SERVICE & MAINTENANCE Models 1532E2 1932E2 2032E2 2632E2 2646E2 3246E2 3120855 May 10, 2006
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 maintenance personnel pay strict attention to these warnings 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.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS REVISON LOG Original Issue - June 1998 Revised - March 5, 1999 (Added 3246E2) Revised - September 15, 1999 (Added 3246E2 w/ Proportional Control) Revised - April 17, 2001 Revised - January 16, 2002 Revised - April 25, 2002 May 15, 2002 - Revised August 26, 2003 - Revised June 25, 2004 - Revised November 8, 2004 - Revised May 10, 2006 - Revised b – JLG Sizzor – 3120855
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A.A A.B A.C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a-a Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Continued) LIST OF FIGURES FIGURE NO. 1-1. 1-2. 2-1. 2-2. 2-3. 2-4. 2-5. 2-7. 2-8. 2-9. 2-10. 2-11. 2-12. 2-13. 2-14. 2-15. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. TITLE PAGE NO. Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SPECIFICATIONS SECTION 1. SPECIFICATIONS 1.1 Drive Motors CAPACITIES 1932E2 - 126 cm3 displacement Hydraulic Oil Tank 2032E2 - 229.4 cm3 displacement 1932E2 2632E2 - 310.3 cm3 displacement 11.4 liters at full mark on tank 2646E2 - 265.5 cm3 displacement 9.5 liters at add mark on tank 2032E2/2632E2/2646E2/3246E2 3246E2 - 294 cm3 displacement 14.8 liters at full mark on tank Hydraulic Filter - Inline 12.
SECTION 1 - SPECIFICATIONS Gradeability Machine Weight All Models - 25% 1932E2 - approx. 1360 kg Inside Turning Radius 1932E2 - 0.5 m 2032E2/2632E2 - 1m 2032E2 - approx. 2091 kg 2632E2 - approx. 2415 kg 2646E2 - approx. 2086 kg 3246E2 - approx. 2812 kg 2646E2 - 1 m 3246E2 - 1.1 m Wheelbase 1932E2 -1.3 m Lift (No Load in Platform) 2032E2/2632E2/2646E2/3246E2 - 1.7 m 1932E2 Up - 27 seconds Platform Height (Elevated) 1932E2 - 5.8 m Down -26 seconds 2032E2 - 6.1 m 2032E2 2632E2/2646E2 - 7.
SECTION 1 - SPECIFICATIONS Ground Clearance 1.5 LUBRICATION With Platform Lowered Hydraulic Oil All Models - 8.0 cm With Platform Elevated Table 1-2. Hydraulic Oil (Pothole Protection System Lowered) HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGEc All Models - 1.9 cm Maximum Tire Load 1932E2 - 492 kg 2032E2 - 662 kg 2632E2 - 885 kg 2646E2 - 746 kg Maximum Bearing Pressure 1932E2 - 6.4 kg/cm2 2032E2 - 7.0 kg/cm2 2632E2 - 8.
SECTION 1 - SPECIFICATIONS 1.6 SERIAL NUMBER LOCATIONS 1.8 For machine identification, a serial number plate is affixed to the machine. On 2032E2/2632E2/2646E2 and 3246E2 the plate is located on the front, center of the machine frame, on 1932E2 it is located above the right rear tire. The serial number will also be stamped on the front center of the machine frame. CYLINDER SPECIFICATIONS NOTE: All dimensions are given in inches (in), with the metric equivalent, centimeters (cm), given in parenthe ses.
SECTION 1 - SPECIFICATIONS 1.9 PRESSURE SETTINGS 1.11 MAJOR COMPONENT WEIGHTS Table 1-6. Major Component Weights Pressure Settings for Non Proportional Control Machines COMPONENT KG LB Platform (31 in. x 62 in.) - 1932E2 113 250 Platform (31 in. x84 in.) - 2032E2/2632E2 176 388 Platform (46in. x 84 in.
SECTION 1 - SPECIFICATIONS Figure 1-2. Torque Chart.
SECTION 2 - PROCEDURES SECTION 2. PROCEDURES 2.1 items must be maintained on a scheduled basis in order to function properly. GENERAL This section provides information necessary to perform maintenance on the scissor lift. Descriptions, techniques and specific procedures are designed to provide the safest and most efficient maintenance for use by personnel responsible for ensuring the correct installation and operation of machine components and systems.
