Document Outline

• Section A. Introduction - Maintenance Safety Precautions
  • A. General
  • A. Hydraulic System Safety
  • A. Maintenance
• Section 1. Specifications
  • 1.1 Specifications
    • Capacities
    • Fluid Capacities
    • Tires
    • Batteries
    • Motors
    • Battery Charger
    • Travel Speed
    • Lift Speed (No Load in Platform)
    • Model Dimensions
  • 1.2 Torque Requirements
  • 1.3 Lubrication
    • Hydraulic Oil
  • 1.4 Limit Switches
    • Tilt Alarm
    • High Drive Speed Cutout
    • Pressure Settings
  • 1.5 Cylinder Specifications
  • 1.6 Major Component Weights
  • 1.7 Critical Stability Weights
  • 1.8 Torque ChartS
• Section 2. General
  • 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 Service and 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
    • Battery
    • Lubrication and Servicing
  • 2.3 Lubrication and Information
    • Hydraulic System
    • Hydraulic Oil
    • Changing Hydraulic Oil
    • Lubrication Specifications
  • 2.4 Cylinder Drift Test
    • Platform Drift
    • Cylinder Drift
  • 2.5 Pins and Composite Bearing Repair Guidelines
  • 2.6 Preventive Maintenance and Inspection Schedule
• Section 3. Chassis & Scissor Arms
  • 3.1 Diagnostic Port
  • 3.2 MDI (Multifunction Digital Indicator) and brake release
  • 3.3 Traction System
    • Theory of Operation
  • 3.4 Torque Hub
    • Roll Test
    • Leak Test
    • Oil Check/Fill Procedure
    • Manual Disengage Procedure
    • Manual Disengage Procedure
    • Manual Disengage Procedure
    • Motor and Brake Disassembly
    • Motor Disassembly
    • Drive Motor Removal
    • Main Gearbox Disassembly
    • Input Carrier Disassembly
    • Hub Disassembly
    • Spindle Disassembly
    • Spindle Sub-Assembly
    • Hub Sub-Assembly
    • Input Carrier Sub-Assembly
    • Main Gearbox Assembly
    • Motor and Brake Assembly
    • Motor Assembly
    • Motor Assembly
    • Tightening and Torquing Bolts
    • Assembly Tools
  • 3.5 Electric Drive Motor
    • Disassembly
    • Replacing Motor Bearing
    • Inspecting Motor Brushes
    • Replacing Motor Brushes
    • Replacing the Motor Cable
    • Reassembling the Motor
    • Motor Maintenance
    • Disassembly
    • Inspection and Service
    • Reassembly
  • 3.6 Electric Drive Motor
    • Drive Motor Troubleshooting
    • Drive Motor Disassembly
    • Drive Motor Inspection and Service
    • Drive Motor Reassembly
    • Drive Motor Servicing Guidelines
  • 3.7 Drive Motor Electrical Evaluation
    • Servicing Guidelines
    • Common Traction System Difficulties
  • 3.8 Power Module - Sevcon
    • Power Module Electrical Evaluation
  • 3.9 Power Module - ZAPI
    • ZAPI Power Module Electrical Evaluation
  • 3.10 Battery Removal
    • Battery Maintenance and Safety Practices
  • 3.11 Battery Charger
    • Battery Charger Maintenance
    • Battery Charger Troubleshooting
  • 3.12 Battery Charger/Inverter (Option)
    • Battery Charger/Inverter Troubleshooting
  • 3.13 Drive Motor Cable Routing
  • 3.14 Pothole Switch Replacement
    • Rotary Angle Sensor Replacement
  • 3.15 Ground Control Station
    • Printed Circuit Board (PCB) Replacement
    • Tilt Sensor Replacement
  • 3.16 Arms and Platform Positioning and Support
  • 3.17 Platform Removal
  • 3.18 Scissor Arms Removal
  • 3.19 Platform Control Station
    • Joystick Controller
• Section 4. Hydraulics
