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Service and Maintenance Manual

1. 2 4 2 5 2 10 Lift Cylinder Removal and 2 6 2 11 Lift 23 et grace dao icon RU e ei Rr leather Rb RR Rd e 2 6 2 12 Lift Cylinder icem RD x dex eee dier ees 2 11 2 13 Brake Cylinder Repair EAE uda Lue odas 2 13 2 14 Steer Cylinder Repair isesi eg Rar are e RE a E Red 2 15 2 15 Tilt Switch Adjustment If 2 17 2 16 Eirhit Switch Adj stment e Ele ees bris 2 17 2 17 Pressure Setting Procedures 2 18 2 18 Drive Motor Sauer 5 1 1 2 20 2 19 pothole protection system limit switch 2 22 2 20 JLG SMART System Analyzer Kit 2 22 2 21 Machine Personality lt 5 2 26 2 22 Machine Model Default Settings 2 1 2 27 2 23 Machine Configuration 2 28 2 24 Smart System H
2. LEFT gt gt gt Oy Op 1 por gt 4 24 VOLTS gt gt CENTER TAP gt B gt Sti DIRECTIONAL CONTROLLER IE DOM CSA LAT JPN AND J2 __ o LOAD TILT a amp S YEL RED 2 3 pas M VOLTS LED S 4 2c 889 X DECK SELECT LIGHT gt IN 55 8 SGD un secr gt E SCP vex DED ur suc YELAD 2 3 24 VOLTS SWITCHES ORANGE 55 3 a ORANGE 55 1 E IHE ORANGE 55 2 M DRIVE SELECT LIGHT Je 59 DECK x SWITCH MICROPROCESSOR 562 59 U3 JLG SMART SYSTEM E 15 1 lt 1 BLK DRIVE 0 t NES SWITCH 66 1 lt 9 DNAN DECK SWITCH FOR 8 8159 BLK 9 x J7 1 lt 8 N 19 1 gt lt gt 19 2 BLU ORN 52 4 ALARM WHT YEL 48 1 THE TORQUE APPLIED TO THE NUTS SECURING THE BATTERY CABLES TO THE CONTROLLER SHOULD NOT EXCEED 60 IN LBS Figure 3 3 Electrical Schematic Sheet 2 of 2 JLG Lift U1 MEMBRANE SWITCH PAD 1282880 L 3 5 SECTION 3 TROUBLESHOOTING Figure 3 4 Electrical Componants In
3. dL Service and Maintenance Manual Models 1532E3 1932E3 2033E3 2046E3 2646E3 2658E3 3120878 May 15 2002 1509001 Ee REGISTERED COMPANY 015 MG JLG Industries Australia PO Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 PI Castellbisbal Sur 08755
4. 2 28 2 5 Flelp Messages cee e Delos ARR 2 30 2 6 JLG SMART System Flash Codes amp Help Messages 2 31 2 7 Analyzer Menu 2 33 2 8 Preventive Maintenance and Inspection Schedule 2 40 3 1 Hydraulic System 3 2 ii JLG Lift 3120878 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 1 1 CAPACITIES Hydraulic Oil Tank 1532E3 1932E3 14 0 liters 3 7 gallons at full mark on tank 12 1 liters 3 2 gallons at add mark on tank 2033E3 2046E3 2646E3 2658E3 14 8 liters 3 9 gallons at full mark on tank 12 9 liters 3 4 gallons at add mark on tank Hydraulic System Including Tank 1532E3 1932E3 Approximately 16 8 liters 4 4 gallons 2033E3 2046E3 2646E3 2658E3 Approximately 19 3 liters 5 1 gallons 1 22 COMPONENT DATA Hydraulic Pump Electric Motor Assembly 24 Volts DC motor w single section gear pump All models 11 4 lpm 3 0 Battery Charger 20 Amp SCR 120 240 Volts AC 50 Hz input 24 Volts DC 20 Amp output w auto timer Batteries 4 All models 6 Volt 220 Amp Hour Optional 2033E3 2046E3 2646E3 2658E3 6 Volt 245 Amp Hour Steer Drive System 3120878 TIRES 1532E3 1932E3 Standard 4 50 x 14
5. Roe ls 2 25 3 1 Hydraulic Schematic 2033 3 2046 3 2646 3 2658 3 3 3 3 2 Electrical Schematic Sheet 1 2 3 4 3 8 Electrical Schematic Sheet 2 12 3 5 LIST OF TABLES TABLE NO TITLE PAGE NO 1 1 Lift Speeds sad Quit Aiea and ink hy RUM CT IHE TREE IN ee A ea 1 2 1 2 Machine WeightS dzura a pte deed x ate iat de RU A pu 1 2 1 3 Torque Requirements b elu RERO rr EE E REA e gars 1 3 1 4 Hydraulle we eee i s bed obe esM bn ii es 1 3 1 5 L bric tion Chart se pi eI Rte E ER ERE LE 1 5 1 6 Lubrication 1 5 1 7 Cylinder Specifications 1 6 1 8 Critical Stability 1 1 6 2 1 Cylinder Component Torque 2 11 2 2 Machine Personality 0 8 2 26 2 3 Machine Model Default Settings 2 27 2 4 Machine Configuration Programming
6. 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 1 Use adjustable lifting devices whenever possible if mechanical assistance is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 2 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 3 If a part resists removal
7. 1 6 SERIAL NUMBER LOCATIONS For machine identification a serial number plate is affixed to the machine The serial number plate is located on the left rear side of the machine frame just above the left rear tire and wheel assembly In addition if the serial number plate is damaged or missing the machine serial number is stamped on the right front of the frame WARNING TO AVOID PERSONAL INJURY USE SAFETY PROP FOR ALL MAINTENANCE REQUIRING PLATFORM TO BE ELEVATED 1 4 Table 1 5 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F Excellent water resistance and adhe sive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API ser vice classification GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 NOTE Operate lift function through one complete cycle before checking oil level Oil level should be at the full mark or within 1 5 cm 0 5 in below the full mark JLG Lift 3120878 SECTION 1 SPECIFICATIONS Drive Cut Out Models 2033E3 2046E3 2646E3 and 2658E3 with Powered Deck Extension On these machines the Drive function is cut out when the powered deck extension is extended with the platform raised above the stowed position 1 7 CYLINDER SPECIFICATIONS NOTE All di
8. 2 4980 86 ceiz eize 8196p colt 9191 Zrel 189 50 72 7522 osse Elec vsotv 0261 99vc 5586 691 3951 68 6191 181444 2 78 80886 QELS 99S 214 961 20678 2801 S68 6LL G S9Z g i L 89 OL9vE 8681 96 9511 COLLE 6ELL 896 9801 18161 08 lt 6 2 KA 7200 cerl 620 00 acer 080 6 66 ese 61 66 criei 0891 222 zt 2 89 6 156 6 0 00 916 982 199 898 609 11 COEG 1 8 198 8802 586 8 9 S68 92706 SOL 95 57 19 79 66212 22 Tk yj 62 964604 968 9S9 veg 0 88 9 664 Sr 95551 98 11 6 61691 leo ver 0 5 e9e eee 20 96201 260 ocos 9 S6v 09191 OLS 807 08 59951 286 Sce LZZ ESE c996 7878 0 OL 96c CLOLL 655 4144 95 vOL 8SC 206 911 LEZ 6 069 0 6961 SL g s 582 Lozo 955 vvc bec 860 1526 vee 8 orl voc 2659 07 50 LL vee 8026 82 soz 9 ezes Sri pes 99190 S Ole 95 8 98 67 poz 6557 59 cel 60 2925 290 zi 951 EGZ esl 9vL zer 9L 7659 9er 80 88 eei 959 19070 ooz 0 1 v9 egr 05 60 6 58 5 26 GZ zor 50 7 vO9eO i ZOL 7855 Zeb S6 L8 60 vS8v 18 89 89 S seve 91050 02 96 cc8v 601 68 Gl 96 Gl 9 8v 89 480 00 00 vl 8
9. 3120878 JLG Lift 2 29 SECTION 2 PROCEDURES 2 24 JLG SMART SYSTEM HELP MESSAGES AND FLASH CODES Table 2 5 Help Messages NO FLASH CODE IS INDICATED FOR THE FOLLOWING HELP MESSAGES THEY ARE INTENDED TO HINT AT A POSSIBLE PROBLEM IF THE MACHINE IS NOT BEHAVING AS EXPECTED EVERYTHING OK The normal help message in platform mode GROUND MODE OK The normal help message in ground mode ALARM SOUNDING ARMGAURD PROTECTION ACTIVE Arm guard protection has tripped during lift down andis preventing lift down for three seconds ALARM SOUNDING DECK EXTENDED DURING LIFT DOWN The deck extension cutoutis preventing lift down ALARM SOUNDING OVERLOADED The function cutoutis active some functions may be prevented ALARM SOUNDING TILTED amp ABOVE ELEVATION The machine is tilted while above elevation some functions may be prevented DECK PREVENTED NOT AVAILABLE Adeck function has been selected but there is no power deck DIFFERENT FUNCTION SELECTED amp IGNORED Aplatform function selection drive lift or deck has been pressed while another func tion isin use DRIVING AT CUTBACK ABOVE ELEVATION Drive speed is limited to cutback because the machine is above elevation DRIVING AT CUTBACK POTHOLE STILL ENGAGED drive speed is limited to cutback because the pothole protection is still engaged while the machine is not above elevation FUNCT
10. 1 Batteries 2 Battery Charger 3 Hydraulic Pump Motor 4 Valves 5 Hydrau ic Filter See Lubrication Chart 6 Hydrau ic hoses and Tubing 7 Hydrau ic Oil Tank 8 Hydrau ic Tank Breather 9 Lift Cylinder 1 12 10 Limit Switch 1 7 11 Placards and Decals 1 2 12 Wheel and Tire Assemblies 13 Drive Motors 14 Drive Brake 15 Steer Cylinder 16 Steer Components 17 Wheel Bearings A 18 Sizzor Arms 1 4 19 Safety Prop 1 4 20 Wear Pads 21 Pivot Pins Bolts 1 4 7 8 22 Switches Ground Control 1 11 23 Control Tags 12 24 Hose and Cable 4 8 2 40 JLG Lift 3120878 SECTION 3 TROUBLESHOOTING 3120878 SECTION 3 TROUBLESHOOTING 3 1 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform 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 3 2 TROUBLESHOOTING INFORMATION The troubleshooting procedures applicable to the aerial platform are listed and defined in Table 3 1 Hydraulic Sys tem Troubleshooting Each malfunction wit
11. 120 kg 265 Ib 1 person 1 2 JLG Lift Standard Handrails 1532E3 1932E3 2033E3 2046E3 1 0 m 39 5 in 2646E3 2658E3 Fold down rails standard 1 1 m 43 5 in Fold Down Handrails All Models 1 1 m 43 5 in Machine Height Platform Lowered Fold Downs Folded 1532 1 8 m 72 in 1932E3 1 9 m 76 in 2033E3 2046E3 1 7 m 65 5 in 2646E3 2658E3 1 9 m 74 5 in 3120878 SECTION 1 SPECIFICATIONS Machine Length 1 44 TORQUE REQUIREMENTS 1532 3 1932 1 8 m 71 25 in 2033E3 2046E3 2646E3 2658E3 2 5 m 100 in Table 1 3 Torque Requirements Machine Width DESCRIPTION iai hls 1532E3 1932E3 w standard tires 0 8 m 32 5 in Whealliigs m 2033E3 w standard tires 0 8 m 33 0 in 105 120ftlb 2046E3 2646E3 w standard tires 1 2 m 46 0 in e We 1 600 2658E3 w standard tires 1 5 m 58 0 Motor Controller FIRM w optional flotation tires 1 5 m 60 inIb Replacement Only 60 0 in Torque nut to 169 203 Nm dry 125 150 ft Ibs then add extra torque to line up the slot with the hole in the shaft to install the cotter pin Ground Clearance With Platform Lowered NOTE When maintenance becomes necessary or a fas tener has loosened refer to Figure 1 2 Torque Chart to determine proper torque value 1532E3 1932E3 2033E3 7 6 cm 3 00 in 2046E3 2646E3 2658E3 8 9 cm 3 50 in With Platform Elevate
12. Password 33271 will give you access io level 1 which will permit you to change all machine person ality settings There are some settings that JLG strongly recommends that you do not change These settings are so noted below ELEVATION CUTBACK POSITRAC TIMEOUT HIGH DRIVE CURRENT LIMIT HIGH DRIVE TIME LIMIT WARNING CHANGING THESE SETTINGS MAY ADVERSELY AFFECT THE PERFORMANCE OF YOUR MACHINE A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROLLER A IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 52 BAR 750 PSI AT A MINIMUM DISTANCE OF 30 5 CM 12 IN AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION 3120878 SECTION 2 PROCEDURES eys jeuoneziuebio 22 2 0 HO LNIHYNO XVN 15 LON Od 310 pemen 4013 3NIHOVIN GATIVLSNI NOILdO NY S3IVOIONI C_D IVAO NV NI ONIHLANV 3110N nue ans ST3A31 4013 3NIHOVIN CNV S3lL TVNOSH3d JHL S3ONVHO SMV 17266 3009 HA
13. check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3120878 JLG Lift 2 1 SECTION 2 PROCEDURES 3 bearing is found to be serviceable apply a light coat of oil and wrap it in clean waxed paper Do not unwrap reusable or new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes
14. Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
15. CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Place the cylinder barrel into a suitable holding fix ture 3120878 3 Using a suitable pair of snap ring pliers carefully remove the retaining ring from the cylinder barrel 4 Attach a suitable pulling device to the cylinder rod end A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 5 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture 7 Carefully remove the piston locknut and piston from the cylinder rod Remove and discard the piston ring and o rings 8 Carefully remove the guide from the cylinder rod Remove and discard the o ring back up ring rod seal and wiper ring 9 Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning solvent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion of rod for excessive dam age Dress threads as necessary 4 Inspect inner surface of cylinder barrel tube for scor ing or o
16. Inspection 1 10 2 8 JLG Lift Clean all parts thoroughly in an approved cleaning Solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for damage Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect threaded portion of piston for damage dress threads as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect threaded portion of head for damage Dress threads as necessary 3120878 SECTION 2 PROCEDURES 11 12 13 Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect rod and barrel bearings for signs of correct lubrication and exc
17. THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 14 With the barrel clamped securely and while ade quately supporting the rod insert the piston end into the cylinder barrel Ensure that the piston loading o ring and seal ring are not damaged or dislodged 15 Continue pushing the rod into the barrel until the inder head gland can be inserted into the cylinder barrel 16 Secure the cylinder head gland using the washer ring and socket head bolts Refer to Table 2 1 Cylin der Component Torque Specifications for proper bolt torque specifications 3120878 SECTION 2 PROCEDURES SPACER HEAD ASSY CAP CYLINDER SCREWS BARREL WASHER RING Figure 2 14 Rod Assembly Installation 17 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 18 If applicable install the cartridge type holding valve and fittings in the port block using new o rings as applicable Table 2 1 Cylinder Component Torque Specifications Component Torque Value w Loctite Tapered Bushing Retaining 108 Nm Screws Lift Cylinder 801110 Head Retaining Screws 12Nm 9ft lb Piston Nut 1532E3 1932E3 508 610Nm 375 450 Ib Piston Nut 2033E3 2046E3 1085 1356 Nm 2646E3 2658E3 800 1000 ft Ib 2 12 L
