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21SI All Replaceable Components 10539632 Guide
User manual for 21SI All Replaceable Components 10539632
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Table of contents
Document Outline
A. GENERAL
B. HYDRAULIC SYSTEM SAFETY
C. MAINTENANCE
SECTION 1. MACHINE SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS
Platform Capacities
Dimensional Data
Tires
Batteries
Critical Stability Weights
1.2 LUBRICATION
Lubrication Capacities
Hydraulic Oil
Lubrication Specifications
Oil Check Procedure
1.3 CYLINDER SPECIFICATIONS
1.4 TORQUE REQUIREMENTS
1.5 SERIAL NUMBER LOCATIONS
SECTION 2. GENERAL SERVICE INFORMATION
2.1 MACHINE PREPARATION, INSPECTION, AND MAINTENANCE
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE
Maintenance and Inspection Table Codes:
Footnotes:
2.3 SERVICING AND MAINTENANCE GUIDELINES
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication and Servicing
Batteries
2.4 LUBRICATION INFORMATION
Hydraulic System
Lubrication Specifications
Hydraulic Oil
Changing Hydraulic Oil
SECTION 3. THEORY OF OPERATION - 1230ES
3.1 OVERVIEW
3.2 MODES OF OPERATION
Ground Mode
Platform mode
3.3 CAN COMMUNICATIONS
3.4 CONTROLS & SENSORS
Elevation
Joystick
Tilt
3.5 TRACTION
Personalities
Interlocks
3.6 PUMP/LIFT/MAST
Personalities
Interlocks
3.7 STEER
Personalities
Interlocks
SECTION 4. BASE COMPONENTS
4.1 BASE ASSEMBLY COMPONENTS
4.2 BASE FRAME COVERS
Base Top Cover - Installation
Step Plate/Battery Charger Cover - Installation
Battery Tray/Side Door - Installation
4.3 WHEELS AND TIRES - DRIVE AND REAR
Tire Wear and Damage
Wheel and Tire Replacement
Wheel Installation
4.4 REAR WHEEL HUB - INSTALLATION
4.5 STEERING LINKAGE ASSEMBLY - INSTALLATION
4.6 STEER CYLINDER - SERVICING
Steer Cylinder Disassembly
Hydraulic Cylinder Component Inspection
Steer Cylinder - Assembly
4.7 DRIVE MOTOR/SPINDLE ASSEMBLY - INSTALLATION
4.8 WHEEL DRIVE ASSEMBLY - SERVICING
Drive Motor Electrical Evaluation
Roll And Leak Testing
Oil Type & Capacity
Drive Motor Power Harness Routing
Wheel Drive Brake - Manual Disengage Procedure
Wheel Drive Motor Assembly - Removal From Machine
Drive Motor Disassembly
Drive Motor Inspection and Servicing
Drive Motor - Reassembly
Main Gear Box Disassembly
Input Carrier Disassembly
Hub - Disassembly
Spindle Disassembly
Spindle Sub-Assembly
Hub Sub-Assembly
Input Carrier Sub-Assembly
Main Gear Box Sub-Assembly
Motor Assembly
4.9 HYDRAULIC PUMP/MOTOR/VALVE ASSEMBLY - SERVICE PROCEDURE
Common Difficulties
Pump Components
Hydraulic System Pressure Check Port
Hydraulic System Pressure Settings
Pump/Motor/Valve Assembly - Removal/Installation
Motor Cover/Motor Installation
Preventative Maintenance - Brush Wear - Dust Removal Procedure
Motor Brush Installation
4.10 POT HOLE PROTECTION SYSTEM
SECTION 5. CONTROL COMPONENTS
5.1 CONTROL COMPONENTS OVERVIEW
5.2 CONTROL COMPONENTS - SERVICE
Main Power Contactor Relay
Elevation Limit Switch
Ground Alarm
Warning Beacon - Frame Mounted
Manual Brake Release Switch
AC Power - Breaker Box Installation (CE Specification Machines ONLY)
5.3 TRACTION SYSTEM
Common Traction System Difficulties
5.4 POWER MODULE - P/N-1600346
Removal
