Service and Maintenance Manual Model(s) 1230ES P/N - 3121222 April 22, 2013
NOTES:
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. MAINTENANCE 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.
INTRODUCTION - REVISION LOG REVISION LOG Original Issue of Manual . . . . . . . . . . . . . . . . . . June 8, 2006 Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . July 13, 2006 Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . January 23, 2007 Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . February 26, 2007 Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 22, 2007 Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A B HYDRAULIC SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 SECTION 3 - THEORY OF OPERATION - 1230ES 3.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.
TABLE OF CONTENTS Spindle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Spindle Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Hub Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Input Carrier Sub-Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 6.4 PLATFORM AC RECEPTACLE BOX - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.5 MAST ASSEMBLY - COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.6 PLATFORM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Platform - Extending Mast Unpowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 7-7 Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS LIST OF FIGURES FIGURE NO. 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 2-1. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 5-1. 5-2. 5-3. 5-4. 5-5. 5-6. 5-45. 5-46. 5-7. 5-8. 6-1. 6-2. 6-3. 6-4. 6-5. 6-6. 6-7. 6-8. 6-10. 6-9. 6-11. 6-12. 6-14. 6-13. 6-15. 6-16. vi TITLE PAGE NO. Hydraulic Oil Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 6-17. 6-18. 6-19. 6-20. 6-21. 7-1. 7-2. 7-3. 7-4. 7-5. 9-1. 9-2. 9-3. 9-4. 9-5. 9-6. 9-7. 9-8. 9-9. 9-10. 9-11. 9-12. 9-13. 9-14. 9-15. 9-16. 9-17. 9-18. 9-19. 9-20. 9-21. 3121222 Valve Block - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Cylinder #2 and #3 Assembly - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14 Cylinder Rod/Gland - Removal . . . . . .
TABLE OF CONTENTS LIST OF TABLES TABLE NO. 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 2-1 2-2 4-1 4-2 4-3 5-1 5-2 5-3 5-4 5-5 7-1 7-2 7-3 7-4 7-5 9-1 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-11 viii TITLE PAGE NO. Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - MACHINE SPECIFICATIONS SECTION 1. MACHINE SPECIFICATIONS Table 1-1. Operating Specifications Description Model 1230ES Platform Maximum Platform Height 12 ft. (3.66 m) Lift Up Time - w/maximum rated load 11 - 17 seconds Lift Down Time - w/maximum rated load 11 - 25 seconds Driving Maximum Drive Speed Stowed: Elevated: Maximum Stowed Travel Grade (Gradeability) 3 mph (4.8 kph) 0.5 mph (0.8 kph) 25% (14°) Maximum Stowed Travel Grade (Sideslope) 5° Inside Turning Radius 4.4 in. (11.
SECTION 1 - MACHINE SPECIFICATIONS 1.1 OPERATING SPECIFICATIONS Critical Stability Weights Platform Capacities Table 1-2. Capacities Model DO NOT REPLACE ITEMS CRITICAL TO STABILITY, SUCH AS BATTERIES OR SOLID TIRES, WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION. DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. CE/AUST (Indoor Only) ANSI/CSA Max Capacity Max Persons Max Capacity Max Persons 500 lb 2 230 kg 1 1230ES Component Dimensional Data Table 1-3. Dimensions Description Table 1-6.
SECTION 1 - MACHINE SPECIFICATIONS Lubrication Specifications NOTE: Care should be taken not to introduce any impurities (dirt, water etc.) while cap is removed. Table 1-9. Lubrication Specifications Key Specifications MPG Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 1 - MACHINE SPECIFICATIONS Values for Zinc Yellow Chromate Fasteners (Ref 4150707) SAE GRADE 5 BOLTS & GRADE 2 NUTS Torque Lubricated Torque (Dry) Tensile Clamp Load Stress Area Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraTM OR Vibra-TITE 111 or TITETM 131) 140) Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.
SECTION 1 - MACHINE SPECIFICATIONS SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS* Tensile Clamp Load Stress Area Torque (Dry or Loctite® 263) K= 0.20 Torque Torque (Loctite® 242TM or 271TM (Loctite® 262TM or VibraOR Vibra-TITE TM 111 or TITETM 131) 140) K=.18 K=0.15 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Magni Coating (Ref 4150701)* Tensile Stress Area Clamp Load See Note 4 Torque (Dry) K = .17 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.16 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - MACHINE SPECIFICATIONS SOCKET HEAD CAP SCREWS Zinc Yellow Chromate Fasteners (Ref 4150707)* Tensile Stress Area Clamp Load See Note 4 Torque (Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140 OR Precoat 85® K=0.18 Torque (Dry) K = .20 Size TPI Bolt Dia In Sq In LB IN-LB [N.m] IN-LB [N.m] 4 40 48 32 40 32 36 24 32 20 28 0.1120 0.1120 0.1380 0.1380 0.1640 0.1640 0.1900 0.1900 0.2500 0.2500 0.00604 0.00661 0.00909 0.01015 0.01400 0.01474 0.01750 0.02000 0.0318 0.
SECTION 1 - MACHINE SPECIFICATIONS CLASS 8.8 METRIC BOLTS CLASS 8 METRIC NUTS Size PITCH Tensile Stress Area Sq mm Clamp Load Torque (Dry or Loctite® 263TM) Torque (Lub) KN [N.m] [N.m] Torque Torque (Loctite® (Loctite® 262TM 242TM or 271TM OR VibraOR VibraTITETM 131) TITE TM 111 or 140) [N.m] [N.m] 3 0.5 5.03 2.19 1.3 1.0 1.2 1.4 3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.
SECTION 1 - MACHINE SPECIFICATIONS CLASS 10.9 METRIC BOLTS CLASS 10 METRIC NUTS CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5* Size PITCH Tensile Stress Area Clamp Load Torque (Dry or Loctite® 263TM) K = 0.20 Sq mm KN [N.m] Torque (Lub OR Loctite® 242TM or 271TM OR Vibra-TITE TM 111 or 140) K= 0.18 Torque (Loctite® 262TM OR Vibra-TITE TM 131) K=0.15 [N.m] [N.m] 3 0.5 5.03 3.13 3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.
SECTION 1 - MACHINE SPECIFICATIONS Magni Coating (Ref 4150701)* CLASS 12.9 SOCKET HEAD CAP SCREWS M6 AND ABOVE* Size PITCH Tensile Stress Area Sq mm Torque Torque (Lub OR Loctite® Torque (Loctite® 262TM Clamp Load (Dry or Loctite® 242TM or 271TM OR Vibra-TITE TM See Note 4 263TM) OR Vibra-TITE TM 131) K = .17 111 or 140) K = .15 K = .16 kN [N.m] [N.m] [N.m] 3 0.5 3.5 0.6 5.03 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 27 8 1.25 36.60 22.
SECTION 2 - GENERAL SERVICE INFORMATION SECTION 2. GENERAL SERVICE INFORMATION 2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE General This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and maintain its safe operating condition. For maximum service life and safe operation, ensure that all the necessary inspections and maintenance have been completed before placing the machine into service.
SECTION 2 - GENERAL SERVICE INFORMATION Table 2-1. Maintenance and Inspection Requirements. TYPE FREQUENCY PRIMARY RESPONSIBILITY SERVICE QUALIFICATION REFERENCE Pre-Start Inspection Prior to use each day; or At each Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection Prior to each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form.
SECTION 2 - GENERAL SERVICE INFORMATION Table 2-2. Preventive Maintenance & Inspection Schedule.
SECTION 2 - GENERAL SERVICE INFORMATION Table 2-2. Preventive Maintenance & Inspection Schedule.
SECTION 2 - GENERAL SERVICE INFORMATION 2.3 SERVICING AND MAINTENANCE GUIDELINES Cleanliness General The following information is provided to assist you in the use and application of servicing and maintenance procedures 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 component weight. Never attempt to move heavy parts without the aid of a mechanical device.
SECTION 2 - GENERAL SERVICE INFORMATION Bearings Lubrication and Servicing 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. Discard bearings if the races and balls (or rollers) are pitted, scored, or burned. If bearing is found to be serviceable, apply a light coat of oil and wrap it in clean (waxed) paper.
SECTION 2 - GENERAL SERVICE INFORMATION Lubrication Specifications Changing Hydraulic Oil Specified 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 evaluation. Refer to Section 1.
SECTION 2 - GENERAL SERVICE INFORMATION NOTES: 2-8 – JLG Lift – 3121222
SECTION 3 - THEORY OF OPERATION - 1230ES SECTION 3. THEORY OF OPERATION - 1230ES 3.1 OVERVIEW Platform mode The GROUND MODULE is the master system controller. Most functions are dispatched and coordinated from this module, all other system modules handle sub-tasks. All characterized information (values) are stored into the ground module (i.e., Personalities, Machine Setups or Calibrations). If the ground module is reprogrammed, this information is lost.