18. WHEN INSTALLING THE CYLINDER ROD CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAM AGE TO THE PISTON AND CYLINDER BARREL SURFACES JLG Lift With the barrel clamped securely and while ade quately supporting the cylinder rod assembly insert the piston end of the rod assembly into the cylinder barrel Ensure that the piston ring and o ring are not damaged or dislodged Continue pushing the rod into the barrel until the cyl inder rod guide can be inserted into the end of the cylinder barrel Coat the threads of the cylinder rod guide with Loc tite 242 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench On the remaining cylinder rod guide place a new wiper ring rod seal o ring and back up ring into the cylinder rod guide grooves 3120878 SECTION 2 PROCEDURES 13 14 15 Carefully install the cylinder rod guide onto rod sec tion two and slide the guide into the end of the cylin der barrel Coat the threads of the cylinder rod guide with Loc tite 242 then secure the cylinder rod guide to the cylinder barrel using a suitable spanner wrench Reconnect the hydraulic hoses to the applicable cyl inder ports 2 15 TILT SWITCH ADJUSTMENT IF EQUIPPED NOTE The machine may be equipped with a tilt switch sen Sor factory set to activate when the machine is out of level in any direction at 5 and will cut out 2 sp
19. a place to record stamp inspection dates Notify dealer if inspection is over due The inspection and maintenance code numbers are as fol lows 1 Check for proper and secure installation 2 Check for visible damage and legibility 3 Check for proper fluid level 4 Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage 6 Check for presence of excessive dirt or foreign material 7 Check for proper operation and freedom of move ment 8 Check for excessive wear or damage 9 Check for proper tightness and adjustment 10 Drain clean and refill 11 Check for proper operation while pump motor is running 12 Check for proper lubrication 13 Check for evidence of scratches nicks or rust and for straightness of rod 14 Check for condition of element replace as neces sary 15 Check for proper inflation 16 Check Inspection Decal for current inspection stamp Inspection and Maintenance code 10 to be performed every two years 1200 hours JLG Lift 2 39 SECTION 2 PROCEDURES Table 2 8 Preventive Maintenance and Inspection Schedule AREA INTERVAL PLATFORM DAILY WEEKLY MONTHLY 3MONTH 6 MONTH 1YEAR 1 Controller 1 11 2 Switches 1 11 3 Placards and Decals 12 4 Control Tags 12 5 Hoseand Cable 4 8 6 Wear Pads 7 Handrail and Chains CHASSIS
20. and carefully withdraw the complete rod assembly from the cylinder barrel 8 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston and head as possible 9 Remove the lock nut which attaches the piston to the rod and remove the piston 10 Slide the head off the rod from the piston end 11 Remove and discard the sealing o ring wiper u cup seal static o ring static back up ring and wear ring 12 Remove the piston guidelock ring 13 Remove and discard the piston o ring and seals then remove the piston spacer 14 Remove the rod from the holding fixture Remove the cylinder head gland and retainer if applicable Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning Solvent 2 Inspect the cylinder rod for scratches or pits deep enough to catch the fingernail Pits that go to the base metal are unacceptable Scratches that catch the fingernail but are not to the base metal less than 12 7 mm 0 5 inch long and primarily in the circum JLG Lift 2 11 SECTION 2 PROCEDURES 10 2 12 ferential direction are acceptable provided they can not cut the rod seal Chrome should be present over the entire surface of the rod the lack of chrome on the rod surface is unacceptable If an unacceptable condition exists repair or replace the rod Inspect the thread
21. as follows HELP DIAGNOSTICS RUN SYSTEMS TEST NOTE Ensure machine is fully lowered before running systems test ACCESS LEVEL PERSONALITIES MACHINE SETUP CALIBRATIONS level 0 Manufactures Access Only If you press ENTER at the HELP PRESS ENTER display and a fault is present during power up the analyzer dis play will scroll the fault across the screen If there was no fault detected during power up the display will read HELP EVERYTHING OK If ENTER is pressed again the display moves to the fol lowing display LOGGED HELP 1 STARTUP 2 1 At this point the analyzer will display the current fault if any are present You may scroll through the fault logs to view what the last fifteen faults were Use the right and left arrow keys to scroll through the fault logs To return to the beginning press ESC two times NOTE The STARTUP 2 1 is not a fault It is used to sepa rate faults between powerups When a top level menu is selected a new set of menu items may be offered for example PLATFORM GROUND SYSTEMS DATA LOG VERSIONS DRIVE LIFT STEER GROUND MODE MACHINE Pressing ENTER with any of the above displayed menus will display additional sub menus within the selected menu In some cases such as DRIVE the next level is the parameter or information to be changed Refer to the flow chart for what menus are available within the top level menus You may only view the personality settings for sel
22. operating the func tions from the platform control station Lift Relief Adjustments 1 2 18 Install a pressure gauge at gauge port MP located at the bottom fornt of the valve body The port is identi fied by a stamping on the valve body From the platform control station activate the lift up function by pressing the lift switch and activating the controller to the full forward position While monitoring the pressure gauge at adjust the lift up relief as follows 1532E3 112 bar 1625 psi 1932E3 138 bar 2000 psi 2033E3 105 bar 1525 psi 2046 124 bar 1800 psi 2646 124 bar 1800 psi 2658E3 145 bar 2100 psi Main Relief and High Drive Pressure Switch Adjustment NOTE JLG Lift Install a pressure gauge at gauge port MP located at the bottom front of the valve body The port is identi fied by a stamping on the valve body Close the steer relief valve completely by turning clockwise Activate the steer switch in either direction until the steer cylinder bottoms out Adjust your main pressure to 207 bar 3000 psi Once you have adjusted your main pressure be sure and reset your steer pressure to 145 bar 2100 psi In the event that the above procedure will not allow you to reach the proper pressure take the following steps With the pressure gauge still installed and the steer valve still closed remove the power from the drive forward or drive reverse valves
23. suitable supported work sur face JLG Lift 2 5 SECTION 2 PROCEDURES Pivot Mount Garmax Bushing Arm Pin Figure 2 1 Platform Removal Disassembly of Arms NOTE If performing maintenance on any of the arms or arm bushings be sure and pull the pins outward DO NOT try to drive the pins through or they will fall into the cross tubes of the inner arms 1 Remove hardware from the pin that secures the pin to the arm 2 Place a pry bar or suitable prying device behind the washer and retaining ring and pull the arm pin out 3 Using a suitable lifting device lift the arm to be removed and lower to the ground or suitable sup ported work surface 4 Repeatthis if necessary in order to perform mainte nance on various arms NOTE If the removal of the lift cylinder becomes necessary refer to lift cylinder removal section steps 2 through 6 2 10 LIFT CYLINDER REMOVAL AND INSTALLATION Lift Cylinder Removal 1 Place the machine on a flat and level surface Start the motor and raise the platform Shut down the engine and attach a suitable lifting device to the plat form 2 Remove the bolt and locknut securing the cylinder rod attach pin to the upper inner arm assembly Using a suitable brass drift drive out the rod end attach pin from the arm assembly 3 Retract the lift cylinder rod completely 4 Tag and disconnect the hydraulic lines then cap the lift cylinder hydraulic lin
24. the groove between the threads and the flange lip Install a new wear ring into the inside applicable head groove If possible the head seal assembly should sit for at least one hour to allow the seals to elastically restore Carefully slide the head assembly onto the cylinder rod ensuring that the wiper seal o ring and wear ring are not damaged or dislodged Carefully slide the piston spacer on the rod If appli cable align the oil holes in the rod and the spacer Secure the spacer if applicable Place a new o ring in the inner piston diameter groove Carefully place the piston on the cylinder rod ensur ing that the o ring is not damaged or dislodged Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Push the piston onto the rod until it abuts the spacer end and install the attaching nut A WARNING APPLY LOCQUIC PRIMER T AND LOCTITE 242 TO PISTON NUT THREADS THEN TIGHTEN NUT TO TORQUE SHOWN IN TABLE 2 1 9 JLG Lift Torque the piston nut to the proper torque as out lined in the Figure 2 1 Cylinder Component Torque Specifications 3120878 SECTION 2 PROCEDURES 10 Remove the cylinder rod from the holding fixture 11 Install new seals and a new guidelock ring in the applicable outside diameter grooves of the piston 12 Position the cylinder barrel in a suitable holding fix ture A IMPORTANT EXTREME CARE S
25. the guide on the rod ensuring that the wiper ring and rod seal are not damaged or dis lodged Push the guide onto the rod Place a new piston ring and o rings on the piston 5 Carefully place the piston on the threaded end of the cylinder rod ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go 6 Install the piston locknut on the threaded end of the cylinder rod and torque to 136 163 Nm 100 120 ft Ib 7 Remove the cylinder rod from the holding fixture 8 Position the cylinder barrel in a suitable holding fix ture A DANGER EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 9 With the barrel clamped securely and while ade quately supporting the cylinder rod insert the piston end of the rod into the cylinder barrel Ensure that the piston ring and o ring are not damaged or dis lodged JLG Lift 3120878 SECTION 2 PROCEDURES 10 Continue pushing the rod into the barrel until the cyl inder guide can be inserted into the cylinder barrel 11 Using all applicable safety precautions secure the cylinder rod assembly with a new retaining ring 12 Reconnect the hydraulic hoses to the applicable cyl inder ports 2 14 STEER CYLINDER REPAIR Disassembly DISASSEMBLY OF THE CYLINDER SHO
26. this is unacceptable Check for the condition of the dynamic seals looking particularly for metallic particles embedded in the seal surface It is normal to cut the static seal on the retaining ring groove upon disassembly Remove the rod seal static o ring backup ring and rod wiper Damage to the seal grooves particularly on the sealing sur faces is unacceptable If an unacceptable condition exists replace the head Inspect the port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Refer to the Illustrated Parts Manual NOTE Apply a light film of hydraulic oil to all components prior to assembly WHEN INSTALLING NEW POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 7 FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 1 Using round nose pliers or special installation tools twist the loaded u cup seal into a C shape and allow it to snap into the groove Use a similar tech nique for installing the wiper Install a new static o ring and back up o ring into the static seal groove verifying that the back up o ring is closest to the threads Install a new sealing o ring into