SECTION 2 - PROCEDURES Pressure-Fit Parts Hydraulic System When assembling pressure-fit parts, use an anti-seize or molybdenum disulfide base compound to lubricate the mating surface. 1. Keep the system clean. If evidence of metal or rubber particles is found in the hydraulic system, drain and flush the entire system. Bearings 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. 1.
SECTION 2 - PROCEDURES 3. Cloudy oils indicate a high moisture content which permits organic growth, resulting in oxidation or corrosion. If this condition occurs, the system must be drained, flushed, and refilled with clean oil. 4. It is 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 comparable viscosities.
SECTION 2 - PROCEDURES released, the spool automatically returns to neutral, prohibiting any flow through the circuit. Relief Valves Relief valves are installed at various points within the hydraulic system to protect associated systems and components 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.
SECTION 2 - PROCEDURES Cylinders w/Single Holding Valves - Lift Cylinder 3. Retract the lift cylinder rod completely. 4. Tag and disconnect the hydraulic lines, then cap the lift cylinder hydraulic lines and ports. OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY. 1. Using all applicable safety precautions, activate hydraulic system. 5. Remove the bolts and locknuts securing the barrel end to the lower arm assembly. 6.
SECTION 2 - PROCEDURES Figure 2-1. Lift Cylinder Assembly 4. Place the cylinder barrel into a suitable holding fixture 5. If applicable, using a suitable spanner wrench, loosen the spanner nut retainer and remove the spanner nut from the cylinder barrel. 6. Secure a pull bar to the rod end with a 0.75 - 16 capscrew fastener. EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER ROD, HEAD, AND PISTON. AVOID PULLING THE ROD OFFCENTER, WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES.
SECTION 2 - PROCEDURES face of the rod. In the event that an unacceptable condition occurs, the rod should be repaired or replaced. 3. Visually inspect the inside bore of the head for scratches or polishing. Deep scratches are unacceptable. If polishing occurs the bore should be checked for ovality. 4. If ovality occurs it is unacceptable. Check the condition of the seals looking particularly for metal particles embedded in the seal surface. 5.
SECTION 2 - PROCEDURES 1. Using a special tool, pictured in the following illustration, install a new rod seal into the applicable cylinder head gland groove. 12. Thoroughly rinse the inside of the rod weldment and allow to drain. Wipe with a lint free rag. 13. Clean and visually inspect all parts for material defects and contamination. 14. Lubricate the head, piston, and all seals with hydraulic fluid prior to installation. 15.
SECTION 2 - PROCEDURES 2.11 BRAKE CYLINDER REPAIR DO NOT FULLY EXTEND CYLINDER TO END OF STROKE. RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRESSURE. Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. 2. Place the cylinder barrel into a suitable holding fixture. 1. Tag and disconnect the hoses from the cylinder ports. 3. Using a suitable pair of snap ring pliers, carefully remove the retaining ring from the cylinder barrel. 4.
SECTION 2 - PROCEDURES Cleaning and Inspection 6. Install the piston locknut on the threaded end of the cylinder rod and torque to 136-163 Nm. 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 damage. Dress threads as necessary. 4.
SECTION 2 - PROCEDURES EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYLINDER 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 a suitable hammer, tap around the outside of the cylinder barrel and guide to shatter the Loctite. 7.
SECTION 2 - PROCEDURES 8. Inspect seal and o-ring grooves in guide for burrs and sharp edges. Dress applicable surfaces as necessary. 10. Continue pushing the rod into the barrel until the cylinder rod guide can be inserted into the end of the cylinder barrel. 9. Inspect cylinder guide outside diameter for scoring or other damage and ovality and tapering. Replace as necessary. 11.
SECTION 2 - PROCEDURES 4. Slowly back off the nut, counting the number of turns, until the circuit is closed again 5. Divide the number of turns determined in step 4in half. Tighten the nut this many turns. The line determined by this nut and the (X) nut is now parallel to the ground. 6. Repeat steps 3 through 5 for the remaining (Y) nut. The switch is now level. Voltmeter Adjustment 1. Park the machine on a flat, level surface and ensure the machine is level. 2.