Installation
Power Module Electrical Evaluation
Power Module Diagnostics
5.5 Power Module - P/N-1001092456
ZAPI Power Module Electrical Evaluation
5.6 GROUND CONTROL MODULE - SERVICE PROCEDURE
Ground Control Station
Printed Circuit Board (PCB) Replacement
5.7 PLATFORM CONTROL STATION - SERVICE INFORMATION
Platform Control Station Assembly
Upper Control Box - Component Replacement
Lower Control Box - Component Replacement
5.8 Battery/Battery Charger
Battery Maintenance and Safety Practices
Battery Installation
5.9 BATTERY CHARGER - INSTALLATION
Battery Charger Troubleshooting
5.10 BATTERY CHARGER/INVERTER (OPTION) - INSTALLATION
SECTION 6. MAST COMPONENTS
6.1 MAST COMPONENTS OVERVIEW
6.2 PLATFORM TOOL TRAY - INSTALLATION
6.3 MAST COVER PLATE - INSTALLATION
6.4 PLATFORM AC RECEPTACLE BOX - INSTALLATION
6.5 MAST ASSEMBLY - COMPONENTS
6.6 PLATFORM ASSEMBLY
Platform - Extending Mast Unpowered
Platform Removal
Platform Installation
6.7 MAST ASSEMBLY
Mast Removal
Mast Disassembly
Mast - Reassembly
Mast Installation
Multi-Stage Hydraulic Cylinder - Cylinder Bleeding Procedure
Mast Installation Completion
6.8 MULTI-STAGE HYDRAULIC CYLINDER - SERVICING
Overview
Hydraulic Cylinder - Disassembly
Hydraulic Cylinder Component Inspection
Hydraulic Cylinder - Assembly
Hydraulic Cylinder Assembly Testing
SECTION 7. JLG CONTROL SYSTEM
7.1 ELECTRONIC CONTROL SYSTEM
To Connect the Hand Held Analyzer:
Using the Analyzer:
Changing the Access Level of the Hand Held Analyzer:
Machine Setup
Diagnostic Trouble Codes (DTC)
7.2 MACHINE CONFIGURATION PROGRAMMING INFORMATION
7.3 MACHINE PERSONALITY - ADJUSTMENT SETTINGS
7.4 TILT SENSOR CALIBRATION
Ground Module Software Version 1.5
Ground Module Software Version 1.4
Calibration Failures
7.5 TILT SENSOR ELECTRICAL EVALUATION
7.6 ELEVATION ANGLE SENSOR ELECTRICAL EVALUATION
Tilt vs. Allowed Height Evaluation
7.7 ELEVATION SENSOR CALIBRATION
SECTION 8. DIAGNOSTIC TROUBLE CODES
8.1 Introduction
8.2 X-CONNECTOR REFERENCES
8.3 DTC Index
8.4 DTC Check Tables
0-0 Help Comments
2-1 Power-Up
2-2 Platform Controls
2-3 Ground Controls
2-5 Function Prevented
3-1 Line Contactor Open Circuit
3-2 Line Contactor Short Circuit
3-3 Ground Output Driver
4-2 Thermal Limit (SOA)
4-4 Battery Supply
6-6 Communication
6-7 Accessory
7-7 Electric Motor
8-1 Tilt Sensor
8-2 Platform Load Sense
9-9 Hardware
SECTION 9. GENERAL ELECTRICAL INFORMATION & SCHEMATICS
9.1 GENERAL
9.2 MULTIMETER BASICS
Grounding
Backprobing
Min/Max
Polarity
Scale
Continuity Measurement Over Long Distances
Requirements:
Procedure
9.3 ELECTRICAL SWITCH TESTING
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side
9.4 APPLYING SILICONE DIELECTRIC COMPOUND TO AMP CONNECTORS
Assembly
Disassembly
Wedge Lock
Service - Voltage Reading
9.5 WORKING WITH DEUTSCH CONNECTORS
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
9.6 X-CONNECTOR REFERENCES
9.7 CONNECTOR LOADING DIAGRAMS
9.8 X-CONNECTOR ID INDEX
9.9 MACHINE LOCATION OF COMPONENT X-CONNECTORS
9.10 ELECTRICAL LAYOUT AND SCHEMATICS
9.11 PIN INPUT/OUTPUT TYPES
9.12 AC POWER RECEPTACLES AND WIRING (PLATFORM) - CE SPEC MACHINES ONLY
9.12 HYDRAULIC SCHEMATIC
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