27. 00 Solid Non Marking Optional 4 50 x 14 00 Solid Rib TIRES 2033E3 2046E3 2646E3 2658E3 Standard 5 00 x 16 00 Solid Non Marking Optional 5 00 x 16 00 Solid Rib Optional 2046E3 2646E3 2658E3 7 50 x 16 00 Solid Flotation Tread PARKING BRAKE Single cylinder spring applied hydraulically released DRIVE MOTORS 1532E3 1932E3 162 cm 3 9 9 in 3 displacement 2033E3 229 cm 3 14 0 in 3 displacement 2046E3 2646E3 2658E3 266 cm 3 16 2 in 3 displace ment Hydraulic Filter Inline Return Bypass Type 10 Microns Nominal Platform Size 1532E3 1932E3 0 8 m x 1 6 30 in x 64 in 2033E3 0 8 m x 2 4 30 in x 94 in 2046E3 2646E3 1 1 m x 2 4 m 42 in x 94 in 2658E3 1 4 m x 2 4 m 54 in x 94 in 1 3 PERFORMANCE DATA Travel Speed 1532E3 1932E3 Low Speed 2 1 kmh 1 3 mph Elevated Speed 0 80 kmh 0 5 mph Maximum Speed 3 7 kmh 2 3 mph 2033E3 Low Speed 2 4 kmh 1 5 mph Elevated Speed 0 80 kmh 0 5 mph Maximum Speed 3 9 kmh 2 4 mph 2046E3 Low Speed 2 1 kmh 1 3 mph Elevated Speed 0 80 kmh 0 5 mph Maximum Speed 3 9 kmh 2 4 mph 2646E3 2658E3 Low Speed 2 1 kmh 1 3 mph Elevated Speed 0 80 kmh 0 5 mph Maximum Speed 3 4 kmh 2 1 mph JLG Lift 1 1 SECTION 1 SPECIFICATIONS Gradeability Machine Weight Models 25 Inside Turning Radius 1532E3 1932E3 2033E3 7 6 cm 3 in 2046E3 2646E3 2658
28. 0sec 1 0sec 1 0sec 1 0sec DRIVE DECELERATION 0 5 sec 0 5sec 0 5sec 0 5sec 0 5sec 0 5sec DRIVE CREEP 10 10 12 12 12 12 DRIVE SPEED MAX LOW 70 70 100 100 100 100 DRIVE SPEED MAX HIGH 70 70 85 85 85 85 ELEVATION MAX 25 25 30 30 37 36 POSITRAC TIME 10sec 10sec 10sec 10sec 10sec 10sec HIGH DRIVE OVER CURRENT 140 amps 140 amps 140 amps 140 amps 140 amps 140 amps HIGH DRIVE TIME OUT 5 0 sec 5 0 sec 5 0 sec 5 0 sec 5 0 sec 5 0 sec LIFT ACCEL 1 0 sec 1 0sec 1 0sec 1 0sec 1 0sec 1 0sec LIFT DECEL 0 0 sec 0 0sec 0 0sec 0 0sec 0 0 sec 0 0sec LIFT CREEP 10 10 15 15 15 15 LIFT UP MAX 90 90 100 100 100 100 DECK ACCEL 0 5sec 0 5sec 0 5 sec 0 5sec 0 5sec 0 5 sec DECK DECEL 0 0sec 0 0sec 0 0sec 0 0sec 0 0 sec 0 0sec DECK CREEP 10 10 10 10 10 10 DECK EXTENSION SPEED MAX 100 100 100 100 100 100 DECK RETRACTION MAX 80 80 80 80 80 80 STATIC STEER 30 30 30 30 30 30 STEER DRIVE COMP 15 15 15 15 15 15 GROUND LIFT UPMAX 100 100 100 100 100 100 GROUND DECK IN MAX 50 50 50 50 50 50 GROUND DECK OUT MAX 50 50 50 50 40 40 NOTE WARNING Changing the machine model will set all personalities back to the factory default settings check the machine model adjustment chart for the correct settings for each model if your machine does not match the proper settings for each model adjust the settings as necessary in accordance with the chart NOTE JLG strongly recommends that t
29. 2 T Oil lite Bearing 1 5 2 9 2 8 Rod Seal mm mm 2 9 2 9 Wiper Seal Installation RR RERO RR ETRAS EE 2 9 2 10 Installation of Head Seal Kit 1 2 10 2 11 Piston Seal Kit 2 10 2 12 Tapered Bushing Installation 1 4 24 4 12 5 2 10 2 13 Poly Pak Piston Seal 2 2 10 2 14 Rod Assembly Installation lille III 2 11 2 15 Brake Cylinder Assembly 4 2 14 2 16 Steer Cylinder Repair 2 16 2 17 Switch Leveling Manual 2 17 2 18 Switch Leveling Voltmeter 2 18 2 19 Pressure Setting 2 2 19 2 20 Drive Motor Sauer 5 2 20 2 21 JLG SMART System 2 22 2 02 Organizational Chart o cec uo Rp tuer Rem Pave a
30. 9 865 92 9 8v 89 895 vS vt 8v 042 06660 2 lt 60 vc g g 9 6vt 89 8v 9 9 15 8v 9 Le LV 69610 OL 26 LEO LY Le ve LESZ 6c c 6L 9c 879 4VVO 866 0 vc ve 44 LV 05 ve LVL 9c 8L tc 9191 LEELOO 81 6 LSOL LZ vi 887 Eus OL w esor 56600 oco o 8 jj 9l 765 ZI LL 916 80800 02 9 8 8 Y 9 585 80500 aS zE LCS 2 y 5 808 57200 22870 2 Ob S 668 Y v1 00 21796 S Zs y gor 95500 199 70 2 8 2 ZIZ 85200 Or LIA ao Se Z ege zezoo L ZZ L6L 89100 Z zi 89100 19820 61 7 INN py WN WN WN WN INN INN VAN 9AI9291 SV LLZ 272 B LLZ 5 3fbuoL avri Cam QVO1 hea Can HUE avol Nos id 1 ZI YB80L dINV19 diNV 12 SS3MIS 321 einer aan Od AVS 02372 096 ll SM3U9S dV diiviaNf 61108 31 14 9NIZ H03 S360 1VA 3120878 JLG Lift 1 6 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 1 GENERAL This section provides information necessary to perform maintenance on the scissor lift Descriptions techniques and specific proce
31. ART System may be adjusted using a custom designed ana lyzer or special system software installed on a personal computer PC or a laptop computer operating under DOS or Windows Both the analyzer JLG kit no 2901443 and the computer software JLG kit no 2900874 are available from JLG and include a connecting cable and SMART System adjustment procedures A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CON TROLLER FOR THE PROPER MACHINE CONFIGURATION INCLUDING OPTIONS REFER TO ANALYZER KIT NO 2901443 JLG Lift 3 1 SECTION 3 TROUBLESHOOTING Table 3 1 Hydraulic System Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Hydraulic pump noisy Air bubbles in oil Reservoirtoo low Oil filter dirty Replenish oil as necessary Clean and or replace filter as necessary Pumpcavitating Vacuum in pump dueto oil starvation Oilin reservoir low Restrictedly reservoir air vent Oil viscosity too high Replenish oil as necessary Clean vent Drain system and replace with recommended oil Rrefer to Hydraulic Oil Table System overheating Oil viscosity too high Main relief set too high Hydraulic system too low Drain system and replace with recommended oil Rrefer to Hydraulic Oil Table Adjust relief valve to proper pressure Replenish oil as necessary Pump not delivering Defective pump on motor Repair
32. Activate the joystick in the direction that the power was removed from Adjust your main pressure to 207 bar 3000 psi 3120878 SECTION 2 PROCEDURES Steer Adjustment check steer right pressure If necessary adjust steer right pressure to 145 bar 2100 psi 1 If necessary connect a pressure gauge to gauge port MP then open the Steer Tow valve 3 Activate drive by pressing the drive switch and acti vating the controller to the full forward position 2 Activate drive by pressing the drive switch and acti While holding the controller activate steer left and vating the controller to the full forward position check steer left pressure If necessary adjust steer While holding the controller activate steer right and left pressure to 145 bar 2100 psi Lift Shuttle Check Valve Valve Block Drive Steer Drive Valve Common Shuttle Lift Relief Lift Up Valve Steer Shuttle Steer Relief teer Val Steer Valve Load Sense High Drive Valve Tow Valve MP Port Posi Trac Valve Drive Valve Flow Divider Capscrew TORQUE Counterbalance Decel TO 60 IN LBS 7 Nm NOTE When valve components are removed and or replaced the following torque values apply when re installing the components Shuttle Valve Cartridges 25 30 ft Ib 34 41 Nm Steer Relief Cartridges 25 30 ft Ib 34 41 Nm Check Valve Cartridges 25 30 ft Ib 34 41 Nm Main Relief Cartridge 25 30 ft Ib 34 41 Nm T
33. Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform It is of utmost importance that main tenance personnel pay strict attention to these warn ings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be followed to ensure that the machine is safe to operate WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFI CATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consider ation when engaging in the maintena
34. E3 40 6 cm 16 in Inside Turning Angle 1532E3 1932E3 2033E3 87 2046E3 2646E3 2658E3 80 Lift No Load in Platform Table 1 1 Lift Speeds MODEL LIFT UP sec LIFT DOWN sec 1532E3 16 21 24 32 1932E3 17 22 24 32 2033E3 33 38 30 35 2046E3 34 39 28 33 2646E3 48 53 30 35 2658E3 59 69 30 35 Platform Capacity Table 1 2 Machine Weights MODEL CE AUST 1532E3 1250kg 1160 kg 1932E3 1315kg 1315kg 2033E3 2035 kg 2035 kg 2046E3 1970kg 1790kg 2646E3 2165kg 2075kg 2658E3 2330 kg 2125kg Wheelbase 1532 3 1932 1 3 m 50 0 2033E3 2046E3 2646E3 2658E3 1 9 m 73 0 in Machine Height Platform Fully Elevated 1532 4 6 m 15 ft 1932 5 8 m 19 ft 2033E3 2046E3 6 1 m 20 ft 2646E3 2658E3 7 9 m 26 ft Machine Height Platform Lowered 1532E3 270 kg 600 Ib 1932E3 230 kg 500 Ib 2033E3 2646E3 Standard 340 kg 750 Ib 2046E3 2658E3 450 kg 1 000 Ib If machine is equipped with optional pipe racks maximum load on pipe racks is 45 kg 100 Ib Maximum total capac ity of pipe racks and platform combined is as follows 2033E3 2646E3 295 kg 650 Ib 2046E3 2658E3 408 kg 900 Ib Manual Platform Extension Capacity 1532E3 1 9 m 75 75 in 1932E3 2 0 m 79 75 in 2033E3 2046E3 2 0 m 79 0 in 2646E3 2658E3 2 2 m 88 0 in Platform Railing Height Models
35. ECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS REVISON LOG January 1999 Original Issue March 16 1999 Revised May 30 2001 Revised December 14 2001 Revised January 18 2002 Revised May 15 2002 Revised JLG Lift 3120878 TABLE OF 5 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS General MP A B Hydraulic System a A C Maintenance See PD XC A ACE oe EE SECTION 1 SPECIFICATIONS 1 1 ba EAE LL EL E LLL burg 1 1 1 2 Component re
36. HOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 13 With barrel clamped securely and while adequately supporting the rod insert the piston end of the rod into the cylinder barrel Ensure that the piston seals are not damaged or dislodged 14 Continue pushing the rod into the barrel until the inder head can be inserted into the cylinder barrel 15 Slide the head into the barrel and engage the threads Turn the head counterclockwise until the first thread just passes the engagement point the head will move noticeably then turn the head clockwise until it is hand tight or fully seated Insert a spanner wrench into the holes provided and tighten 1 8 to 1 4 turn past fully seated 16 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 17 If removed install the cartridge type holding valve and fittings in the port block using new o rings as applicable Torque the holding valve cartridge to 68 75 Nm 50 55 ft Ib 2 13 BRAKE CYLINDER REPAIR Disassembly A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Tag and disconnect the hoses from the cylinder ports WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT
37. IFT CYLINDER REPAIR Disassembly IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE A DIRT FREE WORK AREA SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES FROM CYLINDER OPENINGS PARTICULARY AT THE HEAD 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 3120878 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable 3 Remove the cartridge type holding valve and fittings from the cylinder port block Discard o rings 4 Place the cylinder barrel into a suitable holding fix ture CARE SHOULD TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 5 Using a suitable spanner wrench inserted in the holes provided turn the cylinder head counter clockwise to remove it from the cylinder barrel If the head is difficult to turn or moves erratically tap the tube adjacent to the head with a brass or plastic mallet while turning it 6 Attach a suitable pulling device to the cylinder rod end 7 With the barrel clamped securely apply pressure to the rod pulling device
38. ION SELECTED BUT TRIGGER SWITCH OPEN Afunction has been selected but the trigger switch is open when the trigger switch is closed the function will begin if itis still selected HIGH DRIVE PROBLEM CUTOUT The high drive function has been selected butis prevented by a cutout high drive is not allowed while above elevation or when the deck is extended HIGH DRIVE PROBLEM MOTOR CURRENT EXCEEDED The high drive function was selected but was ended because pump motor current was tohigh JOYSTICK MOVED BUT NO FUNCTION SELECTED The drive lift or deck function must be selected before the joystick is moved from neu tral POSITRAC PROBLEM NOT ALLOWED DURING HIGH DRIVE The positrac function has ben selected butis not allowed while the high drive function is inuse PUMP MOTOR AT CURRENT LIMIT Pump motor current has reached the maximum allowed is being limited STEER SELECTED BUT TRIGGER SWITCH OPEN Steering has been selected but the trigger switch is open when the trigger switch is closed steering will begin ifitis still selected TESTS ACTIVE RECYCLE EMS TO END The system tests have been activated normal machine operation is not allowed 2 30 JLG Lift 3120878 SECTION 2 PROCEDURES Table 2 6 JLG SMART System Flash Codes amp Help Messages Code Description 2 1 Indicates problems with EMS inputs STARTUP Neither EMS is active the system
39. LTIPLEXER BOARD YEL RED 2 3 LIFT SELECT LI D gt ORIVE SELECT LI D C seer 2X9 gt lt 2G gt lt power gt E camer gt lt XS wx output Dp etat 91 1 OK BLUE GREEN 55 12 gt gt qi sp a gt BLU ORN 52 2 gt gt gt TAN 55 8 BLK RED SGM 55 2 8 YELLOW pm 55 10 ssp Sap era Sep 5 9 Ti ORN BLK gt Q 49 2 J1 2 41 7 E BROWN 49 1 x 5 U3 JLG SMART SYSTEM MICROPROCESSOR YEL RED 2 5 gt gt gt SWITCH GREEN 17 1 YEL RED 2 5 yo 8 5 18 1 Gen 8 3 gt e S6LIFT gt DON TAN 4 1 3 YEL RED 2 5 lt v8 2 3 1 18 1 toc p r o S g J E 3 egt 8 B E zs 3 25 3 2 g YEL RED 2 3 GREEN 18 2 DECK OUT GREEN 17 2 Em 9 FA RIGHT YELLOW 10 1 f YEL RED 2 6 PLATFORM CHTS FAY GaL ORANGE 55 5 Figure 3 2 Electrical Schematic Sheet 1 of 2 JLG Lift 3120878 SECTION 3 TROUBLESHOOTING 3120878 J1 1 10042w IK POT gt E gt we DOD mie 56 ww P aD sor DOD NC EE NOS gt SITES