SECTION 3 - THEORY OF OPERATION - 1230ES Platform Control Station X050 1 E STOP X048 B 2 X047 C 4 3 D A G F Ignition Ground CAN High X046 E 120Ω 3 4 7 6 5 3 4 7 6 5 X108 X105 X106 J1 1 Ignition 2 Ground 9 10 3 4 7 6 5 3 4 7 6 5 X108 2 3 4 7 6 5 1 2 3 4 7 6 5 FOOTSWITCH ACCY MODULE (OPTIONAL) X107 J2 1 PLATFORM BOARD CAN Low CAN High CAN Low X104 X017 OPTIONAL POWER MODULE BVbatt (-) X027 X017 120Ω 1 Ignition 11 CAN Low 10 CAN High G
SECTION 3 - THEORY OF OPERATION - 1230ES 3.4 CONTROLS & SENSORS other markets, the vehicle is considered Tilted if the vehicle tilt angle front to back is greater than or equal to 3.0° or tilt left to right is greater than or equal to 1.5°. Elevation The elevation sensor is an inductive proximity switch. It must be powered to operate. There is a 1.3k Ohm resistor where it connects to the ground module to produce the proper signal for the ground module. (See electrical schematic in Section 9 for details.
SECTION 3 - THEORY OF OPERATION - 1230ES 24V Line Contactor + + + Left Armature + Right Armature BF1 BF2 T +B + + Right Field Winding B F2 F1 Armature MOSFET Field MOSFETS Shunt Left Field Winding Power Module Figure 3-3. Drive Motors Schematic - 1001092456 (ZAPI) Power Module The Field Windings also provide direction reversal for traction. When driving forward, MOSFET switches 1 and 4 turn On to apply positive potential to F2 and ground potential to F1.
SECTION 3 - THEORY OF OPERATION - 1230ES 3.6 PUMP/LIFT/MAST An electrically driven hydraulic pump provides hydraulic pressure to actuate the steering and lift up. Lift down is "powered" by gravity. The lift actuator is a three stage hydraulic cylinder. The cylinder pistons are not sealed so fluid can flow from one cylinder to the next. The area of the piston that fluid touches on both sides does not provide lift because the forces on both sides cancel each other.
SECTION 3 - THEORY OF OPERATION - 1230ES apply all available Battery power to the pump motor (as in Lift Up at full speed). Line Contactor +B Series DC Pump Motor 3.7 STEER Steering is actuated by a double action hydraulic cylinder. To change steering angle of the drive wheels, the steer left or steer right solenoid is energized and the pump is energized. Pressure is applied to one side of the piston and drained from the other.
SECTION 4 - BASE COMPONENTS SECTION 4. BASE COMPONENTS 4.1 BASE ASSEMBLY COMPONENTS Figure 4-1. Base Assembly Components. 1. Hydraulic Pump/Tank/Valve Assy. 2. Steering Linkage Assembly 3. Drive Motor/Spindle Assemblies 4. Pot Hole Protection Assembly 5. Static Strap 6. Steer Cylinder Assembly 7. Left Side (Battery Tray) Door 8. Right Side (Battery Tray) Door 9. Rear Wheel Assembly NOTE: Base assembly shown without base top weldment for illustrative purposes only.
SECTION 4 - BASE COMPONENTS 4.2 BASE FRAME COVERS Battery Tray/Side Door - Installation Base Top Cover - Installation NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL THE PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING. Battery Tray/Side Door - Installation (Same for both sides) Base Top Cover Installation 1. Base Top Cover 2. (4) Attach Screws/Washers Step Plate/Battery Charger Cover - Installation 1. Battery Tray/Door 2. Cutout in Base Frame 3. Washer(s) NOTE: 4.
SECTION 4 - BASE COMPONENTS 4.3 WHEELS AND TIRES - DRIVE AND REAR 1. Start all lug nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. Tire Wear and Damage 2. Tighten lug nuts in the following sequence. Inspect tires periodically for wear or damage. Tires with worn edges or distorted profiles require replacement. Tires with significant damage in the tread area or side wall, require immediate evaluation before replacing the machine into service.
SECTION 4 - BASE COMPONENTS 4.4 REAR WHEEL HUB - INSTALLATION Rear Wheel Hub Installation 1. 2. 3. 4. 5. Hub Cap Cotter Pin Spindle Nut Washer Outer Tapered Roller Bearing (a) 6. 7. 8. 9. 10. Outer Bearing Race (a) Wheel Mounting Hub (a) Inner Bearing Race (a) Inner Tapered Roller Bearing (a) Hub Seal NOTE: (a) Bearing race (6, 8) are press fitted to wheel mounting hub (7) and are only available for service as a complete hub assembly.
SECTION 4 - BASE COMPONENTS 4.5 STEERING LINKAGE ASSEMBLY - INSTALLATION 4 3 1 2 8 12 11 7 5 10 6 9 Steering Linkage Assembly - Installation (Shown with top of base frame weldment removed for illustrative purposes only) 1. 2. 3. 4. 5. 6. NOTE: 3121222 Left Steering Knuckle Lug Left Steering Arm Link Right Steering Arm Link Right Steering Knuckle Lug Steering Cross Link Hydraulic Steer Cylinder 7. 8. 9. 10. 11. 12.
SECTION 4 - BASE COMPONENTS 4.6 STEER CYLINDER - SERVICING 9 8 7 6 5 4 3 2 1 10 11 12 13 Steer Cylinder Components 1. 2. 3. 4. 5. NOTE: Rod End Bushing Cylinder Head (Gland) (a) O’Ring Seal Backing Ring O’Ring Seal 6. 7. 8. 9. 10. Cylinder Rod Piston (b) Piston Seal Bushing Piston Set Screw 11. Main Gland Seal 12. Wiper Seal 13. O’Ring Seal (a) On final assembly torque cylinder head (Gland) to 500Nm (112 ft. lb.) (b) Apply Loctite #242 to threads before final assembly and torque to 260Nm (55 ft.
SECTION 4 - BASE COMPONENTS Steer Cylinder Disassembly DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. PROTECT THE CYLINDER ROD SURFACE. DAMAGE TO THE CYLINDER ROD CHROME FINISH DUE TO SCRATCHING, INDENDATION, CHIPPING OR OTHERWISE WILL CAUSE EVENTUAL GLAND SEAL FAILURE. THE CYLINDER ROD MUST BE REPLACED IF DAMAGED. Piston - Removal 1. Piston (Kban) Seal 2. Piston Set Screw 3. Piston 4. Spanner Wrench 1. Remove the piston (kban) seal from the piston. 2.
SECTION 4 - BASE COMPONENTS Steer Cylinder - Assembly Hydraulic Cylinder Component Inspection Cylinder Rod There should be no 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 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal.
SECTION 4 - BASE COMPONENTS 5. Apply Loctite #222 to the threads of the piston set screw, thread the screw into the hole in the side of the piston and tighten to 20Nm (5 ft. lb.). 7. Lubricate the o’ring seals on the cylinder head. Check that the threads on the cylinder head and inside the cylinder barrel are clean and free of any debris. 6. Place a new piston (kban) seal onto the piston. EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD, HEAD, AND PISTON INTO THE CYLINDER BARREL.
SECTION 4 - BASE COMPONENTS 4.7 DRIVE MOTOR/SPINDLE ASSEMBLY - INSTALLATION Drive Motor/Spindle Assembly - Installation (Left front shown - installation same for both sides) 1. 2. 3. 4. NOTE: 4-10 DriveMotor/Spindle Assembly 60mm External Retaining Ring Spindle Retaining Washer Knuckle Lug Attach Screws (a) 5. 6. 7. 8.
SECTION 4 - BASE COMPONENTS 4.8 WHEEL DRIVE ASSEMBLY - SERVICING The component parts of the left and right drive motor assemblies are identical. The left drive motor is run in the reverse direction of the right motor. FOR DETAILS ON THE TRACTION SYSTEM ELECTRICAL THEORY OF OPERATION SEE SECTION 4. Drive Motor Electrical Evaluation Several basic electrical tests can be performed on the Drive Motors. Failure of one of these evaluations is significant and may indicate that the device is physically damaged.
SECTION 4 - BASE COMPONENTS Roll And Leak Testing Oil Type & Capacity Torque-Hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit's gears, bearings and seals are working properly. The following information briefly outlines what to look for when performing these tests. NOTE: The brake must be released before performing the roll test. This can be accomplished by supplying 24 Volts D.C. to the gray 2-pin brake connector.
SECTION 4 - BASE COMPONENTS Wheel Drive Brake - Manual Disengage Procedure Figure 4-4. Brake Manual Disengage Procedure In the event of a power loss to the Torque-Hub, the parking brake will engage as a safety precaution. Should the unit need to be towed or pushed to an area where it can be serviced or recharged the operator will need to manually disengage the parking brakes. The following procedure outlines how this is to be done. 3.