SECTION 2 - PROCEDURES Figure 2-11. Control Valve Components 2.14 PRESSURE SETTING PROCEDURES NOTE: Make all pressure adjustments with motor operating and hydraulic 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 operating the functions from the platform control station. Lift Relief for Non Proportional Control Machines 3.
SECTION 2 - PROCEDURES Main Relief Pressure Switch for Non Proportional Control Machines Steer Adjustment for Proportional Control Machines 1. With pressure gauge at "MP" port on control valve activate steer in either direction. 1. Install a pressure gauge at gauge port MP, located at the bottom front of the valve body. The port is identified by a stamping on the valve body. 2. Activate drive by pressing the drive switch and activating the controller to the full forward position.
SECTION 2 - PROCEDURES Figure 2-12.
SECTION 2 - PROCEDURES WELDER TERMINAL CONNECTOR FIRE EXTINGUISHER Figure 2-13.
SECTION 2 - PROCEDURES Figure 2-14. Drive Motor (Sauer Danfoss) 4. With the housing in the holding device, press the shaft out of the housing. Collect the needle bearings for possible re-use. 2.15 DRIVE MOTOR (SAUER DANFOSS) Dismantling 1. Place motor in proper holding device that allows access to the output shaft. 2. Carefully remove end cover sideways being sure to catch any parts that may fall from the gearwheel. 3. The needles bearings will fall out during dismantling and can be collected and reused.
SECTION 2 - PROCEDURES Assembly and the gearwheel engage (15°). Turn the gearwheel to line up the screw holes. NOTE: Before assembly, inspect all parts and replace if necessary. Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with Vaseline. 13. Rotate the end cover to line up the screw holes. 14. Use new washers and a 13 mm socket spanner. Torque to 330-380 lb in (3.75 - 4.25 daNm). 15. Screw in plastic plugs. 1. Turn motor housing so the rear end faces upwards.
SECTION 2 - PROCEDURES 4. Screw in the 8 socket head cap screws. Using a Torque wrench, tighten to 80 in lb (8 Nm). 5. After turning the motor around introduce the control sleeve. Make sure that the cylindrical roll of the output shaft clicks into the groove of the control sleeve. 6. Insert the O-ring into the housing. 7. Installation of the check valves: Insert 2 ball valves and carefully drive them in using a mandrel. 8. Insert the limit stop and put the filler into position for the lower valve.
SECTION 2 - PROCEDURES . . 4. Remove end cover assembly (2) and seal ring (4). Discard seal ring 3120855 NOTE: Refer to the appropriate “alternate cover construction” on the exploded view to determine the end cover construction being serviced.
SECTION 2 - PROCEDURES 1. Special Bolts 2. End Cover 3. Seal Ring-Commutator 4. Seal Ring 5. Commutator Ring 6. Commutator Ring 7. Manifold 8. Rotor Set 8A.Rotor 8B. Stator or Stator Vane 8C. Vane 8D. Stator Half 9. Wear Plate 10. Drive Link 12. Coupling Shaft 13. Bearing/Bushing, Inner 14. Thrust Washer 15. Thrust Bearing 16. Seal 17. Back-up Washer 18. Housing 18A. O-Ring 19. Bearing/Bushing, Outer 20. Dirt & Water Seal 21. Plug Figure 2-15. Parker Drive Motor 5.
SECTION 2 - PROCEDURES 6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures, including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover as necessary. these conditions exist, replace commutator and commutator ring as a matched set. NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is normal.
SECTION 2 - PROCEDURES 10. Remove rotor set (8) and warplane (9), together to retain the rotor set in its assembled form, maintaining the same rotor vane (8C) to stator (8B) contact surfaces. The drive link (10) may come away from the coupling shaft (12) with the rotor set, and wearplate.You may have to shift the rotor set on the warplane to work the drive link out of the rotor (8A) and warplane.
SECTION 2 - PROCEDURES 13. Remove thrust bearing (11) from top of coupling shaft (12). Inspect for wear, brinelling, corrosion and a full complement of retained rollers. 14. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used . NOTE: Minor shaft wear in seal area is permissible. If wear exceeds 0.020 inches (0.
SECTION 2 - PROCEDURES 21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion. The bushing (19) or (13) to coupling shaft diameter clearance must not exceed 0.010 inch (0.