40. OPENINGS PARTICULARY AT THE HEAD 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting 2 6 JLG Lift 3120878 SECTION 2 PROCEDURES 1 Valve Cartridge amp Solenoid 6 Piston 2 Relief Valve 7 O Ring 3 Locknut 8 O Ring 4 Ring Lock 9 Ring Back Up 5 Seal 10 Ring Wear 11 Seal 12 O Ring 13 Head 14 Wiper 15 Rod Assembly Figure 2 2 Lift Cylinder Components Assembly PROTECTED ROD CLAMP SUPPORT TABLE WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if nec essary 3 applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture 5 To aid in realignment mark cylinder head and barrel with a center punch 6 Using a suitable spanner wrench loosen the span ner nut retainer and remove the spanner nut from the cylinder barrel 3120878 JLG Lift Figure 2 3 Barrel Support 7 Attach a suitable pulling device to the cylinder rod port block or cylinder rod end as applicable SECTION 2 PROCEDURES CAPSCREWS S SS L WASHER Fig
41. RE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRI CAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC REC OMMENDS A MAXIMUM PRESSURE OF 52 BAR 750 PSI AT A MINIMUM DISTANCE OF 30 5 CM 12 IN AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION INTRODUCTION The JLG designed SMART System is a 24 Volt multiplex motor control unit installed on the electric scissor lift mod els 1532E3 1932E3 2033E3 2046E3 2646E3 and 2658E3 The SMART System has reduced the need for exposed terminal strips diodes and trimpots and provides simplic ity in viewing and adjusting the various personality set tings for smooth control of acceleration deceleration creep and max speed for the lift drive steering and optional power deck functions The function select mem brane board in the upper control box also eliminates the need for toggle switches and a separate power enable button as this feature is built into each function select but ton on the board itself The lift drive and optional power deck functions are con trolled by a joystick with steering being controlled by a rocker switch built into the top of the joystick Drive lift and the optional power deck functions are selected by first pushing the appropriate momentary select buttons on the membrane board and then moving the joystick either in the or B dire
42. RELEASE THEN RESELECT A ground mode function lift or deck was selected when ground mode was selected 2 5 Indicates a function is prevented due to a cutout DECK PREVENTED FUNCTION CUTOUT ACTIVE DRIVE PREVENTED DECK EXTENDED amp ABOVE ELEVATION DRIVE PREVENTED DRIVE CUTOUT ACTIVE Driveis selected while drive cutoutis active and drive cutoutis configuredto prevent drive DRIVE PREVENTED FUNCTION CUTOUT ACTIVE Drive is selected while function cutout overload is active and configured to cut out drive functions DRIVE PREVENTED POTHOLE NOT ENGAGED DRIVE PREVENTED TILTED amp ABOVE ELEVATION Drive is selected while tilted and above elevation and tiltis configured to prevent drive LIFT DOWN CUTOUT ARMGAURD PROTECTION ACTIVE LIFT DOWN PREVENTED DECK EXTENDED LIFT PREVENTED FUNCTION CUTOUT ACTIVE LIFT UP PREVENTED TILTED amp ABOVE ELEVATION STEER LOCKED OUT RELEASE THEN RESELECT STEER PREVENTED DECK EXTENDED amp ABOVE ELEVATION STEER PREVENTED FUNCTION CUTOUT ACTIVE STEER PREVENTED AVAILABLE STEER PREVENTED TILTED amp ABOVE ELEVATION 3 1 Indicates that a contactor did not close when ener gized OPEN CIRCUIT LINE CONTACTOR The capacitor bank charge did not increase to battery supply when line contactor was energized this could be due to a power wiring error 3 2 Indicates that a contactor did not open when de ener gized WELDED LINE CONTACTOR The capacito
43. RSONALITY SETTINGS 2 26 Table 2 2 Machine Personality Settings PERSONALITY MIN MAX DRIVE ACCEL 0 5 SEC 5 0 SEC DRIVE DECEL 05 5 05 DRIVE CREEP 196 25 096 DRIVE SPEED MAX LOW 50 100 DRIVE SPEED MAX HIGH 50 100 ELEVATION 0 40 POSI TRAC TIME 0 60 Sec HIGH DRIVE OVERCURRENT 50 Amp 200 Amp HIGH DRIVE TIME OUT 0Sec 25 Sec LIFT ACCEL 0 5 Sec 5 0 Sec LIFT DECEL 0 0 Sec 1 55 LIFT CREEP 196 25 LIFT UP 50 100 DOWN 30 100 DECK ACCEL 0 5 Sec 5 0 Sec DECK DECEL 0 Sec 5Sec DECK CREEP 196 25 DECK EXT 0 100 DECK RET 0 100 5 20 50 STEER DRIVE COMP 0 35 GROUND LIFT UP MAX 096 100 GROUND LIFT DOWN 0 100 GROUND DECK OUT 0 100 GROUND DECKIN 0 100 JLG strongly recommends that these settings not be changed Changing these settings may adversely affect the performance of your machine NOTE Personality settings can be adjusted within the adjustment range in order to achieve optimum machine performance JLG Lift 3120878 SECTION 2 PROCEDURES 2 22 MACHINE MODEL DEFAULT SETTINGS Table 2 3 Machine Model Default Settings Chart Adjustment 1532E3 1932E3 2033E3 2046E3 2646E3 2658E3 DRIVE ACCELERATION 1 0 sec 1 0sec 1
44. RY Displays maximum measured battery voltage VERSIONS ASPC Displays controller software version ANALYZER Displays analyzer software version ACTIVATE TESTS Notavailable once tests are activated YES ENTER NO ESC ENTER activates system test NOTE Cannotbedonewhile controller is use trigger switch closed RUNSYSTEM TEST ENTERstarts system test Machine must be fully lowered before run Notavailable until tests are activated ning systems test Displays messages while system test runs Some messages are prompts requiring user intervention ENTER can be pressed if a fault has been noted and to con tinue the system test NOTE A flashing message is critical and prevents the sys tem test from running 3120878 JLG Lift 2 35 SECTION 2 PROCEDURES Table 2 7 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY ACCESSLEVEL Displaysthe current access level Level 3 Personalities cannot be changed Level 2 Most personalities canbe changed Level 1 All personalities can be changed CODE Allows access level password to be entered Use LEFT RIGHT to select digit Use UP DOWN to change digit Use ENTER to update access level PERSONALITIES DRIVE ACCEL Displays adjusts drive acceleration DECEL Displays adjusts drive deceleration CREEP Displays adjusts minimum drive speed LOW MAX Displays adjusts maximum low drive speed NOTE Used when high drive not select
45. STICS ASPCIN Displays current controller mode NEUTRAL DRIVE FORWARDLLIFT etc PLATFORM JOYSTICK Displays joystick demand 0 100 Preceded by for forward up out or by for reverse down in STEER Displays steer status NONE LEFT RIGHT etc POSI TRAC Displays posi trac switch status OPEN CLOSED HIGHDRIVE Displays high drive switch status OPEN CLOSED TRIGGER Displaystrigger switch status OPEN CLOSED DRIVE Displays drive mode select switch status OPEN CLOSED LIFT Displays lift mode select switch status OPEN CLOSED DECK Displays deck mode select switch status OPEN CLOSED Notdisplayedif POWER DECK NO GROUND UP Displays ground lift up switch status OPEN CLOSED DOWN Displays ground lift down switch status OPEN CLOSED OUT Displays ground deck out switch status OPEN CLOSED Notdisplayedif POWER DECK NO IN Displays ground deck in switch status OPEN CLOSED Notdisplayedif POWER DECK NO 3120878 JLG Lift 2 33 SECTION 2 PROCEDURES Table 2 7 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY SYSTEMS BATTERY Displays measured battery voltage NOTE Only accurate when line contactor closed TEMPERATURE Displays measured heatsink temperature PUMP VOLT Displays calculated pump motor voltage PUMP AMP Displays calculated pump motor current ELEVATION Displays elevation cutout switch status OPEN CLOSED Closed with platform fully
46. T 1 Overload switch for French Japanese machines Cuts outall functions Sounds platform alarm for two seconds two seconds off while operator tries to perform the function that has been cut out provided the platform alarm is installed 6 0 No ground alarm installed 0 GROUND ALARM 1 Descentalarm Sounds when LIFT DOWNis active 2 Travel alarm Sounds when DRIVE function is active 3 Motion alarm Sounds whenever the DRIVE LIFT or DECK function is active 7 0 No drive cutout switch installed 0 DRIVE CUTOUT 1 Cuts out DRIVE when deckis elevated above a predetermined elevation varies with machine model 8 0 Noarm guard cutout 0 ARM GUARDS 1 European CE Specification machines LIFT DOWN cutout mustactivate when the gap between the arms is 5in to 8 in 13 cm to 20 cm Here it will cutout LIFT DOWN and sound the platform alarm for 1 2 second 1 2 second off and repeat this for three seconds After three seconds the operator must re select the LIFT function and continue to operate LIFT DOWN Ifthe wires to the limit switch used to detect the deck heightare cutor the switch has failed the platform alarm will sound as mentioned The operator can re select the LIFT function and then LIFT DOWN for ten seconds at which time itwill cut out again and the process must be repeated 9 0 LED Only 0 Flash Codes 1 LED and lamps in platform control box 2 LED and alarm 3 LED lamps in control box and alarm
47. ULD BE PERFORMED A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA 1 Tag and disconnect the hoses from the cylinder ports WARNING DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Place the cylinder barrel into a suitable holding fix ture 3 Using a suitable hammer tap around the outside of the cylinder barrel and guide to shatter the Loctite 4 Using a suitable spanner wrench carefully remove the guide from the rod Clevis end of the cylinder bar rel 5 Attach a suitable pulling device to the clevis end of cylinder rod section one A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD GUIDE AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 6 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 7 Using a suitable hammer tap around the outside of the cylinder barrel and guide to shatter the Loctite 8 Using a suitable spanner wrench carefully remove the remaining guide from the cylinder barrel Remove and discard the wiper ring rod seal back up ring and o ring 9 Using suitable protection clamp cylinder rod sec tion two in a vise or similar holding fixture 3120878 10 Carefully remove cylinder rod section one from cyl inder rod section two and carefull
48. ained access to level 1 and a personality item is selected press the UP or DOWN arrow keys to adjust its value for example PERSONALITIES DRIVE ACCEL 1 0s There will be a minimum and maximum for the value to ensure efficient operation The value will not increase if the UP arrow is pressed when at the maximum value nor will the value decrease if the DOWN arrow is pressed and the value is at the minimum value for any particular personal ity If the value does not change when pressing the up and down arrows check the access level to ensure you are at access level 1 When a machine digit item is selected press the UP or DOWN arrow keys to adjust its value for example GROUND ALARM 2 DRIVE The effect of the machine digit value is displayed along with its value The above display would be selected if the machine was equipped with a ground alarm and you 2 24 JLG Lift wanted it to sound when driving There are certain set tings allowed to install optional features or select the machine model When selecting the machine model to match the size of the machine the personality settings will all default to the factory recommended settings Note Refer to the appro priate Machine Personality Settings Table and the Machine Setup Table in the JLG Service Manual for the recommended factory settings Refer to the JLG part number of the controller printed on the front label to select the correct table in the manual NOTE
49. amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed 2 2 Batteries Clean batteries using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry batteries and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Section 1 2 3 LUBRICATION INFORMATION Hydraulic System 1 primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution must be taken to keep hydraulic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied
50. balance valve is defective and must be replaced 5 f no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 6 Remove lifting device from platform activate hydrau lic system and run cylinder through one complete cycle to check for leaks 2 9 ARM ASSEMBLY MAINTENANCE A IMPORTANT IT IS RECOMMENDED THAT WHEN PERFORMING MAINTENANCE ON THE ARM ASSEMBLY THE MACHINE BE PARKED IN THE STOWED POSITION FULLY LOWERED Platform Removal Remove the platform from the arm assembly with the plat form extension and rail assemblies intact as follows 1 Disconnect electrical control cable from platform control box 2 Disconnect any other options that lead to the plat form from the arm assembly NOTE The approximate weight of the platform and rail assemblies is 227 kg 500 Ib When removing the platform and rail assemblies be sure the lifting device being used is capable of handling these weights 3 Using an overhead crane or suitable lifting device use nylon straps to support platform and rail assem blies 4 Remove pin retaining hardware from front and rear deck pins 5 Using a suitable brass drift and a hammer remove pins from the pivot mounts on the under side front of the platform and from the slide blocks in rear 6 Using all applicable safety precautions carefully lift platform and rail assemblies clear of arm assembly and lower to ground or