SECTION 4 - BASE COMPONENTS Wheel Drive Motor Assembly - Removal From Machine 4. Remove the drive wheel mounting lugs and remove the wheel(s). The electric wheel drive assemblies are mounted indepentent of each other on the base frame at the front of the machine. The wheel drive assembly consists of an 24V DC electric motor driving a 45.13:1 ratio gear box, the assembly also included a friction disk parking brake assembly. This brake assembly is mounted on the end of the drive motor assembly. 1.
SECTION 4 - BASE COMPONENTS Drive Motor Disassembly Figure 4-5. Drive Motor Disassembly 1. Remove the 2 (#8-32UNC x .500in long) screws holding the cover plate (12) in place (See Figure 4-6.) and remove the cover plate from the motor. 2. Remove the 2 (M5 x 0.8 x 20mm long) screws holding the cover (15) in place and set aside. These screws are needed later to manually release the brake. Slide the strain relief bushing (14) and wire harness out of the cover and remove the cover from the motor.
SECTION 4 - BASE COMPONENTS Figure 4-6. Drive Motor Side View Figure 4-7. Drive Motor End View (Brake End) Drive Motor Inspection and Servicing (Reference Figure 4-5. - Drive Motor Disassembly Illustration) 1. Carefully blow out any accumulated carbon dust and dirt from the end head and the frame and field assembly using clean, oil free, compressed air. 2. Replace brushes (3) that are worn below their usable length (.600 in.
SECTION 4 - BASE COMPONENTS Drive Motor - Reassembly motor aligning wires with groove in commutator end head. Secure brake assembly to commutator end head using 3 bolts and apply small bead of RTV Silicone sealant around wires between friction disc and commutator end head and in notch in friction disc. (See Figure 4-5.) 1. After inspection and servicing, reassemble the wiring in the commutator end head (9) as originally found.
SECTION 4 - BASE COMPONENTS Main Gear Box Disassembly Main Gear Box isassembly 1. Using a screwdriver, pry the end of the Retaining Ring (19) out of the groove in the Hub Subassembly, then grasp the loose end of the Retaining Ring (19) with pliers and pull the rest of the way out. 2. Remove Cover (11). Thrust Washer (21) should remain in the inner counterbore of the Cover (11) when removed. NOTE: To remove the cover the motor must be removed.
SECTION 4 - BASE COMPONENTS Input Carrier Disassembly Input Carrier Disassembly 1. Remove Retaining Rings (18) from each of the three Planet Shafts (6). NOTE: Do not overstress these Retaining Rings when removing them. 2. Remove Thrust Plate (23). 3. Remove Thrust Washer (25) from each Planet Shaft (6). 4. Slide each Input Planet Gear (5) off the Planet Shaft (6). 5. Press out Bushing (26) from the bore of each Planet Gear (5). Bushings cannot be reused when removed. 6.
SECTION 4 - BASE COMPONENTS Hub - Disassembly Hub Disassembly 1. Remove Main Wheel Bearing (14). NOTE: This part is held in the hub with a press fit. To remove have the hub setting seal side up. Use a plate or rod with a large enough diameter push in the inner race of the bearing. Apply force to the push the bearing out. This bearing will need to be replaced upon reassembly. 2. Remove main Lip Seal (16). NOTE: 4-20 This Lip Seal (16) is also held in with a press fit.
SECTION 4 - BASE COMPONENTS Spindle Disassembly Spindle Disassembly 1. Place unit on bench with Planet Gears (9) facing up. 2. Remove three Output Planet Shafts (10) NOTE: These Planet Shafts are held in with a press fit. Use the tapped hole in the end of the pin in conjunction with a slide hammer or similar tool to remove them. 3. Remove the Output Planet Gear (9), Thrust Washer (25), and Tanged Washer (32) out each of gear "window" of the Spindle (1).
SECTION 4 - BASE COMPONENTS Spindle Sub-Assembly Spindle Sub-Assembly 1. Using the appropriate pressing tool (T-207925), press in the 2 Main Bushings (12) in the upper bore of the Spindle (1). The lower bushing needs to flush with the bottom of the bore and the upper bushing needs to be flush with the bottom of the bore. 2. Using the appropriate pressing tool (T-182377), press on Main Bearing (14) until it is fully seated. 3. Insert the Motor Shaft Bearing (15) into the center bore of the Spindle (1).
SECTION 4 - BASE COMPONENTS 11. Press the Output Planet Shaft (10) into the Spindle (1) until it bottoms out. Make sure the Output Planet Gear (9) turns freely after the Planet Shaft is pressed in. 12. Repeat Steps 5-11 for the other two Output Planet Gears (9). 13. Turn the Spindle (1) over so that the carrier end is down. 14. Using a flat plate or rod, press the Motor Shaft Seal (17) into the center bore so that it is flush with the face of the Spindle (1).
SECTION 4 - BASE COMPONENTS Hub Sub-Assembly Hub Sub-Assembly 1. Put Hub (2) on a table with the tapped holes facing down. 2. Using a flat plate in conjunction with a pressing tool, press in the Seal (16) so it is flush with the edge of the hub. NOTE: NOTE: The Seal has a thin outer shell that can be easily damaged if not installed with care. It is a good idea to start the Seal into the bore with a rubber mallet before pressing. 3. Flip the Hub (2) over 4.
SECTION 4 - BASE COMPONENTS Input Carrier Sub-Assembly Input Carrier Sub-Assembly 1. Use the Input Planet Shaft (6) as a pressing tool to install the Planet Bushing (26) into the bore of each Planet Gear (5). The shaft will help guide the bushing into the bore as well as prevent damage from the press. 2. Press three Input Planet Shafts (6) into the three holes of the Input Carrier (7). The head of the Input Planet Shaft (6) needs to sit flush in the counterbore of the Input Carrier (7) hole 3.
SECTION 4 - BASE COMPONENTS Main Gear Box Sub-Assembly Main Gear Box Sub-Assembly 1. Inspect seal surface of Spindle (1). Remove any debris that may be present. 2. Apply a coating of grease to the Lip Seal (not shown) in the Hub Subassembly. 3. Place Spindle (1) Sub-Assembly on table with carrier side up. 4. Carefully install the Hub Subassembly (seal side down) onto the Spindle (1). This installation should be a slip fit and takes place in 3 stages. 5.
SECTION 4 - BASE COMPONENTS 9. Using the appropriate pressing tool (T-174356), press in the Input Ring Gear (3) into the bore of Hub Subassembly. NOTE: Do not use excessive pressing force because it will be reacted by the main wheel bearings. 10. Install the Input Carrier Subassembly into mesh.
SECTION 4 - BASE COMPONENTS Motor Assembly Motor Assembly 1. Insert motor (13) into back of the gearbox. Motor will pilot on the 4 bosses in the gearbox. Try to keep the end of the motor shaft from causing damage to the lip seal in the gearbox. NOTE: The motor may need to be rotated to line up the sun gear splines with the motor shaft splines. 2. Install the 2 Motor Mounting Bolts (M7) and Washers (M8). Tighten to 9-11 ft-lbs. 3.
SECTION 4 - BASE COMPONENTS 4.9 HYDRAULIC PUMP/MOTOR/VALVE ASSEMBLY - SERVICE PROCEDURE Refer to Section 3.6, PUMP/LIFT/MAST - Theory of Operation for more detailed information on Pump/Motor/Valve System. Common Difficulties The following difficulties can be examined using the JLG Analyzer, a voltmeter, and simple hand tools. Unless otherwise noted, the Control System shall be energized in Ground Mode during testing.
SECTION 4 - BASE COMPONENTS Figure 4-10. Main Electrical Power Connections - (1600346 - SEVCON Power Module) 1. 2. 3. 4. 5. 4-30 Right Side Batteries Left Side Batteries Power Module Main Power Contactor Relay Hydraulic Pump Motor 6. 7. 8. 9. 10.
SECTION 4 - BASE COMPONENTS 6 A1 A2 A1 A2 4 3 Figure 4-11. Main Electrical Power Connections - (1001092456 - ZAPI Power Module) 1. 2. 3. 4. 5. 3121222 Right Side Batteries Left Side Batteries Power Module Main Power Contactor Relay Hydraulic Pump Motor 6. 7. 8. 9. 10.
SECTION 4 - BASE COMPONENTS Pump Components Hydraulic System Pressure Check Port The following is a complete disassembly/assembly of the machines’ pump/motor/valve assembly. NOTE: During reassembly of the pump/motor assembly, lubricate all seals and o-rings with JLG recommended hydraulic fluid. Also keep all internal metal parts clean and coated with hydraulic fluid to prevent surface corrosion. JLG recommends replacing all seals and o-rings when disassembling and reassembling the pump/ motor unit.