  • 4.1 Cylinders - Theory of Operation
  • 4.2 Valves - Theory of Operation
    • Solenoid Control Valves (Bang-Bang)
    • Relief Valves
    • Crossover Relief Valves
    • Proportional Valve
    • Manual Descent Valve
  • 4.3 Cylinder Checking Procedure
    • Cylinders Without Counterbalance Valves and Steer Cylinder
  • 4.4 Lift Pressure Setting Procedure
  • 4.5 Hydraulic Oil Fill
    • Oil Check Procedure
    • Slide Block Lubrication
  • 4.6 Lift Cylinder Removal
  • 4.7 Pump/Motor
    • Pump Motor Electrical Evaluation
    • Pump Removal
    • Motor Removal
  • 4.8 Cylinder Repair
    • Disassembly
    • Steer Cylinder Piston Removal - Cyl. p/n- 1684456
    • Cleaning and Inspection
    • Assembly
• Section 5. JLG Control System
  • 5.1 Hand Held Analyzer
    • To Connect the Hand Held Analyzer:
    • Using the Analyzer:
    • Changing the Access Level of the Hand Held Analyzer:
    • Adjusting Parameters Using the Hand Held Analyzer
    • Machine Setup
  • 5.2 Tilt Sensor Calibration
    • Ground Module Software Version 1.5
    • Ground Module Software Version 1.4
    • Failure Troubleshooting for The Field
  • 5.3 Tilt Sensor Electrical Evaluation
  • 5.4 Elevation Angle Sensor Electrical Evaluation
    • Tilt vs. Allowed Height Evaluation
  • 5.5 Elevation Sensor Calibration
  • 5.6 Updating Software
  • 5.7 Troubleshooting
    • Analyzer Flow Chart
    • Analyzer Flow Chart
  • 5.8 Machine Model Adjustment - SEVCON - 1600346 Power Module
  • 5.9 Machine Model Adjustment - ZAPI - 1001092456 Power Module
  • 5.10 Machine Configuration Programming Information - SEVCON - 1600346
  • 5.11 Machine Configuration Programming Information - ZAPI - 1001092456
• Section 6. Diagnostic Trouble Codes
  • 6.1 Introduction
  • 6.2 DTC Index
  • 6.3 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 7. General Electrical Information & Schematics
  • 7.1 General
  • 7.2 Multimeter Basics
    • Grounding
    • Backprobing
    • Min/Max
    • Polarity
    • Scale
    • Continuity Measurement Over Long Distances
    • Requirements:
    • Procedure
  • 7.3 Applying Silicone Dielectric Compound To Amp Connectors
    • Assembly
    • Disassembly
    • Wedge Lock
    • Service - Voltage Reading
  • 7.4 Working With Deutsch Connectors
    • DT/DTP Series Assembly
    • DT/DTP Series Disassembly
    • HD30/HDP20 Series Assembly
    • HD30/HDP20 Series Disassembly
  • 7.5 Switches
    • Basic check
    • Limit Switches
    • Automatic Switches
    • Switch Wiring - Low Side, High Side
  • 7.6 Circuit Boards: Inputs and Outputs
  • 7.7 Electrical Schematics and Layouts
    • Electrical Schematic - 1870164G - Sheet 1 of 2
    • Electrical Schematic - 1870164G - Sheet 2 of 2
    • Electrical Schematic - 1870205B - Sheet 1 of 2
    • Electrical Schematic - 1870205B - Sheet 2 of 2
    • Electrical Schematic - Sheet 1 of 2 (Machines with MDI)
    • Electrical Schematic - Sheet 2 of 2 (Machines with MDI)
    • Inverter/Charger Schematic
    • Electrical Components - Sheet 1 of 2
    • Electrical Components - Sheet 2 of 2
    • Electrical Components - Sheet 1 of 2
    • Electrical Components - Sheet 2 of 2
    • Electrical Components - Sheet 1 of 2
    • Electrical Components - Sheet 2 of 2
    • Electrical Components - Sheet 1 of 2 (Machines with MDI)
    • Electrical Components - Sheet 2 of 2 (Machines with MDI)
  • 7.8 Hydraulic Schematic