51. ction If the joystick is not activated within three seconds of selecting a function it will be nec essary to re select a function High drive and positive trac tion are used in conjunction with the drive function The motor controller will control current output as pro grammed for smooth operation and maximum cycle time Ground control speeds for platform lift and the optional power deck are also programmed into the motor control ler The motor controller also features an adjustable time limit for positive traction Another power saving feature is the high speed drive current limit This feature will auto matically control the drive speed and controller output when it exceeds the pre set current limit for a specified time and reduce the motor speed thus conserving power For safety the machines are equipped with pothole pro tection and elevation cutback The pothole protection is employed as the platform is raised If the pothole protec tion does not extend the drive function will be disabled When the platform is raised the drive function goes into creep mode 3120878 SECTION 2 PROCEDURES 3120878 The JLG SMART System controller has a built in LED to indicate any faults The system stores recent faults which may be accessed for troubleshooting Optional equip ment includes an hourmeter beacon light tilt switch light and or alarm power deck power deck extension limit function cutout and ground alarm These
52. d Pothole Protection System Lowered 1 5 LUBRICATION All Models 1 9 cm 0 75 in Hydraulic Oil Maximum Tire Load Table 1 4 Hydraulic Oil 1532E3 481 kg 1 060 Ib HYDRAULIC SYSTEM 1932E3 499 kg 1 100 Ib OPERATING SAE VISCOSITY GRADE TEMPERATURE RANGE 2033E3 640 kg 1 410 Ib 0 Fto 23 10W 2046 776 kg 1 710 Ib 18 Cto 5 C 2646E3 794 kg 1 750 Ib 0 Fto 210 F 10W 20 10W 30 18 Cto 99 C 2658E3 885 kg 1 950 Ib 50 Fto 210 F 20 20 Maximum Bearing Pressure S NOTE Hyaraulic oils must have anti wear qualities at least Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 1532E3 6 5 kg cm 92 psi 1932E3 6 6 kg cm 94 psi 2033E3 7 2 kg cm 102 psi 2046E3 8 2 kg cm 117 psi 3 NOTE When temperatures remain consistently below 7 20 F recommends the use of Mobil DTE13M 2646E3 8 4 kg cm 119 psi hydraulic oil 2658E3 9 1 kg cm 130 psi 3120878 JLG Lift 1 3 SECTION 1 SPECIFICATIONS SERIAL NUMBER SERIAL NUMBER PLATE Figure 1 1 Serial Number Location
53. dOud 3H L ONIB3IN3 YALA T3A31 9309 V nue L LT3A31 5399 NI OL SANAN 713437 dOL IHL H NOHHL 110828 NYO SA34 ISIHL SNISS3Hd NOISYAA WASKIVNY NOISUA 245 40 CAAVINYYV SNOISUIA NAIRLIVS NIW 00 awas D im 1Nauuno NINYI H HITRUS Coni N40 LATI WWW waor H Tas saraso Em SNOLIVUSITVD vx TAS AATA ason hama sso quang 9 Cas 07 avausoa asom wowavi9 sian Cmn gt TN Cw D aao sama nom E NMOG TEE aw sw osusu num naa omo Nato aso Cro waa gt NO LIII uou sm Hiv amp ona woa woun H 3l H anono vouowna moma voan wusor WAA 43404 HOLAS 10 TOV fisan narsis wo owwa SESS now naoa 0 edeos3 1 0 T 01999014 MO DNIHIANAAA 2 25 JLG Lift 3120878 SECTION 2 PROCEDURES 2 21 MACHINE PE
54. dures are designed to provide the saf est and most efficient maintenance for use by personnel responsible for ensuring the correct installation and oper ation of machine components and systems NOTE Maintenance procedures provided in this section apply to all six scissor lift models covered in this manual Procedures that apply to a specific model will be so noted CAUTION WHEN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapter Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness
55. e Et pere Perlen e IRE ace dos Pande shoes 1 1 1 3 RUE C E Nom Ts doom E 1 1 1 4 Torque Requirements 2 4 eire 1 3 1 5 Lubrication ee ee adie EDS UN RR E E ru RS RR E REUS 1 3 1 6 Serial Number 4 1 4 1 7 Cylinder Specifications 1 6 1 8 Pressure Settirigs re ees ve i vad 1 6 1 9 Lirnit Switches Re Ren idee e dabei Few ghee EY ed ce ipea 1 6 1 10 Critical Stability Weights 1 6 SECTION 2 PROCEDURES 2 1 General oc rhe EROR ERTEILEN pP LAE 2 1 2 2 Servicing and Maintenance Guidelines 2 1 2 3 Lubrication Information llis uh 2 2 24 Cylinders Theory of 2 3 2 5 Valves Theory of 2 3 2 6 Component Functional Description 1 2 4 2 7 Wear Pads 2 pe hea ea acce iren Oda dre ea cade oe 2 4 2 8 Cylinder Checking 4 2 4 2 9 Arm Assembly
56. eal Kit 7 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 8 Carefully thread the piston on the cylinder rod hand tight ensuring that the o ring and back up rings are not damaged or dislodged 9 Thread the piston onto the rod until it abuts the spacer end and install the tapered bushing NOTE When installing the tapered bushing the piston and mating end of the rod must be free of oil GUIDE LOCK RING SEAL BACK UP GUIDE LOCK RING Figure 2 11 Piston Seal Kit Installation WARNING WHEN REBUILDING THE LIFT CYLINDER APPLY LOCTITE 242 TO TAPERED BUSHING BOLTS THEN TIGHTEN BOLTS SECURELY REFER TO TABLE 2 1 CYLINDER COMPONENT TORQUE SPECIFICATIONS FOR PROPER BOLT TORQUE VAL UES 10 Install the bolts into the bushing using Loctite 242 Refer to Table 2 1 Cylinder Component Torque Specifications for proper bolt torque values 2 10 JLG Lift PISTON TAPERED BUSHING CAP SCREWS Figure 2 12 Tapered Bushing Installation 11 Remove the cylinder rod from the holding fixture 12 Place new guidelock and hydrolock seals in the applicable outside diameter grooves of both the pis ton and the cylinder head PISTON REF Figure 2 13 Poly Pak Piston Seal Installation 13 Position the cylinder barrel in a suitable holding fix ture A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING
57. ecks are listed and defined in the following table This table is divided into two basic parts the to be inspected and the INTERVAL at which the inspection is to take place Under the portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries A IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM NOTE This machine requires periodic safety and mainte nance inspections be a JLG Dealer A decal located on the frame affords
58. ected menus while in access level 2 Remember you may always cancel a selected menu item by pressing the ESC key 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 configuration settings which cannot be changed until you enter a pass JLG Lift 2 23 SECTION 2 PROCEDURES word to advance to a lower level This ensures that a set ting cannot be accidentally altered To change the access level the correct password must be entered To enter the password scroll to the ACCESS LEVEL menu For exam ple MENU ACCESS LEVEL 2 Press ENTER to select the ACCESS LEVEL menu Using the UP or DOWN arrow keys enter the first digit of the password 3 Then using the RIGHT arrow key position the cursor to the right one space to enter the second digit of the pass word Use the UP or DOWN arrow key to enter the second digit of the password which is 3 Repeat this process until you have entered all five digits of the password which is 33271 Once the correct password is displayed press ENTER The access level should display the following if the pass word was entered correctly MENU ACCESS LEVEL 1 Repeat the above steps if the correct access level is not displayed or you can not adjust the personality settings Adjusting Configuration Using the Hand Held Analyzer on 1600289 Controllers Once you have g
59. ed HIGHMAX NOTE Used when high drive not selected ELEVATED MAX Displays adjusts maximum drive speed elevated NOTE Used when elevation or pothole cutout switches are limiting max speed NOTE Only adjustable in access level 1 POSI TRAC Displays adjusts posi trac engaged time out HIGH DRIVE AMP Displays adjusts high drive motor overload current NOTE Only adjustable in access level 1 HIGHDRIVE Displays adjusts high drive motor overload time out LIFT ACCEL Displays adjusts lift acceleration DECEL Displays adjusts lift deceleration CREEP Displays adjusts minimum lift up speed MAX UP Displays adjusts maximum lift up speed MAX DOWN N A Displays if there is no lift down gravity Displays adjusts for power down machines for maximum lift down speed 2 36 JLG Lift 3120878 SECTION 2 PROCEDURES Table 2 7 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY DECK ACCEL Displays adjusts deck acceleration DECEL Displays adjusts deck deceleration CREEP Displays adjusts minimum deck speed MAXOUT Displays adjusts maximum deck out speed Displays adjusts maximum deck in speed STEER STATIC Displays adjust steer speed NOTE Used when not driving DRIVE COMP Displays adjusts steer compensation speed NOTE Used as additive when driving NOTE Only adjustable in access level 1 GROUND MODE LIFT UP Displays adjusts fixed lift up speed LIFT DOWN N A Displays if no po
60. ed portion of the rod for excessive damage Dress the threads as necessary Inspect inner surface of cylinder barrel tube for scratches and pits There should be no scratches or pits deep enough to catch the fingernail Scratches that catch the fingernail but are less than 12 7 mm 0 5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the piston seal Inspect the threaded portion of the barrel tube for damage Dress the threads as necessary Inspect piston outside surface for scratches or pol ishing Deep scratches are unacceptable Polishing indicates uneven loading and when this occurs the diameter should be checked for out of roundness If out of roundness exceeds 0 178 mm 0 007 inch this is unacceptable Check the condition of the seal and o ring looking particularly for metallic particles embedded in the seal and o ring surfaces Remove the seal and o ring Damage to the seal grooves particularly on the sealing surfaces is unacceptable If an unacceptable condition exists replace the pis ton Inspect the piston spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent Inspect the cylinder head inside bore for scratches or polishing Deep scratches are unacceptable Pol ishing indicates uneven loading and when this occurs the bore should be checked for out of roundness If out of roundness exceeds 0 178 mm 0 007 inch
61. eed drive Consult factory for tilt sensor adjustment The only field adjustment necessary is leveling the switch on the spring loaded studs There are two methods of adjustment a manual adjustment and an adjust ment using a voltmeter CAUTION PERFORM TILT ALARM SWITCH LEVELING PROCEDURE MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 Park the machine on a flat level surface and ensure the machine is level NOTE Ensure switch mounting bracket is level and securely 3120878 attached Level the base of the indicator by tightening the three flange nuts Tighten each nut through approxi mately one half of its spring travel DO NOT ADJUST THE NUT DURING THE REMAINDER OF THE PROCEDURE With the electrical connections complete slowly tighten one of the Y nuts until the circuit is closed the light on the Platform Control Console illumi nates the tilt alarm sounds Slowly back off the nut counting the number of turns until the circuit is closed again Divide the number of turns determined in step 4 in half Tighten the nut this many turns The line deter mined by this nut and the X nut is now parallel to the ground Repeat steps 3 through 5 for the remaining Y nut The switch is now level Figure 2 17 Tilt Switch Leveling Manual Adjustment 7 Individually push down on one corner at a time there should be enough travel
62. elp Messages and Flash Codes 2 30 2 25 Analyzer Menu 2 33 2 26 Preventive Maintenance and Inspection 2 39 SECTION 3 TROUBLESHOOTING 3 1 rl tae hee 3 1 3 2 Troubleshooting 2222222 2 3 1 3 3 Hydra lic Circuit Ghecks ed NE Pu pedore erii e Apt Gr meu reed dele 3 1 3 4 JEG SMART Systetn stone ee veces See eae Lione dia woe et Fane een aa n 3 1 3120878 JLG Lift TABLE CONTENTS Continued LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Serial Number 4 1 4 1 2 Lubrication Diagram 1 5 1 3 Torque Charts eere mE Set Ree weit elt evi ed ies 1 7 2 1 Plattform Removal RE EUR ER IDEE aM ee 2 6 2 2 Lift Cylinder Components 2 7 2 8 Barrel SUPPO ou itor opes Me dido Mi de 2 7 2 4 Capscrew 2 7 1 2 8 2 5 Rod Supports cider dE Ro PU ao de 2 8 2 6 Tapered Bushing 1 102 m 2 8