SECTION 4 - BASE COMPONENTS Hydraulic System Pressure Settings Perform final hydraulic pressure setting with oil at normal operating temperature. If pressure is set when cold, function may not operate properly after oil has warmed. Turning relief adjustment screw clockwise - increases pressure, turning adjustment screw counterclockwise decreases pressure. DO NOT EXCEED MAXIMUM PRESSURE SETTINGS. (See Figure 4-13.) Table 4-2.
SECTION 4 - BASE COMPONENTS Pump/Motor/Valve Assembly - Removal/Installation Hydraulic Pump/Valve/Tank - Installation 1. Pump/Valve/Tank Assembly 2. Pump Assy. Mounting Screw/Nuts 3. Static Strap 4. Valve Bank Solenoid Connections 5. Steer/Lift-Up/Return Hydraulic Lines 6. Pump Motor Power Connection Terminals (a) NOTE: (a) Apply dielectric grease to terminals during installation of cables. Torque nuts to 5 - 7 ft. lb.
SECTION 4 - BASE COMPONENTS Hydraulic Pump/Valve/Tank - Assembly 1. 2. 3. 4. 5. 6. 7. 8. 3121222 Pump Motor Assembly Motor to Pump Coupler Pump to Frame Mounting Flange Pump Valve Body Tank Oil Ring Seal Hydraulic Pump Pick-Up w/Filter Screen Return Flow Filter/Diffuser 9. 10. 11. 12. 13. 14. 15. 16.
SECTION 4 - BASE COMPONENTS Motor Cover/Motor Installation for wear, replace if necessary. Once complete, reassemble for operation, do not overtighten the motor cover bolts into the aluminum valve body, 8 Nm (70 in. lb.). DISCONNECT THE BATTERIES BEFORE PERFORMING THESE PROCEDURES. This procedure requires removing the pump to frame mounting bolts and nuts and rotating the pump assembly horizonally far enough to allow removal of the pump motor cover.
SECTION 4 - BASE COMPONENTS 4.10 POT HOLE PROTECTION SYSTEM Pot-Hole-Protection System Components (Some components hidden for illustrative purposes only.) 1. 2. 3. 4. PHP Actuator (Platform) Right/Left PHP Limit Switch Right Side Counterbalance Link Left Side Counterbalance Link 5. 6. 7. 8. PHP Link Plate Right PHP Bar Left PHP Bar Spacer Tube and Torsion Springs PHP Pin and Flange Bearing Installation 1. PHP Link Plate Pin 3121222 2. Flange Bearing 3. PHP Counterweight Link – JLG Lift – 4.
SECTION 4 - BASE COMPONENTS 1 2 3 4 5 6 7 8 9 10 Actuator - Limit Switch - Counterweight Installation (Machines Prior to S/N-0130013258) 1. 2. 3. 4. 5. Actuator Attach Screws/Nuts PHP Actuator Assembly Limit Switch (a) Limit Switch Mounting Block (b) Limit Switch Attach Screws 6. 7. 8. 9. 10. Torsion Spring (c) Tube Spacer Counterbalance Link Mounting Pin Pin Retaining Ring Left Side Countbalance Link NOTE: Assembly same for both the left and right side PHP components.
SECTION 4 - BASE COMPONENTS 1 2 3 4 5 6 7 8 9 10 Actuator - Limit Switch - Counterweight Installation (Machines S/N-0130013258 to Present) 1. 2. 3. 4. 5. Actuator Attach Screws/Nuts PHP Actuator Assembly Limit Switch (a) Limit Switch Mounting Bracket (b) Limit Switch Attach Screws 6. 7. 8. 9. 10. Torsion Spring (c) Tube Spacer Counterbalance Link Mounting Pin Pin Retaining Ring Left Side Countbalance Link NOTE: Assembly same for both the left and right side PHP components.
SECTION 4 - BASE COMPONENTS NOTES: 4-40 – JLG Lift – 3121222
SECTION 5 - CONTROL COMPONENTS SECTION 5. CONTROL COMPONENTS 5.1 CONTROL COMPONENTS OVERVIEW Control Components Overview 1. 2. 3. 4. Platform Control Station Ground Control Station Manual Brake Release Switch Battery Charger or Inverter/Charger 3121222 5. 6. 7. 8. Warning Beacon Right Side Batteries Ground Alarm Power Module – JLG Lift – 9. Main Contactor Power Relay 10. Elevation Cut-Back Sensor 11.
SECTION 5 - CONTROL COMPONENTS 5.2 CONTROL COMPONENTS - SERVICE Ground Alarm Main Power Contactor Relay The main power contactor relay is located on the bulkhead on the right-front, inside the compartment as shown following. Ground Alarm - Installation 1. Ground Alarm Note: Remove the charger/step-plate cover on the rear of the machine, mounted just above the battery charger. Main Power Relay - Installation 1. Main Power Relay 2. Attach Screws 2.
SECTION 5 - CONTROL COMPONENTS Manual Brake Release Switch AC Power - Breaker Box Installation (CE Specification Machines ONLY) The AC power breaker box is wired inline on the power circuit of the AC receptacle box mounted in the platform. See illustration below for mounting instructions, for Information on the various plugs types and specific wiring for each plug type see Section 9.12, AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY in Section 9 of this manual.
SECTION 5 - CONTROL COMPONENTS 5.3 TRACTION SYSTEM Refer to Section 3.5, TRACTION - Theory of Operation for more detailed information on Traction System. Common Traction System Difficulties 1. Ground Module Interlocks There are a variety of interlocks that prevent Drive due to system events (Elevated but Pot-Hole Mechanism Failed to Deploy, etc.). Before investigating Traction System issues, examine the JLG Analyzer's HELP Menu while attempting to Drive from Platform Mode.
SECTION 5 - CONTROL COMPONENTS Figure 5-1. Main Electrical Power Connections - (1600346 - SEVCON Power Module) 1. 2. 3. 4. 5. 3121222 Right Side Batteries Left Side Batteries Power Module Main Power Contactor Relay Hydraulic Pump Motor 6. 7. 8. 9. 10.
SECTION 5 - CONTROL COMPONENTS 6 A1 A2 A1 A2 4 3 Figure 5-2. Main Electrical Power Connections - (1001092456 - ZAPI Power Module) 1. 2. 3. 4. 5. 5-6 Right Side Batteries Left Side Batteries Power Module Main Power Contactor Relay Hydraulic Pump Motor 6. 7. 8. 9. 10.
SECTION 5 - CONTROL COMPONENTS To find the source of the difficulty, remove the rear cover from either drive motor. Insert voltmeter leads into the white connector leading to the brake solenoid (yellow and brown wires) and attempt to drive (Platform Mode). The Ground Module will apply approximately 24V to the brake release solenoids (wired in parallel) during drive, but will reduce this voltage in the event of a short-circuit.
SECTION 5 - CONTROL COMPONENTS DO NOT OVERTIGHTEN THE TERMINAL BOLTS, OR DAMAGE TO THE UNIT COULD OCCUR. 3. Torque the terminal bolts to 5 ft lb. (7 Nm). 4. After all connections to the power module are made, the battery can be reconnected. 1. RESISTANCE >100K OHMS ALL TERMINALS TO HOUSING. Ensure that there is an open-circuit between all terminals of the Power Module and the module's aluminum housing. The device is fully potted and all electronics are insulted from the housing.
SECTION 5 - CONTROL COMPONENTS Power Module Diagnostics The Power Module has the ability to detect many fault scenarios and communicate them to the JLG Analyzer. Useful diagnostic information can also be determined from the Green LED located on the Power Module. 1. OPEN CIRCUIT LINE CONTACTOR (3-1) a. The Power Module's Line Contactor Drive Circuitry passed power-up self-tests, but the Line Contactor did not close when energized. b.
SECTION 5 - CONTROL COMPONENTS 10. CANBUS FAILURE: POWER MODULE (6-6) a. The control system failed to receive messages from the Power Module. Check wiring at the Ground Control Box and Power Module. Recycle power to clear difficulty. 12. POWER MODULE FAILURE: RANGE ERROR (9-9) a. The Power Module detected an out-of-range or corrupt personality setting. b. Enter Access Level 1 on the JLG Analyzer, reselect Model, and cycle EMS after 5 seconds. May indicate a Power Module issue if it cannot be reset. b.
SECTION 5 - CONTROL COMPONENTS 5.5 POWER MODULE - P/N-1001092456 ZAPI POWER MODULE P/N - 1001092456 Figure 5-5. ZAPI Power Module Location 1. Turn machine power off and disconnect the batteries. 1230ES SCISSORS BUILT STARTING IN MID YEAR 2010 REPLACED THE SEVCON POWER MODULE (P/N-1600473) WITH THE ZAPI POWER MODULE (P/N-1001092456). Table 5-1. ZAPI Power Module Specs 2. Locate and remove the power module from the machine. 3. Note the wire terminal locations when removing the old power module.