SECTION 2 - PROCEDURES NOTE: The depth or location of bearing/bushing (13) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counter bore should be measured and noted before removing the bearings/ bushings. This will facilitate the correct reassembly of new bearings/bushings. Assembly Replace all seals and seal rings with new ones each time you reassemble the Torqlink™ unit.
SECTION 2 - PROCEDURES NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.
SECTION 2 - PROCEDURES The Torqlink™ dirt and water seal (20) must be pressed in until its’ flange is flush against the housing. 4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. ORIGINAL DESIGN LARGE FRAME, TF & TG TORQLINKS™ THAT DO NOT HAVE BACKUP WASHER (25) WHEN DISASSEMBLED MUST BE ASSEMBLED WITH A NEW BACKUP WASHER (17), NEW BACKUP WASHER (25), AND NEW SEAL (16). 6.
SECTION 2 - PROCEDURES 7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal. . 8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against the thrust bearing (15) in the housings. 9. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove.
SECTION 2 - PROCEDURES 10. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines. NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines. 11. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18). .
SECTION 2 - PROCEDURES 15. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. 16. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 17. Assemble the commutator ring (6) over alignment studs onto the manifold. 19.
SECTION 2 - PROCEDURES . NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed on the cover to radially align the end cover into its original position. 21. Assemble the 5 or 7 special bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 22-26 ft. lbs. 45-55 ft.
SECTION 2 - PROCEDURES lbs.(61-75 N m) if cover is so equipped. 3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with rotor splines into mesh with drive link (10) splines. One Piece Stator Construction A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be assembled by the following procedures. 1.
SECTION 2 - PROCEDURES the seventh or full complement of seven vanes. Assemble the seven vanes using minimum force. run over any uneven terrain or dropped into any void. The clearance between the top of the bolts and the frame should be a min.of 2.0 cm to a max. of 4.0 cm. 2.20 JLG SMART SYSTEM™ ANALYZER KIT INSTRUCTIONS NOTE: The following instructions involving the JLG SMART System™ Control are used only for Model 3246E2 with the Proportional Control option.
SECTION 2 - PROCEDURES INTRODUCTION The JLG designed SMART System™ is a 24 Volt multiplex motor control unit installed on the electric scissor lift model 3246E2. The SMART System™ has reduced the need for exposed terminal strips, diodes and trimpots and provides simplicity in viewing and adjusting the various personality settings for smooth control of: acceleration, deceleration, creep and max-speed for the lift, drive, steering and optional power deck functions.
SECTION 2 - PROCEDURES 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 separate faults between powerups.
SECTION 2 - PROCEDURES NOTE: Refer to the appropriate 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: Password 33271 will give you access to level 1, which will permit you to change all machine personality settings. There are some settings that JLG strongly recommends that you do not change.
Figure 2-17.
SECTION 2 - PROCEDURES 2.21 MACHINE PERSONALITY SETTINGS Table 2-4. Machine Personality Settings PERSONALITY MIN MAX DRIVE-ACCEL 0.5 SEC 5.0 SEC DRIVE-DECEL 0 SEC 5.0 SEC DRIVE CREEP 1% 25.0% DRIVE SPEED MAX (LOW) 50% 100% DRIVE SPEED MAX (HIGH) 50% 100% *ELEVATION MAX *0% *40% *POSI-TRAC TIME *0 Sec *60 Sec *50 Amp *200 Amp 0 Sec 25 Sec LIFT ACCEL 0.5 Sec 5.0 Sec LIFT DECEL 0.0 Sec 1.
SECTION 2 - PROCEDURES 2.22 MACHINE MODEL DEFAULT SETTINGS Table 2-5. Machine Model Default Settings Chart Adjustment 3246E2 DRIVE ACCELERATION 1.0 sec DRIVE DECELERATION 0.5 sec DRIVE CREEP 12% DRIVE SPEED MAX (LOW) 100% DRIVE SPEED MAX (HIGH) 85% ELEVATION MAX* 42%* POSITRAC TIME 10 sec HIGH DRIVE OVER CURRENT 140 amps HIGH DRIVE TIME OUT* 5.0 sec** LIFT ACCEL 1.0 sec LIFT DECEL 0.0 sec LIFT CREEP 15% LIFT UP MAX 100% DECK ACCEL 0.5 sec DECK DECEL 0.