63. es adja cent to the long tab on the disc valve 10 11 12 13 14 15 16 17 JLG Lift Place the needles in the outer ring and hold them in place with grease Carefully place the distributor plate on the bearing housing so that the shaft enters the bearing Press the distributor plate until it stops on the housing and line up the screw holes Place the O rings greased in the gearwheel O ring recesses If there is a recess on one end of the splined hole position the gearwheel with recess on the same side as the smallest screw hole stage hole in the gearwheel rim Fit the gearwheel set with this side facing the motor Clockwise Revolution Fit the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel is vertically over the mark on the cardan shaft Turn the gearwheel set counterclockwise until the cardan shaft and gearwheel engage 15 Turn the gear wheel rim to line up the screw holes Counterclockwise Revolution Fit the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel is vertically over the mark on the cardan shaft Turn the gearwheel set clockwise until the cardan shaft and the gearwheel engage 15 Turn the gearwheel to line up the screw holes Rotate the end cover to line up the screw holes Use new washers and a 13 mm socket spanner Torque to 3 75 4 25 daNm 330 380 Ibf in Screw in
64. es and ports 5 Remove the bolt and locknut securing the barrel end attach pin to the lower arm assembly Using a suit able brass drift drive out the barrel end attach pin from the arm assembly 6 Carefully remove the cylinder from the scissor lift and place in a suitable work area Lift Cylinder Installation 1 Install lift cylinder in place using suitable slings aligning barrel end attach pin mounting holes on lower arm assembly 2 Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the lower arm assembly Secure in place with the bolt and locknut 3 Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports 4 Extend the cylinder rod until the attach pin hole aligns with those in the upper arm assembly Using a suitable drift drive the cylinder rod attach pin through the aligned holes taking care to align the pin retaining hole with the hole in arm assembly Secure the pin in place with the bolt and locknut 5 Lower platform to stowed position and shut down motor Check hydraulic fluid level and adjust accord ingly 2 11 LIFT CYLINDER REPAIR NOTE The following procedures apply to the lift cylinder only Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA BE SURE TO CLEAN ALL DIRT OR OTHER FOREIGN SUBSTANCES FROM CYLINDER
65. essive wear If necessary replace bearings as follows a Thoroughly clean steel bushing hole of burrs dirt etc to facilitate bearing installation b Inspect steel bushing for wear or other damage If steel bushing is worn or damaged rod or bar rel as applicable must be replaced c Lubricate inside of steel bushing with WD 40 prior to bearing installation d Using arbor of the correct size carefully press the bearing into the steel bushing Install the cylinder pin into the Oll lite bearing dry Lubrication is not required with chrome pins and bearings STEEL OIL LITE BUSHING BUSHING ARBOR 14 15 16 17 Figure 2 7 Bearing Installation Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary Assembly NOTE 3120878 Prior to cylinder assembly ensure that the proper cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly 1 Using a special tool pictured in the following illustra tion install a new rod seal into the applicable cylin der head gland g
66. hese settings not be changed Changing these settings may adversely affect the performance of your machine 3120878 JLG Lift 2 27 SECTION 2 PROCEDURES 2 23 MACHINE CONFIGURATION INFORMATION NOTE The following information is to be used when working must be completed before any personality settings can be changed Changing the personality settings first and then changing the model number of the machine configuration will cause the personality set with the MACHINE SETUP menu When configuring tings to return to default values the E Series scissor lift the machine configuration Table 2 4 Machine Configuration Programming Information Configuration Digit Number Description Default Setting Before Programming 1 MODEL NUMBER MODEL 1532E3 MODEL 1932E3 MODEL 2033E3 MODEL 2046E3 MODEL 2646E3 MODEL 2658E3 3 2 TILT SWITCH No tilt switch installed Tilt switch installed for North american CE and optional for Latin American machines This digit will allow the SMART System to indicate when the machineis out of level by lighting the lightin the platform box Ifthe machine is elevated and tilted the SMART System will also sound the platform alarm continuously No functions are cutback or cutout Tilt switch for Australia Japanese and option for Latin American machines This digit will allow the SMART System to indicate when the machine is out
67. hin an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the remedial action should where possi ble be checked in the order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should be recognized that the majority of the problems arising in the machine will be centered in the hydraulic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting any circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil and electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS The first reference for improper f
68. his is probably due to power wiring error PUMP MOTOR OPEN CIRCUIT CHECK MOTOR amp WIRING Pump point Ais col lapsing when the pump MOSFETs are pulsed This is probably due to an open circuit pump motor or a power wiring error PUMP MOTOR STALLED CHECK MOTOR amp WIRING The pump MOSFET protec tion circuitis active This is due to massive current drain and could be a stalled pump motor or power wiring error 9 9 Indicates problems with the controller CONTROLLER FAILURE HWFS TEST STALLED The hardware fail safe tests did not complete but no reason can be determined CONTROLLER FAILURE HWFS TEST STALLED 15 The hardware fail safe tests failed because the contactor drive fail safe did not trip within the allowed test time NOTE Anytime a reading of a 15 code aooears the controller must be replaced 2 32 JLG Lift 3120878 SECTION 2 PROCEDURES 2 25 ANALYZER MENU STRUCTURE between items in the same level The UP DOWN arrow keys alter a value if allowed In the following structure descriptions an intended item is selected by pressing ENTER pressing ESC steps back to the next outer level The LEFT RIGHT arrow keys move Table 2 7 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY HELP PRESS ENTER HELP Displays currenthelp fault message LOGGED HELP Log of most recent help fault messages LEFT RIGHT view DIAGNO
69. in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles is found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the
70. intervals required in Section 1 Always examine filters for evidence of metal particles 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 15 not advisable to mix oils of different brands or types except as recommended as they may not contain the same required additives or be of compa rable viscosities Good grade mineral oils with vis cosities suited to the ambient temperatures in which the machine is operating are recommended for use NOTE Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents Hydraulic Oil JLG Lift 1 Refer to Hydraulic Oil Table in previous section for recommendations for viscosity ranges 3120878 SECTION 2 PROCEDURES 2 JLG recommends Mobilfluid 424 which has an SAE viscosity of 10W 30 and a viscosity index of 152 which has an SAE viscosity of 10W 20 and a viscos ity index of 152 NOTE Start up of hydraulic system with oil temperatures below 26 C 15 is not recommended If it is necessary to start the system in a sub zero environ ment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 26 15 F 3 The only exception to the above is to drain and fill the system with Mobil DTE 13M oil or its eq
71. is just switching on or is discharging the capacitor bank Awelded line contactor might also cause this 2 2 Indicates problems with platform controls ALL FUNCTIONS PREVENTED NO DATA FROM PLATFORM BOX The signal from the MUXboardinthe platform boxis notavailable drive liftand deckfunctions cannotbe selected FUNCTION PROBLEM PERMANENTLY SELECTED The drive liftor deck function selectis active for more than ten seconds any active function will be stopped FUNCTIONS LOCKED OUT RELEASE THEN RESELECT The selected function is notallowed release the joystick to clear the fault HIGH DRIVE PROBLEM PERMANENTLY SELECTED The high drive function select is active for more than ten seconds the high drive function will be stopped FUNCTION SELECTED BUT TRIGGER NEVER CLOSED Occurs after ten seconds with the joystick in neutral but trigger switch never closed JOYSTICK FAULTY WIPER OUT OF RANGE Occurs if wiper voltage is invalid JOYSTICK FAULTY CENTER OUT OF RANGE Occurs if center tap voltage is invalid JOYSTICK FAULTY STEER SWITCHES ACTIVE TOGETHER JOYSTICK LOCKED OUT RELEASE THEN RESELECT PORITRAC PROBLEM PERMANENTLY SELECTED TRIGGER INTERLOCK TRIPPED Trigger switch was closed for more than ten sec onds with no function selected WAITING FOR TRIGGER SWITCH TO BE OPEN Trigger switch was closed when plat form mode was selected 2 3 Indicates problems with ground controls GROUND FUNCTIONS LOCKED OUT
72. lic hose from cylinder extend port 6 Activate motor and activate cylinder retract function Check extend port for leakage 7 cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks Cylinders w Single Counterbalance Valves Lift Cylinder OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE DO NOT FULLY EXTEND LIFT CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Raise platform completely then retract cylinder slightly to avoid trapping pressure Place a suitable overhead lifting device approximately 2 5 cm 1 in below the platform 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes Carefully remove hydraulic hoses from cylinder port block 3120878 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counter
73. lowered DIAGNOSTICS SYSTEMS FUNCTION C O Displays function cutout switch status OPEN CLOSED Continued Not displayed if FUNTION CUTOUT NO DECKC O Displays function cutout switch status OPEN CLOSED Not displayed if POWER DECK NO DRIVE C O Displays function cutout switch status OPEN CLOSED Not Displayed if DRIVE CUTOUT NO Displays pothole cutout switch status OPEN CLOSED TILT Displays tilt switch status LEVEL TILTED Not Displayed if TILT SWITCH NO ARMGUARD Displays armguard cutout switch status OPEN CLOSED Not displayed if ARMGUARD CUTOUT NO 2 34 JLG Lift 3120878 SECTION 2 PROCEDURES Table 2 7 Analyzer Menu Structure ITEM TO BE VIEWED TOP LEVEL MENU SUB LEVEL MENU OR CHANGED DESCRIPTION DISPLAY DATALOG ON Displays total controller on time NOTE Upto four minutes lost at switch off DRIVE Displaystotal controller drive operation time LIFT Displays total controller lift operation time DECK Displaystotal controller deck operation time NOTE Not displayed if POWER DECK NO PUMP Displays total controller pump running time NOTE Includes drive lift up deck and steer RENTAL Displays total controller pump running time NOTE Canbe reset ERASE RENTAL Notavailable in level 3 YES ENTER NOESC ENTERresets rental datalog time to zero MAX TEMP Displays maximum measured heatsink temperature MIN TEMP Displays minimum measured heatsink temperature MAX BATTE
74. mensions are given in inches in with the met ric equivalent centimeters cm given in parenthe Ses Table 1 6 Cylinder Specifications DESCRIPTION BORE STROKE RODDIA Electronic Armguard Switch Lift Cylinder 1532E3 3 00 30 38 2 00 Lift down is cut out when the gap between the arms is in 1932E3 7 6 77 2 5 1 the range of 13 cm to 20 cm 5 in to 8 in This will cut out Lift Cylinder 2033E3 3 50 48 19 2 00 lift down and sound the platform alarm for 1 2 second on 2046E3 8 9 122 40 5 1 1 is second _ 22 Lift Cylinder 2646 4 00 48 44 2 50 2 Ln M gd dd 2658E3 10 2 123 0 6 4 9 88 m 1 9 This switch ts the high drive function f EVER is switch prevents the high drive function from engag a 35 ing when the oil temperature is very cold The machine will ERES 5 1 4 remain low drive until the has warmed and will then automatically move up to high drive 1 8 PRESSURE SETTINGS Main Relief 3000 psi 50 0 psi 207 3 4 0 bar 1 10 CRITICAL STABILITY WEIGHTS Steer Relief 2100 psi 145 bar Table 1 7 Critical Stability Weights Lift Up Relief 1532 112 bar 1625 psi 2033E3 2046E3 Component 1532E3 1932E3 2646E3 2658E3 1932E3 138 bar 2000 psi Tires Solid each 2416 3116 2033 105 bar 1525 psi 11 14kg 124 1 i Tires Solid N
75. n worn to 48 mm 1 875 in 2 8 CYLINDER CHECKING PROCEDURES NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinder w o Counterbalance Valves Platform Extension Cylinder If Equipped Brake Cylinder and Steer Cylinder A IMPORTANT OPERATE FUNCTIONS FROM GROUND CONTROL STATION ONLY A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE PLAT FORM COMPLETELY AND SUPPORT THE PLATFORM USING A SUITABLE OVERHEAD LIFTING DEVICE DO NOT FULLY EXTEND CYLINDER TO END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 1 Using all applicable safety precautions activate motor and fully extend cylinder to be checked Shut down motor 3120878 SECTION 2 PROCEDURES 2 Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port 3 Activate motor and activate cylinder extend function Check retract port for leakage 4 If cylinder leakage is 6 8 drops per minute or more piston seals are defective and must be replaced If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to retract port and retract cylinder 5 With cylinder fully retracted shut down motor and carefully disconnect hydrau