SECTION 5 - CONTROL COMPONENTS ZAPI Power Module Electrical Evaluation "HEALTH" (STATUS LED) INTEGRATED HEALTH INDICATOR The ZAPI Power Module provides a green STATUS LED that shines through the cover to indicate module "health" status. The LED shall be illuminated when the device is powered on. The LED blinks (2Hz) when an internal issue is detected that cannot be repaired by a technician, this will trigger replacement of the device. Table 5-2.
SECTION 5 - CONTROL COMPONENTS 5.6 GROUND CONTROL MODULE - SERVICE PROCEDURE NOTE: The Ground Control Station supplied with the ZAPI Power Module P/N-1001092456 (production start mid-year 2010) does not require use of the printed circuit board inside the ground control module. However box installation and removal instructions shown are exactly the same as the ground control box which does contain a printed circuit board and is used with previous machines supplied with the SEVCON Power Module.
SECTION 5 - CONTROL COMPONENTS Figure 5-6. Ground Control Station Assembly 1. Rear Cover 2. Battery LED Circuit Board 3. Main Ground Control Circuit Board - (1600473 Drive Module Only) 4. Front Cover 5. LED Indicator Decal 6. Control Functions Decal 7. Hourmeter 8. Blank Plug 9. Unused 10. Controls/Indicators Mounting Plate 5-14 – JLG Lift – 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
SECTION 5 - CONTROL COMPONENTS Tilt Sensor, JLG P/N 1810140 and 1001114933: 4 1 3 2 1 2 1. Ground Control Station 2. Tilt Sensor (JLG P/N 1810140 or 1001114936) Figure 5-45. Tilt Sensor Location Tilt Sensor Removal: NOTE: Refer to Figure 5-46., Tilt Sensor Removal for numbers in parenthesis. 1. Tilt Sensor (JLG P/N 1810140 or 1001114936) 2. Sensor Mount 1. Disconnect the batteries. 3. Screw, 3.5 x 0.6 x 16 LG 2. Open the Ground Control Station to gain access to the Tilt Sensor Assembly.
SECTION 5 - CONTROL COMPONENTS 5.7 PLATFORM CONTROL STATION - SERVICE INFORMATION Platform Control Station Assembly 5 2 4 3 4 7 1 6 4 1 Figure 5-7. Platform Control Station Assembly 1. 2. 3. 4. Assembly Bolts Nuts Side Panel Mounting/Reinforcement Plates 5. Upper Control Box 6. Lower Control Box 7. Upper Control Box Wiring Harness Upper Control Box - Component Replacement 3. Loosen and remove the long through bolts that hold the two side control housings together. (See Figure 5-7.) 1.
SECTION 5 - CONTROL COMPONENTS 4. Loosen and remove the four (4) screws from the upper box assembly that hold the cover to the upper box. 2. Disconnect the two (2) front button switch ribbon cables from the circuit board. 3. Remove the five (5) screws attaching the printed circuit board to the control box. 4. Replace board and reassemble upper control box. 1 2 2 3 4 3 5 5 3 Upper Control Box Cover - Installation 1. Upper Box Assembly 2. Upper Box Cover 3.
SECTION 5 - CONTROL COMPONENTS Lower Control Box - Component Replacement Emergency Stop/Shut-Down Switch - Installation 1. Switch Base 2. Switch Button/Barrel 3. Base Release Screw 1. Loosen the release screw, then spin the switch base if necessary to access the barrel release lever. Lower Control Box Cover - Installation 1. Lower Control Box Cover 4. Barrel Release Lever 5. Switch 2. Attach Screws 1. Remove the four (4) attach screws and remove the cover from the other half. 2.
SECTION 5 - CONTROL COMPONENTS 5.8 BATTERY/BATTERY CHARGER Battery Maintenance and Safety Practices JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES. ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING SODA AND WATER.
SECTION 5 - CONTROL COMPONENTS 5.9 BATTERY CHARGER - INSTALLATION Battery Installation The battery charger is located in the compartment at the rear of the machine, remove the charger/step-plate cover to gain access to the charger. 2 3 4 5 6 1 Left Side Battery Installation 1. Batteries 2. Bolt 3. Hold Down Clamp 4. Washer 5. Locking Nut 6. Attach Battery Temperature Sensor To This Terminal Battery Charger Assembly - Installation 1. Battery Charger Assembly 2. Attach Screws/Washers 3.
SECTION 5 - CONTROL COMPONENTS BATTERY CHARGER Battery Charger Troubleshooting SPECIFICATION No Lights at all OUTPUT Nominal DC Output Voltage 24V No Lights at all indicate that AC power to the charger is not connected or that the AC voltage is too low. It could also indicate an internal failure in the charger. Maximum DC Output Voltage 33.6V Maximum DC Output Current 25A Maximum Interlock Current 1A 1. Check the connections to AC power.
SECTION 5 - CONTROL COMPONENTS 4. If this problem does not clear after the battery voltage is confirmed to be higher than 1.0V per cell and all connections are good, return the charger for service. [5 Flashes] - Over Temperature This fault indicates the charger has become too hot during operation. Though not damaging to the charger, charge time will be extended significantly. [3 Flashes] - Charge Time-out 1.
SECTION 5 - CONTROL COMPONENTS Excessive Battery Watering Requirements or Strong Sulphur (Rotten Egg) Smell These symptoms indicate over-charging or high battery temperature. These symptoms are unlikely to be caused by too high a charge current since the maximum charge current of the charger will be small compared to even a moderately sized battery pack. The most likely cause for this problem is incorrect charge algorithm setting and/or high ambient temperatures.
SECTION 5 - CONTROL COMPONENTS 5.10 BATTERY CHARGER/INVERTER (OPTION) - INSTALLATION The battery charger-AC-inverter is located in the compartment at the rear of the machine, remove the charger/stepplate cover to gain access to the charger. BATTERY CHARGER/AC INVERTER SPECIFICATION AC INVERTER - SPECS Output Power (Continuous) 1000 W Output Power (Surge) 3000 W AC Output Current 36 A AC Output Voltage 115 to 125 VAC Output Frequency 60 Hz DC Input Voltage 21.
SECTION 6 - MAST COMPONENTS SECTION 6. MAST COMPONENTS 6.1 MAST COMPONENTS OVERVIEW Figure 6-1. Mast Components. 1. Platform Assembly 2. Tool Tray 3. Mast Cover Plate 3121222 4. Mast Assembly 5. AC Power Receptacle 6.
SECTION 6 - MAST COMPONENTS 6.2 PLATFORM TOOL TRAY - INSTALLATION 6.4 PLATFORM AC RECEPTACLE BOX INSTALLATION Platform Tool Tray - Installation 1. Tool Tray AC Receptacle Box - Installation 2. Attach Screws (a) 1. AC Voltage - Receptacle Box Components 2. Attach Screws Note: (a) Do not use a screw with the threaded portion longer than 1/2 in. (12mm) when attaching to the side of the mast. 6.3 MAST COVER PLATE - INSTALLATION 3.
SECTION 6 - MAST COMPONENTS 6.5 MAST ASSEMBLY - COMPONENTS Figure 6-3. Mast Assembly - Orientation (Top View) 1. Front of Machine 2. Rear of Machine 3. Platform/Outer Mast Section 4. Outer Mid Mast Section 5. Inner Mid Mast Section 6. Mount/Inner Mast Section Note: (a) Always mount slide pads with the groove oriented to the side of the mast not the front or rear, for clearance of the pad mounting rivets during operation.
SECTION 6 - MAST COMPONENTS 6.6 PLATFORM ASSEMBLY This procedure shows the platform assembly (only) removal/installation to the mast assembly. The platform and outer mast section are a one piece manufactured weldment.
SECTION 6 - MAST COMPONENTS Figure 6-5. Platform to Mast - Installation 1. Platform Outer Mast Section - Lower Slide Pad Location 2. Lift Cylinder #3 - Attach Bolt and Nut Location 10. While feeding the electric harness cables for both the AC receptacle box and the platform control station into the top of the mast, carefully start to lift the platform sliding it up off of the mast assembly. Once clear of the mast assembly, move to a suitable area for later assembly. 3121222 3.
SECTION 6 - MAST COMPONENTS NOTE: It may be necessary to pull down or push up on the rear of the platform to keep the platform level while lifting it off of the mast assembly. 3. Lower the platform assembly approximately half way down the mast, then reinstall the slide pads at the bottom corners of the platform mast section. (See Figure 6-5.) - Item 1. 6.7 MAST ASSEMBLY It is recommended that the platform assembly be removed (See Section 6.6) before removing the mast assembly separately. 4.
