platform Module
    162
    
    6635 Canbus Failure - Chassis Tilt Sensor
    163
    
    Accessory
    163
    
    Accessory Fault
    163
    
    Canbus Failure - Accessory Module
    163
    
    Canbus Failure - Load Sensing System Module
    163
    
    Capacitor Bank Fault - Check Power Circuits
    163
    
    Electric Motor
    163
    
    Open Circuit Drive Motor Wiring
    163
    
    Short Circuit Field Wiring
    163
    
    Stalled Traction Motor or Power Wiring Error
    163
  - Open Circuit Field Wiring
    164
  - Stalled Pump Motor or Power Wiring Error
    164
  - Open Circuit Pump Motor Wiring
    164
  - Traction T High - Check Power Circuits
    164
  - Traction T Low - Check Power Circuits
    164
  - 7710 Pump P High - Check Power Circuits
    164
  - 7711 Pump P Low - Check Power Circuits
    164
  - 7741 Armature Braking Current too High
    164
    
    7742 Field Voltage Improper
    165
    
    Hardware
    165
    
    Lss Cell #1 Error
    165
    
    Lss Cell #2 Error
    165
    
    Lss Cell #3 Error
    165
    
    Lss Cell #4 Error
    165
    
    Lss Eeprom Error
    165
    
    Lss Watchdog Reset
    165
    
    Platform Load Sense
    165
    
    Tilt Sensor
    165
  - Power Module Failure - Internal Error
    166
  - Power Module Failure - Check Power Circuits or Mosfet Short Circuit
    166
  - Eeprom Failure - Check All Settings
    166
  - Function Locked out - Power Module Software Version Improper
    166
  - 9910 Function Locked out - Platform Module Software Version Improper
    166
  - 9911 Function Locked out - Lss Module Software Version Improper
    166
  - 9912 Power Module Failure - System Monitor
    166
  - 9924 Functions Locked out - Machine Not Configured
    166
  - 9956 Power Module Failure - Internal Error
    167
  - 99145 Power Module Failure - Internal Error
    168
- Section 7 - General Electrical Information & Schematics
  
  169

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