76. nce of equip ment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is pro vided WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPON SIBILITY OF THE OWNER OPERATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic sys tems operate at extremely high potentially danger ous pressures Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system 3120878 Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss A C MAINTENANCE WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO B
77. of level by lighting the lightin the platform box Ifthe machine is elevated and tilted the SMARIT Sys tem will also sound the platform alarm continuously and the lift up and drive func tions are cutout 3 POWER DECK No power deck installed Machine equipped with power deck 4 DECK EXT LIMIT SWITCH Deck extension limit switch notinstalled This cannot be zero if there is a power deck installed Cuts out LIFT DOWN when deck is extended This digitis used with roll out decks that require a deck extension cutout Sounds platform alarm for one second on one sec ond off one second on and three seconds off while operator tries to perform the func tion that has been cut out provided the platform alarm has been installed Cuts out HIGH DRIVE when deckis extended and below elevation Cuts out DRIVE when deck is extended and above elevation This digitis used with a power deck Sounds platform alarm for one second on one second off one second on and three seconds off while operator tries to perform the function that has been cut out and dur ing the LIFT DOWN function provided the platform alarm has been installed 2 28 JLG Lift 3120878 SECTION 2 PROCEDURES Table 2 4 Machine Configuration Programming Information Default Setting Configuration Digit Number Description Before Programming 5 0 No function cutout installed 0 FUNCTION CUTOU
78. on 241b 301b 2646E3 124 bar 1800 psi Marking each 11 kg 14 kg 2658 145 bar 2100 psi Motor Pump 41 Ib 41 Ib Assembly 19kg 19kg Powered Deck Extension Relief If Equipped Batteries Stan 6316 6316 207 bar 3000 psi dard each 21 kg 21 kg Batteries Stan 25210 25210 1 9 LIMIT SWITCHES dard combined 114 kg 114 kg The machines are equipped with the following limit switches Tilt Alarm optional 1 1 2 or 2 Illuminates a light on the platform and sounds an alarm when the machine is 1 1 2 or 2 depending on which tilt the machine is equipped with out of level in any direction High Drive Cut Out High drive speed is cut out when the platform is raised above the stowed position 3120878 JLG Lift 1 5 SECTION 1 SPECIFICATIONS enbaJo 72 8 avs S 3av39 avs poye d uinipeo Ajdde jou op 69912 CCG 9686 2096 O0CCVL SLLE 9794 ESEZ L8Z6 0018 ze 15189 civ 057 005 085 19 64 c 0861 089 18595 1898 9 8055 87969 8907 6 lt 62 99 2 889 01959 EZEZ cvoc 8011 8465 ze SYE 16626 6555 98562 tive Lece 8902 6 086 97066 75562 9 6
79. on solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consists of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral pro hibiting any flow through the circuit JLG Lift 2 3 SECTION 2 PROCEDURES Proportional Control Valves The proportional control valves provide a power output matching that required by the load A small line connected to a load sensing port feeds load pressure back to a sequence valve The sequence valve senses the differ ence between the load and pump outlet pressure and varies the pump displacement to keep the difference con stant This differential pressu
80. options may be added later but some must be programmed into the motor controller when installed The SMART System may be accessed by utilizing a cus tom designed hand held analyzer JLG kit no 2901443 which will display two lines of information at a time by scrolling through the program NOTE The date code is determined by the first four dig its of the controller serial number which is located on the label attached to the front of the controller The part number of the controller is located on the controller decal To Connect the Hand Held Analyzer 1 Connect the four pin end of the cable supplied with the analyzer to the top connection of the motor con troller and connect the remaining end of the cable to the analyzer NOTE The cable has a four pin connector at each end of the cable the cable cannot be connected back wards 2 Power up the SMART System by turning the lower key to the platform position and pulling both emer gency stop buttons on Using the Analyzer With the machine power on and the analyzer connected properly the analyzer will display the following HELP PRESS ENTER At this point using the RIGHT and LEFT arrow keys you can move between the top level menu items To select a displayed menu item press ENTER To cancel a selected menu item press ESC then you will be able to scroll using the right and left arrow keys to select a different menu item The top level menus are
81. or replace motor System pressure too low Main relief valve set too low Resetas required Hydraulic pump not functioning properly Repair or replace pump Leakin component line or fitting Scored valve spool scored cylinder Repair or replace component line or fitting Replace valve replace cylinder System s operate erratically Sticking or binding valve cartridge piston rod etc Hydraulic oil not at operating temperature Clean repair or replace components as neces sary Allow oil sufficient time to warm up JLG Lift 3120878 SECTION 3 TROUBLESHOOTING BRAKE CYLINDER 3120878 LEFT DRIVE MOTOR STEER CYLINDER LIFT RELIEF SET SEE MANUAL PER MODEL STEER RELIEF 2 ser zi00Psi 1 CONTROL VALVE nm NOTE TEMP SWITCH TO BE cured TO RETURN 1282879 D Figure 3 1 Hydraulic Schematic 2033E3 2046E3 2646E3 2658E3 JLG Lift 3 3 SECTION 3 TROUBLESHOOTING 2 JLG KEYSWI TCH 51 6 6 E STOP 3 4 53 PLATFORM CONTROL E STOP YEL RED 2 3 HORN PUSHBUTTON ee 4 4 YEL RED 2 2 BLU ORN 52 1 gt S BLU RED 29 gt gt YEL RED 2 3 Ht PLATFORM ALARM OPTIONAL BLU ORN 52 3 YEL RED 2 3 BATTERY INDICATOR YEL RED 2 3 Bt DISCHARGE BLACK YEL RED 2 4 YEL RED 2 3 U2 MU
82. ow Valve Cartridge 25 30 ft Ib 34 41 Nm Flow Divider 25 30 ft Ib 34 41 Nm Brake Valve Cartridge 35 40 ft Ib 47 54 Nm Load Sense 25 30 ft Ib 34 41 Nm Lift Relief Cartridge 25 30 ft Ib 34 41 Nm Counterbalance Valve Cartridges 35 40 ft Ib 47 54 Nm Drive Valve Cartridge 35 40 ft Ib 47 54 Nm Socket Head Cap Screws 60 in Ib 7 Nm Figure 2 19 Pressure Setting Adjustments 3120878 JLG Lift 2 19 SECTION 2 PROCEDURES Castellated Nut Washer Dust Seal Ring Housing O Ring Shaft Seal Bearing Race Axle Needle Bearing Radial Needle Bearing Parallel Key Shaft Tapered O Ring Spring Washer Balance Plate Disc Valve Radial Needle Bearing Bearing Race Distributor Plate Cardan Shaft O Ring Gearwheel Set End Cover Name Plate Washers Screws Plugs ONOORWOND Figure 2 20 Drive Motor Sauer Danfoss 2 18 DRIVE MOTOR SAUER DANFOSS Dismantling 1 2 20 Place motor in proper holding device that allows access to the output shaft Carefully remove end cover sideways being sure to catch any parts that may fall from the gearwheel The needles bearings will fall out during dismantling and can be collected and reused The outer ring and thrust bearing need not be removed JLG Lift With the housing in the holding device press the shaft out of the housing Collect the needle bearings for possible
83. pecified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to the Lubrication Specifications Table in the previous section for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDERS THEORY OF OPERATION Cylinders are of the double acting type The Lift and Steer systems incorporate double acting cylinders A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of the rod will stop By directing oil to the rod side of the cylinder the piston will be forced in the opposite direction and the cyl inder rod will retract A holding valve is used in the Lift circuit to prevent retrac tion of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 2 5 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three positi
84. plastic plugs Turn the motor over and strike the dust seal into place with a plastic hammer and suitable mandrel Secure the key in place with tape 2 21 SECTION 2 PROCEDURES 2 19 POTHOLE PROTECTION SYSTEM LIMIT SWITCH Adjustment 1 With the pothole protection system in the fully down position mount the limit switch on the bracket in the rear of the machine 2 Adjust the switch to provide for 1 6mm maximum clearance between the roller and the cam A CAUTION WHEN MOUNTING OR ADJUSTING THE LIMIT SWITCH BE SURE THAT THE SAFETY PROP IS BEING USED PROPERLY 3 Tighten the switch mounting hardware 2 20 JLG SMART SYSTEM ANALYZER KIT INSTRUCTIONS Da G Ah Om ie 49 Torque Battery Cable J7 60 in Lb DO NOT D Figure 2 21 JLG SMART System Controller WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER THE MACHINE IT WILL BE NECESSARY TO PROGRAM THE CON TROLLER FOR THE PROPER MACHINE CONFIGURATION INCLUDING OPTIONS REFER TO ANALYZER KIT NO 2901443 A IMPORTANT WHEN INSTALLING A NEW SMART SYSTEM CONTROLLER ON THE MACHINE ELECTRICAL SILICONE GREASE JLG PART NUMBER 0100076 OR 7016397 MUST BE APPLIED TO THE BACK OF THE CONTROLLER 2 22 JLG Lift A IMPORTANT IT IS A GOOD PRACTICE TO AVOID PRESSURE WASHING ELEC TRICAL ELECTRONIC COMPONENTS SHOULD PRESSU
85. r bank charge did not decrease from bat tery supply when line contactor was de energized this could be due to a power wiring error 3120878 JLG Lift 2 31 SECTION 2 PROCEDURES Table 2 6 JLG SMART System Flash Codes amp Help Messages Code Description 3 3 Indicates that a contactor coil is short circuit SHORT CIRCUIT LINE CONTACTOR COIL The line contactor was not energized when required due to coil over current protection VALVE OR LINE CONTACTOR ENERGIZED CHECK WIRING The drive circuitto the line contactor or a valve is active when no driver circuitis turned on this could be due to a wiring error to the valves or line contactor 4 2 indicates that the controller is over temperature CONTROLLER TO HOT PLEASE WAIT The controller heat sink temperature reached 75 degrees The controller is shut down until it cools to below 70 degrees 4 4 Indicates problems with the battery supply BATTERY TOO LOW SYSTEM SHUT DOWN Battery voltage is below 17V EMS recycle required BATTERY TOO HIGH SYSTEM SHUT DOWN Battery voltage is above 30 V EMS recycle required 7 7 Indicates problems with a motor CAPACITOR BANK FAULT CHECK MOTOR WIRING The capacitor bankis not charging This is probably due to a power wiring error causing illegal current drain it couldalso be due to a very low battery supply POINT A LOW CHECK POWER CIRCUITS Pump point A is low when the MOSFETs are off T
86. re is applied across the valve s meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load pressure Return lines are connected together simplifying routing of return flow and to help reduce cavi tation Load sensing lines connect through shuttle valves to feed the highest load signal back to the sequence valve Integral actuator port relief valves anti cavitation check valves and load check valves are standard Relief Valves Main relief valves are installed at various points within the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Crossover Relief Valves Crossover relief valves are used in circui
87. re use Remove the housing from the holding device and place on a workbench With a screwdriver gently lever the dust seal ring from the housing Extract the shaft seal from the housing Press the remaining parts out using hydraulic equip ment Clean all parts carefully with a low aromatic kero sene 3120878 SECTION 2 PROCEDURES Assembly 3120878 NOTE Before assembly inspect all parts and replace if nec essary Before assembly lubricate all parts with hydraulic oil and grease rubber parts with vasoline Turn motor housing so the rear end faces upwards Press shaft seal into housing The bearing race can be fitted in any position Place the needle bearings in the outer ring and hold them in place with grease Place the whole bearing into the housing Press the bearing into position using pressure equipment if necessary Carefully insert shaft through bearing housing Place O ring greased in bearing housing O ring recess Place spring washer on balance plate insert O ring in recess and lubricate with grease Place balance plate lightly in position so that it engages Be careful not to damage the O ring Place the disc valve on the shaft with channels upwards so that the long tab on the disc valve engages with the slot in the shaft If there is a difference in the spline length fit the car dan shaft with he long spline end in the output shaft Mark the bottom of the cardan spline that li