SECTION 6 - MAST COMPONENTS Mast Removal NOTE: To ease removal and installation of the mast assembly it is recommended that the complete machine be elevated on suitable stands to allow easy access to the mounting bolts on the base of the mast assembly. 3 1. Lower the mast assembly completely before beginning the mast removal process to ensure no residual pressure remains in the lift cylinder. 2. Attach an overhead crane by strap through the cross supports on the top of mast sections. 1 2 Figure 6-8.
SECTION 6 - MAST COMPONENTS Mast Disassembly Figure 6-9. Hydraulic Cylinder Connections - Removal 1. Lift Down Valve Selenoid Harness 2. Extend and Return Hydraulic Lines (a) Note: (a) Open hydraulic lines carefully, have a container ready to catch draining oil, cap ports and lines immediately once lines are removed. Figure 6-11. Hydraulic Cylinder Top End Bolts - Removal 1. Cylinder #1 Attach Bolt/ Nut 7. Disconnect the wire harness connector from the lift down valve selenoid.
SECTION 6 - MAST COMPONENTS Mast - Reassembly (Refer to the Mast Disassembly illustrations when required) 3 1. If required, assemble the external slide pads to the top of the outer-mid, inner-mid and mount/inner mast section. Orient the groove in the pads to the side of the mast and attach with the proper rivets from the inside of the mast. (See Figure 6-3.) 1 2 Figure 6-13. Power-Trak - Removal 1. Attach Screws 3. Power-Trak Guide 2.
SECTION 6 - MAST COMPONENTS 4. Slide the inner-mid and the mount/inner mast sections into the outer-mid mast section. Mast Installation 1. Move the mast assembly near the machines base frame. At the top of the mast assembly attach a lifting strap and lift the mast assembly into a vertical position. 5. At the top of the mast assembly, install the powertrak assembly into the power-trak compartment of the mount/inner mast section. (See Figure 6-13.) 6.
SECTION 6 - MAST COMPONENTS 11. Before tightening the mast mounting bolts/nuts, check mast for vertical front/rear and left/right plumb. Per following table: Plumb, maximum - Front/Rear Plumb, maximum - Left/Right 3 in. (76mm) 2 in. (50mm) Tighten the mast mounting bolts/nuts to 62 ft. lbs. (88Nm), in the following sequence: 1. Left Front 2. Right Rear 3. Left Rear 4. Right Front 2 2 1 3 Mast Lower End - Installation - Later Design 1. Control Cable Frame P3.
SECTION 6 - MAST COMPONENTS Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure 6. Loosen the bleeder valve on the cylinder being bled. Be certain the other end of the bleeder tube is in the catch container. THE THREE STAGE CYLINDER MUST BE BLED IN THE SEQUENCE OF CYL. #1, THEN CYL. #2, THEN CYL. #3. 7. Set the platform control station to platform lift mode and push the joystick to lift the platform.
SECTION 6 - MAST COMPONENTS 6.8 MULTI-STAGE HYDRAULIC CYLINDER - SERVICING Refer to Section 3.6, PUMP/LIFT/MAST - Theory of Operation for more detailed information on Hydraulic System. Overview The hydraulic cylinder for this machine is a multi-stage - three cylinder design. Figure 6-15. 1230ES Lift Cylinder Internal Components - Top End 1. 2. 3. 4. 5. 6. 3121222 Cyl. #3 - Gland Cyl. #3 - Wiper Seal Cyl. #3 - Main Seal Cyl. #3 - Gland Wire Retaining Ring Cyl. #3 - Gland O-Ring Seal Cyl.
SECTION 6 - MAST COMPONENTS Figure 6-16. 1230ES Lift Cylinder Internal Components - Lower End 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Note: (a) (b) (c) (d) (e) 6-14 Extend Port (a) Return Port Proportional Lift Selenoid (b) Valve Port Block (c) O-Ring Seal Cyl. #1 - Rod Wiper Seal Cyl. #1 - Gland (d) Cyl. #1 - Main Seal Cyl. #1 - Gland Wire Retaining Ring Cyl. #1 - O-Ring Seal Cylinder Joint Cyl. #2 and #3 - End Attach Cap (c, d) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Cyl.
SECTION 6 - MAST COMPONENTS Hydraulic Cylinder - Disassembly Cylinder #2 and #3 - Removal from Stack The following disassembly procedures shows the complete disassembly sequence of the cylinder assembly. However, your situation may not require complete disassembly, choose which procedures are required to repair the cylinder assembly for your situation. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA. Removing the Valve Block Assembly Figure 6-18.
SECTION 6 - MAST COMPONENTS Cylinder Rod Assembly - Removal from the Cylinder Barrel Piston - Removal from Cylinder Rod The following disassembly procedure for removing the gland end of the cylinder is the same for cylinders 1, 2, and 3. Figure 6-20. Cylinder Rod Piston - Removal 1. Piston Retaining Ring 2. Piston 3. Compression Spring Figure 6-19. Cylinder Rod/Gland - Removal 1. Cylinder Barrel 2. Gland Wire Retaining Ring 3. Retaining Ring Slot/Hole 4. Piston Guide Ring 5.
SECTION 6 - MAST COMPONENTS Hydraulic Cylinder Component Inspection Hydraulic Cylinder - Assembly Cylinder Rod There should be no 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 0.5 inch long and primarily in the circumferential direction are acceptable provided they cannot cut the rod seal.
SECTION 6 - MAST COMPONENTS Cylinder #2 and #3 Assembly to Cylinder #1 Valve Body Installation PROTECT THE CYLINDER ROD SURFACE. DAMAGE TO THE CYLINDER ROD CHROME FINISH DUE TO SCRATCHING, INDENTATION, CHIPPING OR OTHERWISE WILL CAUSE EVENTUAL GLAND SEAL FAILURE. THE CYLINDER ROD MUST BE REPLACED IF DAMAGED. 1. Lubricate and place a new o-ring in the groove on the tapered end of cylinder rod #1.
SECTION 7 - JLG CONTROL SYSTEM SECTION 7. JLG CONTROL SYSTEM 7.1 ELECTRONIC CONTROL SYSTEM The top level menus are as follows: (Also see menu flow charts - Figure 7-1. and Figure 7-2.) To Connect the Hand Held Analyzer: HELP 1. Connect the four pin end of the cable supplied with the analyzer, to the four position connector on the PCB and connect the remaining end of the cable to the analyzer.
SECTION 7 - JLG CONTROL SYSTEM 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. For example: When a top level menu is selected, a new set of menu items may be offered; If for example you choose Personalities: Press ENTER to select the ACCESS LEVEL menu.
SECTION 7 - JLG CONTROL SYSTEM Machine Setup When a machine digit item is selected, press the UP or DOWN arrow keys to adjust its value. NOTE: Refer to the appropriate Machine Personality Settings Table, and the Machine Setup Table on the following pages in this Service Manual for the default settings. Password 33271 will give you access to level 1, which will permit you to change all machine personality and/or machine setup settings.
7-4 LIFT: DECEL 0.1-1.0S LIFT: UP MIN 0-50% LIFT: UP MAX 1-100% LIFT: UP MIN 0-60% DRIVE: ACCEL 0.1-5.0 S DRIVE: DECEL 0.1-10.0 S DRIVE: MINIMUM 0-25% DRIVE: MAXIMUM 0-100% DRIVE: ELEV.MAX 0-25% – JLG Lift – MENU: CALIBRATIONS MENU: MACHINE SETUP LIFT: ACCEL 0.1-5.
3121222 DIAGNOSTICS: GROUND GROUND: LIFT UP OPEN GROUND: LIFT DN OPEN CURRENT HELP MESSAGE DIAGNOSTICS: PLATFORM PLATFORM: DRIVE SEL OPEN PLATFORM: LIFT SEL OPEN MENU: DIAGNOSTICS – JLG Lift – TRACTION: ARM VOLT XX.XV TRACTION: ARM PWM 0-100% * * PLATFORM: STEER RT OPEN PLATFORM: IN/OUT OPEN PLATFORM: ZONE A/B OPEN TRACTION: FLD CUR XX.XA PLATFORM: JOYSTICK 0% PUMP: PUMP CUR XXX.
Figure 7-3.
Figure 7-4.
Figure 7-5.
SECTION 7 - JLG CONTROL SYSTEM 7.2 MACHINE CONFIGURATION PROGRAMMING INFORMATION ality settings first and then changing the model number of the machine configuration will cause the personality settings to return to default. NOTE: When configuring an 1230ES machine, the machine configuration must be completed before any personality settings can be changed. Changing the person- Shaded entries are not available for the selected market. Table 7-1.
SECTION 7 - JLG CONTROL SYSTEM Table 7-2.