SECTION 2 - PROCEDURES 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 settings to return to default values. 2.23 MACHINE CONFIGURATION INFORMATION NOTE: The following information is to be used when working with the MACHINE SETUP menu. When configuring the E Series scissor lift, the machine configuration Table 2-6.
SECTION 2 - PROCEDURES Table 2-6. Machine Configuration Programming Information Configuration Digit Number 5 (FUNCTION CUTOUT) 0 No function cutout installed. 1 Overload switch for French, Japanese machines. — Cuts out all functions. Sounds platform alarm for two seconds on, two seconds off, while operator tries to perform the function that has been cut out (provided the platform alarm is installed). 0 No ground alarm installed. 1 Descent alarm. — Sounds when LIFT DOWN is active.
SECTION 2 - PROCEDURES 2.24 JLG SMART SYSTEM™ HELP MESSAGES AND FLASH CODES Table 2-7. 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 and is preventing lift down for three seconds.
SECTION 2 - PROCEDURES Table 2-8. JLG SMART System™ Flash Codes & Help Messages Code Description 2-1 - Indicates problems with EMS inputs STARTUP - Neither EMS is active - the system is just switching on or is discharging the capacitor bank. A welded line contactor might also cause this.
SECTION 2 - PROCEDURES Table 2-8. JLG SMART System™ Flash Codes & 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 circuit to the line contactor or a valve is active when no driver circuit is turned on (this could be due to a wiring error to the valves or line contactor).
SECTION 2 - PROCEDURES between items in the same level. The UP/DOWN arrow keys alter a value if allowed 2.25 ANALYZER MENU STRUCTURE 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 2-9.
SECTION 2 - PROCEDURES Table 2-9.
SECTION 2 - PROCEDURES Table 2-9.
SECTION 2 - PROCEDURES Table 2-9.
SECTION 2 - PROCEDURES Table 2-9.
SECTION 2 - PROCEDURES Table 2-9. Analyzer Menu Structure TOP LEVEL MENU SUB LEVEL MENU ITEM TO BE VIEWED OR CHANGED DESCRIPTION DISPLAY MACHINE SETUP MODEL NUMBER Displays/adjusts machine model NOTE: All personalities reset to default when model number is altered TILT SWITCH Displays/adjusts tilt switch presence/function POWER DECK Displays/adjusts power deck presence DECK EXT.
SECTION 2 - PROCEDURES 2.26 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table. This table is divided into two basic parts, the AREA to be inspected and the INTERVAL at which the inspection is to take place. Under the AREA portion of the table, the various systems along with the components that make up that system are listed.
SECTION 2 - PROCEDURES Table 2-10.
SECTION 3 - TROUBLESHOOTING 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.
SECTION 3 - TROUBLESHOOTING Table 3-1. Electricl Troubleshooting Chart TROUBLE PROBABLE CAUSE REMEDY All machine functions do not operate Emergency stop switch not activated Activate Emergency stop switch Joystick not in neutral position Release joystick, then select function Platform cable not connected to platform box Re-connect cable to platform box and check or at base wiring at base Battery voltage out of range If battery cahrger is plugged in Check voltage with VOM.
SECTION 3 - TROUBLESHOOTING Table 3-2. Hydraulic System Troubleshooting Chart TROUBLE PROBABLE CAUSE REMEDY Hydraulic pump noisy Air bubbles in oil (reservoir to low.) Replenish oil as necessary Oil filter dirty Clean and/or replace filter as necessary Oil is reservoir too low Replenish oil as necessary Pump cavitating. (Vacume in pump due to oil starvation) Restricted reservoir air vent Clean vent Oil viscosity too high Drain system and replace with recommended oil.
SECTION 3 - TROUBLESHOOTING Figure 3-1.
SECTION 3 - TROUBLESHOOTING 1870117 C Figure 3-2.
SECTION 3 - TROUBLESHOOTING U3 JLG SMART SYSTEM MICROPROCESSOR Figure 3-3.
SECTION 3 - TROUBLESHOOTING U3 JLG SMART SYSTEM MICROPROCESSOR 1870107B Figure 3-4.
3-8 – JLG Sizzor – Figure 3-5.
Figure 3-6.
SECTION 3 - TROUBLESHOOTING Figure 3-7.
SECTION 3 - TROUBLESHOOTING Figure 3-8.
SECTION 3 - TROUBLESHOOTING This page left blank intentionally.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