88. rial Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used Refer to the Illustrated Parts Manual Apply a light film of hydraulic oil to all components prior to assembly 1 Using suitable protection clamp the cylinder rod section one in a vise or similar holding fixture JLG Lift 2 15 SECTION 2 PROCEDURES 2 16 1 Rod Section One 2 Guide 3 Wiper Ring 4 U Cup 5 Back Up Ring 6 O Ring 7 Cylinder Barrel 8 Piston Seal 9 Piston 10 O Ring 11 O Ring 12 Rod Section Two Figure 2 16 Steer Cylinder Repair Place a new wiper ring rod seal o ring and back up ring into the cylinder rod guide grooves Carefully install the cylinder rod guide on rod section one ensuring that the wiper ring and rod seal are not damaged or dislodged Push the guide onto the rod section Place a new piston ring on the piston and a new o ring on the threaded end of cylinder rod section two Carefully place the piston on the threaded end of cylinder rod section two ensuring that the o ring is not damaged or dislodged Push the piston onto the rod as far as it will go Attach cylinder rod section one to the threaded end of cylinder rod section two and assemble Remove the cylinder rod assembly from the holding fixture Position the cylinder barrel in a suitable holding fix ture A IMPORTANT EXTREME CARE SHOULD BE TAKEN
89. roove Refer to the following illustration for the proper tool size SEAL TOOL 1 7004275 SEAL 11 2 7004276 Jt CYLINDER 2 7002826 9 Figure 2 8 Rod Seal Installation WHEN INSTALLING NEW POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 13 POLY PAK PISTON SEAL INSTALLATION FOR CORRECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLINDER OPERATION 2 Using a soft mallet tap a new wiper seal into the applicable cylinder head gland groove Install a new wear ring into the applicable head gland groove CYLINDER MALLET HEAD Note When installing wiper seal ensure seal are installed properly Install seal so that the flat part of seal is facing into head Figure 2 9 Wiper Seal Installation 3 Place a new o ring and back up seal in the applica ble outside diameter groove of the cylinder head 4 Install a washer ring onto the rod then carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dislodged Push the head along the rod to the rod end as applicable 5 Carefully slide the piston spacer onto the rod 6 If applicable correctly place a new o ring and back up rings in the inner piston diameter groove JLG Lift 2 9 SECTION 2 PROCEDURES CYLINDER BACKUP RING Figure 2 10 Installation of Head S
90. stallation Sheet 1 3 6 JLG Lift 3120878 SECTION 3 TROUBLESHOOTING HAND HELD ANALYZER W 165 eoo D LOCKOUT AUSTRALIAN ONLY Figure 3 5 Electrical Componants Installation Sheet 2 3120878 JLG Lift SECTION 3 TROUBLESHOOTING This page left blank intentionally 3 8 JLG Lift 3120878 Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Customer Support Toll Free 877 554 5438 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 25 England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Street Meadowdale Germiston South
91. ther damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary 6 Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary 7 Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect seal and o ring grooves in guide for burrs and sharp edges Dress applicable surfaces as nec essary JLG Lift 2 13 SECTION 2 PROCEDURES 1 Cylinder Barrel 6 Piston Ring 11 Wiper Ring 2 Piston Locknut 7 O Ring 12 Retainer Ring 3 Piston 8 Back Up Ring 13 Rod 4 O Ring 9 Seal 5 O Ring 10 Guide Figure 2 15 Brake Cylinder Assembly 9 Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary 10 Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper 2 14 cylinder seal kit is used Apply a light film of hydraulic oil to all components prior to assembly Using suitable protection clamp the cylinder rod in a vise or similar holding fixture Place a new wiper ring rod seal o ring and back up ring into the applicable cylinder guide grooves Carefully install
92. to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the X nut and repeat steps 3 through 7 Voltmeter Adjustment 1 Park the machine on flat level surface and ensure the machine is level 2 Ifthe motor is not running turn the ignition switch to ON 3 Connect the black lead of the voltmeter to ground and the red lead to the yellow wire protruding from the pot on the bottom of the sensor 4 Adjust the leveling nuts to obtain the highest possi ble voltage reading 5 Check the voltage at the trip point in all four direc tions If the voltage reading is not symmetrical repeat step 4 above 2 16 LIMIT SWITCH ADJUSTMENT Platform Limit Switch The platform limit switch is located on the left side of the frame of the machine When activated the switch cuts out the High Drive function Adjust the switch to activate when the platform is raised above the stowed position JLG Lift 2 17 SECTION 2 PROCEDURES BLACK YELLOW Figure 2 18 Tilt Switch Leveling Voltmeter Adjustment 2 17 PRESSURE SETTING PROCEDURES NOTE Make all pressure adjustments with motor operating and hyaraulic oil at normal operating temperature In addition all functions must be operated from the platform control station in order to achieve full pump speed It may be necessary to use an assistant to adjust the pressure settings while
93. ts where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir Indi vidual integral reliefs are provided for each side of the circuit 2 6 COMPONENT FUNCTIONAL DESCRIPTION Hydraulic Pump The main hydraulic pump is an integral part of the electric motor pump assembly located at the rear of the battery and ground control tray on the frame of the machine The pump is a single section pump that provides an output of 11 4 Ipm 3 0 gpm 2 4 JLG Lift Lift Cylinder Counterbalance Manual Descent Valve The lift cylinder counterbalance manual descent valve is located on top of the lift cylinder The counterbalance valve is used to hold the platform in place when raised A cable is connected to the valve which when pulled manu ally opens the lift down port and allows the platform to be lowered in the event hydraulic power is lost Positive Traction Valve The positive traction solenoid valve is located on the main control valve and is activated by a switch on the platform control box When activated it equally divides the flow of hydraulic oil in the drive circuit to send an equal amount of oil to each drive motor 2 7 WEAR PADS Sliding Pads The original thickness of the sliding pads is 51 mm 2 0 in Replace sliding pads whe
94. uivalent This will allow start up at temperatures down to 29 C 20 F However use of this oil will give poor per formance at temperatures above 49 C 120 F Sys tems using DTE 13M oil should not be operated at temperatures above 94 C 200 F under any condi tion Changing Hydraulic Oil 3120878 1 Use of any of the recommended crankcase or hydraulic oils increases JLG s recommended oil change interval to 1200 hours However filter ele ments must be changed after the first 50 hours of operation and every 300 hours thereafter When changing the oil use only those oils meeting or exceeding the specifications appearing in this man ual If you are unable to obtain the same type of oil supplied with the machine consult your local sup plier for assistance in selecting the proper equiva lent Avoid mixing petroleum and synthetic base oils 2 Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace the cartridge any time the system oil is changed 3 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications S
95. unction of a hydraulic sys tem where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic check of the circuit components beginning with the control would follow For aid in troubleshooting refer to the Illustrated Parts Manual for hydraulic diagrams of the various circuits 3 4 JLG SMART SYSTEM The JLG SMART System uses 24 Volt multiplex motor control unit working in conjunction with a joystick control ler and several switches to operate all machine functions The SMART System has a built in LED to indicate any faults which occur during operation of the machine The system also stores the last ten trouble faults for use in troubleshooting the machine Each fault is indicated by a first sequence of flashes then short pause followed by a second sequence then a long pause before everything repeats When a fault occurs in normal operation the flash fault repeats while the fault is present as far as possible nor mal operation continues If there is more than one fault present the most important two will be indicated alter nately Faults are grouped according to the first digit the second digit provides an extra diagnostic indication In addition the control unit may be programmed for any future options that are added to the machine The SM
96. ure 2 4 Capscrew Removal EXTREME CARE SHOULD TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES Figure 2 5 Rod Support 8 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder barrel 9 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 10 If applicable loosen and remove the nut which attaches the piston to the rod then remove the pis ton from the rod 11 If applicable loosen and remove the cap screw s securing the tapered bushing to the piston 12 Insert the capscrew s in the threaded holes in the outer piece of the tapered bushing Progressively tighten the cap screw s until the bushing is loose on the piston then remove the bushing from the pis ton 13 14 15 16 PISTON rd TAPERED BUSHING CAP SCREWS Figure 2 6 Tapered Bushing Removal Screw the piston counter clockwise by hand and remove the piston from the cylinder rod Remove and discard the piston o rings back up rings guidelock rings and hydrolock seals If applicable remove the piston spacer from the rod Remove the rod from the holding fixture Remove the cylinder head and retainer plate from the rod Cleaning and
97. wer lift down NOTE Adjustable for power down machines DECK OUT Displays adjusts fixed deck speed out NOTE Not displayed if POWER DECK NO DECKIN Displays adjusts fixed deck speed in NOTE Not displayed if POWER DECK NO MACHINE CURRENT Displays adjusts maximum motor current NOTE DO NOT ADJUST 3120878 JLG Lift 2 37 SECTION 2 PROCEDURES Table 2 7 Analyzer Menu Structure TOP LEVEL MENU SUB LEVEL MENU Ho Sid de DESCRIPTION DISPLAY MACHINE SETUP MODEL NUMBER Displays adjusts machine model NOTE All personalities resetto defaultwhen model number is altered TILT SWITCH Displays adjusts tilt switch presence function POWER DECK Displays adjusts power deck presence DECK EXT LIMIT Displays adjusts deck extension cutout switch presence function FUNCTION CUTOUT Displays adjusts function cutout switch presence function GROUND ALARM Displays adjusts ground alarm presence function DRIVE CUTOUT Displays adjusts drive cutout switch presence function ARMGAURD CUTOUT Displays adjusts armgaurd cutout switch presence function FLASH CODE Displays adjusts how fault flash codes are indicated CALIBRATIONS NOTE Only available at level 1 CURRENT Displays motor current calibration TEMPERATURE Displays heatsink temperature calibration 2 38 JLG Lift 3120878 SECTION 2 PROCEDURES 3120878 2 26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection ch
98. y remove the pis ton from the cylinder rod Remove and discard the piston seal and o ring 11 Carefully remove the guide from cylinder rod section one Remove and discard the o ring back up ring rod seal and wiper ring 12 Remove the cylinder rod from the holding fixture Cleaning and Inspection 1 Clean all parts thoroughly in an approved cleaning Solvent 2 Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion of rod for excessive dam age Dress threads as necessary 4 Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary 5 Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary 6 Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary 7 Inspect cylinder guide inside diameter for scoring or other damage and for ovality and tapering Replace as necessary 8 Inspect seal and o ring grooves in guide for burrs and sharp edges Dress applicable surfaces as nec essary 9 Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering Replace as necessary 10 Inspect the oil ports for blockage or the presence of dirt or other foreign mate

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