SECTION 7 - JLG CONTROL SYSTEM 7.3 MACHINE PERSONALITY - ADJUSTMENT SETTINGS Table 7-3. Machine Personality Adjustment (4150472-H) Machines Equipped with Sevcon (1600346) Power Module Function Adjustment Range Table 7-4. Machine Personality Adjustment (1001115627B) - Machines Equipped with ZAPI (1001092456) Power Module 1230ES (Factory Setting) Function Adjustment Range 1230ES (Factory Setting) ACCEL 0.1 - 5.0 (Sec) 0.8 1.0 DRIVE DRIVE ACCEL 0.1 - 5.0 (Sec) 0.8 DECEL 0.1 - 1.0 (Sec) 1.
SECTION 7 - JLG CONTROL SYSTEM 7.4 TILT SENSOR CALIBRATION carefully. Observe whether the tilt sensor is properly seated. Be sure that the machine is parked and stowed on level ground. c. Tilt sensor has developed an offset shift: Remove the tilt sensor from the Ground Control box but keep both the tilt sensor and Ground Control box electrically connected. Level one axis of the tilt sensor and observe the raw reading (should be within ± 2.0). Do the same for the other axis.
SECTION 7 - JLG CONTROL SYSTEM 7.5 TILT SENSOR ELECTRICAL EVALUATION This basic check using the JLG Analyzer can be used to test the Tilt Sensor. • If angle measurements read +20.0, then a sensor/ wiring/connector fault exists. If the readings intermittently display expected angles, then there is likely a wiring/connector problem and not a failed sensor. In either case, open the ES Ground box.
SECTION 7 - JLG CONTROL SYSTEM NOTES: 7-14 – JLG Lift – 3121222
SECTION 8 - DIAGNOSTIC TROUBLE CODES SECTION 8. DIAGNOSTIC TROUBLE CODES 8.1 INTRODUCTION This section provides a reference for Diagnostic Trouble Codes (DTC) read from the Multifunction Digital Indicator (MDI). This section should only be used for machines equipped with a SEVCON Power Module-(ground board software version P1.13 or higher) or ZAPI Power Module-(ground board software version P1.0 or higher).
SECTION 8 - DIAGNOSTIC TROUBLE CODES 2-5 3-1 3-2 3-3 4-2 4-4 232 GROUND LIFT UP / DOWN ACTIVE TOGETHER .........................................................................................................6-6 233 FUNCTION PROBLEM - BRAKE RELEASE PERMANENTLY SELECTED ....................................................................6-6 251 ELEV ANGLE SENSOR FAULTY - VOLTAGE OUT OF RANGE ....................................................................................
SECTION 8 - DIAGNOSTIC TROUBLE CODES 6-6 6-7 7-7 8-1 8-2 9-9 661 CANBUS FAILURE - POWER MODULE ...................................................................................................................... 6-13 662 CANBUS FAILURE - PLATFORM MODULE ................................................................................................................ 6-14 663 CANBUS FAILURE - LOAD SENSING SYSTEM MODULE .....................................................................................
SECTION 8 - DIAGNOSTIC TROUBLE CODES 9971 POWER MODULE FAILURE - INTERNAL ERROR.....................................................................................................9-20 99143 POWER MODULE FAILURE - INTERNAL ERROR...................................................................................................9-20 99144 POWER MODULE FAILURE - INTERNAL ERROR...................................................................................................
SECTION 8 - DIAGNOSTIC TROUBLE CODES 8.4 DTC CHECK TABLES 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 001 EVERYTHING OK The normal help message in platform mode. Displays on the analyzer only. 002 GROUND MODE OK The normal help message in ground mode. Displays on the analyzer only. 003 ALARM SOUNDING - TILTED Control system senses that the platform & ABOVE ELEVATION is elevated and the vehicle is tilted, and the machine not configured to cutout.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK The vehicle has reached the maximum • Check that the zone is set appropriately for the platform load. height and further lift up motion is not pos- • Check that the platform height is at the rated maximum height sible. Applicable to 2630ES or 3246ES. specification (20’ for 2630 or 26’ for the 3246). • Check that the elevation angle sensor is securely mounted.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 2-2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK • Check if the indoor/outdoor (zone A / zone B) capacity switch is damaged, obstructed or jammed. • Replace platform board. 222 FUNCTION PROBLEM INDOOR / OUTDOOR PERMANENTLY SELECTED The indoor / outdoor (zone A / zone B) switch was closed during power-up in platform mode.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 2-2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK 2210 TRIGGER CLOSED TOO LONG WHILE IN NEUTRAL The trigger switch was closed for more than five seconds while the joystick was centered. • Check if the trigger switch is obstructed or jammed. • Check the trigger switch signal and wiring to the platform board. The trigger input (24V) is from platform board terminal J1-1, and its output (24V when closed) is to platform board terminal J1-8.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 2-5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 253 DRIVE PREVENTED - CHAR- Driving is not possible while the vehicle is • Check if the charger is connected to off board power source and GER CONNECTED charging. disconnect if desired. • Check ANALYZER -> MACHINE SETUP -> CHARGER INTERLOC is set as desired. • Check that charger's red (positive) battery wire connector terminal is receiving power (24V) from batteries.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 2-5 Function Prevented DTC 259 FAULT MESSAGE DESCRIPTION CHECK MODEL CHANGED The model selection has been changed. • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER. HYDRAULICS SUSPENDED • Replace ground board. CYCLE EMS 2510 DRIVE PREVENTED BRAKES NOT RELEASING While driving on a level surface, armature • Ensure vehicle is not stuck on something preventing movement. current was > 150A for five seconds.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 3-2 Line Contactor Short Circuit DTC 322 FAULT MESSAGE DESCRIPTION CHECK CONTACTOR DRIVER PER- The power modules line contactor drive MANENTLY ON circuitry failed to de-energize when requested. Drive, steer and lift up prevented. • Check continuity between contactor connector pin 1 and ground board socket J1-19. • Check continuity between contactor connector pin 2 and power module 12 position connector terminal 8. • Replace power module.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK • Check for continuity through this circuit. Steer left solenoid resistance should measure about 30 Ohms. The steer left solenoid is powered with 24V from ground board J1-21, and its ground is to ground board J1-30, 37. • Inspect the wiring for physical damage. • Replace ground board.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 3-3 Ground Output Driver DTC FAULT MESSAGE 33297 LEFT BRAKE - SHORT TO GROUND DESCRIPTION CHECK Drive and Steer Prevented • Excessive current flow to the Left Brake Solenoid was detected (J134 NLB). • ZAPI - HEALTH (Status LED) - ON 33298 STEER LEFT VALVE - SHORT Drive, Steer and Lift Up Prevented TO GROUND • Excessive current flow to the steer left solenoid detected (J2-9 NLV).
SECTION 8 - DIAGNOSTIC TROUBLE CODES 4-2 Thermal Limit (SOA) DTC 423 FAULT MESSAGE DESCRIPTION CHECK LIFT UP AT CUTBACK The lift up portion of the power module POWER MODULE CURRENT has reached thermal limit. LIMIT • Check for jammed or obstructed arm stack or pivot bushing. • Check for excessively high current consumption in the pump, ANALYZER -> DIAGNOSTICS -> PUMP -> PUMP CUR over 130 Amps with an empty deck. • Refer to Pump Motor Electrical Evaluation in Section 4.8.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 6-6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK CANBUS FAILURE - PLATFORM MODULE In platform mode, the control system • Turn on machine in ground mode. If DTC 661 is not present check failed to receive messages from the platfor 24V between platform box connector terminals D and A. If not form board.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 6-6 Communication DTC FAULT MESSAGE DESCRIPTION CHECK 663 CANBUS FAILURE - LOAD With load sensing system enabled, the • Check ANALYZER -> MACHINE SETUP -> MODEL NUMBER is SENSING SYSTEM MODULE control system failed to receive mescorrect. sages from the load sensing system mod- • Check ANALYZER -> MACHINE SETUP -> MARKET is correct. ule. • Check ANALYZER -> MACHINE SETUP -> LOAD is correct. • Check for 24V between load sense system module connector J11 and J1-2.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 7-7 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 775 OPEN CIRCUIT FIELD WIRING Drive, Steer, and Lift Prevented • The System Module applied field current, but could regulate the desired current. The situation is caused by improper field wiring or a damaged motor. • ZAPI - HEALTH (Status LED) - ON 776 STALLED PUMP MOTOR OR Drive, Steer, and Lift Prevented POWER WIRING ERROR • The System Module measured improper pump current feedback (>4.5V or <0.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 7-7 Electric Motor DTC FAULT MESSAGE 7742 FIELD VOLTAGE IMPROPER DESCRIPTION CHECK Drive, Steer, and Lift Prevented • The System Module voltage at the F1 and F2 terminals was improper at power-up (expected to be ½ Battery Voltage). This is caused by an open- or short-circuit in the field wiring or motor. Disconnect the field and motor wiring from the System Module and connect F1 / F2 with a short wire.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 996 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented INTERNAL ERROR • The System Module’s analog to digital converter does not respond for the power PCB. This is an internal failure. • Cycle machine, if error still exists, replace System Module. • ZAPI - HEALTH (Status LED) - FLASHING 997 POWER MODULE FAILURE - The power module detected an error in CHECK POWER CIRCUITS the power wiring for the drive or pump.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 9956 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented INTERNAL ERROR • The System Module’s field current control or MOSFET’s are malfunctioning. • Cycle machine, if error still exists, replace System Module.
SECTION 8 - DIAGNOSTIC TROUBLE CODES 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 99145 POWER MODULE FAILURE - Drive, Steer, & Lift Prevented INTERNAL ERROR • The System Module’s enable for the power PCB requested a drive motor or valve activation when not expected. • Cycle machine, if error still exists, replace System Module.
SECTION 8 - DIAGNOSTIC TROUBLE CODES NOTES: 8-22 – JLG Lift – 3121222
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS SECTION 9. GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.1 GENERAL This section contains schematics to be used for locating and correcting most of the operating problems which may develop. If a problem should develop which is not presented in this section or which is not corrected by listed corrective actions, technically qualified guidance should be obtained before proceeding with any maintenance.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Voltage Measurement Resistance Measurement Figure 9-1. Voltage Measurement (DC) Figure 9-2. Resistance Measurement • If meter is not auto ranging, set it to the correct range (See multimeter’s operation manual) • First test meter and leads by touching leads together.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Current Measurement Figure 9-3. Continuity Measurement Figure 9-4.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Continuity Measurement Over Long Distances When trying to determine continuity of a harness or wire, longer than the reach of standard instrument leads, is possible to perform the check without excessively long leads. Using the other wires in the harness one can determine the condition of a particular wire in the harness. Requirements: • Harness with at least three separate wires including the wire under test.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.3 ELECTRICAL SWITCH TESTING Basic Check The following check determines if the switch is functioning properly, not the circuit in which the switch is placed. A switch is functioning properly when there is continuity between the correct terminals or contacts only when selected. 1. De-energize the circuit. 2. Isolate the switch from the rest of the circuit if possible. If not possible, keep in mind it may affect readings. 3.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Automatic Switches If the switch is actuated automatically, by temperature or pressure for example, find a way to manually actuate the switch to test it. Do this either by applying heat or pressure, for example, to the switch. These switches may need to be energized to actuate. 1. Connect instrumentation to monitor and/or control the parameter the switch is measuring. 2. Observe switch state in control system with the Analyzer.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.4 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS Silicone Dielectric Compound must be used on the AMP connections for the following reasons: • To prevent oxidation at the mechanical joint between male and female pins. • To prevent electrical malfunction caused by low level conductivity between pins when wet. Use the following procedure to apply Silicone Dielectric Compound to the electrical connectors. 1.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Assembly Check to be sure the wedge lock is in the open, or as-shipped, position (See Connector Assembly Figure 1). Proceed as follows: Connector Assembly Figure 1 1. To insert a contact, push it straight into the appropriate circuit cavity as far as it will go (See Connector Assembly Figure 2). 2. Pull back on the contact wire with a force of 1 or 2 lbs. to be sure the retention fingers are holding the contact (See Connector Assembly Figure 2). 3.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Connector Assembly Figure 3 Connector Assembly Figure 4 3121222 – JLG Lift – 9-9
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Disassembly 5. Insert a 4.8 mm (3/16”) wide screwdriver blade between the mating seal and one of the red wedge lock tabs. 6. Pry open the wedge lock to the open position. 7. While rotating the wire back and forth over a half turn (1/4 turn in each direction), gently pull the wire until the contact is removed. Connector Disassembly NOTE: The wedge lock should never be removed from the housing for insertion or removal of the contacts.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-5.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.5 WORKING WITH DEUTSCH CONNECTORS DT/DTP Series Assembly Figure 9-6. DT/DTP Contact Installation 1. Grasp crimped contact about 25mm behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place. 4. Once all contacts are in place, insert wedgelock with arrow pointing toward exterior locking mechanism.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 10. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place. Figure 9-9. HD/HDP Locking Contacts Into Position NOTE: For unused wire cavities, insert sealing plugs for full environmental sealing HD30/HDP20 Series Disassembly Figure 9-10. HD/HDP Contact Removal 11. With rear insert toward you, snap appropriate size extractor tool over the wire of contact to be removed.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.7 CONNECTOR LOADING DIAGRAMS Table 9-1.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 9-1. Connector Loading Diagrams (Continued) ID DHD14P Description Diagram Deutsch 14 position HD series alum. Plug PE N D M F A C G B L H K J REAR VIEW DHD14R Deutsch 14 position HD series alum.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 9-1.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Table 9-1. Connector Loading Diagrams (Continued) ID Description MMF03P Diagram Molex 3 position plug 3 MMF12P 2 1 Molex Mini Fit 12 position plug 7 8 1 MMF16P Molex Mini Fit 16 position plug 9 2 10 3 11 4 12 5 6 12 13 9 10 11 14 15 16 1 2 3 4 5 6 7 8 9.8 X-CONNECTOR ID INDEX ID X001 X002 X003 X008 X009 X010 X011 X012 X013 X014 X017 X018 X019 X020 X021 X022 X023 X024 X025 X026 X027 X028 X029 3121222 Table 9-2.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ID X030 X031 X032 X033 X034 X035 X036 X037 X038 X039 X040 X041 X042 X043 X044 X046 X047 X048 X049 X050 X051 X052 X053 X054 X056 X057 X058 X059 X060 X061 X062 X063 X064 X065 X066 X069 X070 X071 X072 X073 X074 X075 X076 X077 X078 X079 X080 9-18 Table 9-2.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS ID X081 X082 X083 X084 X085 X086 X087 X088 X089 X090 X091 X092 X093 X094 X095 X096 X097 X098 X099 X104 X105 X106 X107 X108 X109 X110 X111 X112 3121222 Table 9-2.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS X003 X002 X001 X029 X030 X033 X034 X028 X031 X032 (1 WIRE) X035 X040 X003 X038 X010 X039 X036 X037 (2 WIRES) Figure 9-13. 1230ES -Location of Component X-Connectors on Ground Control Module.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.10 ELECTRICAL LAYOUT AND SCHEMATICS PLATFORM CONSOLE BOX BRAKE DISCONNECT SWITCH PLATFORM RECEPTACLE PUMP/ MOTOR/ TANK MODULE (JAPANESE SPEC) J2 ALARM J1 BEACON LIGHT POTHOLE PROTECTION SWITCHES R DIAGNOSTIC ANALYZER L GROUND CONTROL BOX DRIVE MOTORS Figure 9-14. 1230ES - Overview of Electrical System Components.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BATTERIES BATTERY CHARGER BATTERY CHARGER/ INVERTER INVERTER POWER SWITCH TO AC POWER CONTACTOR RELAY PROXIMITY SENSOR LIFT CYLINDER POWER MODULE Figure 9-14., 1230ES - Overview of Electrical System Components.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BRAKE DISCONNECT SWITCH PLATFORM CONSOLE BOX PLATFORM RECEPTACLE PUMP/ MOTOR/ TANK ALARM BEACON LIGHT HANDHELD ANALYZER CONNECTION GROUND CONTROL BOX POTHOLE PROTECTION SWITCHES DRIVE MOTORS Figure 9-15. 1230ES - Overview of Electrical System Components.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS BATTERIES BATTERY CHARGER BATTERY CHARGER/ INVERTER INVERTER POWER SWITCH TO AC POWER RELAY DRIVE CONTROLLER +BF1 –T PROXIMITY SENSOR J1 +B LIFT CYLINDER +BF2 –B J2 –P CONTACTOR RELAY F1 F2 Figure 9-15., 1230ES - Overview of Electrical System Components.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-16. Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1870188_E Figure 9-16., Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-17. Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-1 Figure 9-17., Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-18. Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-2 Figure 9-17., Electrical Schematic.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 1001114879_F-3 Figure 9-19.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.11 PIN INPUT/OUTPUT TYPES Table 9-3.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Pin 1 2 3 4 Table 9-5. Ground Board J3 - Connector X003 Function Type Range (V) Tilt Sensor Power Power Output 12 Tilt Sensor X-Axis (PWM) Input 12 Tilt Sensor Y-Axis (PWM) Input 12 Ground Power Output 0 Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Table 9-6.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3121222 Table 9-10.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 9-36 Table 9-11.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS Figure 9-20.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3121222 – JLG Lift – 9-39
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9-40 – JLG Lift – 3121222
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 3121222 – JLG Lift – 9-41
SECTION 9 - GENERAL ELECTRICAL INFORMATION & SCHEMATICS 9.12 HYDRAULIC SCHEMATIC Figure 9-21. Hydraulic Diagram.
CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other harmful chemicals known to the State of California.
3121222 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng.